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The paper extends the earlier work entitled “Making the PI and PID Controller Tuning Inspired by Ziegler and Nichols Precise and Reliable”, to higher-order controllers and a broader range of experiments. The original series PI and PID controllers, based on automatic reset calculated by filtered controller outputs, are now augmented by higher-order output derivatives. This increases the number of degrees of freedom that can be used to modify the resulting dynamics, accelerates transient responses, and increases robustness to unmodeled dynamics and uncertainties. The fourth order noise attenuation filter used in the original work allows for the addition of an acceleration feedback signal, thus resulting in a series PIDA controller or even a jerk feedback that leads to a PIDAJ series controller. Such a design can further use the original process and filter approximation of the step responses through the integral-plus-dead-time (IPDT) model, while allowing experimentation with disturbance and setpoint step responses of the series PI, PID, PIDA and PIDAJ controllers, and thus, evaluating the role of output derivatives and noise attenuation from a broader perspective. All controllers considered are tuned using the Multiple Real Dominant Pole (MRDP) method, which is complemented by a factorization of the controller transfer functions to achieve the smallest possible time constant for automatic reset. The smallest time constant is chosen to improve the constrained transient response of the considered controller types. The obtained excellent performance and robustness allow the proposed controllers to be applied to a wider range of systems with dominant first-order dynamics. The proposed design is illustrated on a real-time speed control of a stable direct-current (DC) motor, which is approximated (together with a noise attenuation filter) by an IPDT model. The transient responses obtained are nearly time-optimal, with control signal limitations active for most setpoint step responses. Four controllers with different degrees of derivative with generalized automatic reset were used for comparison. It was found that controllers with higher-order derivatives may significantly improve the disturbance performance and virtually eliminate overshoots in the setpoint step responses in constrained velocity control.

This paper discusses optimal design of the series proportional–integral–derivative–accelerative (PIDA) controller for integral-plus-dead-time (IPDT) plants. The article starts with the design of disturbance reconstruction and compensation based on proportional-derivative-accelerative (PDA) stabilizing controllers. It shows that by introducing positive feedback by a low-pass filter from the (limited) output of the stabilizing PDA controller, one gets disturbance observer (DOB) for the reconstruction and compensation of input disturbances. Thereby, the DOB functionality is based on evaluating steady-state controller output. This DOB interpretation is in full agreement with the results of the analysis of the optimal setting of the stabilizing PDA controller and of its expanded PIDA version with positive feedback from the controller output. By using the multiple real dominant pole (MRDP) method, it confirms that the low-pass filter time constant in positive feedback must be much longer than the dominant time constant of the stabilized loop. This paper also shows that the constrained PIDA controller with the MRDP setting leads to transient responses with input and output overshoots. Experimentally, such a constrained series PIDA controller can be shown as equivalent to a constrained MRDP tuned parallel PIDA controller in anti-windup connection using conditional integration. Next, the article explores the possibility of removing overshoots of the output and input of the process achieved for MRDP tuning by interchanging the parameters of the controller transfer function, which was proven as very effective in the case of the series PID controller. It shows that such a modification of the controller can only be implemented approximately, when the factorization of the controller numerator, which gives complex conjugate zeros, will be replaced by a double real zero. Neglecting the imaginary part and specifying the feedback time constant with a smaller approximative time constant results in the removal of overshoots, but the resulting dynamics will not be faster than for the previously mentioned solutions. A significant improvement in the closed-loop performance can finally be achieved by the optimal setting of the constrained series PIDA controller calculated using the performance portrait method. This article also points out the terminologically incorrect designation of the proposed structure as series PIDA controller, because it does not contain any explicit integral action. Instead, it proposes a more thorough revision of the interpretation of controllers based on automatic reset from the controller output, which do not contain any integrator, but at the same time represent the core of the most used industrial automation. In the end, constrained structures using automatic reset of the stabilizing controller output can ensure a higher performance of transient responses than the usually preferred solutions based on parallel controllers with integral action that, in order to respect the control signal limitation, must be supplemented with anti-windup circuitry. The excellent properties of the constrained series PIDA controller are demonstrated by an example of controlling a thermal process and proven by the circle criterion of absolute stability.

The article discusses the control of nonlinear processes with first-order dominant dynamics, focusing on implementation using modern hardware available in various programmable devices and embedded systems. The first two approaches rely on linearization with an ultra-local process model, considering small changes of the process input and output around a fixed operating point, which can be adjusted through gain scheduling with the setpoint variable. This model is used to configure either the historically established automatic reset controller (ARC) or a stabilizing proportional (P) controller enhanced by an inversion-based disturbance observer (DOB). This solution can be interpreted as an application of modern control theory (MCT), as DOB-based control (DOBC) or as advanced disturbance rejection control (ADRC). Alternatively, they can be viewed as a special case of automatic offset control (AOC) based on two types of linear process models. In the third design method, setpoint tracking by exact linearization (EL) is extended with a nonlinear DOB designed using the inverse of the nonlinear process dynamics (EEL). The fourth approach augments EL-based tracking with a DOB derived from the transfer functions of nonlinear processes (NTF). An illustrative example involving the control of a liquid reservoir with a variable cross-section clarifies motivation for the definition of (linear) local and ultra-local process models as well as their advantages in designing robust control that accounts for process uncertainties. Thus, the speed, homogeneity, and shape of transient responses, the ability to reconstruct disturbances, control signal saturation, and measurement noise attenuation are evaluated according to the assumptions specified in the controller design. The novelty of the paper lies in presenting a unifying perspective on several seemingly different control options under the impact of measurement noise. By explaining their essence, advantages, and disadvantages, it provides a foundation for controlling more complex time-delayed systems. The paper emphasizes that certain aspects of controller design, often overlooked in traditional linearization procedures, can significantly improve closed-loop properties.

