PID control for dummies: Temperature

control
Everything you need to know White Book

PID Control for Dummies is designed for those looking for a better understanding
of PID control without getting bogged down in complex technical concepts.

Whether you’re a technician or a student in the field of instrumentation,

this article is intended as a resource to guide you towards knowledge
of the pid controller.

You’ll learn about the origins of PID control, how it works, the
importance of PID control in different industries, and tips for optimizing
your process.

Key points
The PID controller controller is an integral part of the control system in many industries and applications.

The main purpose of a PID controller is to compare a setpoint value with the measurement during the process,
in order to minimize error

The right settings for your PID temperature controllers can have a major impact on your process performance.

Getting an explanation of the terms PID, on/off, proportional band, derivative, integral, loop, setpoint and many other related
concepts, will enable you to harness the full power of your PID system.

History of the PID controller

It’s difficult to discuss PID control without touching on its history. At the beginning of the
20th century, Nicolas Minorsky observed that ships were unable to maintain a constant
course despite the continuous efforts of the piloting staff.

Mr. Minorsky then developed a solution to the need: the use of an automatic controller,
which, by exploiting deviations between the desired direction and the actual course, could
adjust the rudder to ensure smoother navigation.

This was the basis for the birth of PID control, and its effect on industrial process control
has been major.

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The operating principle

To easily understand how a PID controller works, let’s consider a

simple and common example of a control loop - a pottery kiln.

The temperature inside the oven must be maintained at a constant

setpoint , say 800°C.

Instead of a simple all-or-nothing control system (the oven is either on or

off), the temperature controller PID will maintain this temperature
constant to avoid any deviation that could deteriorate the quality
of the product inside the oven.

Here’s how it works.

The start of the control process involves a

thermocouple temperature sensor which
monitors the temperature inside the furnace.

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This temperature measurement is compared with the temperature
setpoint (800°C in this example).

The difference between these two values, called an error, is sent

to the PID controller, which formulates a correction action on the
output to mitigate this error.

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This correction is the product of three functions or quantities:

Proportional (P), Integral (I) and Derivative (D) together form the acronym PID (Proportional Integral Derivative).

Proportional (P)

The proportional band action is equivalent to multiplying the

error by a proportional coefficient (Kp). This action adjusts the
controller output to be proportional to the error. So, if the error
or disturbance is large, the correction will be equally large, and
vice versa.

Integral (I)

Integral action aims to eliminate persistent error by accumulating

past errors and integrating them over time. This action brings
the system progressively closer to the setpoint by adjusting the
output according to the integrated error. The integral coefficient
(Ki) determines the influence of this component.

Derivative (D)

The derived action concerns the rate of change of the error. This
predictive action enables the system to react to future events
based on observed trends. The derived coefficient (Kd) adjusts
the influence of this action for better control.

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Setting a PID controller

Setting up a Proportional Integral Derivative controller may seem daunting, but it’s essential
to ensure that your process runs smoothly. Each of the tuning parameters, P, I and D, impacts
the way the controller reacts to process value variations.

The right settings can significantly improve the stability and performance of your system.

On the other hand, incorrect settings can lead to oscillations, over-excitations and under-
reactions, impairing the quality of process control.

Ziegler-Nichols method

The Ziegler-Nichols method is a well-known approach to setting

the parameters of a PID controller.

This method consists of making the system or process oscillate

by adjusting the proportional gain (Kp) until it reaches the stability
limit.

The oscillation period and critical gain are then used to determine
the optimum proportional (Kp), integral (Ki) and derivative (Kd)
coefficients.

While this method is convenient for initial setting of PID parameters, it is important to note that optimization of the control system may require
further adjustments. These adjustments will depend on the desired response and specific process constraints.

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PID control limits

If your system has inherent instability, or other prevailing

problems such as delays, disturbances, external pressures, etc.,
then a P, I, D controller can only temper them, not eliminate them
completely. It is sometimes useful to redesign the process.

