Faculty of Engineering

Mechanical Engineering Department

Industrial Process Control

(22MTRN12I)
(Lect.2 )
Dr. Nader A. Mansour
naderabdelwahab@gmail.com
Course Content
PID Controller

PID Controller is the most widely used control

technique.
PID Controller is also called the Three Term
Controller.
PID = Proportional + Integral + Derivative
Each of these terms is a function in the error
signal e(t)
PID Controller

PID Controlled system (Block Diagram)

 Proportional Controller

𝑈 𝑡 = 𝐾𝑝 𝑒 𝑡
is a function of the present value of the error.
The larger the error, the larger the control
action.
Simple to be implemented.
Proportional Controller

Disadvantages
It can’t eliminate the steady state error.
High values of proportional gain reduces the
stability of the system
Proportional Controller

Simulink Model
Proportional Controller

Increasing the controller gain

Fast process response
Steady state error reduced but not eliminated
Too large controller gain
Undesirable degree of oscillation or even
Unstable response
An intermediate value
Best control result
Integral Controller
𝑡
𝑈 𝑡 = 𝐾𝑖 න 𝑒 𝑡 𝑑𝑡
0

Accumulates the past values of the error signal.

If e(t) is non-zero for any length of time, the
control signal gets larger as time goes on.
control action will continue correcting the error
until it vanishes.
Eliminates steady state error.
Integral Controller

Simulink Model
 Integral Controller

Disadvantages
More oscillatory response &
overshoot
For a very slow system the error
signal will accumulate fast and a
large integrator action will be
introduced
this can cause serious overshoots
the system response becomes
more oscillatory
 Integral Controller

Disadvantages
Integral windup
refers to the situation where the integral action
continues to integrate (ramp) indefinitely
This usually occurs when the controller's output can
no longer affect the controlled variable, which in
turn can be caused by controller saturation
Integral Windup

Due to limits of max. input accepted by process

Or max. output that can be created by the actuator.

 uin , if , uin  u0

1 1
uout =  + u0 , if , uin  u0
u_In u_Out
− u , if , u  −u
Saturation  0 in 0
Integral Windup

Effect of Saturation
Damage to the actuator due to the excessive input signals.
Slow down the system behavior.
Nonlinear behavior of the control signal.
Integral Windup

Simulink Model
Anti-Windup Mechanisms

Integrator clamping (conditional integrator)

Stops the integrator term during saturation
Back calculation
Generates feedback signal to modify the integrator value.
Integrator Clamping

Integrator is switched off upon saturation

Integrator Clamping

Simulink Model
Back Calculation

Feedback signal is generated only when the actuator is

saturated
Back Calculation

Simulink Model
 Derivative Controller

𝑑𝑒(𝑡)
𝑈 𝑡 = 𝐾𝑑
𝑑𝑡
It uses the present and past values to predict the
future error signal.
the control action is based on the rate of change of
the error.
Derivative Controller

Avoiding overshoot
 if the error is decreasing too fast that means that the
current control action is very high so it needs to be
decreased substantially to avoid overshoots in the
system.
Braking system
 derivative action is against other actions like the
proportional or the integral actions, so the derivative
action acts as a braking system for the response.
Derivative Controller

Advantages
 Reduces the system oscillations which reduces the
settling time accordingly.
 Quick response for abrupt changes
Derivative Controller

Disadvantages
 Amplifies the high frequency noise
(d/dt(a sin(ωt)) = (a ω cos(ω t)))
thus needs filtering the error signal.
 Derivative Controller

Disadvantages
 Derivative kick problem
ideal derivative with the transfer function = ‘s’ is
not practical, so a system of the following form
is adopted
  Ds 
 
  D s + 1 
 of where  is very small (still has a derivative like behaviour)
Derivative Controller

Simulink Model