Email: mahmoudelshenawy@h-eng.Helwan.edu.eg Telephone: 01224535402 Faculty of engineering, Helwan university Lecture 7
Industrial controllers
2 Different types of industrial controllers 1. Two Position Controller 2. Proportional Controller 3. Integral Controller 4. Differential Controller 5. PI – Controller 6. PD – Controller 7. PID-Controller 8-Intelligent Controller ( Fuzzy , Neural , …) 9-Other Controllers.
3 1-Two position (ON-OFF) controller
• For some systems, on-off signaling is sufficient. For example, a thermostat, when the heater is either on or off, and control systems as airflow or speed control also do it. • Depending on the frequency of control, overhead of on-off, etc, this could cause overshoots and undershoots (ripples) . • Oscillation is a common behavior in control systems Need to avoid it at all costs… well, almost all costs
Two position controller
Two position controller with dead zone
4 Some applications of two position controller
a) Temperature control using ON-OFF controller
open loop temperature control
closed loop temperature control
ON-OFF controller operation and the system response
5 Some applications of two position controller
b) Level control using ON-OFF controller
Plant: water tank water q1(t)
Input: water flow piston Output: water level h (t ) Expected value: h lever float Sensor: float 0
Controller: lever h0 Actuator: piston h(t)
Controller Actuator Plant
h0 threshold q1 (t ) Water h(t ) Lever Piston Tank q2(t)
Float Sensor The Controller as a System • We usually specify a value we want some output of the system to have , usually called the Setpoint (SP) • The set point can be motor speed, temperature of a room, level in a tank, flow rate in a pipe… • The value can be fixed, or may change with time ( tracking or time table) • We need some kind of control input which can create changes in the behavior of the process • Can be a heater, a valve, a pump… • Typically it is not the same physical quantity as what we are controlling • If we knew exactly how the process worked, we would know what the output would be for a given control input… • Most of the time we don’t know exactly, so we need to measure what the process does – Usually called Measured Variable (MV) or Process Variable (PV) The Controller as a System • Now we have a measurement (MV), some value that we want it to be (SP), and some way to make changes to the process (control input) • We can ‘close the loop’ • Now we can see that any controller can be thought of as a system that takes a setpoint and a measured value as inputs, and gives a control signal as an output
SP Control Controller MV
• The controller needs to convert two signals of one physical quantity (such as temperature) into one signal of another (such as valve position) The Controller as a System • We know that the process is a dynamic system: – Its outputs depend on current inputs as well as its past state • For the controller to deal with this, it makes sense that it should be a dynamic system too • Very often we can think of the controller acting on the difference between SP and MV:
+ error SP Σ Controller Process -
MV Classic closed loop block diagram representation of a control system The Controller as a System • We said that since the process is dynamic (dependent on inputs made at different times), it makes sense that the controller should be too • How do we usually think of time? – ‘Present’ – ‘Past’ – ‘Future’ The Controller as a System The Present • This part of the controller is only concerned with what the error is now • Let’s take a simple law: let the control signal be proportional to the error: 𝒖 = 𝒌𝒑 × 𝒆 The past • This part of the controller is only concerned with what is the error past. • We can let the control be given by the sum of past values of the error, scaled by some gain. In continuous time the sum is an integral: 𝒕 𝒖 = 𝒌𝒊 න 𝒆 𝒕 𝒅𝒕 𝟎 The future • This part of the controller is only concerned with what the error will be in future. • Let’s let the control be dependent on the derivative of the error: 𝒅𝒆(𝒕) 𝒖 = 𝒌𝒅 𝒅𝒕 The Controller as a System 𝒕 𝒅𝒆(𝒕) 𝒖 = 𝒌𝒑 𝒆 𝒕 + 𝒌𝒊 න 𝒆 𝒕 𝒅𝒕 + 𝒌𝒅 𝟎 𝒅𝒕
Proportional + e u SP Σ Integral Process - Derivative
- advantages of p-controller are : simplicity and fast response.
-Drawback is : it does not eliminate the steady state error .
13 Characteristics of proportional controller
14 3-Integral controller
This controller is called an integral controller because it approximates the
mathematical function of integration. The integral control method is also known as reset control. . It is commonly used in industries to eliminate the steady state error. . Time equation is : p(t ) = k i e(t )dt where KI is the integral constant.
. The controller transfer function is: T .F = k i
Electronic circuit of the integral controller
= 1 I-controller block diagram k i Rc 15 Advantages and disadvantages of integral controllers
. The major advantage of integral controllers is that they have the unique ability to return the controlled variable back to the exact set point following a disturbance (i.e, eliminating ess).
