Mechatronics

UNIT –VI
CONTROL
SYSTEMS
 Syllabus

Control Systems

• P, I and D control actions,

• P, PI, PD and PID control systems,

• Transient response:- Percentage overshoot, Rise time, Delay

time, Steady state error

• PID tuning (manual)

 Objectives
1. Understand key elements of Mechatronics system,
representation into block diagram
2. Understand concept of transfer function, reduction and analysis
3. Understand principles of sensors, its characteristics, interfacing
with DAQ microcontroller
4. Understand the concept of PLC system and its ladder
programming, and significance of PLC systems
5. in industrial application
6. Understand the system modeling and analysis in time domain
and frequency domain.
7. Understand control actions such as Proportional, derivative
and integral and study its significance in industrial
applications.
 Outcomes
1. Identification of key elements of mechatronics system and its
representation in terms of block diagram
2. Understanding the concept of signal processing and use of
interfacing systems such as ADC, DAC, digital I/O
3. Interfacing of Sensors, Actuators using appropriate DAQ micro
-controller
4. Time and Frequency domain analysis of system model (for
control application)
5. PID control implementation on real time systems
6. Development of PLC ladder programming and implementation
of real life system
 Assumed Knowledge

Dynamics:

� Engineering Mechanics

Electrical & Electronics

� Elements of Electrical Engineering

Mathematics

� Engineering Mathematics (I, II & III)

 Reference Books

• Astrom & Hagglund, PID Controllers: Theory, Design &

Tuning, Chapter 2, 2nd Ed, Instrument Society of America, 1995.

• Golnaraghi & Kuo, Automatic Control System, Chapter 1/5/9,

9th Ed, John Wiley & Sons, 2009

 Why is Controller Necessary?
▪ Blue response resembles an un-controlled system. This response is
oscillatory as well as it takes much longer to settle down.
▪ For a mechanical system, this could be due to Inertia effect,
friction, backlash etc
▪ The red response is of a controlled system. This response contains no
oscillations and it settles to equilibrium / steady state in lesser time.
▪ Job of a control system is to “generate a control input / effort that can
be used to drive the un-controlled system, albeit externally, to achieve
the desired performance”.
 Illustration: What does Controller do?

-imaginary

X Undesirable Open Loop Pole Location

X
u X Desired Closed Loop Pole Location

-real X +real

Control is all about shifting of system

u poles from un-desirable to desirable
X location.

This shifting is done by the control

signal, u, provided the system allows it
+imaginary i.e. the system is “controllable”
Analysis of Response: Transient Specifications

Unit Step Response of Second Order System

 Transient Response Specifications
▪ Percentage Overshoot (% O.S): It is the amount that the
response overshoots the steady state, or final, value at the peak
time, expressed as a percentage of the steady-state value.
▪ Rise Time (Tr): Time required for the step response to rise from
10% to 90% of its final value.
▪ Delay Time (Td): Time required for the step response to reach
50% of final value
▪ Settling Time (Ts): Time required for the step response to
decrease and stay within ±2% of its final value
▪ Steady State Error (ess): It is the difference between the output
and the reference input after the steady state has reached
 Feedback Controller

Block Diagram of Feedback Controller

• Feedback controller generates an control signal / effort / external

disturbance based on the input signal it receives.
• The input signal is error; difference between measured value and
desired value, or set point.
• Feedback counters disturbance as well as variation in process
 Controllability
Advanced Learning (Out of Syllabus)

• Before a controller is implemented it is necessary to determine

is the system is controllable

• Test the “Controllability” of the system

• Controllability is the ability of the system to be controlled

provided an external disturbance is available.

 Proportional Integral Derivative Control

+ e u
Input ∑ PID Plant Output

Block Diagram of PID Controller

• PID stands for Proportional Integral Derivative Control.

• Being robust & easy to implement, it is one of the most widely used closed
loop control for precise operation of industrial applications and processes.
 Proportional Control

• In Proportional Control, the control signal, u, is directly

proportional to the error, e.

• As the gain is increased the system responds faster to changes in

set-point but becomes progressively under damped and eventually

unstable.
Proportional Control Action

P Control Signal
 Proportional Control
Advantages:
• Simple and easy to design and tune
• Rapid Response / Reduces Rise Time
• Reduces Steady State Error
Disadvantages:
• Not possible to eliminate Steady State Error / Offset
• Could lead to instability / rise in overshoot/ oscillations
Applications:
• Float Valve, Thermostat etc
 Derivative Control

• Derivative control produces a control signal proportional to the

rate at which the error is changing.
• Also known as rate controller.
• While sudden/rapid change in error leads to a control signal of
larger magnitude, gradual change leads to small magnitude.
• Even if the error is huge, the derivative control will generate no
signal if the error is constant
• Thus, not used alone; used with P control
Derivative Control Action

D Control Signal
 Derivative Control
Advantages:
• Reduces Settling time; Adds lead
• Reduces Overshoot; Adds more stability
Disadvantages:
• Not possible to eliminate Steady State Error / Offset
• Not possible to use alone
• Excessive use may make the system slow
• Amplifies Noise
Applications:
• In conjunction with P Control
 Integral Control

• Rate of change of integral control signal is proportional to

error.
• Control signal proportional to integral of error.
• When the error is zero, the control signal is a constant value.
• When the error is constant, the control signal varies at constant
rate.
Integral Control Action

I Control Signal
 Integral Control
Advantages:
• Eliminates steady state error/offset
• Decreases Rise Time
Disadvantages:
• Causes Integral Wind Up
• Leads to minor increase in overshoot
• Could make the system less stable
• Increases Settling time
Applications:
• In conjunction with P Control
 Integral Wind Up
Advanced Learning (Out of Syllabus)

• Caused by actuator saturation.

