Overview of Tuning Methods

There are several methods for tuning a PID loop. The most effective methods generally involve
the development of some form of process model, then choosing P, I, and D based on the dynamic
model parameters. Manual tuning methods can be relatively inefficient, particularly if the loops
have response times on the order of minutes or longer.

The choice of method will depend largely on whether or not the loop can be taken "offline" for
tuning, and on the response time of the system. If the system can be taken offline, the best tuning
method often involves subjecting the system to a step change in input, measuring the output as a
function of time, and using this response to determine the control parameters.

Table 1: Choosing a Tuning Method

Method Advantages Disadvantages

Manual No math required , Online Requires experienced personnel

Tuning

Process upset, some trial-and-

Ziegler- Proven Method, Online error, very aggressive tuning
Nichols

Some math; offline; only good

Cohen-Coon Good process models for first-order processes

Consistent tuning; online or offline - can

Software employ computer-automated control Some cost or training involved

Tools system design (CAutoD) techniques;
1. Open Loop Methods

In these methods, the PID is being tuned in open loop, isolated from the process plant. First a step
input is applied to the plant and the process reaction curve is obtained. Using the process reaction
curve with one of the First Order Plus Dead Time (FOPDT) estimation methods an approximation
of the process is calculated. Knowing 𝐾𝑚, τ𝑚 and 𝑡𝑑 the PID parameters can be evaluated from
the related correlations according to the method used.

First Order Plus Dead Time (FOPDT) is given by

K
Gp (s) = e−tds
τm s + 1

Ziegler-Nichols Open Loop Method

In the 1940's, Ziegler and Nichols devised two empirical methods for obtaining controller
parameters. Their methods were used for first order plus dead time situations, and involved intense
manual calculations. With improved optimization software, most manual methods such as these
are no longer used. However, even with computer aids, the following two methods are still
employed today, and are considered among the most common.

This method remains a popular technique for tuning controllers that use proportional, integral, and
derivative actions. The Ziegler-Nichols open-loop method is also referred to as S-shaped curve
method, because it tests the open-loop reaction of the process to a change in the control variable
output. This basic test requires that the response of the system be recorded, preferably by a plotter
or computer. Once certain process response values are found, they can be plugged into the Ziegler-
Nichols equation with specific multiplier constants for the gains of a controller with either P, PI,
or PID actions.

In this method, we obtain experimentally the open loop response of the FOPDT to a unit step input.
This method only applied if the response to a step input exhibits an s-shaped curve as shown in
figure 1. This means that if the plant involves integrators (like 2nd order prototypes system) or
complex-conjugate poles (general 2nd order system), then this method can’t be applied since s-
shaped will not be obtained.
This method remains a popular technique for tuning controllers that use proportional, integral, and
derivative actions. The Ziegler-Nichols open-loop method is also referred to as a process
reaction method, because it tests the open-loop reaction of the process to a change in the control
variable output.

The Tuning Procedure:

To use the Ziegler-Nichols open-loop tuning method, you must perform the following steps:

1. Make an open loop step test

2. From the process reaction curve determine the transportation lag or dead time, t𝑑, the
process time constant or time for the response to change, τ𝑚, and the ultimate value that
the response reaches at steady-state, 𝐾𝑚, for a step change of 𝑋𝑜.

3. Determine the loop tuning constants. Plug in the reaction rate and lag time values to the
Ziegler-Nichols open-loop tuning equations for the appropriate controller (P, PI, or PID) to
calculate the controller constants as given in the table.

Open Loop of First order system plus dead Time (s-shaped curve)
 Open-loop Calculation of 𝐾c, τ𝑖, τD

Controller Kc τi τD

P controller 𝑋𝑜 𝜏𝑚 α 0
𝐾𝑚 𝑡𝑑

PI controller 𝑋𝑜 𝜏𝑚 3.3td 0
0.9
𝐾𝑚 𝑡𝑑

PID controller 𝑋𝑜 𝜏𝑚 2 td 0.5 td

1.2
𝐾𝑚 𝑡𝑑

 Advantages Ziegler-Nichols Open Loop Tuning Methods

1. Quick and easier to use than other methods
2. It is a robust and popular method

 Disadvantages Ziegler-Nichols Open Loop Tuning Methods

1. It depends upon purely 𝑡𝑑to estimate I and D controllers.
2. Approximations for the 𝐾𝑝. 𝑇𝑖, and 𝑇𝑑 values might not be entirely accurate for
differentsystems.
3. It does not hold for I, D and PD controllers

Cohen-Coon Method

The Cohen-Coon tuning rules are suited to a wider variety of processes than the Ziegler-Nichols
tuning rules. The Ziegler-Nichols rules work well only on processes where the dead time is less
than half the length of the time constant. The Cohen-Coon tuning rules work well on processes
where the dead time is less than two times the length of the time constant. Also it provides one of
the few sets of tuning rules that has rules for PDcontrollers.
 Like the Ziegler-Nichols tuning rules, the Cohen-Coon rules aim for a quarter-amplitude damping
response. Although quarter-amplitude damping-type of tuning provides very fast disturbance
rejection, it tends to be very oscillatory and frequently interacts with similarly-tuned loops.
Quarter-amplitude damping-type tuning also leaves the loop vulnerable to going unstable if the
process gain or dead time doubles in value.

