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net ISSN (ONLINE): 2250-0758, ISSN (PRINT): 2394-6962

Volume-6, Issue-5, September-October 2016

International Journal of Engineering and Management Research
Page Number: 61-69

A Review of Tuning Method for Cascade Control

Somnath Garai1, Rijoy Maity2, Swarnib Das3, Samprit Chakraborty4, Shubhrajit Ghosh5
1
Assistant Professor, Instrumentation & Control Engineering, Calcutta Institute of Engineering & Management, Kolkata,
INDIA
2,3,4,5
Student of 4th year Department of Instrumentation and Control Engineering,Calcutta Institute of Engineering &
Management, Kolkata, INDIA

ABSTRACT
Cascade control is the family of control loop makes
the explicit use of model to obtain advance control signal. The
reason for its popularity in industry and academia is its
capability of noise rejection. There is various type of cascade
control based on cascade control tuning method. This paper
provides a review of the most commonly used methods of
Cascade controller tuning. The most widely used strategies
based on closed loop step responses, self- tuning of fuzzy logic
controller in cascade control, auto tuning of cascade control
system using the multiple integration method, robust analysis
and PID tuning of cascade control system, PID controller
tuning of cascade control system by a simple relay feedback
test and auto tunning of parallel cascade control using set
point relay have been described with basic idea, properties
and their controller formulation and tuning.
Keywords---- Cascade Control; PID Tuning, Process
Control IMC, Multiple Integration method, Magnitude
Optimum (MO) criterion, Fuzzy Logic Controller, Robust.
I. INTRODUCTION
Cascade control can improve control system
performance over a single loop control, whenever either a
disturbance a measurable intermediate or secondary
process output that directly affects the primary process
output that we want to control. The configuration of the
cascade control scheme is shown in fig1, where an inner
loop is embedded with in an outer loop and the outer loop
output variable is to be controlled. The control system
consists of two process and two controllers with outer loop
transfer functionG P , inner loop transfer function G P2 and
outer loop controller G C1 , inner loop controller G C2
respectively. In cascade control, the inner loop with fast
dynamic response to eliminate input disturbances, and an
outer loop to regulate output performance. Conventionally,
61 Copyright © 2016. Vandana Publications. All Rights Reserved.
they are tuned in a sequential manner. First the outer loop
controller is put on manual and the inner loop controller is
tuned. Subsequently, the inner loop controller is
commissioned and the outer loop controller is tuned to
complete the tuning process. If the control performance
achieved is unsatisfactory, the entire sequence must be
repeated. So, tuning of cascade control is a time
consuming task. Cascade controller auto-tuning relieves
the pain of manually tuning a controller and has been
successfully applied in many industry fields. We will
discuss some useful cascade tuning method. Among few of
them, a simple relay feedback test both inner and outer
loop model parameter [1], Jyh-Cheng, M.W Lee proposed a
new automatic tuning method for cascade control system
based on a single closed loop step test [2]. Alberto-Leva
proposed on IMC based controller to achieve fast tuning
and moderate process upset [3]. M. Santos proposed a self-
tuning of fuzzy logic controller of cascade control [4]. Ivan
Ganchev developed a new technique of auto tuning of
cascade control system by using multiple Integration
method [5], Wen Tanand and Jizhen Liu produced a new
method of robust analysis and PID tuning of cascade
control system [6].
II. REVIEW OF METHOD OF
CASCADE CONTROL
2.1 Simple relay feedback test method
In 2001, Sihai Song, WenjianCai developed a
method of auto tuning of cascade control system. In this
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method a simple relay feedback test is used. Here in both
outer and inner loop PID tuning rules are applied to tune
both loops. Two controllers of cascade control system are
standard feedback controller (P,PI,PID).Usually a
proportional controller is used for inner loop process and
when the inner loop process contains essential time delays,
the integral action is needed and the outer loop process is
such that the inner loop must be limited[1].To serve the
purpose of reducing or eliminating the inner loop
disturbance ‘d 2 ’ before its effect can spill over to the outer
loop, it is essential that the inner loop exhibit a faster
dynamic response than that of the outer loop. The
crossover frequency is higher than that for the outer loop,
which allows higher gains in the inner loop controller in
order to regulate more effectively the effect of
disturbances occurring in the inner loop without affecting
the stability of the system. When the process output lags
behind the input by – π radians, the closed loop system
may generate sustained oscillation around the ultimate
