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In this paper, first we analyze why the conventional PID controller is not suitable to control
integrating processes mathematically and intuitively. To overcome its structural limitation,
we add an internal feedback loop, which can convert the integrating process to an open-loop
stable process. Second, we propose a new and simple on-line process identification and
autotuning method for the integrating process. Here we use only the process input and output
to obtain a process transfer function directly, while other previous closed-loop identification
methods require the information of the closed-loop control structure. This identification method
can be applied not only to integrating processes but also to all those encountered in chemical
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engineering processes which are open-loop stable or unstable. From simulation studies, we can
recognize that, in spite of its simplicity, the proposed on-line process identification and autotuning
method shows not only good model accuracy but also superior control performances for both
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servo and regulatory problems. It also gives strong robustness to measurement noises and
disturbances.
the conventional PID controller, including Marlin’s are the desired output trajectory and closed-loop time
method (1995), have a structural limitation in control- constant, respectively, kc, τi, and τd are the proportional
ling the integrating process (this will be discussed in gain, integral time, and derivative time of the PID
section 2). That is, all previous control methods with controller, respectively, and ai and bi are arbitrary
only the PID controller show poor control performances constants. Note that a long time delay can be ap-
for the integrating process inevitably. Therefore, a new proximated by a rational polynomial accurately as much
control strategy should be developed to control it ef- as desired so that (2) can represent a large time delay
ficiently. process effectively. Thus, (2) can be considered as a
In this paper, we analyze the structural limitation of general form of all actual linear processes.
the PID controller in controlling the integrating process If a perfect tracking is assumed, the left-hand and
in section 2. On this basis, we develop a control strategy right-hand side of (4) can be rewritten like (5) and (6),
( )
using an internal feedback loop to overcome this limita-
tion. In sections 3 and 4 we propose an on-line process anys(-1)n+1
identification method to obtain a high-order rational t
exp -
polynomial model and corresponding PID tuning rule
+
n τdesired
( )
τdesired
with model reduction to tune the PID controller auto-
matically for the integrating process. an-1ys(-1)n t
The proposed on-line process identification method exp - + ... +
and control strategy are very simple and guarantee on- τdesiredn-1 τdesired
( ) ( )
line operation and show a good model accuracy and
superior control performances simultaneously for both a1ys(-1)2 t t
the set-point tracking and disturbance rejection problem exp - - ys exp - +
τdesired τdesired τdesired
( )( )
compared with previous control methods.
The cores of the paper are the identification method n ai(-1)i+1
t
for the automatic tuning of PID controllers and justifi-
cation to use the internal feedback loop in controlling
ys ) ys + ys exp -
τdesired
∑ - 1 (5)
i)1 (τdesired)i
integrating processes. Other techniques such as model
{
reduction and tuning are also described in detail for
dm(ys - y)
completeness in constructing an autotuner.
bmkc +
dtm
}
2. Analysis on Structural Limitations of PID
Controllers 1 dm dm d(ys - y)
In general, the PID controller is structurally suitable τi dt m
∫0
t
(ys - y) dt + τd
dt
+
dtm
{
and shows an acceptable control performance for open-
dm-1(ys - y) 1 dm-1
loop stable processes. On the other hand, it is inher-
ently difficult to control the integrating process with it bm-1kc + ∫0
t
(ys - y) dt +
dtm-1 τi dt m-1
} {
efficiently. The reasons why it is not suitable to control
the integrating process are discussed from mathematical dm-1 d(ys - y) d(ys - y)
as well as intuitive viewpoints in this section. τd + ... + b1kc +
dtm-1 dt dt
}
The following mathematical analysis would show the
structural limitation of the PID controller in controlling
1 d d d(ys - y)
the integrating process. From this analysis we can
conclude that the PID controller cannot match the τi dt
∫ t
0 s
(y - y) dt + τd
dt dt
+
{ }
process output with a desired trajectory inherently.
