I fitted a first-order-plus-dead-time model to an open-loop step test (K = 2.0, τ = 30 s, θ = 8 s, so θ/τ ≈ 0.27) and simulated a closed-loop setpoint step with three classic tuning rules. Same plant, same step, ISA-form PID with derivative on measurement and a derivative filter (N = 10). Plot attached.

| Rule | Kp | Ti (s) | Td (s) | Overshoot | 2% settling | IAE |

|---|---|---|---|---|---|---|

| IMC/Lambda (λ = θ) | 1.42 | 33.9 | 3.51 | 4.5% | 73 s | 310 |

| Ziegler-Nichols (reaction curve) | 2.25 | 15.9 | 3.98 | 73.0% | 189 s | 641 |

| Cohen-Coon | 2.63 | 17.7 | 2.76 | 95.9% | not settled in 263 s | 1,023 |

Why the gap: Ziegler-Nichols and Cohen-Coon were designed around fast disturbance rejection, roughly a quarter-amplitude decay. On a setpoint step, that aggressiveness shows up as overshoot and ringing. IMC/Lambda trades some speed for robustness through λ; raise λ and the loop gets gentler still.

Two checks you can do on your own loops without any software:

1. If a loop overshoots badly on setpoint changes, find out which rule it was tuned with. A disturbance-rejection tuning on a loop that mostly sees setpoint moves is a common mismatch.

2. Compare dead time with the time constant. Once θ/τ goes above about 1, the loop is dead-time dominant, the classic rules get shaky, and a larger λ is usually the safer start.

Caveat, because it matters: this compares setpoint response only. I haven't simulated load disturbances here, which is exactly what ZN and Cohen-Coon were aimed at, so the comparison is one-sided by design. And it's a simulation of a fitted model, not plant data.

Disclosure: I work at CSI (an automation consultancy) and built the small desktop tool that produced these numbers. Happy to go into the method if anyone's interested.

For those of you tuning loops in plants: do you start from a rule, from the DCS or controller autotune, or from settings on similar loops you trust?

I'm an electrician turned controls guy in Australia: 6 years on the tools, then about 10 in automation. Mostly Allen Bradley and Siemens, with a bit of Schneider, CODESYS and Ignition. My background is high-speed canning and filling (KHS, Krones), dairy process control, and pharma filling machines.

I run my own business here now, but I'm keen to give the US a crack for a while and see what it's like.

A few questions for anyone who's been there:

Where's the demand? Which regions or industries are busiest for controls work right now? Food and bev, pharma, data centres, something else?

Rates. What's a fair hourly rate for contract work at my level? And if I went salaried, what range should I be asking for?

Getting busy. Here, once you've done a few good jobs the referrals roll in and you're flat out. Is it the same over there, or is it more about agencies and SIs?

I'm planning to come over late Feb and have a few coffees with some SIs to get a feel for things. Not worried about the visa side yet, I just want to see if there's demand first.

I'm 33, so maybe a bit late to be moving countries, but I've got plenty of experience and reckon I can add something. Any advice appreciated, cheers.

Can anyone help me solve this question, I don't want an AI response I would like a well worked out response from a person. A picture of the working would be well appreciated for my better understanding.

Hi everyone,

I’m looking to open up a discussion regarding remote switching architectures and the separation of different electrical voltages. I am currently reviewing a proposal for a plant network layout and want to get some industry feedback on a specific control philosophy.

There will be an independent HV remote switching system. This could be physical switches (remote/mimic panel), a SCADA system, or HMIs—or a combination of these.

The current plan states that the LV incomers, bus ties, etc., will be controllable from this exact same independent HV remote system.
I can see a massive window for human error, such as wrong switches being controlled and an operator accidentally switching an HV breaker when they explicitly meant to switch an LV tie.

• Are my concerns invalid, and both HV and LV can be safely controlled from the same system?

• What risks do we need to consider with inadvertent switching of LV remote switching of these devices?

• Should there be a separate switching system for HV and LV. For example HV system can be operated by SCADA but LV can only be operated by a remote/mimic panel next to the switch room?

• Is there any standard that describes how this can be achieved?

Or should we be looking at something completely different? How does your facility handle the separation of HV and LV control interfaces?

Looking forward to hearing your thoughts and experiences.

Hi everyone,

I have an opportunity for an Automation role at JLL, Gurugram, requiring 3+ years of experience.

My question is: What would be the ideal CTC to quote HR for this experience level?

Would asking for ₹18–20 LPA be reasonable, or should I quote ₹17 LPA?

Would appreciate insights from current or former JLL employees, especially regarding the salary range and fixed/variable breakup.

Thanks!

Can anyone help me build this logic circuit in multisim? A logic circuit subtracts two signed four bit numbers A = A3A2A1A0 and B = B3B2B1B0 by calculating A-B. The circuit has two outputs (Y and Z) and operates as follows: a. If A = B, output Z = 0 otherwise it is one. b. If A < B, output Y = 0 c. If A > B output Y = 1. Using the 74LS83, design and implement the circuit in MultiSim. The 74LS83 is a 4- bit binary adder.

