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Is Automated PID Tuning Dependable?

It Is Surprising That More Than 30% Of All Factory PID Control Loops Are
Operating In Manual Rather Than Automatic Mode. To Make Matters Worse,
Of Those Loops Operating In Automatic Mode, 65% Produce Less Variance
When In Manual. This Reality Is Possibly Due To A Dearth Of Personnel
Having Sufficient Know-how To Tune And Optimize A PID Loop, Which Is One
Reason So Many Vendors Provide Automated...
Greg Baker, Watlow

01/28/2009

It is surprising that more than 30% of all factory PID control loops are operating in manual rather
than automatic mode. To make matters worse, of those loops operating in automatic mode, 65%
produce less variance when in manual. This reality is possibly due to a dearth of personnel having
sufficient know-how to tune and optimize a PID loop, which is one reason so many vendors provide
automated configuration features. Unfortunately, these are all not created equal, and utilities from
various vendors provide much different results. We will describe these features in the context of
temperature control units, with the results of a performance comparison between several
anonymous vendors.

Some controllers offer different degrees of

aggressiveness in executing a set point change. Make Poll Of The
your choice based on how fast the process needs to
Week
change against the product's ability to tolerate being
overheated.
When selecting a
wireless vendor
There are two levels of sophistication in this technology, commonly referred to as auto-tune and what do you
adaptive-tune (or continuous tune). Auto-tune is generally offered as a standard feature and relies consider most
on characterizing the system through artificial manipulation of control output power levels. however, important?
this is generally impractical to do during production operation. The software watches the process and F eat ures
analyzes its response while applying either a step increase in fixed power level, or cycle-tune using Pric e
oscillating power levels. The step-tune approach performs best when started from a stable, constant Tec hnic al Serv ic e
process. The cycletune is not as dependent on initial conditions, but the process must be able to
Reput at io n
handle the amplitude of the necessary oscillations.
O ther
Adaptive-tune generally implies an increase in cost and requires more intelligence built into the Vo t e No w
controller. It must be able to monitor the process during production operation and judge when and
how to modify PID parameters to maintain stability as conditions require. It characterizes the
Click Here for Poll
process without having to manipulate power levels artificially, as is done in both step and cycle style
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auto tune.
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These capabilities reduce puzzling over PID parameters. A user can just let the controller tune itself.
However, the ability of major vendors to deliver satisfactory control after tuning, however, was the
topic of our recent investigation. The findings may shed light on reports of unacceptably poor
performance found industry-wide.

Test Methodology
Identifying differences in control performance requires a platform capable of simulation and accurate
measurement. A PC with high resolution I/O was developed to interface with the controller, simulate
a wide variety of industrial plant conditions, and provide easily repeatable test results. It reads the
controller’s power output levels while running a plant simulation that calculates the proper signal to
feed back to the controller’s input sensor. As the PC continuously graphs process value and power

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