On-line method for optimal tuning of PID controllers using standard OPC interface

Introduction− The controlled PID is the most widely used mathematical algorithm as a regulatory control strategy in industrial environments. The applications are varied; however, its answer depends on the proper calculation of its three parameters: the proportional, the derivative, and the integral. Analytical tuning and experimental methods solve the problem, but new tuning possibilities are now enabled within the digital and process integration context. Objective− Automatically and remotely obtain the optimal parameters of the PID controller, taking advantage of an online connection via the OPC communication protocol to analyze the transient response of the system. Methodology− The study is carried out in three main phases; it begins with a PD3 SMAR thermal process with connection via OPC; in this phase, the mathematical model of the process is built analytically based on fundamental laws. In the second phase, using an analytical tuning method, the PID control architecture is created on which the online experimentation is carried out. In the third phase, the genetic algorithms for automatic tuning are implemented, extracting performance measures from the PID controller through the transient response of the process and optimally determining the values for the proportional, derivative, and integral parameters. Results− The automatic tuning method was tested with two properly instrumented industrial processes. The potential for application can be seen due to its good result and because it does not require specific mathematical knowledge compared to conventional tuning methods. Conclusions− The automatic tuning method can be used remotely to calculate the optimal parameters of a PID controller. The parameters are calculated from the transient response and the definition of design criteria adaptable to any need for control, response, and process