For an open-loop stable process controlled by the 1 d(ys - y)
conventional PID controller, consider the following b0kc (ys - y) +
τ
∫ t
0 s
(y - y) dt + τd
dt
)
( )(
desired output trajectory (eq 1), general linear time- i
invariant process transfer function (eq 2), PID controller 1 Am Am-1 A2
output (eq 3), and general nth-order differential equa- exp - + + ... + +
m
tion (eq 4). Here it should be noted that the following τdesired τ τdesiredm-1 τdesired2
) ( )∑
desired
statements are valid for the first-order desired trajectory
of (1) as well as an overdamped or an underdamped A1 t m Ai
high-order desired trajectory where ydesired and τdesired + A0 ) A0 + exp - (6)
τdesired τdesired i)1(τ
i
desired)
ydesired ) ys - ys exp(-t/τdesired) (1)
1
A0 ) b0kcysτdesired (7)
bmsm + bm-1sm-1 + ... + b1s + b0 τi
Gp(s) ) (2)
ansn + an-1sn-1 + ... + a1s + 1
respectively, by substituting (1) for y and (3) for u in
kc d(ys - y) (4), where Ai are some constants. Note that the constant
u(t) ) kc(ys - y) +
τi
∫0t(ys - y) dt + kcτd dt
(3) term (eq 7) is generated from the integral term of the
PID controller. By comparison of (5) and (6), it is clear
that the left-hand and right-hand sides of (4) have the
dny dn-1y dy same structure: a constant term plus an exponential
an + an-1 n-1 + ... + a1 +y)
dt n
dt dt term. Therefore, we can recognize that it is possible to
satisfy the equality of (4) by choosing appropriate tuning
dmu dm-1u du parameters. Thus, at least, the desired trajectory can
bm m + bm-1 m-1 + ... + b1 + b0u (4)
dt dt dt be achieved from the viewpoint of the structure.
Ind. Eng. Chem. Res., Vol. 36, No. 12, 1997 5331
We can repeat the previous procedure for the inte-
grating process with the assumption of a perfect track-
ing. As explained previously, the integrating process
can be represented by the general form
dn+1y d ny d2y dy
an an-1 ... a1
dt2 dt
+ + + + )
dtn+1 dtn
dmu dm-1u du
bm m + bm-1 m-1 + ... + b1 + b0u (9) Figure 1. Typical closed-loop response of an integrating process
dt dt dt
controlled by the conventional PID controller.
τdesired ( )
anys(-1)n+2
n+1
exp -
t
τdesired
+
an-1ys(-1)n+1
τdesired n
×
Notice that the integral term from the initial time to
the time corresponding to the steady state should go to
zero to guarantee a zero offset in the end for the
( ) ( )
integrating process. On the other hand, because the
t a1ys(-1)3 t process has a time delay or nonminimum phase zero,
exp - + ... + exp - + achievable control performances are confined due to the
τdesired τdesired2 τdesired stability condition. The integral term from the initial
( )
time to the rise time becomes some large positive value
ys(-1)2 t for a positive step set-point change as shown in Figure
exp - ) 1. Therefore, this accumulated integral term to the rise
τdesired τdesired time should be decreased to zero by allowing a large
( )( )
overshoot inevitably as shown in Figure 1 since the final
n+1a i+1 integral term should be zero as shown in (11). If open-
t i-1(-1) 1
ys exp - ∑ + (10) loop stable processes are considered by the same pro-
cedure, the left-hand side of (11) is a real positive
τdesired i)2 (τdesired)i τdesired
number. So this overshoot is relatively smaller than
that of integrating processes.
The right-hand sides of (9) and (4) are the same so the In summary, the integral term of the PID controller
right-hand side of (9) is equal to (6). From (10) and (6), results in a structural limitation in controlling integrat-
it is clear that the left-hand and right-hand sides of (9) ing processes and its structure is suitable to control the
have a different structure: the left-hand side has only open-loop stable process. Therefore, it is obvious that,
an exponential term, but the right-hand side has a first of all, we must convert the integrating process to
constant term plus an exponential term. So any pa- an open-loop stable process to control it effectively by
rameters cannot make both sides the same. As men- using the PID controller. We will mention the strategy
tioned previously, the constant term of (6) is generated to convert an integrating process to an open-loop stable
from the integral term of the PID controller; in other process in section 4.
words, for integrating processes the structural limita-
tion of the PID controller is caused by its integral term.
3. Proposed On-Line Process Identification
If we remove the integral term from it, we can overcome
Strategy
the limitation. However, we cannot do it because the
integral term is essential to remove disturbances and/ In this section we propose a new identification method
or modeling errors. for integrating processes. It can also be used for other
We can also analyze the closed-loop dynamics intu- processes. An identification method using a P controller
itively to understand why the PID controller is not was proposed (Sung and Lee (1996)) to identify the
suitable to control the integrating process effectively. integrating process. It has several drawbacks even
From this analysis, we can recognize that if it is used though it can identify integrating processes efficiently.
