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ICME07-AM-62

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ICME07-AM-62

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Proceedings of the

International Conference on Mechanical Engineering 2007


(ICME2007) 29- 31 December 2007, Dhaka, Bangladesh

ICME07-AM-62

ROBUST ANTI-WINDUP PID CONTROL OF A COUPLE INDUSTRIAL


TANK SYSTEM

Wahyudi, M. Fadhil and M. Shazri

Intelligent Mechatronics Research Group, Department of Mechatronics Engineering, Faculty of Engineering,


International Islamic University Malaysia (IIUM), PO BOX 10, 50728, Kuala Lumpur, Malaysia

ABSTRACT
Liquid tank systems play important role in industrial application such as in food processing, beverage, dairy
filtration, effluent treatment, pharmaceutical industry, water purification system, industrial chemical
processing and spray coating. A typical situation is one that requires fluid to be supplied to a chemical
reactor at a constant rate. An upper tank can be used for filtering the variations in the upstream supply flow.
Feedback control system such as classical PID controller based on the linear model is widely used in
controlling industrial liquid level control application. However aggressive performance requirements may
not be achievable with the PID controller due to the presence of nonlinear dynamics inherent in the liquid
control system and system parameter variations caused by for example corrosive build-up in liquid level
systems creates variation of cross section areas of the tank and discharge orifice. One of nonlinearity which
exists in industrial coupled tank system is actuator saturation. It is well known that integrator windup which
may cause instability and/or performance degradation. To solve this problem, in this paper, a robust
Anti-windup PID controller is designed and implemented for level control of tank system. The
experimental results show that the proposed robust Anti-windup PID controller effectively reduces for the
effect of actuator saturation

Keywords: Robust, PID, controller, anti-windup, saturation, coupled tank.

1. INTRODUCTION industrial coupled tank system is actuator saturation. It is


Liquid tank systems play important role in industrial well known that integrator windup which may cause
application such as in food processing, beverage, dairy, instability and/or performance degradation.
filtration, effluent treatment, pharmaceutical industry, In order to solve the above-mentioned problem,
water purification system, industrial chemical processing robust anti-windup PID controller is adopted for level
and spray coating. A typical situation is one that requires control of industrial coupled tank system. In order to
fluid to be supplied to a chemical reactor at a constant achieve a robust system, the PID controller parameters
rate. An upper tank can be used for filtering the are designed based on the ITAE performance, while an
variations in the upstream supply flow. anti-windup scheme is added to overcome for the effect
In order to achieve high performance, feedback of saturation due to power limitation of the actuator. The
control system is adopted. Classical Proportional Integral effectiveness of the proposed controller is evaluated
Derivative (PID) controller based is widely used in experimentally using a lab-scale industrial coupled tank
controlling industrial liquid level control application system. The experimental results show that the proposed
[1,2]. Advanced control methods also have been robust anti-windup PID controller is effective for
proposed by several researchers such as sliding mode controlling the level of the industrial coupled tank system
control [3] and nonlinear backstepping control [4]. even if the actuator saturation occurs.
Nevertheless, PID controllers are still widely used in
industrial applications including for process control. The 2. INDUSTRIAL COUPLED TANK SYSTEM
reason is that PID controller has a simple structure which Figure 1 shows the lab-scaled coupled tank system.
is easy to be understood by the engineers who design it. This system consists of two tanks with orifices and level
However aggressive performance requirements may sensors, a DC motor driven pump and a liquid basin. The
not be achievable with the PID controller due to the two tanks have same diameters and can be fitted with
presence of nonlinear dynamics inherent in the liquid different diameter outflow orifices. The input is supplied
control system and system parameter variations caused by a DC motor driven variable speed pump which
by for example corrosive build-up in liquid level systems supplies fluid to Tank 1. The orifice, which is connected
creates variation of cross section areas of the tank and between Tank 1 and Tank 2, allows the fluid to flow into
discharge orifice. One of nonlinearity which exists in Tank 2. The other orifice at Tank 2 flows back the fluid to
© ICME2007 1 AM-62
the liquid basin. Two potentiometers are used to measure The robust control method using optimal adjustment
level of the fluid in the both Tank 1 and Tank 2. of the PID parameters based on the integral of time
multiplied by absolute error (ITAE) performance index is
considered in this paper. Hence the three PID controller
parameters are selected to minimize the ITAE
performance index which will produce an excellent
transient response to a step input reference. The
closed-loop system transfer function that will minimize
the ITAE performance index for a step input for general
have been determined for the following general
closed-loop transfer function [5]:
b0
T (s) = n (4)
s + bn−1s n−1 + " + b1s + b0
The optimum coefficients based on the ITAE
performance index for system of Eq. (4) are given in
Table 1. By designing the PID controller and pre-filter
such that the closed-loop system has a transfer function
of Eq. (4), the closed-loop system has a zero steady-state
Fig 1: Lab-scale couple industrial tanks error to a step input. In addition, since the damping ratio
of 0.7 is used, the system also has a small overshoot.
As most of the feedback control system design
process including classical PID controller design needs Table 1: The optimum coefficients based on ITAE
the dynamics model of the plant as well as its parameters
[5], a mathematical model of the industrial coupled tank s + ωn
system was developed and its parameters are identified
[6]. The developed dynamics model of the tank system is s + 1.4ωn s + ω n2
2

