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Control Systems
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u r Dr. S. S. OHOL,

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Associate Professor,
Mechanical Engineering Department,

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Faculty coordinator Robot Study Circle ,

t u College of Engineering , Pune – 411 005.

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Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 1
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Content o n
 Control System Engineering
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 Steady State Error
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 Open Loop Control
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 Closed Loop Control – Types , PID
 Method of PID Control

u d  PID + Positional Feedback

S t  Ziegler–Nichols method
 Limitations of PID Control

o r  Summary

F Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 2
 Control System Engineeringnly
e o
o s
 Control Systems Engineering is the engineering approach taken
to understand how the process can be managed by automation

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devices and to implement such into operation.

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 Control engineering or control systems engineering is
an engineering discipline that applies control theory to design

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systems with desired behaviors in control environments.

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Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 3
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Steady-state error
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Steady-state error is
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defined as the difference
between the input
p o
(command) and the output
of a system in the limit as
u r
time goes to infinity (i.e.
when the response has
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reached steady state).
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u d
S t
The steady-state error will
depend on the type of input

o r
(step, ramp, etc.) as well as
the system type (0, I, or II).

F Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 4
 Open-Loop Control
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 Open-loop refers to a control technique that does not
measure and act upon the output of the system. Most o n
piezoelectric systems and inexpensive micrometer-
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replacement actuators are open-loop devices.

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 Open-loop positioners are useful when remote control is

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critical components by touching them. r
desired for improved accessibility or to avoid disturbing

well.
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 Stepper and ministepper motors often use open-loop as

Closed-Loop Control

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 Closed-loop refers to a control technique that measures the

S t
output of the system compared to the desired input and takes

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corrective action to achieve the desired result.
 Electronic feedback mechanisms in closed-loop systems enhance

F the ability to correctly place and move loads.

Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 5
 Closed-Loop Control Techniques
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 Proportional Control (Gain factor Kp) – It multiplies

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the error signal and uses it as a corrective signal to the
motion system. It exaggerate the error and react n
Basic Control
immediately to correct it.

s e
 Integral Control (Gain factor Ki) – It accumulates the

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error signal over time, multiplies the sum by a gain factor
Ki and uses the result as a corrective signal to the motion
Actions
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system. The integral gain has an important negative side
effect. It can be a destabilizing factor for the control loop.
Large integral gains or integral gains used without proper

1) On / Off u
damping could cause severe system oscillations. Integral

P
term yields zero steady-state error in tracking a constant
setpoint. It also rejects constant disturbances
2) P-I
dy  Derivative Control (Gain factor Kd) - It reduces
transient errors. A control technique that multiples the
3) P-D
4) P-I-D
t u rate of change of the following error signal by a user-
specified gain Kd and uses the result as a corrective signal

r S to the motion system. Increasing the value of Kd increases

the stability of the system.

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Proportional-Integral-Derivative (PID) control provides an efficient
solution to many real-world control problems

Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 6
 System under Control ly
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p o
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S t
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F Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 7
 Controller action for Systemn ly
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P u
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Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 8
 Control -PID + Positional Feedback ly
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F Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech)
Courtesy - Newport Corporation
9
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o n
s e
where
Kp: Proportional gain, a tuning parameter
p o
Ki: Integral gain, a tuning parameter
Kd: Derivative gain, a tuning parameter:
u r
Error e = SP − PV

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t = Time or instantaneous time (the present)

u d
S t
o r
F Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 10
 PID Control ly
 There are several methods for tuning a PID loop. The most effective methods
o n
generally involve the development of some form of process model, then

s
choosing P, I, and D based on the dynamic model parameters. Manual tuning e
o
methods can be relatively inefficient, particularly if the loops have longer

p
r
response times on the order of minutes or longer.
Manual tuning

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 If the system must remain online, one tuning method is to first

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set Ki and Kd values to zero. Increase the Kp until the output of the loop
oscillates, then the Kp should be set to approximately half of that value for a

d
"quarter amplitude decay" type response.

u
S t
 Then increase Ki until any offset is corrected in sufficient time for the process.
However, too much Ki will cause instability. Finally, increase Kd, if required,

r
until the loop is acceptably quick to reach its reference after a load disturbance.
However, too much Kd will cause excessive response and overshoot.