frequency (the frequency where the phase lag is (– π). The
proposed relay feedback test for auto-tuning cascade
control system.
When the relay feedback test begins, Switch-A
point to position’2,Switch-B point to position‘4’ and
Switch-C points to position’6’.As the inner loop process
acts much faster than outer loop process, the output the
inner loop in fig-2. Under the feedback test acts as a step
response in half of the period of the stationary oscillation.
Therefore, a single relay feedback test can be used to
obtain simultaneously both the inner loop process and
outer loop process. In this case a low order dead time
model is used as real time process model.
𝐾𝐾1
𝐺𝐺𝑝𝑝1 (𝑆𝑆) = 𝜏𝜏 𝑒𝑒 −𝐿𝐿1 𝑆𝑆 …………………………
1 𝑆𝑆+1
(1)
𝐾𝐾2
𝐺𝐺𝑝𝑝2 (𝑆𝑆) = 𝜏𝜏 𝑆𝑆+1 𝑒𝑒 −𝐿𝐿2 𝑆𝑆 …………………………
2
(2)
Equation (1) & (2) represent the outer process
model and inner process model respectively. This model is
characterized by three parameters –the static gain(k),the
time constant(τ),and dead time (L).It describes a linear
monotonic process quite well is many industrial
applications and often sufficient for PID controller tuning.
As the inner loop output ‘u’ can be considered as a step
response in half –period of relay feedback test, in this
method proposed due to its robustness. Suppose that the
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ISSN (ONLINE): 2250-0758, ISSN (PRINT): 2394-6962
inner process model is represented by equation (2)and a
unit step change occurs at t=0 in the process input, and
output are collected until process enters a new steady state
gain. The process response after dead time t=L 2 is
described by –
𝑒𝑒 (𝑡𝑡−𝐿𝐿2 )
𝑢𝑢(𝑡𝑡) = �1 − � + 𝜔𝜔(𝑡𝑡) … … … … (3) 𝑡𝑡
𝑇𝑇2
≥ 𝐿𝐿2
Where ω(t) is the white noise in the measurement of u(t). It
follows from the above relation that,
𝑇𝑇2
[𝑢𝑢(𝑡𝑡)𝐾𝐾2 ] � � = 𝐾𝐾2 − 𝐴𝐴(𝑡𝑡) − 𝜕𝜕(𝑡𝑡), 𝑡𝑡 ≥ 𝐿𝐿2 … (4)
𝐿𝐿2
Where A(t) is the area under the process response 𝜕𝜕(𝑡𝑡)is
the integration of measurement noise, they are given
asfollows
𝜏𝜏
𝐴𝐴(𝑡𝑡) = � 𝑢𝑢(𝑡𝑡)𝑑𝑑𝑑𝑑
0
𝜏𝜏
𝜕𝜕(𝑡𝑡) = ∫0 𝜔𝜔(𝑡𝑡)𝑑𝑑𝑑𝑑……………………………….
(5)
The inner process model static gain
K 2 is computed from the process steady state of input and
output
𝐾𝐾2
∆𝑢𝑢
= … … … … … … … … … … … … … … … … (6)
∆𝑢𝑢𝑑𝑑
Where, ∆𝑢𝑢denotes the change of process output
and ∆𝑢𝑢𝑑𝑑
stands for the derivations in the manipulated input. As the
main purpose of the inner loop control is to eliminate the
input disturbance, a Por PI controller is used for tuning. In
the tuning method Ziegler-Nichols,Cohen-Coon tuning
rule are applied. This feature marks it very easy to
integrate the tuning method in to the existing auto-tuning
system.
2.2. Cascade Controller tuning based on Closed Loop
step Response
This is a tuning method based on single closed-
loop step test of cascade control. This method identifies
the required process information with the help of B-spline
series expansions of the step responses. The twoPID
Controller is tuned using an Internal Modal Control (IMC)
method. The secondary controller is designed for enhanced
disturbance rejection and the primary controller is
designed without requiring an additional test, based on an
identified process.
Model that accurately accounts for the inner loop
dynamics. The proposed method is robust for measurement
of noise because the filtering property of the B-splines, and
can provide satisfactory control performance. In this
method the process identification is accomplished by
conducting a simple step test in the set-point during closed
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loop operation of a cascade control system compared with
open-loop test and it has the significant advantage of not
excessively disturbing the system. The controller
parameter can be chosen arbitrary. Then the step response
data of process variable and manipulated variable are
collected until the new steady state is reached. An example
of this method is described where two process model is
considered.
𝐺𝐺1 (𝑠𝑠)
1 respectively. There have two relay tests in many cascade
= 𝑒𝑒 −2𝑠𝑠 … … … … … … … … … … . . … (7)
5𝑠𝑠 + 1
𝐺𝐺2 (𝑠𝑠) =
1
𝑠𝑠+1
𝑒𝑒 −𝑠𝑠 … … … … … … … … … … … … . . … (8)
To tune the primary controller, the proposed method
identifies a SOPTDZ model for the apparent process as
𝐺𝐺𝑚𝑚1 (𝑠𝑠)
0.361(0.634𝑠𝑠 + 1)
= 𝑒𝑒 −3.57𝑠𝑠 … … (9)
(1.698𝑠𝑠 2 + 5.34𝑠𝑠 + 1)
Choosing𝑀𝑀𝑠𝑠1 = 1.7, the resulting PID parameters are
obtained as𝐾𝐾𝐶𝐶1 = 3.157, 𝜏𝜏𝐼𝐼1 = 5.936, 𝜏𝜏𝐷𝐷1 = 0.766. On
other hand, the method of Lee uses the following
approximated model for the primary controller design.
𝐺𝐺𝑚𝑚1 (𝑠𝑠)
1
= 𝑒𝑒 𝜃𝜃2 𝑠𝑠 … … … … … … … … … … (10)
𝜆𝜆2 𝑠𝑠 + 1
𝐺𝐺1 (𝑠𝑠)
1
= 𝑒𝑒 −3𝑠𝑠 … … … … … (11)
(1.18𝑠𝑠 + 1)(5𝑠𝑠 + 1)
The tuning parameter 𝜆𝜆1 is selected so that the resulting
system has the same 𝑀𝑀𝑆𝑆1 with the proposed system,
leading to 𝐾𝐾𝐶𝐶1 = 2.3, 𝜏𝜏𝐼𝐼1 = 7.5, 𝜏𝜏𝐷𝐷1 = 1.99. The closed
loop response to a unit step set-point change at
t=0,followed by unit step disturbance inputs
𝑑𝑑2 and𝑑𝑑1 𝑎𝑎𝑎𝑎 𝑡𝑡 = 60 and 𝑡𝑡 = 120 respectively. Their
results show the superior performance at the proposed
method on the model consideration [2].
Significantly deviates from the actual apparent