In this method the process response curve is obtained first, by an open loop test and then the
process dynamics is approximated by a first order plus dead time model, with following
parameters:

The open loop response of plant

Sundaresan and Krishnaswamy’s method to find the parameters for FOPDT model

The parameters can be estimated using the previous method of using tangent and finding the
parameters for FOPDT approximation. To avoid this, another method known as Sundaresan and
Krishnaswamy’s method can also be used and is described in this section.

This method avoids the use of the inflection point to estimate the time constant τ and transport
delay τd . They proposed that two times, t1 and t2, to be estimated from the one-step response curve
corresponding to 35.3% and 85.3% of the response respectively. The time delay and time constant are
then estimated from the following equations:
 τd = 1.3t1 − 0.29t 2
τ = 0.67(t1 − t 2 )

The FOPDT model of the given transfer function is written as

K
Gp (s) = e−τds
τs + 1
Where K- Steady state gain
τ – Process time constant
τd – Delay time

Again the particular rules for this method are used to calculate the PID parameters and are given in
the following table.
Parameter of Cohen-Coon Method

Type of control Kc τI τD
Proportional (P) τ τd
[1 + ]
Kτd 3τ
Proportional – τ
τ τd 30 + 3 τd
Integral (PI) [0.9 + ] τd [ τ ]
Kτd 12τ 9 + 20 τd

Proportional- τ
τ 4 τd 32 + 6 τd 4
Integral-Derivative [ + ] τd [ τ ] τd [ τ ]
Kτd 3 4τ 13 + 8 τd 11 + 2 τd
(PID)

Closed loop tuning method

Ziegler-Nichols Closed - Loop Tuning Method

The Ziegler-Nichols closed-loop tuning method allows you to use the critical gain value, 𝐾u, and
the critical period of oscillation, Tu, to calculate 𝐾c. It is a simple method of tuning PID
controllers and can be refined to give better approximations of the controller. We can obtain the
controller constants 𝐾𝑝 , τ𝑖 , and τ𝑑 in a system with feedback. The Ziegler-Nichols closed-loop
tuning method is limited to tuning processes that cannot run in an open-loop environment.

Determining the ultimate gain value, 𝐾u

Finding 𝐾u is accomplished by finding the value of the proportional- only gain that causes the
control loop to oscillate indefinitely at steady state. This means that the gains from I and D
controller are set to zero so that the influence of P can be determined. It tests the robustness of
the 𝐾c value so that it is optimized for the controller. Another important value associated with
this proportional-only control tuning method is the critical period (Tu). The ultimate period is the
time required to complete one full oscillation while the system is at steady state. These two
parameters, 𝐾u and Tu, are used to find the loop-tuning constants of the controller (P, PI, or PID).
To find the values of these parameters, and to calculate the tuning constants, use the following
procedure:

The Tuning Procedure:

1. Remove integral and derivative action. Set integral time (τ𝑖) to ∞ or its largest value and
set the derivative controller (τD) to zero.
2. Create a small disturbance in the loop by changing the set point. Adjust the proportional,
increasing and/or decreasing, the gain until the oscillations have constant amplitude.
3. Record the gain value (𝐾u) and period of oscillation (Tu).
4. Plug these values into the Ziegler-Nichols closed loop equations and determine the
necessary settings for the controller.

The Control system with Gain 𝐾c

 Zeigler Nichols Tuning parameters
Type of Control Kc τI τD

Proportional (P) 0.5 Ku

Proportional-Integral (PI) 0.45 Ku Tu/1.2

Proportional-Integral- 0.6 Ku Tu/2 Tu/8

Derivative (PID)

 Advantages Ziegler-Nichols Closed-Loop Tuning Methods

1. Easy experiment; only need to change the P controller
2. Includes dynamics of whole process, which gives a more accurate picture of how the
system is behaving
 Disadvantages Ziegler-Nichols Closed-Loop Tuning Methods
1. Experiment can be time consuming
2. Can venture into unstable regions while testing the P controller, which could cause the
system to become out of control