Fo
 A fast PID loop tuning usually overshoots slightly to reach the set-point more
quickly; however, some systems cannot accept overshoot, in which case an over-
damped closed-loop system is required, which will require a Kp setting
Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 11
significantly less than half that of the Kp setting causing oscillation.
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Ziegler–Nichols method
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 PID tuning software
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 Modifications to the PID algorithm

p o
Integral windup where a large change in set-point occurs

u r
(say a positive change) and the integral term accumulates an
error larger than the maximal value for the regulation

P
variable (windup), thus the system overshoots and
continues to increase as this accumulated error is unwound.

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Overshooting from known disturbances The integral

u d
function of the controller tends to compensate this error by
introducing another error in the positive direction.

S t
Replacing the integral function by a model based part
Derivative of output

o r Set-point ramping
Set-point weighting

F Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 12
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PID Tuning---First Method
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FTransfer Function of PID Controller Tuned Using the First Method
Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 13
 Limitations of PID control ly
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 PID controllers are applicable to many control problems, can perform poorly in some
applications. The fundamental difficulty with PID control is that it is a feedback system,
with constant parameters, and no direct knowledge of the process, and thus overall

p o
performance is reactive . PID control is the best controller with no model of the process,
better performance can be obtained by incorporating a model of the process.

u r
 The most significant improvement is to incorporate feed-forward control with

P
knowledge about the system, and using the PID only to control error. Alternatively, PIDs
can be modified in more minor ways, such as by changing the parameters (either gain

dy
scheduling in different use cases or adaptively modifying them based on performance),
improving measurement (higher sampling rate, precision, and accuracy, and low-pass
filtering if necessary), or cascading multiple PID controllers.

t u
 PID controllers, when used alone, can give poor performance when the PID loop gains

r S
must be reduced so that the control system does not overshoot, oscillate or hunt about
the control set point value. They also have difficulties in the presence of non-linearities,

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may trade-off regulation versus response time, do not react to changing process behavior
(say, the process changes after it has warmed up), and have lag in responding to large

F disturbances.

Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 14
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Linearity
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 Another problem faced with PID controllers is that they are linear, and in particular symmetric.
Thus, performance of PID controllers in non-linear systems (such as HVAC systems) is variable.

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For example, in temperature control, a common use case is active heating (via a heating element)
but passive cooling (heating off, but no cooling), so overshoot can only be corrected slowly – it

u
cannot be forced downward. In this case the PID should be tuned to be over-damped, to prevent
or reduce overshoot, though this reduces performance (it increases settling time).

P
Noise in derivative
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t u
 A problem with the derivative term is that small amounts of measurement or process noise can
cause large amounts of change in the output. It is often helpful to filter the measurements with

r S
a low-pass filter in order to remove higher-frequency noise components. However, low-pass
filtering and derivative control can cancel each other out, so reducing noise by instrumentation

o
means is a much better choice. Alternatively, a nonlinear median filter may be used, which
improves the filtering efficiency and practical performance. In some case, the differential band can

F be turned off in many systems with little loss of control. This is equivalent to using the PID
controller as a PI controller.
Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech) 15
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Summary
o n
 PID control--- At present most widely used control strategy.
s e
p o
u
derivative gain set to zero (PI control) r
 Over 90% of control loops employ PID control, often the

y P
 The three terms ( Kp, Kd & Ki ) are intuitive. It does not

u d
require the operator to be familiar with advanced math to
use PID controllers

S t
r
 Engineers prefer PID controls over untested solutions

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Dr. S S Ohol, Mechanical Engg. Dept., COEP Technological University Pune (COEP Tech)
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