PID Controllers, 2nd Edition

Chapter 7.2.5 - Control Paradigms: Integral Windup

Integral Windup

If integral action is used in both the secondary and primary control loops, it is necessary to have a scheme to avoid integral windup. The inner loop can be handled in the ordinary way, but it is not a trivial task to avoid windup in the outer loop. There are three situations that must be covered:

  1. The control signal in the inner loop can saturate.
  2. The secondary control loop may be switched to internal setpoint.
  3. The secondary controller is switched from automatic to manual mode.

The feedback loop, as viewed from the primary controller, is broken in all these cases, and it is necessary to make sure that its integral mode is dealt with properly. This problem is solved automatically in a number of process controllers that have cascade control capabilities, but if we build up the cascade control using two independent controllers, we have to solve the problem ourselves. This requires being able to inject a tracking signal into the primary controller.

If the output signal of the secondary controller is limited, the process variable of the secondary controller should be chosen as the tracking signal in the primary controller. This also needs a digital transfer from the secondary to the primary controller telling it when the tracking is to take place.

In the case where the secondary controller switches to working according to its local setpoint instead of the external one from the primary controller, the local setpoint should be sent back to the primary controller as a tracking signal. In this way one can avoid both integrator windup and jumps in the transition to cascade control.

When the secondary controller switches over to manual control, the process variable from the secondary controller should be sent back to the primary controller as a tracking signal.

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