4.1 Objective:
1. To understand the closed loop control system in three different processes.
2. To identify the manipulated and controlled variables
3. To identify the components (sensors, controllers, actuators) in a closed loop system
for different types of process control.
4. To control and tune the process using PID controller.
4.2 Introduction
Process control is an engineering discipline that deals with architectures, mechanisms and
algorithms for maintaining the output of a specific process within a desired range. Process
control is extensively used in industry and enables mass production of consistent products
from continuously operated processes such as oil refining, paper manufacturing, chemicals,
power plants and many others. Process control enables automation, by which a small staff of
operating personnel can operate a complex process from a central control room.
There is some terminology which is commonly used in process control. Controlled
variables are the variables which quantify the performance or quality of the final product,
which are also called output variables. Manipulated variables are input variables that are
adjusted dynamically to keep the controlled variables at their set-points. Disturbance
variables are also called "load" variables and represent input variables that can cause the
controlled variables to deviate from their respective set points. Set-point change is
implementing a change in the operating conditions. The set-point signal is changed and the
manipulated variable is adjusted appropriately to achieve the new operating conditions. It is
also known as servomechanism (or "servo") control. Disturbance change is the process
transient behaviour when a disturbance enters, also called regulatory control or load change.
A control system should be able to return each controlled variable back to its set-point.
A familiar example of feedback control is cruise control on an automobile. Here
speed is the measured variable. The operator (driver) adjusts the desired speed set point
(e.g. 100 km/hr) and the controller monitors the speed sensor and compares the measured
speed to the set point. Any deviations, such as changes in grade, drag, wind speed or even
using a different grade of fuel (for example an ethanol blend) are corrected by the controller
making a compensating adjustment to the fuel valve open position, which is the manipulated
variable. The controller makes adjustments having information only about the error
(magnitude, rate of change or cumulative error) although settings known as tuning are used
to achieve stable control. The operation of such controllers is the subject of control theory.
In this experiment, we are going to determine the properties of P, PI and PID
controller and learn how to tune this controller.
0 | Page
1. 1 Pump,
2. 1 motor controller,
3. I proportional valve,
4. 1 digital industrial controller,
5. Tubing, electrical and mechanical components,
6. 1 container,
7. 1 Control Console,
8. 1 profile plate,
9. 1 flow sensor,
10. Capacitive proximity sensor
4.4 Procedure
1 | Page
First, the set point is set to 3.5. Wait for the graph to stabilize at set point.
Tr and Td is set to a fix value.
Value of Kp is manipulated.
The set point then is change to 4.0.
The graph of the response is captured.
4.4.2 PI Controller
1.
2.
3.
4.
5.
6.
First, the set point is set to 3.5. Wait for the graph to stabilize at set point.
Kp and Td is set to a fix value.
Value of Tr is manipulated.
The set point then is change to 4.0.
The graph of the response is captured.
Step 1 to 5 is repeated, but this time, Tr and Td value is fixed and Kp value is
manipulated.
First, the set point is set to 3.5. Wait for the graph to stabilize at set point.
The Kp is set to a fix value.
Value of Tr and Td is manipulated.
The set point then is change to 4.0.
The graph of the response is captured.
Step 1 to 5 is repeated but this time, Tr is kept constant and Kp and Td is
manipulated.
7. Step 1 to 5 is repeated but this time, Td is kept constant and Kp and Tr is
manipulated. (Td must not exceed 1.5)