to control the integrating process, there will be an First, it uses a very simple integrating model: first order
excessive overshoot. The reason why an excessive plus time delay with one integrator. It is not possible
overshoot exists can be understood intuitively by con- to consider a high-order integrating process systemati-
sidering (9) carefully. When the process reaches a cally. Second, it has an inherent shortcoming since it
steady state, all derivative terms with respect to time is based on an identification method using a P control-
are zero, so all terms of the right-hand side of (9) are ler. That is, kc value of the P controller should be chosen
zero and also all terms of the left-hand side of (9) are appropriately to guarantee an underdamped closed-loop
zero except the last term (b0u). Strictly speaking, on response.
the assumption that the offset is zero, only the integral For a process model, we use a relay as a signal
part of the PID controller in the last term remains. generator to activate the process as shown in Figure 2,
Therefore, we can rewrite (9) at steady state as follows. and then from measured data sets, we can obtain a
5332 Ind. Eng. Chem. Res., Vol. 36, No. 12, 1997
( )
1 + jR 1 + jR cannot be complete until exp(-s1t)y(t) and exp(-s1t)u(t)
) s1 < s2 ) < ... < almost go to zero. We recommend the following equa-
τmax τ2
( )
tion as a criterion to end the integral.
1 + jR 1 + jR
sns-1 ) < sns ) (19)
τns-1 τmin exp(-tend/τmax) < 0.0005 (20)
Ind. Eng. Chem. Res., Vol. 36, No. 12, 1997 5333
stable process efficiently as mentioned in the above
analysis section. In this section we will show conversion
as follows.
As shown in Figure 4, the overall process input is the
summation of the PID controller output and the internal
feedback signal.
Figure 4. Proposed control strategy to control an integrating
process.
unet(t) ) u(t) - kiy(t) (23)
To obtain a continuous model from the calculated From substitution of unet(t) for u(t) in (9), the following
G(si)’s, the following high-order rational polynomial is obtained:
model is used.
dn+1y d ny d2y dy
m m-1 an an-1 ... a1
bms + bm-1s + ... + b1s + b0 dt2 dt
+ + + + )
dtn+1 dtn
Gm(s) ) (21)
n
s(ans + an-1s n-1
+ ... + a1s + 1) dmunet dm-1unet dunet
bm bm-1 + ... + b1 + b0unet )
dt
m
+ m-1
Then a least-squares method minimizing the following dt dt
objective function can be used to obtain the coefficients dm(u - kiy) dm-1(u - kiy)
of (21) from the calculated G(si)’s bm + bm-1 + ... +
dtm dtm-1
b,a ns d(u - kiy) dmu
min[ ∑
i)1
|anG(si)sin+1 + an-1G(si) sin + ... + b1
dt
+ b0(u - kiy) ) bm m +
dt
dm-1u dmy
a1G(si) si2 - bmsm - bm-1sm-1 - ... - bm-1 + ... + b0 u - bm ki -
dtm-1 dtm
b1si - b0 + G(si) si|2] (22)
dm-1y
bm-1ki m-1 - ... - b0kiy (24)
where b and a denote vectors composed of the coef- dt
ficients of the denominator and the numerator, respec-
tively, and |‚| represents Euclidean norm. We recom- By a simple manipulation (25) is obtained. That is, the
mend ns g 6(n + m) with an equal interval between
si’s to guarantee accuracy of the least-squares method. dn+1y d ny d2y dy dmy
an an-1 ... a1 bmk i
Here, we can use a low order plus time delay model dt2 dt
+ + + + + +
dtn+1 dtn dtm
instead of the high-order model of (21). However, to use
it, a nonlinear optimization problem should be solved dm-1y dy
bm-1ki m-1 + ... + b1ki + b0kiy )
to estimate the model coefficients due to the time delay. dt dt
It is much more difficult to solve the nonlinear optimi- dn+1y dmy
zation problem compared with the linear optimization an n+1 + ... (am-1 + bmki) m +
problem using a least-squares method. Therefore, we dt dt
should use the high-order model of (21) rather than a dm-1y
(am-2 + bm-1ki) m-1 + ... + b0kiy )
low order plus time delay model as the process model. dt
In summary, from the controller output and the
measured process output data, (15)-(17) can be calcu- dmu dm-1u du
bm m + bm-1 m-1 + ... + b1 + b0u (25)
lated, and then we can estimate the coefficients of (21) dt dt dt
using the least-squares method to satisfy (22). The
proposed on-line process identification method is very overall system including the internal feedback loop
simple and does not require any structural information becomes the following open-loop stable system since
on the closed-loop and any complicated numerical b0kiy appears in the left-hand side of (26) where ci are
techniques such as root-finding or nonlinear optimiza-
tion tools. It shows good accuracy in modeling the dn+1y dmy dm-1y
cn + ... + cm + cm-1 + ... + b0kiy )
integrating process, which will be shown in section 5. dtn+1 dtm dtm-1
dmu dm-1u du
4. Proposed Control Strategy bm m + bm-1 m-1 + ... + b1 + b0u (26)
dt dt dt
As mentioned previously, the conventional PID con-
troller cannot control the integrating process effectively some constants made up of ai, bi, and ki. We can say
without converting it to an open-loop stable process. We that the outer-loop PID controller can effectively control
use a control structure as shown in Figure 4 to control the overall system based on the results of the previous
the integrating process effectively. This structure which analysis given in section 2.