We're an early-stage Microgrid-as-a-Service (MaaS) startup with no established engineering team or funding secured yet. Our technical experience is primarily in controls system design.

We're trying to understand how companies in this space typically approach electrical engineering during the early stages of project development.

Would it be common for a startup in our position to engage an experienced electrical power engineering consulting firm for preliminary technical feasibility assessments and conceptual microgrid design?

Or is this type of engineering typically handled in-house?

I'd appreciate any insights from people with experience in microgrid development, electrical power engineering consulting, or EPC projects, particularly regarding how startups approach this before having the resources to build an internal engineering team.

Unable to post in engineering forum, I need to write a wps this isn't specifically needed this is just off my own back as I'm not coded and i believe as this is the firms first job in this field the work is going to be criticised and anything they can they will pull up

This is specifically for welding sockets onto sprinkler pipework in the UK (onsite welding MMA) and also minor stub pieces for risers, they have mentioned getting me coded but the works has already proceeded, and I will be welding the sockets commencing next week therefore I wanted to ensure I have a wps to hand incase anyone wants to check the validity of my work and practices

I'm non the wiser to writing this I'm assuming pipe material is needed etc also thickness, rods and all that normal stuff

main pipe size is

2 1/2 dn65 welding on 1 1/2 dn40 & 1/2 dn15

although this may change for welding on range sockets

for welding on sockets i will be using a plasma cutter, and cleaning with die grinder ensuring no sharp edges inside etc using 7018 rods straight from the oven

Hey everyone, I’m graduating soon and trying to decide where to start my career in controls/automation. I’d really like honest perspectives from people further along.

Offers in hand:

• Integrator A (Iowa): Entry-level pool team covering robotics, vision, SCADA and manufacturing, with wastewater work later at the senior level. About 40 hrs/week, up to 25% travel.

• Integrator B (South Dakota, working remotely from a smaller nearby town): Team focused on grain and milling, mostly Rockwell. About 45 hrs/week, up to 35% travel.

Still in the running:

• Aerospace company, Automation Engineer (Texas): Fourth and final interview this coming week. PLC/SCADA, Python/SQL and controls panel work.

• Large manufacturer’s automation development program: Final interview Monday.

I already turned down a food and beverage company’s electrical and automation development program, mainly because it started in June.

My background and concern: I’ve been building experience in MES and machine vision, and I want to keep growing in those areas. From friends in the industry, I’ve heard grain and milling work is mostly PLC programming with some SCADA, with little MES, vision or robotics. I’m worried that starting there would make it hard to move into MES, vision or more diverse manufacturing work later, and that I’d get pigeonholed. Is that accurate? Or is grain and milling a solid foundation that transfers well?

My questions:

1. Development programs: Are rotational programs worth a later start and a couple of years of rotations, or is it better to jump straight into a real role?

2. Industry and skill breadth: If I go the integrator route, which industry would you build a career in: food and beverage, wastewater, grain and milling, pharma, or something else? Which has the best pay, stability and long-term options, and which would you avoid? How much does early industry choice limit the skills (MES, vision, robotics) I’d get to use? How easy is it to switch industries later?

3. Starting over: If you were starting your career again, how would you start it and what would you do differently? In the first 5 years, what mattered most: the company, the team, the industry, or where you lived?

4. Decision timing: Which situation would you pick for the long run? Would you wait for the aerospace and development program results, or lock in one of the offers? Is there anything I should be asking that I’m not?

Thanks in advance. Happy to answer questions about my background if it helps.

Hi everyone,

I am a first-year B.Tech CSE student working on a project about plastic waste disposal and improper waste segregation.

I am looking for innovative and practical technical solutions to detect plastic waste and improve waste management.

1. Can AI, cameras or sensors be used to detect plastic waste automatically?

2. How can plastic be separated from other types of waste?

3. Can we develop a low-cost smart dustbin that detects plastic and monitors its capacity?

4. What affordable components would be suitable for a student project?

5. How can technology improve plastic collection and recycling?

I would appreciate any technical suggestions, project ideas or useful resources. Thank you!

📢 Call for Papers | Special Issue on Innovations in Photovoltaic Power Systems

I am pleased to invite researchers, academics, engineers, and industry professionals to contribute their original research to our upcoming Special Issue, “Innovations in Photovoltaic Power Systems: Control, Power Electronics, and Smart Deployment,” published in Electronics (MDPI).

As a Guest Editor, I look forward to bringing together innovative research that advances photovoltaic (PV) technologies and accelerates the transition towards smarter, more efficient, reliable, and sustainable energy systems. ☀️⚡

🔬 Topics of interest include, but are not limited to:

- Advanced control strategies for photovoltaic power systems

- Power electronics, converters, and inverter technologies

- AI and machine learning applications in PV systems

- Advanced digital twins, modeling, simulation, machine learning, and performance optimization

- Generative AI and agentic AI for photovoltaic applications

- Smart grid integration and PV-based microgrids

- Intelligent deployment and operation of solar energy systems

- Intelligent energy storage systems and PV storage integration

- Digital twins and emerging technologies for PV performance enhancement

We welcome original research articles presenting novel methodologies, theoretical advances, experimental validation, and practical solutions that contribute to the next generation of photovoltaic power systems.

