This paper deals with the design of a DC motor speed control implemented by an embedded controller. The design is simple and brings some important changes to the traditional Ziegler–Nichols tuning. The design also includes a novel anti-windup implementation of the controller and an integrated noise-reduction filter design. The proposed tuning method considers all important aspects of the control, such as pre-processing of the measured signals and filtering (to attenuate the measurement noise), time delays of the process, modeling and identification of the process, and constraints on the control signal. Three important aspects of designing PI and PID controllers for processes with noisy output on Arduino-type embedded computers are considered. First, it deals with the integrated design of the input filter and the controller parameters, since both are interdependent. Secondly, the method of setting the controllers from step responses by Ziegler and Nichols is modified for the case of digital signal processing (without drawing the tangent), while it recommends the suitability of its modification in terms of the use of both integral and static models. Third, the most suitable anti-windup solution for the given controller structure is proposed. In summary, the paper shows that an appropriate design of the embedded controller can achieve excellent closed-loop performance even in a noisy process environment with limited control signals.

This paper contributes toward research on the control of the magnetic levitation plant, representing a typical nonlinear unstable system that can be controlled by various methods. This paper shows two various approaches to the solution of the controller design based on different closed loop requirements. Starting from a known unstable linear plant model—the first method is based on the two-step procedure. In the first step, the transfer function of the controlled system is modified to get a stable non-oscillatory system. In the next step, the required first-order dynamic is defined and a model-based PI controller is proposed. The closed loop time constant of this first-order model-based approach can then be used as a tuning parameter. The second set of methods is based on a simplified ultra-local linear approximation of the plant dynamics by the double-integrator plus dead-time (DIPDT) model. Similar to the first method, one possible solution is to stabilize the system by a PD controller combined with a low-pass filter. To eliminate the offset, the stabilized system is supplemented by a simple static feedforward, or by a controller proposed by means of an internal model control (IMC). Another possible approach is to apply for the DIPDT model directly a stabilizing PID controller. The considered solutions are compared to the magnetic levitation system, controlled via the MATLAB/Simulink environment. It is shown that, all three controllers, with integral action, yield much slower dynamics than the stabilizing PD control, which gives one motivation to look for alternative ways of steady-state error compensation, guaranteeing faster setpoint step responses.

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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.