PROJECT REPORT

SERSHAH ENGINEERING
COLLEGE, SASARAM
(DEPT. OF SCIENCE & TECHNOLOGY, GOVT. OF
BIHAR)

SUBMITTED TO:
SERSHAH ENGINEERING COLLEGE

PID Control System Analysis,Design, and Technology

Guided By:-

Mr. Sailesh Saurabh

PROJECT REPORT
 SERSHAH ENGINEERING
COLLEGE, SASARAM
(DEPT. OF SCIENCE & TECHNOLOGY, GOVT. OF
BIHAR)

SUBMITTED TO:
BIHAR ENGINEERING UNIVERSITY, PATNA

Team Member :-
Shreshth Deep – 21110124025
Safdar Nawaz - 21110124021
 Certificate

This is to certify that project work titled “PID control

system analysis,design and technology” was
successfully carried out in the Department of
Electrical and Electronics Engineering. Shershah
Engineering College Sasaram and the report is
approved for submission in the partial fulfillment of
the requirements for award of degree of Bachelor of
Technology in Electrical and Electronics Engineering.
 DECLARATION
I hereby declare that the internship work entitled “PID control system Analysis, Design, and
Technology” submitted to the SHERSHAH ENGINEERING COLLEGE SASARAM, is a
record of an original work done by me under the guidance of Mr. Sailesh Saurabh and this
project work is submitted In the partial fulfillment of the requirements for the award of the
degree of Bachelor of technology in Electronics and Electronics Engineering. The results
embodied in this report have not been submitted to any other University or Institute for the
award of any degree or diploma.

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 ACKNOWLEDGEMENT

First I would like to thank Dr. Manish kumar, Principal of Shershah engineering College
Sasaram for giving me the opportunity to do an internship within National Instruments. I also
would like to thank all the people that worked along with me with their patience and openness
they created an enjoyable working environment. It is indeed with a great sense of pleasure and
immense sense of gratitude that I acknowledge the help of these individuals. I would like to
thank my Head of the Department, Mr. Raman Kumar for his constructive criticism throughout
my internship. I would like to thank internship coordinator Mr. Raman Kumar for his support
and advices to get and complete internship. I am extremely great full to my department staff
members and friends who helped me in successful completion of this internship.
 Iv

ABSTRACT

The increasing application of flexible and powerful real-time distributed control systems is
presently characterizing the industrial automation field. Such systems involve three main
disciplines: control systems, real-time systems, and communication systems. Control
systems, due their stringent timing constraints, demand real-time computing technology. In
addition, communication systems are needed for the data messaging between field devices.
We propose an integrated approach to the design and implementation of such systems. We
show that by a separate control design and its posterior distributed implementation, the
system performance may suffer degradation. That is, when control loops are closed over
communication networks, timing problems, as communication induced varying delays, can
appear, decreasing the control system performance, and even leading the system to instability.
However, we show that by an adequate integrated approach, that takes advantage of control
theory, real-time communication properties, an adequate timing analysis, and an appropriate
distribution of the control functions, the system performance increases dramatically.
 TABLE OF CONTENTS

ACKNOWLEDGEMENT i
ABSTRACT
CHAPTER 1 INTRODUCTION

1.1 About Control System

1.2 PID Control

CHAPTER 2 TYPES OF CONTROL SYSTEM

2.1 Open Loop Control System
2.2 Closed Loop Control System

2.3 Feedback Control

CHAPTER 2 TYPES OF CONTROL

SYSTEM

CONCLUSION
 Chapter 1
INTRODUCTI
ON
1.1 About Control System

A control system manages, commands, directs, or

regulates the behavior of other devices or systems using
control loops. It can range from a single home heating
controller using a thermostat controlling a domestic boiler
to large industrial control systems which are used for
controlling processes or machines. The control systems
are designed via control engineering process.

For continuously modulated control, a feedback

controller is used to automatically control a process or
operation. The control system compares the value or
status of the process variable (PV) being controlled with
the desired value or setpoint (SP), and applies the
difference as a control signal to bring the process variable
output of the plant to the same value as the setpoint.