uses an internal feedback loop is not a totally new To construct an overall open-loop stable process, we
concept. In recent years, Sung and Lee (1996) used the first should tune the internal feedback loop. In this
same structure. However, their identification and paper we tune ki by using a modified Ziegler-Nichols
control strategy can be used for a very simple model tuning method. Because the original Ziegler-Nichols
(first order plus time delay with one integrator). The tuning method was developed for the open-loop stable
simple model cannot represent a more complicated process, the internal feedback loop tuned by it results
integrating process with an acceptable accuracy. in excessive oscillation. As a result, the overall process
We use an internal feedback loop to convert the becomes severely underdamped. Then the tuning rule
integrating process to an open-loop stable process. Then for the outer-loop PID controller cannot treat it (this
the PID controller can control the overall open-loop will be mentioned later). So we modified the original
5334 Ind. Eng. Chem. Res., Vol. 36, No. 12, 1997
Table 1. Tuning Rule of the PID Controller for the this paper is given in Appendix I. Seborg et al. (1989)
Second Order Plus Time Delay Model indicates disadvantages of this type of reduction. Since
Set-Point Change the fitting frequency region is wide and the frequency
responses are unusual, poor fitting results can be
{ (θτ) }ζ,
-0.983
kkc ) -0.04 + 0.333 + 0.949 ζ e 0.9 obtained. In this approach, the frequency region is
confined by the ultimate frequency and also the restruc-
(θτ) + {1.408(θτ) }ζ, tured PID controller would not treat unusual processes.
-0.832
kkc ) -0.544 + 0.308 ζ > 0.9
Then, there would be no serious problems.
After we get a reduced second order plus time delay
{
τi θ θ
τ
) 2.055 + 0.072
τ
ζ, ( )} τ
e1 model, we can tune the outer-loop PID controller by the
second order plus time delay tuning rule (Sung et al.
{
τi θ θ (1996)). The tuning rule was developed by fitting the
τ
) 1.768 + 0.329
τ
ζ, ( )} τ
>1 optimal data sets obtained from the optimization with
{ [ ]}{ () }
the integral of the time-weighted absolute value of the
τ (θ/τ)1.06ζ θ
-1.09
error (ITAE) as the objective function. Although it is
) 1 - exp - 0.55 + 1.683
τd 0.87 τ composed of only several algebraic equations without
any complicated numerical techniques as shown in
Disturbance Rejection Table 1, the control results by this tuning rule are
almost the same as those of the optimal tuning. Here,
(θτ) + 2.189(θτ) θ
-2.001 -0.766
kkc ) -0.67 + 0.297 ζ, < 0.9 the tuning rule is valid for the second order plus time
τ
delay process of 0.25 < ζm < 5.0 and 0.05 < θm/τm <
θ θ 2 θ
kk ) -0.365 + 0.26( - 1.4) + 2.189( ) 2.0. A too large ki value is not recommended because
-0.766
c ζ, g 0.9
τ τ τ the tuning rule cannot treat a severe underdamped
τi process (ζm < 0.25).
θ 0.52 θ
τ
) 2.2122()
τ
- 0.3,
τ
< 0.4 In summary, a high-order rational polynomial model
Gm(s) is obtained by the proposed identification method
( )
τi θ and then ki is tuned by (27). Using the model reduction
) -0.975 + 0.91 - 1.845 +
τ τ method, we estimate the reduced overall second order
{ 1 - exp - [ ζ
0.15 + 0.33(θ/τ)
× ]} plus time delay model. Finally the outer-loop PID
controller is tuned by Sung et al.’s (1996) tuning rule.