FILLING PROCESS
4.4.4 P Controller
6. First, the set point is set to 35. Wait for the graph to stabilize at set point.
7. Tr and Td is set to a fix value.
8. Value of Kp is manipulated.
9. The set point then is change to 40.
10. The graph of the response is captured.
4.4.5 PI Controller
7. First, the set point is set to 35. Wait for the graph to stabilize at set point.
8. Kp and Td is set to a fix value.
9. Value of Tr is manipulated.
2 | Page
4.5 Result
4.5.1 Flow Rate Control
Set point: 4.00 (desired value)
Manipulated variable: pump (performance of pump)
3 | Page
Kp
28
35
20
Tr
1.0
1.0
1.0
Td
Set point
Manipulated variable
81.83
82.10
83.59
Overshoot, OS
1.325
Rise time, tr
5.5
Settling time, ts
55
undefine
11
0.01
0.01
0.01
4 | Page
Figure 7(a): Flow rate control by controller P when Kp=28 and Tr=1.0
Figure 7(b): Flow rate control by controller P when Kp=35 and Tr=1.0
Figure 7(c): Flow rate control by controller P when Kp=20 and Tr=1.0
4.5.1.2 PI Controller
Table 8: The overshoot, rise time, settling time and steady state error when PI controller is
tuned by fixing the Kp and changing the Tr by 1.5, 5.0, 0.8
5 | Page
Kp
28
28
28
Tr
1.5
5.0
0.8
Td
Set point
Manipulated variable
81.91
79.21
78.49
Overshoot, OS
Rise time, tr
Settling time, ts
15
0.001
Figure 8(a): Flow rate control by controller P when Kp=28 and Tr=1.5
6 | Page
Figure 8(b): Flow rate control by controller P when Kp=28 and Tr=5.0
Figure 8(c): Flow rate control by controller P when Kp=28 and Tr=0.8
Table 9: The overshoot, rise time, settling time and steady state error when PI controller is
tuned by fixing the Tr and changing the Kp by 28, 20.0, 15.0.
Kp
28.0
20.0
15.0
7 | Page
Tr
1.5
1.5
1.5
Td
Set point
Manipulated variable
80.65
84.74
83.48
Overshoot, OS
Rise time, tr
Settling time, ts
0.00
0.2
0.001
Figure 9(a): Flow rate control by controller P when Kp=28 and Tr=1.5
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Figure 9(b): Flow rate control by controller P when Kp=20 and Tr=1.5
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Figure 9(c): Flow rate control by controller P when Kp=15 and Tr=1.5
Set 2
Set 3
Kp
1
28
2
28
3
28
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Tr
Td
Set point
Manipulated variable
Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
5
0.1
4
86.60
0
22.6363
38.4564
0
6
0.2
4
81.44
0
17.64
50.6214
0
7
0.3
4
79.86
0
23.8264
44.8536
0
Set 5
Set 6
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Kp
Tr
Td
Set point
Manipulated variable
Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
20
5
0.3
4
84.11
0
13.8521
28.3409
0
30
5
0.2
4
80.00
0.4091
13.0215
28.0430
0
35
5
0.1
4
84.29
0.5909
12.6345
0
Set 8
Set 9
Kp
Tr
Td
Set point
Manipulated variable
1
20
1.5
0.3
4
86.08
2
30
1.3
0.3
4
73.97
3
40
1.1
0.3
4
72.70
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Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
0
11.1502
9.8
0
0.15
6.2532
11.2
0
0.7
13.6524
0
Table 1: The value of overshoot, rise time, settling time and steady state error when
P controller is tuned.
1
Kp
28
35
42.0
Tr
0.5
0.5
0.5
Td
Set point
40
40
40
Manipulated variable
41.74
68.90
29.81
Overshoot, OS
0.1
0.1
0.1
21.0
20.83
23.21
48.81
55.62
47.62
0.15
0.400
0.6
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Figure 1(a): Filling level control for P controller when Kp=28 and Tr=0.5 (run 1)
Figure 1(b): Filling level control by P Controller when Kp=35 and Tr=0.5 (run 2)
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Figure 1(c): Filling level control by P Controller when Kp=42.0 and Tr=0.5 (run 3)
PI Controller
i.
Table 2: The value of overshoot, rise time, settling time and steady state error when PI
controller is tuned.
1
Kp
25
25
25
Tr
0.5
1.0
1.5
Td
Set point
40
40
40
Manipulated variable
0.12
27.53
43.51
Overshoot, OS
0.1
0.1
0.12
21.56
22.61
23.83
51.78
52.38
64.28
0.875
0.9697
0.7059
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Figure 2(a): Filling level control by PI Controller when Kp=25 and Tr=0.5 (run 1)
Figure 2(b): Filling level control by PI Controller when Kp=25 and Tr=1.0 (run 2)
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Figure 2(c): Filling level control by PI Controller when Kp=25 and Tr=1.5 (run 3)
4.5.2.2 PI Controller
ii.