For sequential and combinational logic, software logic, such

as in a programmable logic controller, is used.

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 FIGURE :1:CONTROL SYSTEM BLOCK DIAGRAM

1.1a Proportional Control

Proportional control is a type of linear feedback control system in which a correction is applied
to the controlled variable which is proportional to the difference between the desired value (SP)
and the measured value (PV). Two classic mechanical examples are the toilet bowl float
proportioning valve and the fly-ball governor.

The proportional control system is more complex than an on–off control system, but simpler
than a proportional-integral-derivative (PID) control system used, for instance, in an
automobile cruise control. On–off control will work for systems that do not require high
accuracy or responsiveness, but is not effective for rapid and timely corrections and responses.
Proportional control overcomes this by modulating the manipulated variable (MV), such as a
control valve, at a gain level that avoids instability, but applies correction as fast as practicable
by applying the optimum quantity of proportional correction.

A drawback of proportional control is that it cannot eliminate the residual SP–PV error, as it
requires an error to generate a proportional output. A PI controller can be used to overcome
this. The PI controller uses a proportional term (P) to remove the gross error, and an integral
term (I) to eliminate the residual offset error by integrating the error over time.

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In some systems, there are practical limits to the range of the MV. For example, a heater has a
limit to how much heat it can produce and a valve can open only so far. Adjustments to the gain
simultaneously alter the range of error values over which the MV is between these limits. The
width of this range, in units of the error variable and therefore of the PV, is called the
proportional band (PB).

FIGURE:2:PROPORTIONAL CONTROLLER BLOCK DIAGRAM

Furnace example

When controlling the temperature of an industrial furnace, it is usually better to control the
opening of the fuel valve in proportion to the current needs of the furnace. This helps avoid
thermal shocks and applies heat more effectively.

At low gains, only a small corrective action is applied when errors are detected. The system
may be safe and stable, but may be sluggish in response to changing conditions. Errors will
remain uncorrected for relatively long periods of time and the system is overdamped. If the
proportional gain is increased, such systems become more responsive and errors are dealt with
more quickly. There is an optimal value for the gain setting when the overall system is said to
be critically damped. Increases in loop gain beyond this point lead to oscillations in the PV and

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such a system is underdamped. Adjusting gain to achieve critically damped behavior is known
as tuning the control system.

In the underdamped case, the furnace heats quickly. Once the setpoint is reached, stored heat
within the heater sub-system and in the walls of the furnace will keep the measured temperature
rising beyond what is required. After rising above the setpoint, the temperature falls back and
eventually heat is applied again. Any delay in reheating the heater sub-system allows the
furnace temperature to fall further below setpoint and the cycle repeats. The temperature
oscillations that an underdamped furnace control system produces are undesirable.

In a critically damped system, as the temperature approaches the setpoint, the heat input begins
to be reduced, the rate of heating of the furnace has time to slow and the system avoids
overshoot. Overshoot is also avoided in an overdamped system but an overdamped system is
unnecessarily slow to initially reach setpoint respond to external changes to the system, e.g.
opening the furnace door.

1.2 PID Control

Pure proportional controllers must operate with residual error in the system. Though PI
controllers eliminate this error they can still be sluggish or produce oscillations. The PID
controller addresses these final shortcomings by introducing a derivative (D) action to retain
stability while responsiveness is improved.

FIGURE:3:PID CONTROLLER BLOCK DIAGRAM

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Derivative action

The derivative is concerned with the rate-of-change of the error with time: If the measured
variable approaches the setpoint rapidly, then the actuator is backed off early to allow it to coast
to the required level; conversely, if the measured value begins to move rapidly away from the
setpoint, extra effort is applied—in proportion to that rapidity to help move it back.

On control systems involving motion control of a heavy item like a gun or camera on a moving
vehicle, the derivative action of a well-tuned PID controller can allow it to reach and maintain
a setpoint better than most skilled human operators. If a derivative action is overapplied, it can,
however, lead to oscillations.

