aut omat ion.isa.org http://automation.isa.

org/2011/12/how-do-you-know-when-feed-forward-is-needed/
Bl ock di agram of a typi cal PID control system. But how do
you know when feed-forward i s needed?
How do you know when feed-forward is needed?
This guest post is authored by Greg McMillan.
In the ISA Automation Week Mentor Program I am providing guidance f or extremely talented individuals f rom
Argentina, Brazil, Malaysia, Mexico, Saudi Arabia, and the USA. We will be sharing a question and the
answers each week. If you would like to provide additional answers, please send them to Susan Colwell at
ISA.
The third question f rom Hector Torres in Mexico is:
How do you know when a f eed-f orward signal is
needed? What characteristics should a f eed-f orward
signal have? How does the lag and dead time get
taken into account?
1. If on a trend recording a change in an input f low
or speed (load) associated with a primary process
loop causes a signif icant change in the primary
process variable, there is an opportunity f or
f eedf orward if the primary loop manipulates a secondary loop f low or speed. If the primary loop
manipulates a valve, the f eedf orward gain is generally too nonlinear unless there is the valve has
linear trim and a constant pressure drop. If the f eedback time delay (primary loop deadtime) minus
the f eedf orward time delay is positive, a f eedf orward correction arrives early possibly causing
inverse response. The primary f eedback time delay can be observed by momentarily putting the loop
in manual and making a step change in output and then immediately putting the primary controller
back in auto and noting the time delay till a change in the primary process variable. The f eedf orward
time delay can be observed as the time delay between the start of the load change and the start of
the process variable change with the primary loop in manual. To ensure the correction arrives in the
process at the same time as the load change, the f eedf orward signal should be passed through a
deadtime block whose deadtime is the dif f erence between f eedback and f eedf orward time delays f or
dynamic compensation of the f eedf orward f or deadtime. If the dif f erence is negative (f eedback time
delay smaller than f eedf orward delay), the f eedf orward arrives late and dynamic compensation is not
possible to make it arrive sooner. For a late f eedf orward, the f eedf orward gain should be reduced by
the ratio of this negative dif f erence to the f eedback loop deadtime. As the dif f erence approaches
the loop deadtime, the f eedf orward gain approaches zero.
2. The computation of lead-lag dynamic compensation is more complicated than realized. Most of the
control literature incorrectly shows the measured disturbance entering downstream of the process
directly into the measured primary process variable. Since most load disturbances enter as a
process, the computations f or dynamic compensation by lead-lag is more complicated. I would f irst
get the deadtime dynamic compensation right. If the response to a load change is in the same
direction without the f eedf orward, the f eedback lag is larger than the f eedf orward lag. A lead-lag can
be added to reduce the deviation f or the load change. The lead should be gradually increased. A lag
should be f irst added that is 1/10 of the lead to smooth out noise that is amplif ied by the lead.
Pages 222 232 in Shinskeys Process Control Systems 4
th
edition of f ers details on the dynamic
compensation of f eedf orward signals f or load disturbances.
3. The f eedf orward gain is the ratio of the change in controller output (without f eedf orward) to the
change in the f eedf orward signal. The ratio calculation should be in the engineering units of the
f eedf orward and controller output. The f eedf orward signal scale should be set to match the
controller output scale. The operator should be allowed to enter a ratio setpoint that becomes the
f eedf orward gain. The operator should see the actual ratio as well. The ratio setpoint should be
adjusted to eliminate any persistent dif f erence between the actual ratio and the ratio setpoint.
4. Contrary to what is of ten portrayed in the control literature, a f eedf orward multiplier is of ten more of
a problem than a solution because of scaling and measurement errors and the nonlinearity
introduced. The possible exception is the ratio control of inline plug f low systems (e.g. extruders)
and sheet lines with high accuracy and rangeability f low and/or speed measurements. Here the
nonlinearity of the f eedf orward multiplier compensates f or the nonlinearity of the processs
composition and temperature response. For most other systems, a f eedf orward summer is more
f orgiving, compensates f or bias errors in measurements, and keeps the controller gain more
constant. The controller gain is proportional to the ratio of the process time constant to the open
loop gain. Most people dont realize that in the control of temperature and composition in volumes
with some degree of mixing, the process time constant and the open loop gain are both inversely
proportional to total f low. A f eedf orward summer simply biases the computed f eedf orward
(f eedf orward signal af ter dynamic compensation and multiplication by the f eedf orward gain) so that
the process gain retains the inverse relationship with f low.
For more inf ormation check out the Match/April 2011 InTech article Feedf orward enables f lexible
sustainable manuf acturing
Demo-Seminar Feedf orward Control (Deminar#11)
Post Flexible Manuf acturing
Post Smart Adaptive Feedf orward
Post Universal Concept Bias