{ θ
(
5.25 - 0.88 - 2.8
τ
2
, )} θ
τ
g 0.4
5. Simulation Study
τ θ
()
-0.53
) -1.9 + 1.576
τd τ
+
Example 1. An Usual Integrating Process. We
{ [ ]}
ζ choose an actual process like (28). By the proposed on-
1 - exp - ×
-0.15 + 0.939(θ/τ)-1.121
{ () }
θ Gp(s) )
e-0.2s
(28)
-1.171
1.45 + 0.969
τ s(s + 1)3
Ziegler-Nichols tuning method to tune the internal line process identification strategy, we get the following
feedback loop for less oscillatory responses as follows. high-order polynomial process model:
Figure 5. Bode plot of the actual process and the identified model
with various τmin and τmax values.
Figure 10. Bode plot of the identified model and the actual
Figure 8. Activated process responses by a relay feedback with process with a disturbance.
hysteresis for a noisy process.
the conclusion that the proposed identification method
provides an acceptable robustness to disturbances.
6. Conclusions
In this paper, we proposed a simple and new on-line
process identification and an autotuning method for
integrating processes. The method has a couple of
advantages. First, it does not require any complicated
numerical techniques such as a root-finding technique
or nonlinear optimization. Second, the process model
is estimated from only measured input-output data sets
without any structural closed-loop information. There-
fore, this method can incorporate an actuator saturation
during the identification step. Also, according to the
desire of the operator, various test signal generators
including the P, PI, and PID controller, relay, and pulse
or step signal generator can be used to activate the
process. From the simulation study we can conclude
that it provides good model performances and robust-
ness to measurement noises and disturbances.
Figure 9. Bode plot of the identified model and the actual process We showed that the conventional PID controller has
with measurement noises. a structural limitation in controlling the integrating
process. On the basis of the analysis, we proposed a
of the process output. Figure 9 compares Bode plots of control strategy using an internal feedback loop to
the identified model and the process. From this and control the integrating process more efficiently. Here,
several additional simulation results, we can recognize the internal feedback loop plays an important role in
that the proposed identification method can incorporate converting the integrating process to an open-loop stable
measurement noises efficiently. However, it should be process.
noted that the variation of the activated process output A model reduction method is introduced to tune the
should be large enough to guarantee a more accurate outer-loop PID controller easily. It reduces the overall
model relatively compared to the magnitude of mea- transfer function to a second order plus time delay
surement noises. model so that the usual second order plus time delay
Example 3. Process Input with a Disturbance. tuning rules can be used to tune the outer-loop PID
Consider the process controller. From simulation study and analysis we
conclude that the proposed control strategy promises to
e-0.3s contribute much to the control problems of the integrat-
Gp(s) ) (34) ing process.
s(s + 1)2(3s + 1)
Acknowledgment
where the process input has a 10% input disturbance
to the magnitude of the relay. Figure 10 shows the This work was supported in part by the Korea Science
result of identification. From Figure 10, we conclude and Engineering Foundation (KOSEF) through the
that Bode plots of the identified model and the process Automation Research Center at Pohang University of
show almost the same frequency shape. So we can get Science and Technology.
Ind. Eng. Chem. Res., Vol. 36, No. 12, 1997 5337
Nomenclature τm4|Goverall(jωi)|2ωi4 +
Ai ) arbitrary constant (4τm2ζm2 - 2τm2)|Goverall(jωi)|2ωi2 )
ai, bi, ci ) coefficients of the process transfer function
Gc(s), Gm(s), Gp(s), Goverall(s), Greduced(s) ) transfer functions km2 - |Goverall(jωi)|2 (A4)
of the controller, model, process, overall process, and
reduced model, respectively
0 < ω0 < ω1 < ... < ωi < ... < ωu (A5)
kc, ki, km, kcu ) controller gain, internal feedback gain, static
gain of the model, and ultimate gain and additionally the following phase lag equation for
si ) complex value to estimate the Laplace transform the second order plus time delay model is used to
numerically estimate the time delay of the reduced model
t, tend ) time and time to end the integration
u(t), unet(t) ) PID controller output and net process input -π ) -θmωu + arctan 2(-2ζmωuτm,1 - ωu2τm2) (A6)
ydesired(t), ys, y(t) ) desired trajectory, set point, and process
output
y(s), u(s) ) Laplace transforms of the process and controller τ + arctan 2(-2ζmτmωu,1 - ωu2τm2)
output, respectively
θm ) (A7)
ωu
Greek Symbols
where ωu denotes the ultimate frequency of the overall
R ) some constant to assign a frequency
transfer function.
θm, θp ) time delay of the model and process, respectively
As a result, we can estimate the second order plus
τd, τi ) derivative and integral time of the PID controller,
time delay model using (A2), (A4), and (A7) if ki and
respectively
Gm(s) are available.
τdesired, τm ) time constant of the desired trajectory and
model, respectively
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