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Tuning PID control loops for fast response

When choosing a tuning strategy for a speci c control loop, it is important to match
the technique to the needs of that loop and the larger process. It is also important to
have more than one approach in your repertoire, and the Cohen-Coon method can be a
handy addition in the right situation.
BY LEE PAYNE JULY 1, 2014

The well-known Ziegler-Nichols tuning rules work well only on processes with very long time constants
relative to their dead times, and on level control loops. However, its performance is not good on ow, liquid
pressure, and many other loops that require fast adjustment. In contrast, the Cohen-Coon tuning rules work
well on virtually all self-regulating processes and were designed to give a very fast response.

The method’s original design resulted in loops with too much oscillatory response and consequently fell Magazines and Newsletters
into disuse. However, with some modi cation, Cohen-Coon tuning rules proved their value for control loops
that need to respond quickly while being much less prone to oscillations. SUBSCRIBE
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Applicable process types

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The Cohen-Coon tuning method isn’t suitable for every application. For starters, it can be used only on self- Poll results: Coronavirus, COVID-19 impact
regulating processes. Most control loops, e.g., ow, temperature, pressure, speed, and composition, are, at on engineers and industry
least to some extent, self-regulating processes. (On the other hand, the most common integrating process MARK T. HOSKE
is a level control loop.)

A self-regulating process Robots developed to 3D-print complex

always stabilizes at some shapes
point of equilibrium, which AVNI SHAH
depends on the process
design and the controller
output. If the controller output More answers about robotic applications
is set to a different value, the MARK T. HOSKE
process will respond and
stabilize at a new point of
equilibrium. Coronavirus Survey
Target controller algorithm

Cohen-Coon tuning rules have Coronavirus diagnostic might be tested on

been designed for use on a patient samples soon
non-interactive controller ANNE TRAFTON, JENNIFER CHU, AND DAVID L.
CHANDLER
algorithm such as that
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provided by the Dataforth MAQ 20 industrial data acquisition and control system. There are controllers with
similar characteristics available from other suppliers.
Department of Energy seeking input in
response to COVID-19
Procedure DEPARTMENT OF ENERGY

To apply modi ed Cohen-Coon tuning rules, follow the steps below. The process variable and controller
output must be time-trended so that measurements can be taken from them. Nano strategy ghts superbugs for
1. Do a controller output step test:
wastewater plants
MIKE WILLIAMS

Put the controller in manual and wait for the process to settle out.
Make a step change in the CO (controller output) of a few percent and wait for the PV (process
variable) to settle out. The size of this step should be large enough that the PV moves well clear of
the process noise and disturbance level. A total movement of ve times more than the peak-to-peak
level of the noise and disturbances on the PV should be su cient.

2. Determine the process characteristics (see

Figure 1):

If the PV is not ranged 0-100%, convert the

change in PV to a percentage of the range:
change in PV [in %] = change in PV [in
engineering units] × 100 / (PV upper
calibration limit – PV lower calibration limit).
Calculate the process gain (gp): gp = total
change in PV [in %] / change in CO [in %].
Find the maximum slope of the PV response
curve. This will be at the point of in ection.
Draw a tangential line through the PV
response curve at this point.
Extend this line to intersect with the original
level of the PV before the step in CO.
Take note of the time value at this intersection and calculate the dead time (td): td = time difference
between the change in CO and the intersection of the tangential line and the original PV level.
If td was measured in seconds, divide it by 60 to convert it to minutes. (Since the Dataforth PID
controller uses minutes as its time base for integral time, all measurements have to be made in
minutes or converted to minutes. Many other controllers are similar.)
Calculate the value of the PV at 63% of its total change.
On the PV reaction curve, nd the time value at which the PV reaches this level.
Calculate the time constant (t): t = time difference between intersection at the end of dead time and
the PV reaching 63% of its total change.
If t was measured in seconds, divide it by 60 to convert it to minutes.

3. Repeat steps 1 and 2 three more times to obtain good average values for the process characteristics.

4. Calculate controller settings for a PI or PID controller using the modi ed Cohen-Coon equations below.
(The modi ed rules calculate the controller gain as ½ of that calculated by the original rules.) 

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5. Enter the values into the controller, make sure the algorithm is set to non-interactive, and put the
controller in automatic mode.
Control Systems
6. Change the setpoint to test the new values.
IIoT, Industrie 4.0
Do ne tuning if necessary. The control loop’s response can be slowed down and made less oscillatory, if
needed, by decreasing KC and/or increasing TI. Discrete Manufacturing
Conclusion

These modi ed Cohen-Coon tuning rules are an excellent method for achieving fast response on virtually
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all control loops with self-regulating processes. They are an effective and highly reliable alternative to the
Ziegler-Nichols tuning method, which does not work well when applied to many self-regulating processes. Networking and Security
Lee Payne is CEO of Dataforth.

Additional reading: G.H. Cohen and G.A. Coon, Theoretical Consideration of Retarded Control, Trans. ASME,
Process Manufacturing
75, pp. 827-834, 1953.
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ONLINE
System Integration
To learn more about PID, look for additional application notes at the Dataforth website: www.dataforth.com 

Read more about PID control and loop tuning below. Workforce Development
Key concepts

Cohen-Coon tuning rules are effective on virtually all control loops with self-regulating processes.
They are designed for use on a noninteractive controller algorithm.
The modi ed Cohen-Coon method provides fast response and is an excellent alternative to Ziegler-
Nichols for self-regulating processes.

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Back to Basics: Closed-loop stability
Understanding Derivative in PID Control
The Three Faces of PID

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