Table 3: The value of overshoot, rise time, settling time and steady state error when PI
controller is tuned.
Kp
Tr
Td
Set point
Manipulated variable
Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
1
20
0.5
0
40
83.80
0.13
25.0
75.8005
0.6159
2
30
0.5
0
40
60.24
0.10
20.24
67.5617
0.6159
3
40
0.5
0
40
60.24
0.10
23.81
66.9495
0.3424
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Figure 3(a): Filling level control by PI Controller when Kp=20 and Tr=0.5 (run 1)
Figure 3(b): Filling level control by PI Controller when Kp=30 and Tr=0.5 (run 2)
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Figure 3(c): Filling level control by PI Controller when Kp=40 and Tr=0.5 (run 3)
Kp
Tr
Td
Set point
Manipulated variable
Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
1
25
0.5
0.2
40
0.57
0.10
18.45
75.0
0.2
2
25
1.0
0.6
40
48.62
0.13
19.05
73.81
0.1
3
25
1.5
1.0
40
45.74
0.14
21.4
63.09
0.04
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Figure 4(a): Filling level control by PID controller when Kp=25, Tr=0.5 and Td=0.2
(run 1)
Figure 4(b): Filling level control by PID Controller when Kp=25, Tr=1.0 and Td=0.6
(run 2)
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Figure 4(c): Filling level control by PID Controller when Kp=25, Tr=1.5 and Td=1.0
(run 3)
Table 5: The value of overshoot, rise time, settling time and steady state error when PID
controller is tuned.
Kp
Tr
Td
Set point
Manipulated variable
Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
1
28
0.5
0.2
40
12.09
0.077
22.62
79.76
0.1
2
35
0.5
0.6
40
31.82
0.083
21.4
64.29
0.08
3
42
0.5
1.0
40
17.88
0.06
22.02
63.10
0.03
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Figure 5(a): Filling level control by PID Controller when Kp=28, Tr=0.5 and Td=0.2
(run 1)
Figure 5(b): Filling level control by PID Controller when Kp=35, Tr=0.5 and Td=0.6
23 | P a g e
(run 2)
Figure 5(c): Filling level control by PID Controller when Kp=42, Tr=0.5 and Td=1.0
(Run 3)
Table 6: The value of overshoot, rise time, settling time and steady state error when PID
controller is tuned.
Kp
Tr
Td
Set point
Manipulated variable
Overshoot, OS
Rise Time, tr (s)
Settling Time, ts (s)
Steady state error
1
28
0.5
0.2
40
4.09
0.0589
22.02
69.64
0.4
2
35
1.0
0.2
40
37.51
0.0961
22.62
67.86
0.2
3
42
1.5
0.2
40
48.91
0.99
23.21
49.40
0.0
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Figure 6(a): Filling level control by PID Controller when Kp=28, Tr=0.5 and Td=0.2
(Run 1)
Figure 6(b): Filling level control by PID Controller when Kp=35, Tr=1.0 and Td=0.2
(Run 2)
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Figure 6(c): Filling level control by PID Controller when Kp=42, Tr=1.5 and Td=0.2
(Run 3)
4.6. Discussion
4.6.1 FLOW RATE CONTROL
First, P controller was used. From the Graph, The values of Kp were selected by
28, 35 and 20. The initial value was 28 and other variable were set to zero. However, Tr
value cannot be set to zero as the smallest value of Tr will be 1.0.The rise time was 5.5,
settling time was 50 and steady state error of 0.01.It has overshoot of 0.The second reading
was 35. The rise time was 3, settling time was cannot be defined and steady state error of
0.01.It has overshot which is 1.325. The third reading was 20. The rise time was 5, settling
time was 11 and steady state error of 0.01.It has no overshoot. The second reading cannot
be defined due tu error occur during experiment. The rise time decreases with the increase
in Kp. This agrees to the theory. Overshoot was reduced, and the theory says that after
certain value of steady state error, the overshoot will increase. The settling time decreases
but theoretically it will have small change. The steady state error remains constant.