What Happens?

• Feedback loop is broken and the system runs in open loop because the actuator
remains saturated.

• While the error is zero, the integral term will keep building and become very large
over a period of time. This in turn would lead to saturation of control signal.

• The condition will prevail even when the error changes and it may take a long time
before the integrator and the controller output comes inside the saturation range.

• The consequence is that there are large time delay.

 PID: Series / Interacting Form
D I

+ +
e + + u
P

• Derivate Action interacts with Integral Action

• Modification in derivative time constant affects integral action

• Commercially used controller

Transfer Function of Series Form
Transfer Function of Series Form
 PID: Parallel / Non-Interacting Form

• Ideal Form

• Derivative Action does not Interact with Integral Action

Transfer Function of Parallel Form
 Parallel Form: PI Control

• Proportional Integral (PI) Control helps minimise rise time,

settling time as well as eliminate steady state error.
PI Control
 Parallel Form: PD Control

• Proportional Derivative (PD) Control helps reduce rise time,

settling time as well as minimize overshoot.
Proportional Derivative Control
Response of P, I & D w.r.t Error
Effect of P, I & D on Transient Specifications
P, I & D Control Action
 PID: Stepwise Procedure for Manual Tuning
1. Obtain an open-loop response and determine what needs to be
improved
2. Add a proportional control to improve the rise time
3. Add a derivative control to improve the overshoot
4. Add an integral control to eliminate the steady-state error
5. Adjust each of P, I & D until you obtain a desired overall
response referring to the table shown previously to find out
which controller controls what characteristics.
6. It is not necessary to implement all three controllers (P, I & D)
into a single system. For example, if a PI controller gives a good
enough response, then you don't need to add D control to the
system. Simple is better.
PID: Stepwise Procedure for Manual Tuning

NOTE

It is not necessary to implement all three controllers (P, I & D)

into a single system.

For example, if a PI controller gives a good enough response,

then you don't need to add D control to the system. Simple is
better!
 Applications of PID Control

90% processes are controlled using PID.

1. Regulation of Processes in Industry; for e.g.

1. Flow

2. Temperature

3. Pressure etc

2. Servo / DC motor Control

3. Linear Position Control

 Example: Time Domain Specifications
▪ Using the values of the natural frequency= =1.414 and the
damping factor=ζ=0.177, determine the values for overshoot,
rise time and 2% settling time
Effect of P, I & D on Transient Specifications
 PID: Stepwise Procedure for Manual Tuning

1. Obtain an open-loop response and determine what needs to be

improved

2. Add a proportional control to improve the rise time

3. Add a derivative control to improve the overshoot

4. Add an integral control to eliminate the steady-state error

 Need for Optimal Control
• System’s performance vs control effort needs to be thought about
• Actuators have limited bandwidth
Leads to need for Optimal Control
• Optimal control works towards providing the end user a optimal
trade-off between performance and control effort
• Performance vs cost!
• Linear Quadratic Regulator (LQR) is a optimal control technique
used to determine feedback gain
• Feedback gain is used to determine control effort
 Linear Quadratic Regulator
• In order to determine feedback gain, k, LQR aims to minimize
below performance index, J

In the above quadratic cost function:

• T = final time, t = initial time. If T = ∞, the LQR works like a
regulator

• X: Vector comprising of state variables

• E.g. in a mass spring damper system, position and velocity
are state variables

• U: Vector comprising of inputs

 Linear Quadratic Regulator

• Q: is a positive definite performance weighting matrix that

relates to achieving a “desired outcome”

• It is a “penalty” for deviation of performance from its desired

• R: is positive definite effort weighting matrix that relates to

limiting the control effort / input

• It is a “penalty” for using large control inputs

 Effect of Q

• Larger the value of Q: ratio of Q/R increases

• Larger the value of gain k

• Larger the control input-could saturate the actuator

• Better performance - settling time improves

• Damped system - implies less overshoot

 Effect of R

• Larger the value of R: ratio of Q/R reduces

• Smaller the value of gain k

• Smaller the control input - reduced control effort

• Limited performance - design objectives not achieved

• Trade off: Performance of system v/s control effort

• Faster performance requires bigger control effort

 LQR vs PID

• Being an optimal control, LQR provides direct trade-off between

performance and cost

• Both LQR and PID require measured / observed feedback

• Tuning of LQR requires an analytical model

• In comparison, PID can be tuned without any analytical model

• In comparison to PID, designing an LQR is more complicated