process because the secondary controller is a P-controller.
Therefore, this gives a superior performance by the
proposed method.
2.3. IMC based Controller to achieve Fast tuning and
moderate process upset
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ISSN (ONLINE): 2250-0758, ISSN (PRINT): 2394-6962
Alberto Leva developed this procedure for fast
auto-tuning of Cascade Controller. This procedure is used
to get fast auto-tuning and to eliminate or reduce the
process disturbance with the help of relay-based tuning
method on a single loop test and IMC principle (a tuning
rule) [3].
In Fig. 3 block diagram R I (s) and R E (s) are the
regulators of inner and outer loop respectively. Similarly,
P I (s) and P E (s) are the processes of inner and outer loop
control systems. One test is used for inner loop tuning and
another relay test is for outer loop with closed condition of
inner loop. There have several methods like Ziegler-Nichol
method with the similar concept which is much time
consuming [7]. So, instead of using two loops, here single
relay-based test is used for tuning purpose of processes- P I
(s) and P E (s).
Actually there have some typical different
characteristics of the controller or regulator in the
fundamental principle of this method. But, there have four
expectations for achieving proper tuning of the regulator
which have proposed. Firstly, there should be a cut-off
frequency of the outer loop which phase of𝑃𝑃𝐸𝐸 (𝑗𝑗𝑗𝑗) =
−90°. Secondly, P I (s) is faster than P E (s) which is
termed as ‘Actuator’ and the phase angle of
𝑃𝑃𝐸𝐸 (𝑗𝑗𝑗𝑗) 𝑃𝑃𝐼𝐼 (𝑗𝑗𝑗𝑗) is -90°. Thirdly, when the Bode plot is -
20dB/decade, the P E (s) (low order) process has phase of -
90° and which has higher slope than the particular plot.
Rather than first two points this expectation is quite
complex from the general point of view. Fourthly, for
smooth and fine control result, the separation of P I (s) and
P E (s) is of 0.5-1 decades between outer & inner loop. In
this point, the main objective is to reduce inner load
disturbance𝑑𝑑𝐼𝐼 .
As per Fig. 4, the single relay test with no
hysteresis with integrator and the processes are cascaded
together to meet those expectations. Also, the important
fact is to take for delay-free models- 𝑃𝑃� I (s) 𝑃𝑃� E (s). The
R R
graphical view is shown in the Fig. 5.
According to Fig. 5, for the auto-tuning of
cascade controller with relay test, there have some
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formulae and procedure developed by Alberto Leva reaches to set point. Also, the robustness of the process can
[3].With the help of oscillating frequency (𝜔𝜔𝑂𝑂𝑂𝑂 ), be achieved with less numerical calculations and proper
magnitudes and phases of processes tuning rule.
(𝑃𝑃𝐼𝐼𝐼𝐼𝐼𝐼 , 𝑃𝑃𝐸𝐸𝐸𝐸𝐸𝐸 &𝜑𝜑𝐼𝐼𝐼𝐼𝐼𝐼 , 𝜑𝜑𝐸𝐸𝐸𝐸𝐸𝐸 ) the regulators- R I (s) and R E (s) are 2.4 Auto-tuning method for cascade control system by
to be tuned as per the proposed method. using Multiple Integration Method
The tuned internal regulator- R I (s) for PI structure- In 2004, Ivan Ganchev developed a new
𝑅𝑅𝐼𝐼 (𝑠𝑠) technique of auto tuning of cascade control system by
1 using Multiple Integration Method. In this paper he
= 𝐾𝐾𝐼𝐼 �1 + � … … … … … … . . … … … . . (12) described an algorithm for auto-tuning the main PI
𝑠𝑠𝑇𝑇𝑖𝑖𝑖𝑖 controller and the parameters of the auxiliary corrector
According to IMC principle formulae [8], based on the Multiple Integration Method. Cascade
𝑇𝑇𝑖𝑖𝑖𝑖 = 𝑇𝑇𝐼𝐼, and Control mainly used in case of long time constants or dead
𝑇𝑇 time between the process variable and the control variable
𝐾𝐾𝐼𝐼 = 𝜇𝜇 𝜆𝜆𝐼𝐼 … … … … … … … … … … (13) and the control variable. Cascade Control arise when the
𝐼𝐼 𝐼𝐼
Where, 𝜆𝜆𝐼𝐼 is a parameter,𝑇𝑇𝐼𝐼 = time constant. main disturbance of the system act in the control input and
Again, according to IMC principle, tuned external the secondary variable reacts to its disturbance much faster
regulator- than the main process variable y 1 can be measured.
𝑄𝑄𝐸𝐸 (𝑠𝑠)𝐹𝐹𝐸𝐸 (𝑠𝑠)
𝑅𝑅𝐸𝐸 (𝑠𝑠) = … … … . … (14)
1 − 𝑄𝑄𝐸𝐸 (𝑠𝑠)𝐹𝐹𝐸𝐸 (𝑠𝑠)𝑃𝑃�𝐸𝐸 (𝑠𝑠)
Where,Q E (s) =inverse of𝑃𝑃 �𝐸𝐸 (𝑠𝑠).
Also,𝐹𝐹𝐸𝐸 (𝑠𝑠) =
1
𝑠𝑠𝜆𝜆 𝐸𝐸 … … … … … … … . . (15)
(1+𝑠𝑠𝜆𝜆 𝐸𝐸 )(1+ )
10
And,
𝜆𝜆𝐸𝐸 = 𝐵𝐵𝑠𝑠 𝜆𝜆𝐼𝐼 … … … … … … … … … … … … . … . (16)
Where, 𝐵𝐵𝑆𝑆 = bandwidth separation between inner & outer In this cascade structure is become active when
loop. the secondary loop is very faster than the primary loop [4].
𝜆𝜆𝐸𝐸 = desired closed loop time-constant for outer loop. The secondary loop is three times faster than the primary
An example is given in below which has proposed in this loop. These frequenciesare expressed as the ultimate
method. frequencies of the two loops (W kp1 <0.3W kp2 ). [9]
Example 1. The processes are described as follows, The Multiple Integration Method
1 The Multiple Integration Method is a most useful
𝑃𝑃𝐼𝐼 (𝑠𝑠) = , 𝑃𝑃 (𝑠𝑠) method for auto-tuning of PI(D) Controllers. It can be
1 + 2𝑠𝑠 𝐸𝐸 expressed as,
1 𝑦𝑦(𝑆𝑆)
= (17) 𝐺𝐺(𝑆𝑆) = 𝑈𝑈(𝑆𝑆) =
(1 + 10𝑠𝑠)(1 + 4𝑠𝑠)(1 + 𝑠𝑠)2
1+𝑏𝑏 𝑆𝑆+𝑏𝑏 𝑆𝑆 2 +𝑏𝑏 𝑆𝑆 3 +⋯+𝑏𝑏 𝑆𝑆 𝑚𝑚
By taking some assumptions as per proposed method 𝑘𝑘 0 1+𝑎𝑎1 𝑆𝑆+𝑎𝑎2 𝑆𝑆 2 +𝑎𝑎3 𝑆𝑆 3 +⋯+𝑎𝑎𝑚𝑚 𝑆𝑆 𝑛𝑛 𝑒𝑒 −𝜏𝜏 0 𝑆𝑆 … . (19)
R

