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From Cruise Control to Complex Industrial Systems – A Deep Dive into PID Control

Posted on by Brittany Smist
[vc_row][vc_column][vc_column_text]When it comes to industrial automation and process control, PID Control (Proportional-Integral-Derivative) is one of the most widely used and effective methods for maintaining stability and precision. You may think you know PID, but you might actually know P&ID, which stands for process and instrumentation diagram—a completely different tool used for illustrating control systems and instrumentation layouts. While P&ID is a blueprint for systems, PID Control is an active feedback mechanism that keeps processes on track by continuously adjusting variables like temperature, pressure, flow, and speed. This distinction is crucial for anyone working in automation or process control. But what exactly is PID Control, and how does it work? Let’s break it down with a relatable example.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

PID in Action: Cruise Control

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]To understand PID Control in an accessible way, think about the cruise control system in your car. This everyday application uses PID to maintain a constant speed, regardless of changes in road elevation or wind resistance. Imagine you set your car’s cruise control to 60 mph – the system continuously monitors your speed (the process variable) and compares it to your desired speed of 60 mph (the setpoint). If there’s a difference, the controller calculates an error and adjusts the throttle to minimize that error. This feedback loop keeps you cruising smoothly, and it does so by leveraging the three components of PID Control: Proportional, Integral, and Derivative.[/vc_column_text][/vc_column][/vc_row][vc_section css=”.vc_custom_1741876245910{margin-top: 10px !important;margin-bottom: 10px !important;}”][vc_row][vc_column][vc_column_text]

Proportional Control (P): Immediate Adjustment

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The Proportional component reacts directly to the current error—the difference between the setpoint and the actual value. The larger the error, the stronger the corrective action.
  • Example in Cruise Control: If you’re driving at 55 mph but your cruise control is set at 60 mph, the controller gives more gas. The greater the difference, the more throttle it applies.
  • Limitation: When used alone, proportional control tends to hunt around the setpoint. This means the car will oscillate, constantly overshooting and undershooting the target speed without ever fully stabilizing. This happens because proportional control reacts only to the current error without considering past trends or future changes.
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Integral Control (I): Remembering Past Errors

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The Integral component accounts for accumulated past errors to eliminate steady-state discrepancies. Instead of just reacting to the current error, it continuously adds up small errors over time and makes adjustments accordingly, ensuring the system reaches and maintains the setpoint.
  • Example in Cruise Control: If you’re driving uphill and the car consistently falls short of 60 mph, the integral component remembers this underperformance and gradually increases the throttle to compensate, ensuring a steady speed.
  • Drawback: Integral action can make the system feel sluggish or slow to respond because it gradually builds up the required adjustment.
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Derivative Control (D): Predicting Future Changes

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The Derivative component anticipates how the error is changing over time. Instead of just reacting to the error itself, it considers the rate of change and applies corrections early to prevent overshooting or instability.
  • Example in Cruise Control: As you approach 60 mph, the derivative component eases off the gas before you reach the setpoint, preventing an overshoot. It effectively “dovetails” into the target speed with smooth adjustments.
  • Benefit: This predictive action reduces overshooting and improves system stability.
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PID Control in Action: How EDC Delivers Precision and Stability

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Wire and Cable

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]While looking at the cruise control in your car is an easy way to start understanding what PID is, we aren’t building cars here at EDC. To get a better sense of how this method comes into our everyday work in the wire and cable industry, a classic use case to look at is in dancer position control. This is commonly used when feeding a material (like wire, cable, or plastic film) from a nip roll into a winder. If the winder is going too fast, it pulls the dancer upwards, indicating that the material is being stretched too tightly. Conversely, if the winder is too slow, the dancer drops, signaling slack in the material.
  • Proportional (P) detects the difference between the dancer’s current position and its setpoint.
  • Integral (I) helps maintain a consistent position, preventing hunting and oscillation.
  • Derivative (D) anticipates overshoot as the dancer approaches its setpoint, easing adjustments for a stable position.

