PID Controller Design

and Tuning
•Model-based design methods
•Controller tuning relations

1
Direct Synthesis
DS Method

2
 12.2 Direct Synthesis Method
• In the Direct Synthesis (DS) method, the controller design is
based on a process model and a desired closed-loop transfer
function.
• The latter is usually specified for set-point changes, but
responses to disturbances can also be utilized (Chen and
Seborg, 2002).
• Although these feedback controllers do not always have a PID
structure, the DS method does produce PI or PID controllers
for common process models.
• As a starting point for the analysis, consider the block diagram
of a feedback control system in Figure 12.2

3
The closed-loop transfer function for set-point changes was
derived in Section 11.2:

Y K mGcGvG p
 (12-1)
Ysp 1  GcGvG p Gm

Fig. 12.2. Block diagram for a standard feedback control system.

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For simplicity, let G = GvG p Gm and assume that Gm = Km. Then
Eq. 12-1 reduces to
Y GcG
 (12-2)
Ysp 1  GcG

Rearranging and solving for Gc gives an expression for the

feedback controller:

1  Y / Ysp 
Gc    (12-3a)
G  1  Y / Ysp 

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• Equation 12-3a cannot be used for controller design because the
closed-loop transfer function Y/Ysp is not known a priori.
• Also, it is useful to distinguish between the actual process G
and the model, G, that provides an approximation of the
process behavior.
• A practical design equation can be derived by replacing the
unknown G by G, and Y/Ysp by a desired closed-loop transfer
function, (Y/Ysp)d:

1 
 Y / Ysp  

Gc  d
(12-3b)
 
G 1  Y / Ysp
d
 


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• The specification of (Y/Ysp)d is the key design decision
• Note that the controller transfer function in (12-3b)
contains the inverse of the process model owing to the
1/ G term.

• This feature is a distinguishing characteristic of

model-based control.

7
Desired Closed-Loop Transfer Function
For processes without time delays, the first-order model in
Eq. 12-4 is a reasonable choice,
 Y  1
   (12-4)
 Ysp d  c s  1

τc is the desired closed-loop time constant

8
• The model has a settling time of ~ 4 τc, as shown in
Section 5. 2.
• Because the steady-state gain is one, no offset occurs for set-
point changes.
• By substituting (12-4) into (12-3b) and solving for Gc, the
controller design equation becomes:
1 1
Gc  (12-5)
G τc s
• The 1/ τc s term provides integral control action and thus
eliminates offset.
• Design parameter τc provides a convenient controller tuning
parameter that can be used to make the controller more
aggressive (small τc ) or less aggressive (large τc).
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• If the process transfer function contains a known time delay θ ,
a reasonable choice for the desired closed-loop transfer
function is:
 Y  e  θs
   (12-6)
 Ysp d τc s  1

• The time-delay term in (12-6) is essential because it is

physically impossible for the controlled variable to respond to
a set-point change at t = 0, before t = θ .
• If the time delay is unknown, θ must be replaced by an
estimate.
• Combining Eqs. 12-6 and 12-3b gives:

1 e  θs
Gc  (12-7)
G τ c s  1  e  θs
10
• Although this controller is not in a standard PID form, it is
physically realizable.
• Next, we show that the design equation in Eq. 12-7 can be used
to derive PID controllers for simple process models.
• The following derivation is based on approximating the time-
delay term in the denominator of (12-7) with a truncated Taylor
series expansion:

e  θs  1  θ s (12-8)

Substituting (12-8) into the denominator of Eq. 12-7 and

rearranging gives
1 e  θs
Gc  (12-9)
G  τc  θ  s
s

Note that this controller also contains integral control action.

11
First-Order-plus-Time-Delay (FOPTD) Model
1 τ
Kc  , τI  τ (12-11)
K θ  τc
Consider the standard FOPTD model,
Keθs
G s  (12-10)
τs  1
Substituting Eq. 12-10 into Eq. 12-9 and rearranging gives a PI
controller, Gc  K c 1  1/ τ I s  ,with the following controller
settings:

Second-Order-plus-Time-Delay (SOPTD) Model

Consider a SOPTD model,
Keθs
G s  (12-12)
 τ1s  1 τ 2 s  1
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Substitution into Eq. 12-9 and rearrangement gives a PID
controller in parallel form,
 1 
Gc  K c 1   τDs  (12-13)
 τI s 
where:
1 τ1  τ 2 τ1τ 2
Kc  , τ I  τ1  τ 2 , τD  (12-14)
K τc   τ1  τ 2

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Example 12.1
Use the DS design method to calculate PID controller settings for
the process:
2e  s
G
10s  1 5s  1

Consider three values of the desired closed-loop time constant:

 c  1, 3, and 10 . Evaluate the controllers for unit step changes in
both the set point and the disturbance, assuming that Gd = G.
Repeat the evaluation for two cases:
a. The process model is perfect ( G = G).
b. The model gain is K = 0.9, instead of the actual value, K = 2.
Thus,
0.9e s
G
10s  1 5s  1
The controller settings for this example are:
τc  1 τc  3  c  10

Kc K  2  3.75 1.88 0.682
K c  K  0.9  8.33 4.17 1.51
τI 15 15 15
τD 3.33 3.33 3.33
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The values of Kc decrease as τc increases, but the values of τ I
and τ D do not change, as indicated by Eq. 12-14.

