A Simulation-Based Method for Building and Evaluating Tuned PID Control Circuits

In industrial control systems, the PID (Proportional-Integral-Differential) controller remains a cornerstone for achieving desired performance metrics such as system robustness, fast response, and effective oscillation suppression. Traditionally, PID tuning has been accomplished through empirical methods, relying heavily on the experience and intuition of engineers. However, the advent of advanced computer simulation technologies has revolutionized the tuning process, making it more precise, efficient, and automated.This paper explores a approach to PID tuning by leveraging Simulink’s PID Tuner tool. The methodology involves using a second-order open-loop transfer function as a test case to demonstrate the tuning process. The theoretical tuning parameters derived from Simulink are then validated through comprehensive circuit simulations conducted on Falstad and Tinkercad platforms. These platforms offer different perspectives and capabilities, providing a robust framework for verification. Eventually, it is extended to first-order systems and third-order systems to validate the feasibility of this method. By demonstrating the consistency and differences between theoretical and simulation-based tuning outcomes, this research provides valuable guidance for engineers seeking to apply Simulink-based PID tuning in practical engineering contexts. The proposed methodology enhances the reliability and effectiveness of PID controllers in industrial systems, contributing to improved system performance and stability.