 

Properly tuned PID control ensures stable tension in the material, preventing breakage or inconsistent winding quality. EDC has utilized this in projects like the traverse winder upgrade and other applications involving spools and winders.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text css=”.vc_custom_1741876648720{margin-top: 10px !important;}”]

Variable Frequency Drives

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]Nearly all drive systems at EDC involve variable frequency drives (VFDs), which often require precise tension control to maintain product quality and consistency; this is another place where we employ PID. In systems with intermediate stages (e.g., between two drive sections), load cells measure the tension. PID control uses this feedback to adjust the speed of each drive, ensuring consistent tension. This approach was particularly relevant in our recent project with a major metals processor, where maintaining precise tension was crucial for operational efficiency and product quality.
  • Proportional (P) provides immediate adjustments to maintain the desired tension.
  • Integral (I) fine-tunes the system by compensating for ongoing errors, preventing long-term drift.
  • Derivative (D) anticipates rapid changes in tension, ensuring smooth transitions and preventing oscillation.
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Temperature Control in Extruders

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]In applications like extruders, where multiple heating zones must be controlled, EDC uses PID for precise temperature regulation. Extruders have several zones, each requiring a specific temperature to ensure consistent material properties. PID control adjusts the heating elements to maintain the setpoint. Accurate temperature control is vital for maintaining material consistency and preventing defects in the final product.
  • Proportional (P) adjusts power to the heating elements based on the current temperature error.
  • Integral (I) compensates for temperature lag, ensuring steady-state accuracy.
  • Derivative (D) anticipates rapid changes, preventing overshoot or oscillation.
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The Benefits of PID Control

[/vc_column_text][vc_column_text]PID control is a cornerstone of modern automation, ensuring process stability, energy efficiency, and high product quality across industries. By continuously adjusting control outputs, PID minimizes fluctuations, leading to smoother, more consistent operations that reduce wear and tear on equipment. This not only extends system lifespan but also lowers operational costs by decreasing the need for frequent maintenance.

In industrial settings, optimized resource utilization is critical, and PID controllers help by minimizing waste and improving efficiency, whether in manufacturing, chemical processing, or energy systems. Additionally, precise process control plays a key role in regulatory compliance, ensuring industries meet strict safety and quality standards.

At the end of the day,PID improves automation reliability, allowing systems to function predictably with minimal human intervention. Whether stabilizing temperatures in an extruder, regulating flow in a chemical process, or ensuring precise motion control in robotics, PID enables smarter, more adaptive automation that drives productivity and consistency.[/vc_column_text][/vc_column][/vc_row]

Employee Spotlight: Ben Ferrara

Posted on by Brittany Smist
[vc_row 0=””][vc_column 0=””][vc_single_image image=”2887″ img_size=”large”][vc_column_text 0=””]At Electronic Drives and Controls (EDC), we know that great engineering starts with great people, so today we’re excited to shine the spotlight on one of our newest team members: Ben Ferrara! A Systems Design Engineer, Ben’s industry-specific experience and creative problem-solving mindset—paired with priorities that align perfectly with how EDC operates—are already making him a valuable addition to the Systems Team.[/vc_column_text][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_column_text 0=””]

From Hands-On Manufacturing to Front-End Design

Ben earned his Mechanical Engineering degree from the University of Pittsburgh and has worked in roles spanning small electronics R&D, vacuum-controlled induction melting, and laminating and converting manufacturing. He’s also no stranger to field work, having traveled with an OEM to install and start up equipment on-site—giving him firsthand insight into how systems operate in real-world conditions.

“I’ve worked with equipment both large and small, mechanical and electrical, and in a variety of manufacturing settings,” Ben explains. “I hope that having seen these systems from so many angles will help me design better solutions and bring real value to the projects I work on for EDC’s clients.”

As a Systems Design Engineer, Ben plays a key role in the early stages of project development—creating first-pass designs and technical proposals that serve as the foundation for client solutions. He’s currently working on integrating a conveyor system in a pasta factory and upgrading rewind controls for a company that manufactures industrial rubber mats—two very different projects that reflect the variety of work EDC takes on, something Ben says drew him to the company in the first place.[/vc_column_text][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_column_text 0=””]

Designing with the End in Mind

When asked what attracted him to EDC, Ben pointed to the diversity of industries and technologies, and the opportunity to keep learning. But more than that, it was about designing systems that provide ongoing value to clients.

“When I design systems, I focus on maintenance and lasting value for the customer,” Ben says. “Having worked on the manufacturing side, I know how important it is to choose reliable vendors with long-term support and great service. I also prioritize ease of use for the operators. The best systems are the ones that just work—you don’t have to think about them.”