Figure 12.3 Simulation results for Example 12.1 (a): correct

model gain.
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Fig. 12.4 Simulation results for Example 12.1 (b): incorrect
model gain.
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Internal Model Control
(IMC)

18
Internal Model Control (IMC)
• A more comprehensive model-based design method, Internal
Model Control (IMC), was developed by Morari and
coworkers (Garcia and Morari, 1982; Rivera et al., 1986).
• The IMC method, like the DS method, is based on an assumed
process model and leads to analytical expressions for the
controller settings.
• These two design methods are closely related and produce
identical controllers if the design parameters are specified in a
consistent manner.
• The IMC method is based on the simplified block diagram
shown in Fig. 12.6b. A process model G and the controller
output P are used to calculate the model response, Y .

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 Figure 12.6.
Feedback control
strategies

• The model response is subtracted from the actual response Y,

and the difference, Y  Y is used as the input signal to the IMC
controller, Gc*.
 
• In general, Y  Y due to modeling errors G  G and unknown
disturbances  D  0  that are not accounted for in the model.
• The block diagrams for conventional feedback control and
IMC are compared in Fig. 12.6.
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• It can be shown that the two block diagrams are identical if
controllers Gc and Gc* satisfy the relation

Gc*
Gc  (12-16)
1  Gc*G

• Thus, any IMC controller Gc* is equivalent to a standard

feedback controller Gc, and vice versa.
• The following closed-loop relation for IMC can be derived from
Fig. 12.6b using the block diagram algebra of Chapter 11:

Gc*G 1  Gc*G
Y Ysp  D (12-17)
1  Gc* G  G  1  Gc* G  G 

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For the special case of a perfect model, G  G , (12-17) reduces to

 
Y  Gc*GYsp  1  Gc*G D (12-18)

The IMC controller is designed in two steps:

Step 1. The process model is factored as

G  G G (12-19)

where G contains any time delays and right-half plane

zeros.
• In addition, G is required to have a steady-state gain equal
to one in order to ensure that the two factors in Eq. 12-19
are unique.

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 Step 2. The controller is specified as
1
Gc*  f (12-20)
G

where f is a low-pass filter with a steady-state gain of one. It

typically has the form:
1
f  (12-21)
 τc s  1 r

In analogy with the DS method, τc is the desired closed-loop time

constant. Parameter r is a positive integer. The usual choice is
r = 1.

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 
For the ideal situation where the process model is perfect G  G , 
substituting Eq. 12-20 into (12-18) gives the closed-loop
expression

Y  G fYsp  1  fG D (12-22)
Thus, the closed-loop transfer function for set-point changes is
Y
 G f (12-23)
Ysp

Selection of τc
• The choice of design parameter τc is a key decision in both the
DS and IMC design methods.
• In general, increasing τc produces a more conservative
controller because Kc decreases while τ I increases.
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• Several IMC guidelines for τc have been published for the
model in Eq. 12-10:

1. τc / θ > 0.8 and τc  0.1τ (Rivera et al., 1986)

2. τ  τc  θ (Chien and Fruehauf, 1990)
3. τc  θ (Skogestad, 2003)

Controller Tuning Relations

In the last section, we have seen that model-based design
methods such as DS and IMC produce PI or PID controllers for
certain classes of process models.

IMC Tuning Relations

The IMC method can be used to derive PID controller settings
for a variety of transfer function models.
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Table 12.1 IMC-Based PID Controller Settings for Gc(s)
(Chien and Fruehauf, 1990).

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28
Tuning for Lag-Dominant Models
• First- or second-order models with relatively small time delays
 θ / τ 1 are referred to as lag-dominant models.
• The IMC and DS methods provide satisfactory set-point
responses, but very slow disturbance responses, because the
value of τ I is very large.
• Fortunately, this problem can be solved in three different ways.
Method 1: Integrator Approximation

Ke s K * e s
Approximate G ( s )  by G ( s ) 
s  1 s
where K * K / .
• Then can use the IMC tuning rules (Rule M or N)
to specify the controller settings.
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Method 2. Limit the Value of I
• For lag-dominant models, the standard IMC controllers for first-
order and second-order models provide sluggish disturbance
responses because τ I is very large.
• For example, controller G in Table 12.1 has τ I  τ where τ is
very large.
• As a remedy, Skogestad (2003) has proposed limiting the value
of τ I :
τ I  min τ1, 4  τ c  θ  (12-34)
where 1 is the largest time constant (if there are two).
Method 3. Design the Controller for Disturbances, Rather
Set-point Changes
• The desired CLTF is expressed in terms of (Y/D)des, rather than (Y/Ysp)des
• Reference: Chen & Seborg (2002) 30
Example 12.4
Consider a lag-dominant model with θ / τ  0.01:
100  s
G s  e
100 s  1
Design four PI controllers:

a) IMC  τc  1
b) IMC  τc  2  based on the integrator approximation
c) IMC  τc  1 with Skogestad’s modification (Eq. 12-34)
d) Direct Synthesis method for disturbance rejection (Chen and
Seborg, 2002): The controller settings are Kc = 0.551 and
τ I  4.91.

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Evaluate the four controllers by comparing their performance for
unit step changes in both set point and disturbance. Assume that
the model is perfect and that Gd(s) = G(s).

Solution
The PI controller settings are:

Controller Kc I
(a) IMC 0.5 100
(b) Integrator approximation 0.556 5
(c) Skogestad 0.5 8
(d) DS-d 0.551 4.91

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Figure 12.8. Comparison
of set-point responses
(top) and disturbance
responses (bottom) for
Example 12.4. The
responses for the Chen
and Seborg and integrator
approximation methods
are essentially identical.

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