H 2 (s) 3.58 s 3 + 1.75ω n s 2 + 1.4ω n2 s + ω n3


= (1)
V (s) 5169s + 196s + 1
2
s 4 + 2.1ωn s 3 + 3.4ω n2 s 2 + 2.7ω n3 s + ω n4
where V(s) and H2(s) are input voltage of the DC motor
driven pump and level of the second tank. s 5 + 2.8ω n s 4 + 5.0ω n2 s 3 + 5.5ω n3 s 2 + 3.4ω n4 s + ω n5

3. ROBUST ANTI-WINDUP PID CONTROLLER


In summary, the design procedure consists of the
3.1 ITAE-based Robust PID Controller following three steps [5] :
In order to keep a simple classical approach, the (1) Determine the natural frequency ωn of the
performance of a robust control scheme based on a PID closed-loop system based on the desired settling time Ts.
controller with two degrees of freedom consisting of a The following equation describes the relation of settling
PID controller and a pre-filter is adopted. Figure 2 shows time, the natural frequency ωn and damping ratio ζ:
the structure of the proposed controller. The closed-loop 4
transfer is Ts = (5)
ζω n
G f ( s )Gc ( s )G ( s )
T (s) = (2) (2) Determine the three PID controller parameters
1 + Gc ( s )G ( s ) using the appropriate optimum equation (Table 1) and the
The controller Gc(s) is the classical PID controller which ωn of step 1.
has the following transfer function: (3) Determine a pre-filter Gf(s) so that the closed-loop
system transfer function T(s) does not have any zeros as
K d s2 + K p s + Ki
Gc ( s ) = (3) required by Eq. (4).
s
where Kp, Ki and Kd are proportional, integral and 3.2 Anti-windup Strategy
derivative gains respectively. In general, the PID PID control system with the wide range of the
controller Gc(s) is designed to make closed-loop system operations may result in the condition that the control
is robust to parameter variation as well as disturbances. signal reaches the actuator limits. In this case, the
On the other hand the pre-filter Gf(s) is designed to feedback is broken and the system runs as an open loop
achieve a desired input/output transfer function [5]. system since the actuator will remain at its limit
independently of the plant output. Since the controller
Prefilter Controller Plant contains integrator action, the error will be integrated.
R(s) + Y(s)
Gf(s) Gc(s) G(s) This means the integral term become very large or, it is
-
“windup”. Then the error must have opposite sign for the
long time before things returned to normal [7].
In order to reduce the effect of the integrator windup
Fig. 2 Proposed control structure in the PID controller, the PID compensator with tracking

