Tuning PID controllers is a multi-step process. While it is important to understand each step in the process, performing the bump test and collecting dynamic data is the most crucial step that generally dictates the outcome. This post delves [...]
At Control Station we’re simplifying process optimization. That’s a tall order – just ask anyone who walks a plant floor. We’ve broken the mold for tuning a production facility’s core regulatory control systems and we’ve equipped them with timely insight [...]
While it doesn’t have the ring of ‘Industry 4.0’ or stir the imagination like the ‘Industrial Internet of Things’, control loop performance monitoring technology enables manufacturers to realize their plant’s full profit potential. Don’t take my word for it - [...]
Predicting the weather is difficult – just ask a meteorologist. Even with the help of advanced analytics few seem to get it right with consistency – just ask any parent who has dealt with an unplanned snow day. In addition to more advanced tools meteorologists rely on basic measures such as Temperature, Wind Speed, and Atmospheric Pressure. Their continued reliance on these simpler metrics provides food for thought.
If you’ve investigated manufacturing trends recently, then the Industrial Internet of Things (IIoT) has probably caught your attention once or twice. IIoT capitalizes on a range of communication and automation technologies that have been applied in industrial applications for years. With its primary focus on the supply chain and enhancing efficiency, however, IIoT often leaves production staff wondering how plant floor operations will be impacted.
If you’re old enough to remember silent movies, then you know what it’s like to see the characters seemingly jiggle around the screen. Black spots would randomly appear as the story was told with the help of subtitles. Spots and subtitles aside, these movies appeared jittery due to their slow speed. The slow frame rate - a precursor of data collection speed - resulted in visual gaps.
Even Simple Metrics Such as Percent Time in Normal Reveal Issues that Negatively Affect Performance and Signal the Need for Controller Tuning It’s easy to get tripped up if a shoelace is untied. Just ask any child. While that’s a lesson most learn early in their lives each of us can occasionally slip up and find ourselves at risk.
Average Absolute Error (AAE) Provides an Intuitive Alternative to Variance and Simplifies the Assessment of Changes in PID Controller Performance.
Quite simply, things at a manufacturing facility can change for the better or they can change for the worse. [ . . . ]
Mode Changes Provide Insight Into a Process' Overall Performance and They're Often Linked to Poor Controller Tuning. Operator interventions and Mode Changes are often viewed negatively. When a PID loop is switched out of automatic there can be a sense [...]
The Oscillation Metric Can Identify a PID Controller that Requires Tuning, But More Often Than Not it Provides an Indication of Loop Interaction or Mechanical Issues. There’s a wealth of information available in most every data historian. The data can [...]