This approach makes Ben a natural fit at EDC, where customer success and system longevity are our top priorities. As a systems integrator, much of the work EDC does happens behind the scenes—but when done right, it leads to seamless, reliable performance for years to come. Ben’s focus on usability, maintainability, and value directly reflects the standards EDC is known for—and ensures clients benefit from both thoughtful design and dependable execution.

Ben’s client-focused approach stood out right away to his supervisor, Bob Pusateri, Director of Business Development:

“Ben’s previous employer was a company in coating and laminating—one of EDC’s key industries. So right off the bat, he had a strong grasp of the kinds of applications we encounter, the control components involved, and the work that goes into modernizing those systems,” Bob says. “That understanding, combined with his focus on what customers really need from their systems, has helped him contribute to proposal efforts right away. Plus, he’s just a terrific guy with an easy, approachable communication style—something our customers (and our team!) really appreciate.”

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Ben After Hours: Cats, Cards, and Competition

Ben’s creativity doesn’t stop at system design. As you might expect from someone who loves to build things and solve problems, he’s taken that curiosity outside of work and into the world of 3D printing, where he’s been crafting custom gifts for friends and family.

But Ben’s not all gears and gadgets—he’s got a competitive side, too. A fan of strategy and high-level play, he’s a regular in Magic: The Gathering and Super Smash Bros. Melee tournaments.

It’s clear that Ben has always prioritized family. He’s made it a point to stay close to home, living in Montclair, NJ, just a short drive from both his hometown of Bernardsville, NJ and EDC’s office. His parents still live nearby, and he’s remained close with his two sisters—one of whom he recently visited on a memorable trip to Alaska.[/vc_column_text][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_single_image image=”2857″ img_size=”large” add_caption=”yes”][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_column_text 0=””]Ben even credits his family with inspiring the career path he’s on today.

“My dad has his PhD in chemical engineering and was my physics teacher in high school,” Ben shares. “He was the biggest inspiration for me to pursue engineering”

That early exposure planted the seed for a lifelong curiosity—and today, it’s what motivates him most in his work.

“I love solving problems for people and collaborating with my team to offer the best solution possible.”

And if starting a new job wasn’t exciting enough, Ben has even more big news—not long after joining EDC, he proposed to his girlfriend, Kayla—and she said yes! With a new role, new projects, and a new chapter of life just beginning, there’s plenty to celebrate.[/vc_column_text][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_single_image image=”2858″ img_size=”large” add_caption=”yes”][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_column_text 0=””]Ben’s strength lies in how he connects the dots—between disciplines, between design and operations, and between what a system does and how people use it. His background spans both mechanical and electrical systems, with time spent on shop floors, in R&D labs, and out in the field. That kind of well-rounded experience is hard enough to find—but to also have deep familiarity with industries like coating, laminating, and converting? That’s a rare combination, and one that makes Ben an especially valuable addition to EDC’s team. His firsthand understanding of how systems actually run helps him design smarter, more intuitive solutions that work not just on paper, but in practice.

With engineers like Ben on board, EDC plans to keep delivering high-performance solutions that stand the test of time. We’re proud to have him on the team—and excited to see what’s next.

Welcome to the team, Ben![/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][/vc_column][/vc_row]

Takeaways and Highlights from Our Trip to Germany with Siemens

Posted on by Brittany Smist
[vc_row][vc_column][vc_single_image image=”2893″ img_size=”full”][vc_column_text]After getting back from a great trip to Germany, first and foremost we want to thank the incredible Siemens team for their hospitality, insights, and support throughout our visit. From coordinating meetings to sharing technical knowledge, they made the experience well worth the travel. A special thanks to:
  • Amer Abubaker – Amer shared a powerful personal story about his journey to U.S. citizenship and was passionate about bringing what he learned in Germany back home.
  • Kaitlin Scott – Drives Specialist who went above and beyond to organize logistics and social events for the U.S. guests. She also happens to be a top-notch engineer.
  • Pradeep Singh – Formerly with Siemens India, now based in Germany, Pradeep played a key role in coordinating the workshop and bringing marketing insight to the table.

While in Germany, the EDC team participated in two major events: Hannover Messe, the largest industrial automation fair in the world, and the SINAMICS Large Power Drives Workshop hosted at Siemens’ Motion Control HQ in Erlangen. Each offered something different—and both were valuable.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

Highlights from Hannover Messe

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]We hit the ground running—literally—by heading straight from the airport into the massive halls of Hannover Messe, the world’s largest industrial technology trade show.

