Adaptive PID Auto-Tuning Algorithm on Omron PLC for Speed Control and Stability

Nanang Rohadi; Liu Kin Men; Akik Hidayat

doi:10.22146/jnteti.v14i4.22693

Nanang Rohadi Universitas Padjadjaran
Liu Kin Men Physical Sciences, Faculty of Mathematics and Natural Sciences, Universitas Padjadjaran, Sumedang 45363, Indonesia
Akik Hidayat Informatics and Computer Sciences, Faculty of Mathematics and Natural Sciences, Universitas Padjadjaran, Sumedang 45363

DOI: https://doi.org/10.22146/jnteti.v14i4.22693

Keywords: Three-Phase Induction Motor, PID Auto-Tuning, Omron PLC, Speed Control, Adaptive Control, Industrial Automation

Abstract

Speed regulation of three-phase induction motors under varying load conditions presents a major challenge in industrial automation due to their nonlinear dynamic behavior. This paper proposes an adaptive speed control system using a PID Auto-Tuning (PIDAT) algorithm implemented on the Omron CP1H-XA40DT-D Programmable Logic Controller (PLC). The initial PID parameters are derived using the Ziegler–Nichols method, and the system continuously monitors steady-state error during operation. When the error exceeds a predefined 5% threshold, the auto-tuning sequence is triggered. This sequence includes a Relay Feedback Test (RFT), system identification using a First-Order Plus Dead Time (FOPDT) model, and real-time PID parameter recalculation. The system hardware integrates an Omron 3G3MX2 inverter, rotary encoder, and NB7W-TW01B Human–Machine Interface (HMI) to form a closed-loop control structure. Experimental validation was performed under both spontaneous and constant load conditions. The PIDAT method consistently demonstrated superior performance compared to classical Ziegler–Nichols tuning, achieving steady-state errors in no-load tests below 1.70 % and under 0.8% in loaded conditions. Furthermore, the system achieved settling times below 9 seconds and recovered from load disturbances in less than 4 seconds. These results validate the proposed PIDAT system as an accurate, fast, and adaptive control solution, reducing the need for manual tuning and enhancing robustness in dynamic industrial environments.

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