bandwidth 1 r/s& 0.2 r/s and similar noise amplitude 4 for 1 2 3 𝑛𝑛

𝑃𝑃𝐼𝐼 (𝑠𝑠) and𝑃𝑃𝐸𝐸 (𝑠𝑠), 𝐴𝐴𝑓𝑓𝑓𝑓 = 3 and𝐵𝐵𝑆𝑆 = 10 produces. So, the Where, k 0 = process steady state gain,
desired tuned regulators are, 𝜏𝜏0 = dead time or process pure time delay,
1 + 2.85𝑠𝑠 and b 1 b 2 b 3 …b m , a 1 a 2 a 3 …a m are the next parameters of the
𝑅𝑅𝐼𝐼 (𝑠𝑠) = 1.033 , process dynamic (m≤n) [9].
𝑠𝑠 Ivan Ganchev, said that the transfer function of
𝑅𝑅𝐸𝐸 (𝑠𝑠) the PID Controller from the research paper of
1 + 17.32𝑠𝑠 + 74.98𝑠𝑠 2 DamirVrancic of New PID Controller Auto-tuning Method
= 0.083 … … . . (18) based on Multiple Integrations. [9]
𝑠𝑠(16 + 0.86𝑠𝑠)
The estimated and true values of The transfer function of the PID controller is,
arg°�𝑃𝑃𝐸𝐸 (j𝜔𝜔𝑂𝑂𝑂𝑂 )�, arg°�𝑃𝑃𝐼𝐼 (j𝜔𝜔𝑂𝑂𝑂𝑂 )�and 𝑈𝑈(𝑆𝑆) 1
𝐺𝐺𝐶𝐶 (𝑆𝑆) = = 𝐾𝐾 �1 +
|𝑃𝑃𝐼𝐼 (𝑗𝑗𝜔𝜔𝑂𝑂𝑂𝑂 )| 𝑎𝑎𝑎𝑎𝑎𝑎 |𝑃𝑃𝐸𝐸 (𝑗𝑗𝜔𝜔𝑂𝑂𝑂𝑂 )|are very close to each other of 𝐸𝐸(𝑆𝑆) 𝑆𝑆𝑇𝑇𝑖𝑖
the result in this proposed method. After achieving these 𝑆𝑆𝑇𝑇𝑑𝑑
two tuned regulators, it can be concluded that only single + � … . (20)
relay with integrator test for single loop is simple and fast 1 + 𝑆𝑆𝑇𝑇𝑓𝑓
response. The controller can be auto-tuned as well as

