A cascade control system comprising the primary and secondary controllers suffers from a cascade-type integral windup problem in which the output saturation of the secondary control loop can considerably increase the integral part of the primary control loop. In this paper, we present a new predictive antiwindup technique that can completely eliminate the possibility of secondary controller output saturation, resulting in no cascade-type integral windup phenomenon. The proposed method does not require any type of process models; thus, its implementation is simple and straightforward, which is a very favorable advantage compared to the model-based antiwindup techniques from the practical viewpoint. Our simulation confirms that the proposed method can completely remove the primary controller's cascade-type integral windup resulting from the saturation of the secondary controller output. Further, the proposed method exhibited good control performance without needing any type of process model for the various types of processes and controllers. Our experimental study successfully demonstrated that there are no problems in applying the proposed method to real plants.
© 2020 American Chemical Society.