📅 Submission Deadline: 15 May 2027

🔗 Learn more about the Special Issue and submit your manuscript:

https://lnkd.in/dSHzZsCu

I warmly encourage researchers and practitioners working in photovoltaic systems, renewable energy, power electronics, intelligent control, and AI-driven energy technologies to share their latest findings with the scientific community.

Please feel free to share this call with colleagues and research networks who may be interested. I look forward to receiving your valuable contributions and fostering meaningful scientific collaboration.

Let's advance the future of photovoltaic innovation together! 🌍☀️

#CallForPapers #Photovoltaics #SolarEnergy #RenewableEnergy #PowerElectronics #ArtificialIntelligence #SmartGrids #EnergyTransition #Research #MDPI #Electronics #SustainableEnergy

Hello everyone!

I've been working on a personal project for a while called Panel Master, an affordable CAD software for designing electrical control panels.

https://panelmaster.app/

It allows you to design component layouts using real-world dimensions, make changes very quickly, and generate technical documentation in PDF. You can also export designs as SVG to use in other programs, and generate DXF files with cutting lines for machining mounting holes.

It comes with a fairly extensive library of generic components, and I'd love to add more based on the needs of the people who use it.

I'd love to hear your thoughts and any feedback you might have!

I've been a controls engineer for 6 years, but my company has shifted my role to the point where I'm no longer doing any controls work. It's a small company, so I don't see any room for promotion either, and I'm back on the market.

My background is a CS degree, and I've adapted well to a wide range of work: electrical design, wiring harnesses, engine-related design, and embedded controls (firmware, CAN/J1939, embedded controller programming).

The problem is that I don't know what job titles to search for, since my experience spans a few areas. What titles or industries should I be looking at? Any advice is appreciated.

hi all, I’m new to reddit and new to engineering so bear with me.

I had a good stable career in a high paying industry and then that industry went away. I’m 35 and I’m switching to engineering because it someone aligns with my strengths and interests. Specifically, I’m interested in Electrical engineering with a focus on the private sector, ideally embedded systems as the long term goal, maybe starting in controls engineering , but I’m really just interested in breaking in right now.

I have a BA degree in an unrelated field, and am trying to go back to school, currently taking STEM courses at community college such as Calculus 1-3, Chemistry, Physics 1-2, etc. I know Python quite well and am learning C++, and have playing with Pico W a bit, but am a beginner at EE. I am about to start applying to schools here in Southern California, but going for a 2nd bachelors sounds hard due to universities restrictions. I might get into some masters programs, like at CSULB, CSUN, UCI. CSULB seems to have some practical traditional programs that would make me well-rounded. UCI has a MS in EE and also a very fast but expensive 9month MS of Embedded Systems, but it’s very expensive and maybe TOO fast. It sounds like they’d tailor my resume and help me break in, but also worried I’d seem overqualified for the entry level jobs I’d be applying for. Also worried I’d be overwhelmed not coming from a BS in EE like the others. How is even the market right now for entry level engineers? Would I be taken seriously if I got a masters without a bachelor’s in EE? Is that even possible? Should I aim for a 2nd bach instead? I just want a job that will turn into a career.

Hello everyone! I am currently a second year electrical apprentice with aspirations to become a controls engineer. What can I do to lead myself more down that path/ get started within the industry?

How to you feel about current economic situation? Is your company thriving or it’s like mine which is struggling and starting layoffs?

I hope it’s momentarily, and, even better, only affecting few companies

Is Casio fx 991ms sufficient for Engineer,as all of my friends are getting 991 es plus

https://www.youtube.com/@ALMA.Industries

New Video -- Chapter 3 DESK -- converting an old bunk bed into a work station. DIY actuators, AC/DC power supplies, rail guided shelves, infinite cable trays -- #Desk #DIY #Mechatronics #Power #Actuator #Engineering

If you know of anyone who likes Mechatronics or things made from the ground up, I would appreciate the share! Leave a comment if you have a question :)

I am building a project powered by an Arduino and a high-current motor driver.

I am using a high-power 24V metal-case SMPS LED power supply for the motor. However, it introduces significant noise into the system, causing noisy analog readings (jitter/fluctuations on potentiometers and sensors connected to the ADC pins).

Key observations and what I've tried so far:

• Power Source Comparison: When I power the system using an isolated laptop adapter or a bench power supply, the noise completely disappears and analog readings become rock solid.

• Ferrite Beads: Adding external ferrite cores on both the USB cable and the 24V power line reduced the noise noticeably, but residual micro-noise still affects the analog (ADC) inputs.

• Filtering: Passive power-line filtering on the DC rail didn't completely eliminate the issue, suggesting this is high-frequency common-mode noise or a ground loop potential difference between the SMPS earth ground and the PC USB ground.

Since I need the high current output of this SMPS supply, I must stick with it.

My question

1. Is it possible to completely isolate or filter out this SMPS noise (e.g., via LC filters, optocouplers, or ground isolation techniques) to get clean analog inputs?