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Here, U and E represents as respectively controller output [𝑎𝑎1 3 + 𝑎𝑎1 2 𝑏𝑏1 + 𝑎𝑎1 𝑏𝑏2 − 2𝑎𝑎1 𝑎𝑎2 + 𝑎𝑎2 𝑏𝑏1
and control error,e = (c-y).
+𝑎𝑎3 − 𝑏𝑏3 + 𝑇𝑇0 (𝑎𝑎1 2 − 𝑎𝑎1 𝑏𝑏1 − 𝑎𝑎2 + 𝑏𝑏2 )
K = Proportional gain,
𝑇𝑇 2 𝑇𝑇 3
T i = Integral time constant,
− 20 (𝑎𝑎1 − 𝑏𝑏1 ) + 60 ]
T d = Derivative time Constant,
𝑘𝑘 =
T f = filter time Constant, 2𝑘𝑘0 [−𝑎𝑎1 2 𝑏𝑏1 + 𝑎𝑎1 𝑎𝑎2 + 𝑎𝑎1 𝑏𝑏1 2 − 𝑎𝑎3 −
C = reference input,
Y = output. 𝑏𝑏1 𝑏𝑏2 + 𝑏𝑏3 + 𝑇𝑇0 (𝑎𝑎1 − 𝑏𝑏1 )2 + 𝑇𝑇0 2 (𝑎𝑎1 − 𝑏𝑏1 )
The closed loop configuration for PID Controller of the 𝑇𝑇
process shown in fig (7) + 30 − 𝑇𝑇𝑑𝑑 (𝑎𝑎1 − 𝑏𝑏1 + 𝑇𝑇0 )2 ]
… … … … … … … … … … … … … … . . (25)
[𝑎𝑎1 3 + 𝑎𝑎1 2 𝑏𝑏1 + 𝑎𝑎1 𝑏𝑏2 − 2𝑎𝑎1 𝑎𝑎2 + 𝑎𝑎2 𝑏𝑏1
+𝑎𝑎3 − 𝑏𝑏3 + 𝑇𝑇0 (𝑎𝑎1 2 − 𝑎𝑎1 𝑏𝑏1 − 𝑎𝑎2 + 𝑏𝑏2 )
𝑇𝑇 2 𝑇𝑇 3
− 20 (𝑎𝑎1 − 𝑏𝑏1 ) + 60 ]
𝑇𝑇 2
[𝑎𝑎1 2 − 𝑎𝑎1 𝑏𝑏1 − 𝑎𝑎2 + 𝑏𝑏2 + 𝑇𝑇0 (𝑎𝑎1 −𝑏𝑏1 ) + 20
−𝑇𝑇𝑑𝑑 (𝑎𝑎1 − 𝑏𝑏1 + 𝑇𝑇0 )]
Here, d = Load disturbance. … … … … … … … … … … … … … . . (26)
The closed loop amplitude frequency response, 𝑇𝑇𝑑𝑑 = 𝑓𝑓(𝑎𝑎1 … 𝑎𝑎3 , 𝑏𝑏1 … 𝑏𝑏3 , 𝑇𝑇0 ) … … … … (27)
𝑦𝑦(𝑗𝑗𝑗𝑗) 𝐺𝐺𝑝𝑝 (𝑗𝑗𝑗𝑗)𝐺𝐺𝐶𝐶 (𝑗𝑗𝑗𝑗) In this solution has a problem which is the exact
|𝐺𝐺𝐶𝐶𝐶𝐶 (𝑗𝑗𝑗𝑗)| = � �=� � and reliable identification of such a number of parameters
𝑊𝑊(𝑗𝑗𝑗𝑗) 1 + 𝐺𝐺𝑝𝑝 (𝑗𝑗𝑗𝑗)𝐺𝐺𝐶𝐶 (𝑗𝑗𝑗𝑗) from real identification is problematic [9].
≈ 1 … … … . (21) For remove this problem they used the concept of
i.e., G CL (j𝜔𝜔 ) as flat and as close to unity approximately for
R
Multiple Integration Method [9]. Then applying the step
a large bandwidth. This process is called Magnitude change of ∆𝑢𝑢 at the input of the process.
Optimum (MO). 𝐴𝐴1 = 𝑦𝑦1 (∞) = 𝑘𝑘0 [𝑎𝑎1 − 𝑏𝑏1 + 𝑇𝑇0 ]
(𝑆𝑆𝜏𝜏0 )2 (𝑆𝑆𝜏𝜏0 )3 𝑇𝑇0 2
𝑒𝑒 −𝜏𝜏 0 𝑆𝑆 = 1 − 𝑆𝑆𝜏𝜏0 + − 𝐴𝐴2 = 𝑦𝑦2 (∞) = 𝑘𝑘0 �𝑏𝑏2 − 𝑎𝑎2 − 𝑇𝑇0 𝑏𝑏1 + �
2! 3! 2!
+ ⋯ … … (22)
This is called the Taylor-Series. This is discussed because
+ 𝐴𝐴1 𝑎𝑎1
to develop or derive the PI and the PID Controller … . 𝐴𝐴𝑘𝑘 = 𝑦𝑦𝑘𝑘 (∞) = 𝑘𝑘0 ((−1)𝐾𝐾+1 (𝑎𝑎𝑘𝑘 − 𝑏𝑏𝑘𝑘 ) +
𝑘𝑘 𝑖𝑖
parameters to the given MO criterion [11]. 𝑇𝑇
𝐾𝐾+1 0
𝑏𝑏𝑘𝑘−𝑖𝑖
The open loop transfer function is expressed as, �(−1) )
𝐺𝐺𝐶𝐶 (𝑆𝑆)𝐺𝐺𝑃𝑃 (𝑆𝑆) 𝑖𝑖!
𝑖𝑖=1
𝑑𝑑0 + 𝑑𝑑1 𝑆𝑆 + 𝑑𝑑2 𝑆𝑆 2 + ⋯ 𝑘𝑘−1
= … … . . (23) + �(−1)𝐾𝐾+𝑖𝑖−1 𝐴𝐴𝑖𝑖 𝑎𝑎𝑘𝑘−𝑖𝑖 . . . (28)
𝐶𝐶0 𝑆𝑆 + 𝐶𝐶1 𝑆𝑆 2 + 𝐶𝐶2 𝑆𝑆 3 + ⋯
Where, d i and c i are the functions of the transfer function 𝑖𝑖=1
of the PID controller parameters. The Optimal criterion of Here, only discussing between areasA 1 and A 3 ,
the PID controller is, 𝑦𝑦(𝑡𝑡) − 𝑦𝑦(0)
2𝑛𝑛+1 ∴ 𝑦𝑦0 (𝑡𝑡) = … … … … … … … … . (29)
∆𝑈𝑈
� (−1)𝑖𝑖 𝑑𝑑𝑖𝑖 𝐶𝐶2𝑛𝑛+1−𝑖𝑖 𝑡𝑡
𝑦𝑦1 (𝑡𝑡) = ∫0 (𝑘𝑘0 − 𝑦𝑦0 (𝜏𝜏)) 𝑑𝑑𝑑𝑑,putting 𝐴𝐴1 = 𝑦𝑦1 (∞)
𝑖𝑖=0 𝑡𝑡
2𝑛𝑛 𝑦𝑦2 (𝑡𝑡) = ∫0 (𝐴𝐴1 − 𝑦𝑦1 (𝜏𝜏)) 𝑑𝑑𝑑𝑑, putting 𝐴𝐴2 = 𝑦𝑦2 (∞)
1 𝑡𝑡
= � 𝐶𝐶 𝑖𝑖 𝐶𝐶2𝑛𝑛−𝑖𝑖 … … … (24) 𝑦𝑦3 (𝑡𝑡) = ∫0 (𝐴𝐴2 − 𝑦𝑦2 (𝜏𝜏)) 𝑑𝑑𝑑𝑑, putting 𝐴𝐴3 = 𝑦𝑦3 (∞).
2
𝑖𝑖=0 ………………………………. (30)
Applying T f =0, and in the equation (20), putting the value
𝐴𝐴3 𝐴𝐴4 − 𝐴𝐴2 𝐴𝐴5
of C i and d i. The PID parameters can be expressed by the 𝜏𝜏𝑑𝑑 = … … … … … … … … . . (31)
unknown process parameters. 𝐴𝐴3 2 − 𝐴𝐴1 𝐴𝐴5
From equation (31) getting,

