This paper proposes and validates an automatic control tuning methodology based on initial frequency response. This approach facilitates the design of robust PID controllers for overdamped systems characterized by S-shaped step responses. In the prior autotuner, which is inherently robust, the critical frequency value is determined via the relay test, while process frequency response and its derivative at this frequency are found using the sine test. Our novel approach offers a fully automated calculation for these parameters based solely on the step response test (i.e., minimal information from the process), eliminating the need for additional calculations by relay and sine tests. For this aim, it estimates these values employing the first order plus dead time models. Firstly, five step response methods are introduced to ascertain the model parameters. Secondly, three alternative estimation methods for the critical frequency of the system are proposed through (i) solving a nonlinear equation, (ii) employing a linear approximation, and (iii) using a power regression. Lastly, the model parameters are then employed to calculate the system frequency response and its derivative at the critical frequency. The remaining design steps are the same as in the initial robustness-based autotuner. In the simulation studies, two types of overdamped systems are considered. The critical frequency estimation values obtained from three estimation methods are compared to each other. Additionally, the impact of the step response methods and the proposed estimation methods within the novel approach on system response and control signal are investigated. The designed controllers use a new approach to the initial autotuner and are implemented on a two-tank liquid-level system. The experimental outcomes are in accordance with the simulation results, confirming the validity and compatibility of the findings. Quantitative performance metrics are used to evaluate the effectiveness of the designs comprehensively.
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