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PLC Overview PID Control and Tuning
PLC Overview PID Control and Tuning
PLC Overview PID Control and Tuning
PLC History
The first Programmable Logic Controller was developed by
General Motors in 1968, when they were looking for an
alternative to replace complex relay control systems that
meets the following requirements:
Simple programming
Program changes without system intervention (no internal
rewiring)
Smaller, cheaper and more reliable than corresponding relay
control systems
Simple, low cost maintenance
Evolution..
Architecture of PLC
Network
Communicatio
n
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
General information
Equipment requirements and tests
Programming Languages
User Guidelines
Communication
Reserved
Fuzzy Control Programming
guidelines for the application and
implementation of programming
languages
Ladder logic
The contact plan or "ladder logic" language allows an easy transition
from the traditional relay logic diagrams to the programming of
binary functions. It is well suited to express combinational logic.
It is not suited to make reusable modules.
IEC 61131 does not prescribe the minimum requirements for a
compiler / interpreter such as number of rungs per page nor does
it specifies the minimum subset to be implemented.
Therefore, it should not be used for large programs made by
different persons
used in manufacturing, not process control
Ladder Diagram
make contact
break contact
relay coil
Y = A(BC+DE) + FE
Q = (AB + C)DEF
SFC diagram
Instruction List
Structured Text
Keyword
Data Type
Bits
BOOL
SINT
INT
DINT
LINT
USINT
Boolean
Short integer
Integer
Double integer
Long integer
Unsigned short integer
1
8
16
32
64
8
UINT
UDINT
ULINT
REAL
LREAL
TIME
DATE
TIME_OF_DAY
or TOD
DATE_AND_TIME
or DT
STRING
BYTE
WORD
DWORD
LWORD
Unsigned integer
Unsigned double integer
Unsigned long integer
Real numbers
Long reals
Duration
Date (only)
Time of day (only)
16
32
64
32
64
8
16
32
64
Discrete Input
Discrete Output
Analog Input
Analog Output
Number of Inputs
Grouping of Inputs
Input Voltage ranges for ON and OFF
switching delay
Source / Sink configurable
Input impedance
Electrical isolation between
field instrumentation to input circuit
Channel to channel
Group to Group
Power consumption
Number of outputs
Grouping of outputs
Switching type
Output Current
Per Channel
Per group
Module
Switching delay
Opto / Galvanic isolation
Between Controller & Outputs
Between groups of outputs
Number of inputs
Current or voltage
Resolution
Electrical input isolation
Input Impedance
Compatibility for use with HART Communicator
Precision
CMRR
Input Filter
Conversion time for all channels
Power consumption
Number of outputs
Current or Voltage
Resolution
Load that can be driven
Precision
Conversion time
Isolation
Between Controller & Outputs
Between groups of outputs
Number of counter
Modes of counters
inputs 16 bit/ 32 bit
input frequency
Input voltage
Input Resistance
Source or Sink Mode Configurable
Power consumption
START
Housekeeping
Program Scan
Processes the program logic
Input
Scan
Output
Scan
Output Scan
Energize/de-energize the outputs
Housekeeping
This step includes communications, Internal
Diagnostics, etc.
The steps are continually repeated - processed in a loop
Program
Scan
Cycle Time
Run
Process algorithms
Environment
software
System
software
CPU synchronization
The transferred User Data includes:
Updation in the process image
Interrupts
Updation of timers
Changing the data through communication links
Located Variables (in State RAM)
Scan Time
Input
Input
HSBY
HSBY
First
Section
Data
Data
Logic
Output
Primary
Output
Standby
Data transfer
(content)
State RAM
Unlocated
data
DFB instances
Input
HSBY
HSBY
5 ms
per 100 KB
Scan Time
First
Section
Logic
Data
(Copro)
Output
Primary
Data
(Copro)
30 ms
per 100 KB
Output
Standby
Primary
Scan Time
Data
Transfer
Output
5 ms
HSBY
Logic
Exec
Result
30 ms
Result
Primary
15 ms
HSBY
Scan Time
90 ms
Logic
Exec
Output
Data
Transfer
PID Control
Open-Loop Systems
An open-loop system cannot compensate for any
disturbances that add to the controllers driving signal
or to the process output.
Closed-Loop Control
Controller Design
1) Experimental Design or Controller Tuning
no quantitative information on process
highly nonlinear process
also called adhoc approach
Proportional control:
u (t ) K p e(t )
t
Integral control:
u (t ) K i e(t )dt
0
Differential control:
d
u (t ) K d e(t )
dt
U ( s)
Kp
E ( s)
U ( s) K i
E ( s)
s
U ( s)
Kd s
E ( s)
Proportional Control
U(t)
Proportional Control
The time response improves.
There is a steady state offset between the desired
response and the output response .
This offset can be reduced by increasing the
proportional gain; but that may also cause increase
oscillations for higher order systems.
The proportional band is the change in input required
to produce a full range of change in the output due to
the proportional control action.
The controlled variable is maintained within a specified
band of control points around a set point.
PI Controller
PI Controller
An integral controller provides an output rate of change that is
determined by the magnitude of the error and the integral constant.
The controller has the unique ability to return the process back to
the exact set point.
The integral control mode is not normally used by itself because
of its slow response to an error signal.
Proportional plus reset control eliminates any offset error that
would occur with proportional control only.
Reset windup is an inherent disadvantage of proportional plus
reset controllers that are subject to large error signals.
PD controller
PD controller
Derivative action is added to a controller to make it
respond to the rate of change of the error signal.
Derivative action cannot be used as a control mode
alone.
Proportional plus rate control does not eliminate offset
error.
Proportional plus rate control increases system stability.
But one must be careful while using derivative action in
control of very fast processes, or if the measurement is
noisy.
PID controller
PID controller
The PID controller combines the three individual modes to achieve
the advantages of each.
The proportional action responds to the error amplitude.
The integral action eliminates the offset error.
The derivative action provides additional stability to the process.
It finds universal application. But proper tuning of the controller is
difficult.
PID controllers can be used to control most processes, even those
that are difficult to control.
PID Tuning
56
57
C s Ke
U s Ts 1
Ls
58
59
60
61
62
PID Tuning
63
64