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𝐴𝐴3
𝑘𝑘 = … … … … (32)
2�𝐴𝐴1 𝐴𝐴2 − 𝐴𝐴3 𝑘𝑘0 − 𝑇𝑇𝑑𝑑 𝐴𝐴1 2 �

Taking T d = 0 and from equation (32) and (33) getting the

PI Controller parameters.
Now due to disturbances some process
uncertainties occur. Then to tune the controller, firstly
robustness has been measured. Suppose, inner and outer
models have following uncertainty structures [5]:
(𝐼𝐼 − 𝛥𝛥1𝑖𝑖 )−1 𝐺𝐺1 (𝐼𝐼 + 𝛥𝛥2𝑖𝑖 ):
𝐺𝐺1∆ = � 𝛥𝛥 0 � … … (34)
𝛥𝛥𝑖𝑖 ≔ � 1𝑖𝑖 �
0 𝛥𝛥2𝑖𝑖
−1
(𝐼𝐼 − Δ1𝑜𝑜 ) 𝐺𝐺2 (𝐼𝐼 + Δ2𝑜𝑜 )
𝐺𝐺2∆ = � Δ 0 � … … . (35)
: Δ𝑜𝑜 = � 1𝑜𝑜 �
0 Δ2𝑜𝑜
Now for analyzing robustness the system is
transferred to an M-𝛥𝛥configuration. M is the matrix from
signals d 1i, d 2i, d 1o and d 2o to signals y 2 , u 2, y1 and u 1 . It
equals-