According to the theory, increase in Kp will decrease rise time, increase overshoot, decrease
steady state error and little effect on settling time. The proportional component depends only
on the Error, which is the difference between the Set Point and the Process Variable. The
Proportional gain (Kc) determines the ratio of Output response to the Error. For instance, if
the Error signal has a magnitude of 10, a Proportional Gain of 5 would produce a
proportional response of 50. In general, increasing the Proportional Gain will increase the
speed of the control system response and also decrease the steady-state error which is the
final difference between Process variable and Set Point. However, if the Proportional Gain is
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too large the Process Variable will begin to oscillate. If Kc is increased further, the
oscillations will become larger and the system will become unstable.
For Proportional-Integral (PI) controller, there were six sets tested. The first three
sets were carried out by setting the Kp value fixed, Td was set to 0 and integral time, Tr was
set to 1.5-Set 1, 5.0-Set 2 and 0.8-Set 3. For set 1, it resulted in 0.001 % of overshoot
assume to be 0%, 2s of rise time, 3s of settling time and 0.001 of steady state error. For set
2, it resulted in 0% of overshoot, 4 s of rise time, 7s of settling time and no steady state error.
For set 3, it resulted in no overshoot, 5s of rise time, 15 s of settling time and no steady state
error. Theoretically, the increase in Tr will decrease rise time, increase overshoot, increase
settling time and eliminate steady state error. Based on the results obtained, the rise time
decreases from set 1 to set 2.The set 3 showed increases in rise time which did not agree to
theory. For settling time, set 2 and set 3 agreed to theory, from set 1 to set 2 it showed
decrease in settling time, which differed from theory. The overshoot and steady state error
showed readings around zero. Theoretically, the overshoot will increase but it was opposite
in the results. This could be due to very small change in the Tr value, which turned to exhibit
only some of the properties or maybe there is an error occur during handling the experiment.
The three other sets were determined by fixing Tr value constant= 1.5 and changing
the Kp value, Kp= 28-Set 4, Kp = 20-Set 5, Kp = 15-Set 6.For set 4, it resulted in no
overshoot, 3 s of rise time, 5s of settling time and no steady state error. For set 5, it resulted
in no overshoot, 4 s of rise time, 7 s of settling time and 0.2 of steady state error. For set 6, it
resulted in no overshoot, 5 s of rise time, 9 s of settling time and 0.001of steady state error.
Theoretically, the increase in Kp will decrease rise time, increase overshoot, decrease
steady state error and has less effect on settling time. The presence of integral controller
must eliminate steady state error. Based on the results, the rise time decreases as the Kp
increase and with the presence of integral action. The settling time showed fluctuations,
which means there is need to introduce the PID controller. The steady state error was very
small and can be considered the value approaching zero for the three sets.The major
advantage in introducing the integral controller is the removal of steady state error. PI
controller has overall better performance than p controller. However, the integral action may
cause overshoot, oscillation, and/or instability problems if the selected integral gain (Tr) is
too small. Integral controllers tend to respond slowly at first, but over a long period of time
they tend to eliminate errors. The integral controller eliminates the steady-state error, but
may make the transient response worse. The controller may be unstable.
For PID Controller, from the graphs, we can see that PID is better than system with
only P controller or P and I controller. In control system, the rise time of a system can be
improved by adding a proportional controller or to increase the value of proportional gain of
the controller. As for steady-state error can be improved by adding an integral controller. In
order to improve the overshoot of a system, a derivative controller will be added. The above
PID graphs have all the three proportional, integral and derivative controllers. Hence the
system will experience less oscillation, fast rise time, short settling time and also less steadystate error.
For PID system, the type of controller used was Proportional-Integral-Derivative (PID)
controller. The first three sets were determined by fixing the Kp value constant to 28 and
increasing both Td and Tr values. For set 1, Kp= 28 , Tr= 5, Td= 0.1, it resulted in almost no
overshoot, 22s of rise time, 38s of settling time and almost no steady state error. For set 2,
27 | P a g e
Kp= 28, Tr= 6, Td=0.2, it resulted in no overshoot, 17s of rise time, 50s of settling time and
almost no steady state error. For set 3, Kp= 28, Tr= 7, Td= 0.3, it resulted in no overshoot,
23s of rise time, 44s of settling time and no steady state error.
