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How to Improve your PID Controller

Javier Gutierrez
LabVIEW Product Marketing

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 Benefits of Advanced Control and Tuning
Model-based Manual
• A poorly tuned control control < 1% control

valve costs additional

$880/year*
• A bad pH loop incurred
chemical waste of
$50,000/month*
• A bad kiln temp loop cost
$30,000/month* PID needs
PID is fine
manual tuning

*Sources: Cybosoft and ExperTune

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Agenda
• What is PID?
• How to improve performance
 Hardware considerations
 Upgrade PID Algorithm
 Advanced Controllers
• Conclusion

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Agenda
• What is PID?
• How to improve performance
 Hardware considerations
 Upgrade PID Algorithm
 Advanced Controllers
• Conclusion

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What is PID
• Set Point (SP) – Desired control point
• Output (OP) – Controller output
• Process Variable (PV) – Plant/process output
• Error = SP - PV

error OP
SP PV

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PID Parameters
• Proportional
 Drive to setpoint
 Error → 0, OP → 0
 “Steady-state error”
• Integral
 Eliminate steady state error
 OP proportional to ∫ error
• Derivative
 Increase response rate
 OP proportional to rate of change of error

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System to control

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Control System Diagram
Temperature Control System
LabVIEW
PID cFP-PWM-520
Front Panel
Toolset Cold Air

Desired Error PID Heater Temp

+-
Temp 20 ºC Compensator Output Chamber
120 ºC 62%
Thermocouple
Measured Sensor
100 ºC Temp
cFP-TC-120
NI LabVIEW

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PID Implementation Demo DEMO

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PID Control – Pros and Cons

• Advantages
 Proven
 Easy to implement
• Disadvantages
 Not easy to tune
 Not suitable for all systems
• Backlash, friction, and so on

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How to program PID

Function Blocks
Windows/Real Time

FPGA Control and Simulation

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Agenda

• What is PID?
• How to improve performance
 Hardware considerations
 Upgrade PID Algorithm
 Advanced Controllers
• Conclusion

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Benefits of Higher Loop Rates

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 PID Loop rates
FPGA

RT PXI

cRIO 1 MHz

cFieldpoint 100 kHz

Desktop
25 kHz

600 Hz
100 Hz
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 Die Casting Machine
The movement of the aluminium injection plunger controlled in a steady
closed loop at a speed varying from 0 up to 10 m/sec.

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Copyright 2007 © EUROelectronics srl – ITALY -
Agenda
• What is PID?
• How to improve performance
 Hardware considerations
 Improve PID Algorithm
 Advanced Controllers
• Conclusion

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Upgrade your PID

Disturbances Feed-forward
Non Linear Gain Scheduling
Time Variant Adaptive PID

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Feed-Forward
• Commonly used to compensate for a
measurable external disturbance before it affects
a controlled variable.
• e.g. product feed rate changes

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Feed-Forward Example

FeedFordward

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Gain Scheduling

PID 3

PID 2

PID 1

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 Gain Scheduling DEMO

• Used to change gain on real-time depending on

OV.
PID
• Bumpless transfers

Gains
Select Gains

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Adaptive PID DEMO

• Mixed of On-Line system identification and

common PID control.
• Can handle time-variant systems

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Agenda
• What is PID?
• How to improve performance
 Hardware considerations
 Upgrade PID Algorithm
 Advanced Controllers
• Conclusion

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Advanced Controllers

National Instruments

●
Optimal Controllers (LQR, LQG)
●
Model Predictive Control (MPC)
●
Kalman Filters
●
Fuzzy Logic

Third Party Partners

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Neural Networks
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Genetic Algorithms
●
Model Free Adaptive

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How to create an advanced Controller

●
Datalogging
●
System Identification
●
Model Validation

Plant Modeling

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 Example v e u v
+
C
Cruise Control
-

V:Velocity u PID - Feedback

umax
u:Gas to Engine u

PID: ‘C’ takes v Time

action when vmax

v
‘V’ is off the
vmin
setpoint. (e <>0)
Time

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MPC C
V

v V
u v
‘C’ takes action
due to future
changes in: umax
u

a)Road slope u

b)Speed Setpoints
Time
v
and Speed-Gas vmax
limits v

vmin

Time

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Temp Chamber - Experiment

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Plant Modeling - Validation

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MPC Control Design

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MPC Control Prototype DEMO

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Tyco Electronics implemens Model Predictive Control in
production Process
Application: Control coating quality
when building electrical cable.
Challenge: Develop a process
control that can handle MIMO
systems with big delays
Products: cFieldPoint, DSC, Control
Design and Simulation.
Key Benefit: Use a common platform
to develop controller and deploy
system able to integrate third
party information systems.

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Advanced Controllers
• Pros
 MIMO
 Improved performance
• Cons
 Model Needed
 Engineering Skill

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Agenda
• What is PID?
• How to improve performance
 Hardware considerations
 Upgrade PID Algorithm
 Advanced Controllers
• Conclusion

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Conclusions
• PID
• Consider
 Upgrading hardware
 Enhance PID Algorithm
 Upgrading Control Algorithm

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