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This paper aims to present an efficient and simplified proportional-integral/proportional-integral and derivative controller design method for the higher-order stable and integrating processes with time delay in the cascade control structure (CCS).

Two approaches based on model matching in the frequency domain have been proposed for tuning the controllers of the CCS. The first approach is based on achieving the desired load disturbance rejection performance, whereas the second approach is proposed to achieve the desired setpoint performance. In both the approaches, matching between the desired model and the closed-loop system with the controller is done at a low-frequency point. Model matching at low-frequency points yields a linear algebraic equation and the solution to these equations yields the controller parameters.

Simulations have been conducted on several examples covering high order stable, integrating, double integrating processes with time delay and nonlinear continuous stirred tank reactor. The performance of the proposed scheme has been compared with recently reported work having modified cascade control configurations, sliding mode control, model predictive control and fractional order control. The performance of both the proposed schemes is either better or comparable with the recently reported methods. However, the proposed method based on desired load disturbance rejection performance outperforms among all these schemes.

The main advantages of the proposed approaches are that they are directly applicable to any order processes, as they are free from time delay approximation and plant order reduction. In addition to this, the proposed schemes are capable of handling a wide range of different dynamical processes in a unified way.