PID control FAQs

What is a closed loop in PID control?

In a closed loop, information on the current state of the process is constantly fed back to the PID controller. It uses this information to
correct its output, thus keeping the process as close as possible to the setpoint. This mechanism considerably improves the precision of
process variable management, enabling tighter control and greater stability. In addition, closed-loop systems effectively counteract external
disturbances, minimizing unwanted fluctuations.

What does all-or-nothing mean in regulation?

All-or-nothing refers to a control mode in which the system is either 100% on or completely off. There are no intermediate operating levels.

What are the disadvantages of On/Off control compared with PID control?
1 - Lack of precision:
Unlike PID control, which finely adjusts power to achieve and maintain the desired temperature, On/Off control operates only in extreme
states (100% on or off). This method tends to generate a temperature overshoot before stabilizing, creating fluctuations rather than the
stability obtained with PID control.

2 - Temperature oscillations:
On/Off operation leads to greater temperature oscillations around the setpoint. This fluctuation can be detrimental to processes requiring
fine, constant temperature control.

3 - Equipment wear and tear:

The frequent switching on and off of equipment with On/Off control places greater stress on mechanical and electrical components,
potentially reducing their lifespan compared to the smoother operation permitted by PID control.

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4 - Energy consumption:
Although On/Off control may appear more energy-efficient due to periods of inactivity, frequent on/off cycles can actually lead to higher
energy consumption over the long term, particularly in cases where the system consumes a lot of energy at start-up. PID control, thanks
to its precise adjustment, tends towards optimized energy consumption.

5 - Response to disturbances :
On/Off control can be less effective in the face of sudden process disturbances (e.g. a door opening in an air-conditioned room), as it
can only respond by switching on or off, whereas PID control can proportionally adjust the energy applied to quickly counterbalance the
disturbance.

In short, On/Off control can be adapted for simple, less demanding applications. However, for precise and efficient temperature control,
particularly in industrial environments or for critical processes, PID control offers significant advantages in terms of stability, energy efficiency
and equipment protection.

What is the proportional band in PID control?

The proportional band is the range of values within which the controller switches from its off state to its full power state (and vice versa) in
a proportional control. It is the part of PID control that reacts according to the deviation between the desired value and the actual value. The
greater the deviation, the greater the correction.

What is the integral band in PID control?

The integral band is the part of the PID control that accumulates over time. If the deviation persists, however small, this correction will
continue to increase until the deviation is corrected.

What is the derivative in PID control?

The derivative action in PID control is the part that reacts to the speed of change of the deviation. It tries to predict the future of this deviation
and to make a preventive correction to minimize too rapid variations.

Where can PID controllers be used?

PID controllers are widely used in various industries such as the pharmaceutical industry, the food industry (e.g. bakery ovens or
pizza ovens), the automotive industry (e.g. paint booths), in laboratories (e.g. automotive materials testing), in special machines such as
packaging machines or plastics processing, in particular for :

• Temperature control
• Fluid flow and velocity control
• Level monitoring
• Pressure regulation

And many other temperature control.

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Don’t let the complexity of PID control stop you!

At Fuji Electric, our temperature control industrial experts are ready to help you select the
ideal PID controllers for your systems. We will assist you during controller commissioning to
fine-tune parameter settings.

Whether you’re a seasoned professional or a novice in the field, our team is here to turn PID
control into a controllable, high-performance asset for your business.

GET A QUOTE DISCOVER THE PID CONTROLLER RANGE

FUJI ELECTRIC FRANCE S.A.S.

46, rue Georges Besse - Zl du Brézet - 63 039 Clermont-Ferrand Cedex 2 - France
Phone: +33 (0)4 73 98 26 98
Email : [email protected]
Web site : www.fujielectric.fr

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ordered, if the modifications do not alter the specifications substantially. The registered marks and names which appear in this document are the property of their respective depositors. All rights reserved.

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