Integral action

The integral term magnifies the effect of long-term steady-state errors, applying an
everincreasing effort until the error is removed. In the example of the furnace above working
at various temperatures, if the heat being applied does not bring the furnace up to setpoint, for
whatever reason, integral action increasingly moves the proportional band relative to the
setpoint until the PV error is reduced to zero and the setpoint is achieved.

FIGURE:4:GRAPH

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Ramp up % per minute

Some controllers include the option to limit the "ramp up % per minute". This option can be
very helpful in stabilizing small boilers (3 MBTUH), especially during the summer, during
light loads. A utility boiler "unit may be required to change load at a rate of as much as 5% per
minute (IEA Coal Online - 2, 2007)".

Other techniques

It is possible to filter the PV or error signal. Doing so can help reduce instability or oscillations
by reducing the response of the system to undesirable frequencies. Many systems have a
resonant frequency. By filtering out that frequency, stronger overall feedback can be applied
before oscillation occurs, making the system more responsive without shaking itself apart.

Feedback systems can be combined. In cascade control, one control loop applies control
algorithms to a measured variable against a setpoint but then provides a varying setpoint to
another control loop rather than affecting process variables directly. If a system has several
different measured variables to be controlled, separate control systems will be present for each
of them.

Control engineering in many applications produces control systems that are more complex than
PID control. Examples of such field applications include fly-by-wire aircraft control systems,
chemical plants, and oil refineries. Model predictive control systems are designed using
specialized computer-aided-design software and empirical mathematical models of the system
to be controlled.

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 TYPES OF CONTROL SYSTEM

2.1 Open Loop Control System

If in a physical system there is no automatic correction of the variation in its output, it is called
an open loop control system. That is, in this type of system, sensing of the actual output and
comparing of this output (through feedback) with the desired input does not take place. The
system on its own is not in a position to give the desired output and it cannot take into account
the disturbances. In these systems, the changes in output can be corrected only by changing the
input manually.

FIGURE:6:OPEN LOOP CONTROL SYSTEM

2.1.a APPLICATIONS

An open-loop controller is often used in simple processes because of its simplicity and low
cost, especially in systems where feedback is not critical. A typical example would be an older
model domestic clothes dryer, for which the length of time is entirely dependent on the
judgement of the human operator, with no automatic feedback of the dryness of the clothes.

For example, an irrigation sprinkler system, programmed to turn on at set times could be an
example of an open-loop system if it does not measure soil moisture as a form of feedback.
Even if rain is pouring down on the lawn, the sprinkler system would activate on schedule,
wasting water.

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Another example is a stepper motor used for control of position. Sending it a stream of electrical
pulses causes it to rotate by exactly that many steps, hence the name. If the motor was always
assumed to perform each movement correctly, without positional feedback, it would be open-
loop control. However, if there is a position encoder, or sensors to indicate the start or finish
positions, then that is closed-loop control, such as in many inkjet printers. The drawback of
open-loop control of steppers is that if the machine load is too high, or the motor attempts to
move too quickly, then steps may be skipped. The controller has no means of detecting this and
so the machine continues to run slightly out of adjustment until reset. For this reason, more
complex robots and machine tools instead use servomotors rather than stepper motors, which
incorporate encoders and closed-loop controllers.

However, open-loop control is very useful and economic for well-defined systems where the
relationship between input and the resultant state can be reliably modeled by a mathematical
formula. For example, determining the voltage to be fed to an electric motor that drives a
constant load, in order to achieve a desired speed would be a good application. But if the load
were not predictable and became excessive, the motor's speed might vary as a function of the
load not just the voltage, and an open-loop controller would be insufficient to ensure repeatable
control of the velocity.

An example of this is a conveyor system that is required to travel at a constant speed. For a
constant voltage, the conveyor will move at a different speed depending on the load on the
motor (represented here by the weight of objects on the conveyor). In order for the conveyor
to run at a constant speed, the voltage of the motor must be adjusted depending on the load. In
this case, a closed-loop control system would be necessary.

Thus there are many open-loop controls, such as switching valves, lights, motors or heaters on
and off, where the result is known to be approximately sufficient without the need for feedback.

