How do you use data analysis and feedback to improve your PID tuning for electro-mechanical systems?

2 What is feedback?

Feedback is the information that you receive from your system or from other sources that tells you how well your PID tuning is working. Feedback can be positive or negative, and it can be direct or indirect. Direct feedback is the output of your system that you can measure or observe, such as the speed, position, temperature, pressure, or other variables. Indirect feedback is the input or the environment of your system that can affect its output, such as the load, friction, voltage, or noise. Feedback can help you adjust your PID parameters to achieve your desired performance and avoid undesirable outcomes, such as instability, oscillation, or error.

3 How to use data analysis and feedback for PID tuning?

There are various approaches and algorithms for PID tuning, such as manual tuning, Ziegler-Nichols method, Cohen-Coon method, or software-based tuning. However, data analysis and feedback can be used to improve your PID tuning regardless of the method. To do so, you must first define the performance criteria and setpoint for your system. Then, collect data from your system before and after applying your PID tuning, using sensors, meters, oscilloscopes, data loggers, or simulation software. Analyze the data to compare the actual output with the desired setpoint and calculate performance indicators. Evaluate the results and provide feedback to check if your PID tuning meets your criteria and setpoint. Lastly, adjust your PID parameters based on the data analysis and feedback. This can help you improve the response, accuracy, or stability of your system.

4 How to optimize your PID tuning?

Optimizing your PID tuning means finding the best values for your PID parameters that achieve your performance criteria and setpoint without compromising the stability, robustness, or efficiency of your system. This may require some experimentation, iteration, and fine-tuning, as there is no universal formula or solution for every system. To optimize your PID tuning, start with a low proportional gain and increase it gradually until you get a satisfactory response or until you see some oscillation, then reduce it slightly to avoid instability. Additionally, add a small integral gain to eliminate the steady-state error or offset, but be careful not to add too much integral gain as it may cause overshoot, oscillation, or windup. For reducing overshoot, oscillation, or noise, add a small derivative gain; however, be careful not to add too much derivative gain as it may amplify the noise or cause instability. Filters or anti-windup mechanisms can be used to reduce the noise or the windup effect of your PID controller. Adaptive or self-tuning PID controllers can also be used to adjust your PID parameters automatically based on the changing conditions or requirements of your system. Finally, use data analysis and feedback to monitor and evaluate your PID tuning regularly and make adjustments as needed.

5 How to troubleshoot your PID tuning?

Troubleshooting your PID tuning requires some diagnosis, testing, and correction to identify and address the issues that prevent your PID controller from achieving your performance criteria and setpoint. To do this, check the wiring, connections, sensors, meters, or other devices involved in your PID controller to ensure they are working properly and accurately. Additionally, make sure the output and input signals of your PID controller are within the expected range and frequency and not corrupted by noise or interference. Ensure the PID parameters and mode of your PID controller are appropriate and consistent for your system and application. Furthermore, check the performance indicators and feedback of your PID controller to make sure they are meeting your performance criteria and setpoint without any signs of instability, oscillation, error, or disturbance. Additionally, ensure the system characteristics and environment of your PID controller are stable and predictable. Use data analysis and feedback to compare the expected and actual output/input of your PID controller with graphs, charts, tables, statistics, software or other tools. Lastly, use trial and error or other methods to correct the problem or issue of your PID controller by changing the PID parameters or mode/algorithm of your PID controller or modifying the system or environment of your PID controller.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?