© ICME2007 2 AM-62
anti-windup system is used instead of pure PID The proposed controller is developed in Simulink using
compensator. The structure of the tracking Anti-windup its blocks, and then it is built so that C code is generated,
PID controller is illustrated in Fig. 3 where KT is called compiled and finally a real-time executable code is
tracking gain [7]. Once PID controller output U(s) generated and downloaded to the Target Computer.
exceeds the actuator limits, a feedback signal will be The Target Computer is another personal computer
generated from the difference of the saturated and the which is booted using xPC boot floppy disk that loads the
unsaturated signals. This signal is used to reduce the xPC Target real-time kernel. Subsequently, the generated
integrator input. Mathematically, the output of the real-time executable code is downloaded to the Target
Anti-windup PID controller is Computer via selected communication protocol without
writing any low-level code. The connection between the
⎡ ⎤ Host Computer and Target Computer is accomplished
U ( s ) = ⎢ K p + i + K d s ⎥ E ( s ) − T [U ( s ) − U s ( s )] (6)
K K
either through serial (RS-232) or network (TCP/IP)
⎣ s ⎦ s
communications. The communication interface have to
where KT, U(s) and Us(s) are tracking anti-windup gain,
be defined during xPC setup process in the MATLAB
control output and saturated control output respectively.
since the communication protocol definition is required
To set the value of KT, a rule of thumb point out that
in creating the xPC boot floppy disk for the Target
KT=Ki may give a good results but higher values may
Computer. In the proposed system, serial
give a further improvement in performance [9].
communications is used since it is inexpensive, easy to
Therefore, the performances of the tracking anti-windup
install and requires only a cable for connecting serial
system depend on selecting the suitable value of KT.
ports of the Host Computer and Target Computer.
4. EXPERIMENTAL SETUP
5. CONTROLLER DESIGN
In order to examine the effectiveness of the proposed
The proposed Anti-windup PID controller has to be
controllers, a series of experiment is done using the
designed their parameters to achieve a specific desired
lab-scale industrial coupled system. The experimental
performance of the level control system. In order to
setup is shown in Fig. 4. The proposed robust
realize fast response, the proposed robust Anti-windup
Anti-windup PID control algorithm is implemented on a
PID controller is designed so that the settling time of
personal computer and are operated with 1 ms sampling
closed-loop system is less than 500 sec. Therefore,
time. The MathWork's MATLAB/Simulink is used for
according to Eq. (6), the closed-loop system should have
real-time controller implementation through RTW and
the natural frequency larger than 0.001143. Then the
xPC Target. The RTW environment provides a real-time
natural frequency of 0.05 is selected. As a result, the
operation using personal computers and multifunction
desired optimal closed-loop transfer function is
I/O boards. However, the use of RTW still requires the
1.25 x10 −4
development of custom interface programs for correct T (s) = 3 (7)
communication with multifunction I/O boards. In order s + 8.75 x10 −2 s 2 + 5.38 x10 −3 s + 1.25 x10 −4
to overcome this problem, xPC Target is included in the The three parameters of the PID controller has to be
software configuration. designed is obtained by direct comparison between Eqs.
(2) and (7). As the result, the PID controller parameters
Simulink & xPC are as follows
Target K p = 7.50 , (8.a)
ADC RS232 K i = 0.181 , (8.b)
K d = 71.7 . (8.c)
Target PC Host PC
Furthermore, in order to make the closed-loop system
transfer function has no any zeros, the following
Sensor 1 Sensor 2
pre-filter transfer function is obtained also by comparing
Tank 1 Tank 2
Eqs. (2) and (7):
2.52 x10 −3
G f (s) = 2 . (9)
s + 1.05 x10 −1 s + 2.52 x10 −3
h1
h2 Finally, in order to suppress the effect of actuator
saturation, the tracking anti-windup gain KT equals to Ki
is used.
Driver
Pump 6. RESULTS
Fig 4: Setup of real-time controller implementation The designed robust Anti-windup PID controller is
tested in the real-time experiment. The performances of
The xPC Target software supports and provides the proposed robust anti-windup PID controller are
built-in drivers for many industry standard DAQ card compared with those of the PID control system. Figs. 4, 5
including the PCI-6024E DAQ card by National and 6 show the responses of the PID controllers when the
Instrument which is used in the prototype of the 5 cm, 10 cm and 15 cm step input references were used
automatic gantry crane system. A personal computer is respectively. The detailed performances are shown in
used as a Host Computer. Windows operating system and Table 2. Here, the performances of level control system
other required software are running in the Host Computer. are evaluated based on overshoot, settling and error at

© ICME2007 3 AM-62
500 sec. a larger overshoot of the system controlled by only PID
6 controller. As shown in the figures and Table 2, the
proposed controller significantly reduced the overshoot
Level h2, cm

4 caused by integrator windup due to actuator saturation.