. The disadvantages of the integral control mode are that it responds relatively slowly to an error signal and that it can initially allow a large deviation at the instant the error is produced which might lead to system instability and cyclic operation. For this reason, the integral control mode is not normally used alone, but is combined with another control mode.
Characteristics of integral controller
16 4-Derivative Controller . It cannot be used individually in industries, but it is usually used with other controllers. . Time equation is: de(t ) p (t ) = k d dt
where Kd the differentiation constant.
Electronic circuit and gain of the derivative
D-controller block diagram controller.
Where : Kd= R C
The controller T.F is :
T .F = k d s 17 The important advantage of the derivative controller is that it has a fast response; on the other hand it does not eliminate the steady state error in addition to amplifying the disturbances.
Characteristics of derivative controller
18 5-Proportional-Integral controller
Time equation is : p(t ) = k p e(t ) + k i e(t )dt
The PI-controller transfer function is : T .F = + k i
k p s
where Kp is the proportional constant and Ki is the integral constant.
The block diagram of the PI controller The PI - controller electronic
circuit.
19 Characteristics of PI controller
20 6-Proportional-Derivative controller
. It is commonly used in industries. de(t )
. Time equation is p(t ) = k p e(t ) + k d dt The PD-controller transfer function is : T .F = k p + k d s where Kp is the proportional constant and Kdis the derivative constant. . The block diagram of the PD controller is :
PD-controller block diagram The PD - controller electronic circuit
. It is commonly used in industries and can be considered as the most powerful controller. . Time equation is: de(t ) p (t ) = k p e(t ) + k i e(t )dt + k d dt T .F = + k i + kd s k p s where Kp is the proportional constant, KI is the integral and Kd is the derivative constant. . The block diagram of the PID controller is :
PID-controller block diagram
PID- controller electronic circuit
22 Characteristics of PID controller
23 Effects of Coefficients and the characteristics of P, I, and D controllers
24 Controllers Tuning
25 Controller Tuning Methods
1-Manual tuning method (trail and error).
2-Ziegler–Nichols tuning method.
3- PID tuning software methods using Matlab.
26 PID Controller Tuning •PID Controllers are everywhere! Due to its simplicity and excellent.
•PID controllers are used in more than 95% of closed-loop industrial processes.
• PID Can be tuned by operators without extensive background in Controls, unlike many other modern controllers that are much more complex but often provide only slight improvement.
K = p T K i i is int egration time cons tan t
K T =K d d
p is derivative time cons tan t
27 1-Manual Tuning Method How do the PID parameters affect system dynamics? Four major characteristics of the closed-loop step response.
1.Rise Time: the time it takes for the plant output y to rise beyond 90% of the desired level for the first time.
2.Overshoot: how much the peak level is higher than the steady state, normalized against the steady state.
3. Settling Time: the time it takes for the system to converge to its steady state.
4.Steady-state Error: the difference between the steady-state output and the desired output. The effects of increasing controller parameters
28 1-Manual Tuning Method
In manual tuning method, parameters are adjusted by watching system responses. Kp, Ki, Kd are changed until desired or required system response is obtained. Although this method is simple, it should be used by experienced personal.
29 1-Manual Tuning Method
50% steady- state error and over damping case 4 1 s2+2s+4 Constant Transfer Fcn Scope
System Response Without Controller
System response with PID controller
Kp=1.3 , ki=2.244 , kd=1.818 steady state error=0. Only
30 one oscillations before steady state. 2- Ziegler and Nichols tuning of PID In the this method, we first remove the I and D controllers and using the proportional control action only (see Figure , increase Kp from 0 to a critical value Kcr at which the output first exhibits sustained oscillations. (If the output does not exhibit sustained oscillations for whatever value Kp may take, then this method does not apply.) Thus, the critical gain Kcr and the corresponding period Pcr are experimentally determined (see Figure ). Ziegler and Nichols suggested that we set the values of the parameters Kp , Ti , and Td according to the formula shown in Table.
Closed Loop Control System with P Controller Only system response at Kcr
31 2- Ziegler and Nichols tuning of PID
T .F = + k i + kd s k p s
Kp= R2/R1 Ki= 1/RiCi Kp= RdCd
32 3- PID tuning software methods.
Using tune option in PID controller block
By clicking the tune option in PID controller block , MATLAB software is automatically linearized the system and tuned the controller.