Our main focus was the Siemens Mega Booth, a 20,000-square-foot experience center showcasing innovations in digitalization, motion control, and system integration. We had the chance to walk through live demonstrations, talk directly with Siemens leadership, and take a closer look at some of their latest drive and control technologies.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_single_image image=”2891″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]A couple of technologies came up a lot during our time at the Siemens booth—both in demos and in casual conversations. These weren’t just marketing buzzwords; people were actively discussing how they’re being used and where things are heading.

Digital Twin

One of the technologies that came up again and again at the show was the digital twin. Basically, it’s a way to build and test a full version of a machine in software before you build anything in real life. You can simulate how the equipment will run, work out any issues ahead of time, and fine-tune the process—all without touching physical hardware.

It’s especially useful in situations where timing is tight. For example, a manufacturer launching a new product might need to go from design to production fast. With a digital twin, the production line can be modeled and optimized in advance so that when it’s time to build, everything runs smoothly.

This isn’t something we’re offering just yet, but it’s a space we’re keeping a close eye on. There’s real potential here for future projects where speed, precision, and testing ahead of time make a big difference.

Industry 4.0

Another big focus at Hannover Messe was Industry 4.0—basically, the push toward smarter, more connected factories. That includes things like machines that talk to each other, remote access for troubleshooting, real-time data tracking, and cloud integration.

These are things we’re already doing in a lot of our projects—especially when we’re working with ProfiNet, TIA Portal, and modern PLC/HMI systems. But it was great to see how Siemens is continuing to move the ball forward. There’s clearly more opportunity ahead for our customers to improve efficiency, cut downtime, and make their systems easier to monitor and support.

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Highlights from SINAMICS Large Power Drives Workshop Roundtable:

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]The second part of our trip was the 2025 SINAMICS Large Power Drives Workshop, a smaller, more focused event held at Siemens’ Motion Control headquarters in Erlangen. Organized by Siemens GMC US and GMC HQ, this invite-only workshop brought together a handful of U.S.-based companies for in-depth technical discussions.

The smaller setting allowed for productive conversations and a better chance to get to know the Siemens team. We talked shop, shared challenges, and exchanged ideas over group sessions and a shared dinner. We’d also like to thank the full Siemens team who presented, facilitated, and made this event possible:

  • Pradeep Singh – Global Business Development, Vertical Metals
  • Fabian Kinner – Global Business Development, Vertical Testing Equipment
  • Kaitlin Scott – Business Development, Vertical Testing Equipment (USA)
  • Danny Schaefer – Head of GMC Vertical Sales Automotive, Tire, Battery, Metals & Paper
  • Thomas Tichatschke – Head of Technical Consulting, Application Support & Simulations
  • Yorck Lange – Principal Technical Consultant, Large Power Drives
  • Fabian Perner – Head of Sales Americas
  • Alexander Stukenkemper – Head of Business Development Verticals & Segments
  • Shashikant Shivajirao Ghorpade
  • Amer Abubaker
[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_single_image image=”2892″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]This event also reinforced how aligned our work is with Siemens’ motion control offerings. At EDC, our integration work regularly involves:
  • PLCs: S7-1500, S7-400, S7-1200, ET-200SP, ET-200MP
  • HMIs / Interfaces: Comfort Panel, Unified Comfort, Nanobox
  • Drives: S120 SINAMICS, S210, G120, G120C, V90, 6RA80 DC
  • Motion: S120 Simotion, 1FT7 & 1FK7 servo motors, 1PH8 asynchronous motors, Simogear
  • Safety & Comms: ProfiSafe, ProfiNet
  • Software: TIA Portal, WinCC
  • Legacy Conversions: S5 PLCs, 6SE70 Masterdrives, Micromaster, 6RA70 DC drives, Profibus, and more

Looking back, this trip was a valuable opportunity to deepen our Siemens relationship, see where the technology is headed, and bring back insights we can apply to EDC projects going forward. We’re grateful to the Siemens team for the warm welcome—and we’re looking forward to what’s next. 