The proposed practice-oriented controller design (POCD) aims at stabilizing the system, reconstructing and compensating for disturbances while achieving fast and smooth step responses. This is achieved through a simple approach to process identification and controller tuning that takes into account control signal constraints and measurement noise. The proposed method utilizes POCD by eliminating the influence of the unstable zero dynamics of the inverse-response processes, which limits the achievable performance. It extends the previous work on PI and PID controllers to higher-order (HO) automatic reset controllers (ARCs) with low-pass filters. It is also extended according to POCD requirements while maintaining the simplified process model. The final result is an extremely simple design for a constrained controller that provides sufficiently smooth and robust responses to a wide family of HO-ARCs with odd derivatives, designed using integral plus dead time (IPDT) models and tuned by the multiple real dominant pole method (MRDP) and the circle criterion of absolute stability. The proposed design can be considered as a generalization of the Ziegler and Nichols step response method for inverse response processes and HO-ARCs.

The new modular approach to constrained control of higher-order processes with dominant first-order dynamics using generalized controllers with automatic resets (ARCs) is addressed. The controller design is based on the multiple real dominant pole (MRDP) method for the integrator plus dead time (IPDT) process models. The controller output constraints are taken into account by inserting the smallest numerator time constant of the controller transfer function into the positive feedback loop representing the automatic reset (integral) term. In the series realization of the proportional–integral–derivative–acceleration (PIDA) controller (and other controllers with even derivative degree), the time constant mentioned is complex, so only the real part of the time constant has been used so far. Other possible conversions of a complex number to a real number, such as the absolute value (modulus), can be covered by introducing a tuning parameter that modifies the calculated real time constant and generalizes the mentioned conversion when designing controllers with constraints. In this article, the impact of the tuning parameter on the overall dynamics of the control loop is studied by simulation. In addition, an evaluation of the stability of the closed-loop control system is performed using the circle criterion in the frequency domain. The analysis has shown that the approximation of the complex zero by its real part and modulus leads to a near optimal response to the set point tracking. The disturbance rejection can be significantly improved by increasing the tuning parameter by nearly 50%. In general, the tuning parameter can be used to find a compromise between servo and regulatory control. The robustness and applicability of the proposed controller is evaluated using a time-delayed process with first-order dominant dynamics when the actual transfer function is much more complicated than the IPDT model. A comparison of the proposed MRDP-PIDA controller with series PI, PID and PIDA controllers based on a modified SIMC method has shown that the MRDP-PIDA controller performs better than the SIMC method, although the SIMC uses a more complex process model.

Almost a century ago, the first industrial controllers were introduced to the market, labeled as automatic reset and later generalized to hyper-reset or pre-act. Recently, it has been shown that such control solutions can be characterized as model-based solutions with a simplified disturbance observer developed for an integrating model. The aforementioned controllers, albeit under the name of proportional–integral–derivative (PID) controllers, are still the most commonly used control solutions in practice. With the help of a new interpretation, however, it can be shown that PID controllers are also very well suited for controlling processes with complex non-linear dynamics. This paper investigates the design and feasibility of a family of gain-scheduling controllers for saturated non-linear systems described by a first-order differential equation. It is shown that the process can be linearized either by using locally applicable linear models or by using more narrowly applicable ultralocal models. By combining both approaches, an innovative linearization method around the steady states of the process input and output is proposed. This novel approach emphasizes that the entire process input signal has to be constructed by adding the control increment calculated by the linearization to the value of the considered operating point. Thus, it avoids the uncertainties of those methods, which are based on achieving the actual controller output by integrating the calculated differential values. Another advantage of model-based design is that the saturation of the control signal is included in the design from the outset. Therefore, the undesired integration (windup), which is typical for controllers with explicit integral action, is prevented. The proposed design is illustrated using the control of a liquid tank with variable cross-section as a function of the liquid level. The model-based approach is also used in the evaluation of the transients, where homogeneous responses were obtained over the whole range of process output values. Responses were more homogeneous when simple ultralocal models were used, regardless of controller saturation constraints. Finally, all important innovative aspects of the design are highlighted by a comparison with gain-scheduled PI controller design based on velocity implementation.

To meet the strict new feature requirements for no-throwing parts and self-closing under bursting condition, a new composite cover is designed and analyzed experimentally and numerically. Test results show that the cover can be broken into 4 split subparts from the center to the flange by the warhead bursting, and the split subparts can be tied to the flange and automatic rebound and close after the missile is out of the launch container. Static finite element model under the pressure-bearing condition and dynamic finite element model under the warhead bursting condition are established. Numerical results, including processes of failure and self-close, are in good agreement with the experimental data. The influence of structural parameters such as the thickness of the main part of the cover and the number and the width of reinforcement layers, on the maximum deformation and the bursting failure load are investigated. The failure mechanism in the weak area and the automatic rebound and reset of the split subparts are also analyzed.