Since there are three types of controlled being integrated, it becomes very difficult to
predict the outcomes. These trials helped to determine the pattern that could be obtained
when Kp fixed, and the increase in Tr and Td.The results obtained showed there is decrease
in rise time and settling time and with little or no overshoot and settling time. For set 2 values
are inaccurate as there was no enough time for the graph in system to settle down before
keying in new values Tr and Td. Hence the result of set 2 shows a great deviation from set 1
and set 3.
Next step(set 4-6) the Tr value was set to constant and increasing Kp and decreasing
Td values. For set 4, Kp= 20, Tr=5, Td= 0.3, it resulted in no overshoot, 13.85s of rise time,
28s of settling time and no steady state error. For set 5, Kp= 30, Tr=5, Td= 0.2, it resulted in
40.91% of overshoot, 13.02s of rise time, 28s of settling time and no steady state error. For
set 6, Kp= 35, Tr= 5, Td= 0.1, it resulted in 59.09% of overshoot, 12.63s of rise time and very
small steady state error. Based on the results, the rise time and settling time reduced and
the steady state error and overshoot can be considered almost zero. This pattern also
makes the response good and better than P and PI controller. For set 6 the graph shows
very large oscillation and the system didnt settle down near to the setpoint. Hence there is
no settling time for set 3 trial. In order to have a shorter rise time and settling time, both Kp
and Td shall be increase or decrease instead of increasing one and decreasing the other.
Sets 7-9 were determined by fixing the Td value constant to and increasing Kp and
decreasing Tr values. For set 7, Kp= 20, Tr=1.5, Td=0.3, it resulted in no overshoot, 11.15 s
of rise time, 9.8 s of settling time and no steady state error. For set 8, Kp=30, Tr=1.3,
Td=0.3, it resulted in little overshoot, 6.25s of rise time, 11.2s of settling time and no steady
state error. For set 9, Kp=40, Tr=1.1, Td=0.3, it resulted in little overshoot, 13.6s of rise time
and no steady state error. For set 9 the graph shows very great oscillation and the graph
didnt settle down to the setpoint. Hence the result of rise time and settling time from set 9 is
greatly deviate from the trials. For this pattern, the rise time and settling time were
decreased; the steady state error and overshoot can be considered as zero. This method is
also very successful as all the criteria have been fulfilled.
Differences occur between the PID controller and normal controllers in the way they work.
The PID controller uses an advanced formula to try and prevent any errors from occurring.
This ensures the devices or system being controlled performs as flawlessly as possible. This
formula type is known as an algorithm. An algorithm directs actions based on what is
happening. The algorithm would have specific directions on how to react to certain changes.
In this way, an algorithm is a series of different procedures that can be followed or altered
based on what the device receiving the orders is doing
Finally, the PID controller participates in a feedback loop. Information is sent out by
the controller, received by the devices, and information from the devices is sent back to the
controller. The controller then makes a decision on how to proceed based on the information
it receives and sends it out, creating a continuous loop. One main advantage stands out
above the rest when using a PID controller. It can control various systems or devices with
little human interaction. Not only does this allow the workers to concentrate on other tasks,
28 | P a g e
but it also allows many processes to run at once. The drawback to this method comes from
the fact that the controller must be tuned, meaning the instructions that tell it what to do must
be tweaked, to keep it functioning properly. To do this, advanced knowledge for setting up
this type of controller is required to avoid error.
is fixed at 0.2 while Kp and Tr are changes throughout the process. Overall, the results of
rise time is increased, settling time decreased. But the overshoot show increased. This may
due to the parallax error while because of the small scale of the graph make it difficult to
read the data. However, the steady-state is successfully eliminated.
4.7 Conclusion
In conclusion, the experiment showed that PID controller is the best among the
controllers. PID controller produced response with fast rise time, lowest overshoot, short
settling time and almost no steady state error. However, a sudden change in set point will
cause derivative terms momentarily to become very large and thus provide a derivative kick
to the final control element.
4.8 Reference
1. PID
Controller
Simplified.
(2008,
May
11).
Retrieved
https://radhesh.wordpress.com/2008/05/11/pid-controller-simplified/
from
2. PID
Controller
Design.
(2012,
January
1).
Retrieved
from
http://ctms.engin.umich.edu/CTMS/index.php?example=Introductionion=ControlPID
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