Learn more about our Siemens capabilities here »[/vc_column_text][/vc_column][/vc_row]

Custom Low-Torque Winding Systems

Posted on by Brittany Smist
[vc_row][vc_column][vc_single_image image=”2937″ img_size=”large”][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_column_text 0=””]How EDC Helped Improve Process Control and Operator Safety In Composite Manufacturing[/vc_column_text][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_separator 0=””][/vc_column][/vc_row][vc_row 0=””][vc_column 0=””][vc_column_text 0=””]

Importance of Torque Control

A client of EDC’s develops composites for some of the most complex and demanding applications in the aerospace industry. One of the company’s core processes involves using winders to wrap continuous composite reinforced film around a rotating mandrel to create strong, lightweight structures. Because these materials are used in critical aerospace components, even small defects—like inconsistencies or contamination—can compromise structural integrity. That’s why precision and quality are essential throughout the winding process.

These winding systems operate at very low speeds, typically just 10 to 20 feet per minute, compared to other industries where speeds can exceed 3,000 feet per minute. Despite the slower pace, the company’s engineers and plant managers were concerned about the risks involved in operator interaction. With hands-on involvement during roll changes and inspections, they wanted greater control over winding torque to reduce the likelihood of injury while also improving process consistency.

A Proof of Concept for Safer, Smarter Winding

As the composite manufacturer’s integration partner, EDC was tasked with developing a reliable low-torque control system. The first step was creating a proof of concept. The client shipped a winder machine frame to EDC’s facility, where engineers designed and validated a custom torque-limiting system. That initial project confirmed that torque could be precisely controlled within strict safety thresholds, laying the groundwork for a full-scale rollout.

The core design logic was based on an empirically determined threshold: 34 pounds of tension. According to the manufacturer’s internal testing, staying under this limit would minimize injury risk during operator contact. From this benchmark, EDC built a control architecture around safety PLCs and redundant torque sensors. Depending on the plant and application, operator presence was managed via scanners, light curtains, or time-based logic that ensured machines entered low-torque mode as needed.

EDC’s approach had to be customized for each site. Three unique low-torque winding systems were ultimately implemented across two different facilities, each tailored to its own equipment configuration, production requirements, and environmental conditions.

Site-by-Site Solutions

Tower Two: Explosion-Proof Environment

This winder operates below the 34-pound threshold at all times, but it’s installed in a Class I, Division 2 explosion-proof zone three feet below floor level due to the use of methyl ethyl ketone (MEK), a low-flashpoint solvent. To meet safety standards, EDC designed a sealed enclosure to house the mechanics and sensors, using a contained explosion-proof motor and hard-plumbed, airtight electrical connections to prevent hazardous vapor infiltration.

Tower Three: Upgrading Manual Control

Previously, operators manually regulated winding tension using pressure clutches and regulators. EDC modernized the system by integrating an AC drive and sensors to automate torque control. A custom stand was fabricated to house a motor and pneumatically actuated tooth clutch, which disconnects the winder from the motor if torque exceeds the threshold.

To add further redundancy, two torque sensors feed data into a safe analog input, read by the safety PLC. If either sensor fails, the system disables operation, ensuring torque remains within specification at all times.

EDC also introduced an automated flagging mechanism: instead of leaning over the winder to place defect stickers manually, operators now press a button and a mechanism applies the sticker automatically, enhancing safety and improving process control.

The Combiner: Multi-Roll System with Operator Interaction

This plant required a dual-motor winding solution for its top-and-bottom roll Combiner. Manual roll changes posed safety and ergonomic risks, so EDC designed a two-motor system and fabricated a custom operator platform that was low enough to avoid the bottom roll, yet tall enough to slide carts underneath for roll swaps.

To manage torque during manual intervention, the system uses a scanner to detect operator presence and enforce low-torque mode for a programmed time window. If the task isn’t completed in time, the winder stops automatically, preventing product contamination from dropped material and ensuring safety during intervention.

Safety light curtains were added in place of originally proposed safety mats (which can be problematic with carts and forklifts). These curtains immediately stop the machine when breached, offering reliable protection without interfering with workflow.

Ongoing Improvement and Industry Relevance

In many facilities, safety upgrades like these only follow incidents or regulatory pressure. In contrast, this manufacturer’s  proactive approach was rooted in a top-down commitment to protecting personnel while enhancing process control. As a result, the company has introduced smarter winding operations that not only improve safety but also reduce downtime and improve quality.

While these projects were specific to aerospace composites, the same principles apply across any web-handling application where operators must manually interact with material during winding. That includes paper, film, packaging, and more—anywhere precision torque control and operator safety intersect.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][/vc_column][/vc_row]