Where, 𝑆𝑆 ∶= (𝐼𝐼 + 𝐺𝐺2 𝐾𝐾2 + 𝐺𝐺2 𝐾𝐾2 𝐺𝐺1 𝐾𝐾1 )−1 … … (37)
𝑇𝑇2 ∶= (𝐼𝐼 + 𝐺𝐺2 𝐾𝐾2 )−1 𝐺𝐺2 𝐾𝐾2 … … … … … (38)

When we getting an error into the on-going

process, for making the system to the stable position then
we can apply the Multiple Integration Method. This
method is mainly Magnitude Optimum (MO) criterion
[11], which is used for calculating the PI(D) Controller
Parameters.
The different areas can be calculated by using the Multiple
Integration Method. This is the simple tuning process for
time domain approach.
2.5 Robust analysis and PID tuning of Cascade Control It was assumed that inner and outer model uncertainties are
Systems independent. So, overall uncertainty has been defined [5].
Robustness and Cascade controller design and ∆1𝑖𝑖 0 0 0
tuning are basically analyzed in the article. Robustness ∆𝑖𝑖 0 0 ∆2𝑖𝑖 0 0
∆= � �=� � … (39)
means the interaction between inner and outer loop of a 0 ∆𝑜𝑜 0 0 ∆1𝑜𝑜 0
cascade control system. The basic diagram of cascade
control system is---- 0 0 0 ∆2𝑜𝑜
Then by structured singular value analysis, the
system becomes stable robustly for all uncertainty

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𝜎𝜎�(∆) ≤ 𝛾𝛾 if and only if 𝜇𝜇∆ (𝑀𝑀) < 1�𝛾𝛾 . Thus 𝜇𝜇∆ (𝑀𝑀) is a performance and stability. But in case of chemical industry
robustness of the cascade system. Now this robustness is the controller parameter value can’t be same with change
used to PID controller tuning and designing. It is done by of time. In case of FLC the controller parameter value also
solving an optimization problem with a given degree of changes with time [6].
robustness. Such as for robustness 𝛾𝛾𝑚𝑚 , optimization Basically FLC has no systematic procedure for
problem is solved, which is- controller parameter tuning. Fuzzy Logic Control deals
∞ with process non-linearities. As it deals with non-
min ∫0 �𝑒𝑒𝑦𝑦1 𝑑𝑑 2 (𝑡𝑡)�𝑑𝑑𝑑𝑑 … … . (40) linearities so there is an only procedure of controller tuning
Under the constraint 𝜇𝜇∆ (𝑀𝑀) < 𝛾𝛾𝑚𝑚 … … … … (41) “Trial and Error”[16] ,[17]. As it deals with process non-
Where,𝑒𝑒𝑦𝑦1 𝑑𝑑 2 is the deviation of the process output y, due linearities, so there must be an initial condition. Under this
to the disturbance d 2 at the inner-loop. For simplifying the condition it is possible to establish an equality between
tuning process inner and outer controller can be tuned with fuzzy logic controller and non-linear controller. The
regard to the inner and outer process respectively with the primary loop contains fuzzy logic controller and the
help of robustness chart [5]. secondary loop contains conventional non-linear
Inner and outer process are represented by the first order controller. the input and output variables of FLC and
plus dead time model conventional controller parameters are determined the
starting point.
𝑒𝑒 −𝜏𝜏 1 𝑆𝑆
𝐺𝐺1 = 𝐾𝐾1 … … … … (42)
𝑇𝑇1 𝑆𝑆 + 1
𝑒𝑒 −𝜏𝜏 2 𝑆𝑆
𝐺𝐺2 = 𝐾𝐾2 … … … … (43)
𝑇𝑇2 𝑆𝑆 + 1
Now a PID controller can be tuned by the following
formula with the help of IMC method
2𝑇𝑇 +𝜏𝜏 𝑇𝑇1 +𝜏𝜏 1
Inner PID:𝐾𝐾𝑝𝑝 1 = 2(𝜆𝜆1 +𝜏𝜏1 ) , 𝑇𝑇𝑖𝑖1 = ,
1 1 2
𝑇𝑇 𝜏𝜏
𝑇𝑇𝑑𝑑 1 = 1 1
2𝑇𝑇 +𝜏𝜏 1 1
…………………………………… (44)
(2𝑇𝑇2 +𝜏𝜏 2 ) 𝑇𝑇 +𝜏𝜏
Outer PID:𝐾𝐾𝑝𝑝 2 =
2(𝜆𝜆 +𝜏𝜏 )
, 𝑇𝑇𝑖𝑖2 = 2 2 2 ,
2 2
𝑇𝑇𝑑𝑑 2 =
𝑇𝑇2 𝜏𝜏 2
… … … … … … … … … … … … … … … (45)
(2𝑇𝑇2 +𝜏𝜏 2 )
There are two tuning parameters 𝜆𝜆1 𝑎𝑎𝑎𝑎𝑎𝑎 𝜆𝜆2 which e, ce, ac are the input variables of FLC and ∆u is the
can be calculated by robustness chart. Then those are put output. The tuning parameters of FLC are GE, GR, GA and
in the above formulas to tune the controller parameter. GU. The Fuzzy logic controller is very much suitable for
The robustness of the cascade control system is the non-linear process, so its control action output is linear
fundamental thing for tuning of the controllers. This with pieces means it is discrete in nature. To obtain the
robustness is measured from overall process uncertainty tuning parameters in FLC the Relay auto tuning method
then that robustness is used for tuning the cascade control proposed by Åström is applied [13]. The FLC scale factors
system to get desired response. (tuning parameters) are calculated from fig. 15 to get the
2.6 A self-tuning of Fuzzy Logic Controller of cascade desired output.
control
Generally, in Cascade control there are two loops
one is primary and the other one is secondary. In this
control the output of the control action of the primary loop
is the set point of the secondary loop. This type of control
increases the efficiency.
In chemical industry the chemical reaction which
introduce the non-linearities, delay etc. which are usually
slow down the process. So this type of process can’t
control in general manner. So here Fuzzy Logic Control
(FLC) is used to control the process. In process control
most critical part is controller parameter tuning. The
controller parameter always has a definite value for