On the other hand, it is also shown in Table 2 that the
2
used of anti-windup does not degrade the performances
PID
in terms of settling time and error. Therefore it can be
PID + Anti-windup
concluded that the proposed robust anti-windup PID
0 controller is effective control the level of Tank 2 even if
0 100 200 300 400 500
Time, s the actuator saturates.
Fig 4: Experimental responses to 5 cm step input
7. CONCLUSIONS
Fig. 4 shows the step responses to a-5 cm step input This paper has introduced the robust anti-windup PID
when the controllers are the level of Tank 2. Their controller for controlling the level of industrial tank
performances are summarized in Table 2. As the system. First the three parameters of the PID controller
reference input is small enough, the 5-cm step input does are designed based on the ITAE performance index. Next,
not cause the saturation of the control signal. Here, all the the pre-filter is designed so that the closed-loop transfer
controllers produce a similar performance in terms of function does not have any zeros. Finally, an anti-windup
overshoot and rise time. However, the error of using the strategy is included in the proposed controller to
proposed controller is slightly higher than that using only compensate for the effect of actuator saturation. The
PID controller. effectiveness of the proposed controller is evaluated
12 experimentally to control the level of Tank 2 of
10 lab-scaled industrial coupled tank system. The results
Level h2, cm

8
confirm that the proposed controller is effective since it
give a good performance even if the actuator saturates.
6
4 PID 8. REFERENCES
2 PID + Anti-windup
1. Visioli, A., 2004, “A new design for a PID plus
0
0 100 200 300 400 500
feedforward controller”, Journal of Process Control,
Time, s 14: 457–463.
Fig 5: Experimental responses to 10 cm step input 2. Tan, K.K., Huang, S. and Ferdous, R., 2002,
“Robust self-tuning PID controller for nonlinear
20 systems”, Journal of Process Control, 12: 753–761.
3. Almutairi, N.B. and Zribi, M., 2006, “Sliding mode
Level h2, cm

15
control of coupled tanks”, Mechatronics, 16:
10 427-441.
5
PID 4. Pan, H., Wong, H., Kapila, V. and de Queiroz, M.S.,
PID + Anti-windup 2005, “Experimental validation of a nonlinear
0 backstepping liquid level controller for a state
0 100 200 300 400 500 coupled two tank system”, Control Engineering
Time, s
Practice, 13:27–40.
Fig 6: Experimental responses to 15 cm step input
5. Dorf, R. and Bishop, R., 2007, Modern Control
Table 2: Performance comparisons System, 11th Ed, Prentice Hall, New Jersey.
6. Wahyudi, Fadhil, M. and Shazri, 2007, “Modeling
Reference Performance Anti-windup PID and Parameters Identification of a Coupled
PID Industrial Tank System”, Proc. National
Conference on Software Engineering and Computer
5 cm Overshoot 8.31% 8.31 % Systems (NaCSES’07).
Settling time 500 sec 498 sec
Error 0.198 cm 0.091 cm 7. Bohn C. and D.P. Atherton, 1994. “A SIMULINK
10 cm Overshoot (%) 4.03% 11.6% Package for Comparative Studies of PID
Settling time 434 sec 500 sec Anti-windup Strategies”, Proc. of IEEE/IFAC Joint
Error 0.186 cm 0.248 cm Symposium on Computer-Aided Control System
15 cm Overshoot (%) 2.60% 33.6% Design, 447-452.
Settling time 302 sec 393 sec
Error 0.065 cm -0.152 cm

Figures 5 and 6 show the step responses to a-10 and


15 cm step inputs when the controllers are the level of
Tank 2. Their performances also are summarized in Table
2. As the reference input is large enough, both step inputs
t cause the saturation of the control signal as indicated by

© ICME2007 4 AM-62

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