Evaluating the effects of PID control parameter migration in PLC upgrades

Abstract In modern industrial applications, automation is achieved using distributed control systems or programmable logic controllers, widely adopted across sectors. Proportional integral derivative control in closed-loop systems is a key strategy. As these controllers have been used for decades, replacements are necessary over time. This research focuses on replacing controllers, firmware, or Input/Output cards, examining the feasibility of adapting proportional integral derivative control parameters to new systems. The study analyses how these changes impact operation, energy consumption, and quality, based on experiments with Wago programmable logic controllers and analytical methods.