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If the obtained values are correct then the output
behavior of FLC is similar to the PI regulator. These
expressions have been obtained based on Buckley’s results
and analyzing the control law of fuzzy logic controller
[18]. In this case we just replace the membership function
which are given by the center of area defuzzification. The
drawback of the system’s aim is here the gain values are
not stationary means they are not stable. But we put the
stationary values in the controller parameters so we search
an another aim or method where we put or get the
stationary values of gains.
have been simulated in the secondary loop of cascade
control scheme. The critical parameters are obtained relay
auto tuning method and from there obtained the PI
controller parameters. In same procedure the equivalent
FLC parameters of primary loop are auto tuned using
Ziegler-Nichols rules, where primary controller is placed
in relay feedback [17]. In secondary loop the value of the
controller parametersareK p2 = 0.2, T i2 =1and the primary
loop controller parameter values are K p1 =0.12, T i1 =1.2
𝐺𝐺2 (𝑠𝑠)
1
= 𝑒𝑒 −0.2𝑠𝑠 … … … … … … … … … … … (44)𝐺𝐺1 (𝑠𝑠)
𝑠𝑠 + 1
1 controller. As a result, it allows to apply a well-known
= 𝑒𝑒−0.8𝑆𝑆 … … … … … … … … … … … (45)
𝑆𝑆 + 1
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Fuzzy logic controller deals with non-linearity behavior of
the process, so it is very useful for chemical industry. But
in process industry the control parameters selection
procedure is depend on stability, efficiency, performance
etc. In Fuzzy control there are no systematic procedure of
control parameter selection. We proposed a simple strategy
of tuning where under a certain condition the equivalency
between FLC and PID controller can be established. Here
the equivalency is done in between initial parameter of
FLC and Classical PID controller [16] ,[17]. As a result, it
allows to apply a well-known tuning method relay auto
tuning method.
III. CONCLUSION
In simple relay feedback test method, the main
purpose of the inner loop control is to eliminate the input
disturbance, a P or PI is used for tuning. In the tuning
method is Ziegler-Nichols and Cohen-Coon tuning rules
are applied. This feature is very easy to integrate the tuning
method into the existing auto tuning system. But in IMC
based controller, the tuning process is faster as compared
to simple relay feedback test method. The estimated true
values of arg°�𝑃𝑃𝐸𝐸 (j𝜔𝜔𝑂𝑂𝑂𝑂 )�, arg°�𝑃𝑃𝐼𝐼 (j𝜔𝜔𝑂𝑂𝑂𝑂 )�and
|𝑃𝑃𝐼𝐼 (𝑗𝑗𝜔𝜔𝑂𝑂𝑂𝑂 )| 𝑎𝑎𝑎𝑎𝑎𝑎 |𝑃𝑃𝐸𝐸 (𝑗𝑗𝜔𝜔𝑂𝑂𝑂𝑂 )|are very close to each other of
the result in this proposed method. After achieving these
two tuned regulators, it can be concluded that only single
relay with integrator test for single loop is simple and fast
response. The controller can be auto-tuned as well as
reaches to set point. Also, the robustness of the process can
be achieved with less numerical calculations and proper
tuning rule. The another approach of Auto-Tuning method
of Cascade Control by Multiple Integration Method is
compare to other method is more faster than other tuning
method of Cascade Control. In this proposed method an
error into the on-going process, for making the system to
the stable position then we can apply the Multiple
Integration Method. This method is mainly Magnitude
Optimum (MO) criterion, which is used for calculating the
PI(D) Controller Parameters. The different areas can be
calculated by using the Multiple Integration Method. This
is the simple tuning process for time domain approach. In
Fuzzy Logic Controller of Cascade Control, it deals with
non-linearity behavior of the process, so it is very useful
for chemical industry. But in process industry the control
parameters selection procedure is depend on stability,
efficiency, performance etc. In Fuzzy control there are no
systematic procedure of control parameter selection.
Weproposed a simple strategy of tuning where under a
certain condition the equivalency between FLC and PID
controller can be established. Here the equivalency is done
in between initial parameter of FLC and Classical PID
tuning method relay auto tuning method. The Robust
analysis of PID tuning of Cascade Control is measured
from the overall process uncertainty. That’s why the
www.ijemr.net ISSN (ONLINE): 2250-0758, ISSN (PRINT): 2394-6962
Robustness is used for Cascade Control system to get the
desired response.
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