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What is Reset Windup

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Nigar Hesenova
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12 views

What is Reset Windup

Uploaded by

Nigar Hesenova
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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What is Reset Windup?

 Reset windup happens when the integral part of a controller keeps over-
integrating , even though the controller’s output has already reached its limit.
 For example:
o If the controller output is stuck at 100% (fully open valve) or 0% (fully
closed valve), it cannot do anything more to fix the process.
o But the integral part keeps "working," building up unnecessary action.

2. Why is it a Problem?
 The "extra integration" causes problems when the error starts to reverse
(e.g., the process variable moves past the setpoint):
o The controller has to "undo" all that extra integration (unwind) before it
can control the process again.
o During this time, the system might overshoot (go too far past the
setpoint in the opposite direction) because the controller is "stuck
unwinding" and isn’t responding fast enough.

3. What is Unwinding?
 Unwinding is when the controller removes the extra integration it built up
during windup.
 It happens when the error changes direction (e.g., the process variable
crosses the setpoint).
 During unwinding:
o The controller reduces its output back into the normal range (0% to
100%).
o However, this takes time, and the controller cannot properly control
the process until it finishes unwinding.

4. Why Does Overshoot Happen?


 While the controller is unwinding, the valve or actuator cannot respond
quickly because the output is still outside the normal range.
 The process variable keeps moving further past the setpoint, causing
overshoot.
Example:
 If you're heating water to 50°C, the controller might overshoot to 55°C while
it unwinds the extra integration.

5. How to Prevent Reset Windup?


 Install windup protection to stop the controller output from going beyond
its normal range (e.g., 0% to 100%).
 This prevents unnecessary integration when the controller can't do anything
more, making the system more stable.

In short:
 Reset windup = Controller "over-integrates" the error and builds up
unnecessary action.
 Unwinding = Controller gradually cancels the extra action when the error
reverses, but this delay causes overshoot.
 Fix = Add windup protection to keep the controller output in its normal
range.

What does it mean when the error "starts to reverse"?


 Error is the difference between the setpoint (desired value) and the process
variable (actual value).
o If the process variable is too low, the error is positive (we need to
increase it).
o If the process variable is too high, the error is negative (we need to
decrease it).
 When the process variable crosses the setpoint, the error changes
direction (its sign reverses):
o Example: If you're trying to maintain 50°C, and the temperature was
at 40°C (positive error), but then overshoots to 55°C (negative error),
the error has reversed.
What happens when the error reverses?
 The controller must now adjust in the opposite direction to bring the
process variable back to the setpoint.
 But because the integral part over-integrated during windup, it first has to
"unwind" all the extra action it built up before it can respond to the new error.

Why is this a problem?


 While the controller is busy "unwinding," it cannot properly control the
process.
 This delay allows the process variable to overshoot further in the opposite
direction before the controller regains control.

Why Doesn't a Limiter Solve the Problem?


 Adding a limiter (to restrict the output to 0%–100%) stops the controller
output from exceeding these limits, but it doesn’t stop the integral part of
the controller (the "reset element") from over-integrating.
 Even with a limiter, the integral action keeps accumulating error inside the
controller and can still "wind up" to values like +107% or -7%.
 The limiter only affects what goes to the valve (fully open or fully closed), so
it doesn’t fix the root cause of the problem: the integral action itself.

What is Reset Windup Protection?


 Reset windup protection is a mechanism that stops the integral action from
building up unnecessarily when the controller output hits its limit.
 It directly prevents the reset element (integral action) from integrating
further when the controller reaches 0% or 100%.

How Does Reset Feedback (RFB) Work?


 The RFB system monitors the controller output.
 When the output hits its limit (0% or 100%), the RFB stops the integral
action from continuing.
 This means the integral part freezes and doesn’t keep adding up error,
preventing windup altogether.

Why Is RFB Better?


 Unlike a simple limiter, RFB addresses the root problem: the integral action
itself.
 By stopping unnecessary integration, it avoids the delay caused by unwinding
and improves system stability.
In short:
 A limiter restricts the output but doesn’t stop the integral part from winding
up.
 Reset windup protection (like RFB) stops the integral from over-integrating,
fixing the actual issue.

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