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2.2 Closed Loop Control System

A closed loop control system is a system where the output has an effect upon the input quantity
in such a manner as to maintain the desired output value.

In a closed loop control system, the controlled variable (output) of the system is sensed at every
instant of time, feedback and compared with the desired input resulting in an error signal. This
error signal directs the control elements in the system to do the necessary corrective action such
that the output of the system is obtained as desired.

The feedback control system takes into account the disturbances also and makes the corrective
action. These control systems are accurate, stable and less affected by noise. But these control
systems are sophisticated and hence costly. They are also complicated to design for stability,
give oscillatory response and feedback brings down the overall gain of the control system.

FIGURE:7:CLOSED LOOP CONTROL SYSTEM

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2.2a APPLICATIONS

There are different kinds of electronic devices that use a closed-loop control system. So the
applications of closed-loop control systems include the following.

In servo voltage stabilizer, the voltage stabilization can be attained by giving output voltage
feedback to the system

⚫ In the water level controller, the level of water can be decided by the input water

⚫ The temperature in the AC can be adjusted depending on the temperature of the room.

⚫ The motor speed can be controlled using a tachometer or current sensor, where the sensor
detects the motor speed and sends feedback to the control system to change its speed.

⚫ Some more examples of these systems include thermostat heater, solar system. missile
launcher, auto engine, automatic toaster, water control system using a turbine.

⚫ Automatic electric iron can be controlled automatically by the heating element’s

temperature in the iron.

2.3 FEEDBACK CONTROL

A feed back control system, such as a PID controller, can be improved by combining the
feedback (or closed-loop) control of a PID controller with feed-forward (or open-loop) control.
Knowledge about the system (such as the desired acceleration and inertia) can be fed forward
and combined with the PID output to improve the overall system performance. The feed-
forward value alone can often provide the major portion of the controller output. The PID
controller primarily has to compensate whatever difference or error remains between the
setpoint (SP) and the system response to the open-loop control. Since the feed-forward output
is not affected by the process feedback, it can never cause the control system to oscillate, thus
improving the system response without affecting stability. Feed forward can be based on the

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set point and on extra measured disturbances. Setpoint weighting is a simple form of feed
forward.

For example, in most motion control systems, in order to accelerate a mechanical load under
control, more force is required from the actuator. If a velocity loop PID controller is being used
to control the speed of the load and command the force being applied by the actuator, then it is
beneficial to take the desired instantaneous acceleration, scale that value appropriately and add
it to the output of the PID velocity loop controller. This means that whenever the load is being
accelerated or decelerated, a proportional amount of force is commanded from the actuator
regardless of the feedback value. The PID loop in this situation uses the feedback information
to change the combined output to reduce the remaining difference between the process setpoint
and the feedback value. Working together, the combined open-loop feed-forward controller and
closed-loop PID controller can provide a more responsive control system in some situations.

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 CONCLUSION

The PID Control System: Analysis, Design, and Technology project has provided a
comprehensive understanding of Proportional-Integral-Derivative (PID) controllers, their
design methodologies, and their applications in modern control systems. Through detailed
analysis, we explored the fundamental principles governing PID controllers and how tuning
techniques impact system performance.
In the design phase, we implemented various tuning methods, such as Ziegler-Nichols,
Cohen-Coon, and modern optimization techniques, to achieve optimal stability, minimal
error, and improved transient response. Simulation results confirmed that a well-tuned PID
controller enhances system accuracy, robustness, and efficiency, making it a widely
adopted solution in industrial automation, robotics, and process control.
Furthermore, the technological advancements in adaptive, fuzzy, and model-based PID
controllers demonstrate the evolving nature of PID control in the era of artificial
intelligence and IoT. These innovations provide smarter and more adaptive control
solutions, expanding the scope of PID beyond traditional applications.
In conclusion, this project highlights the significance of PID controllers in engineering and
industrial automation. While traditional PID control remains a fundamental approach,
continuous advancements in technology are shaping more intelligent and adaptive control
strategies, ensuring higher precision, efficiency, and reliability in various industries.