On Thu, 09 Aug 2007 04:45:33 -0700, Boen S. Liong wrote: (top posting fixed)
It's done every day, in industrial settings the world over. You slap in a controller, you play with the settings for the gains, and if the result is good enough you walk away. Alternately, you push the "autotune" button, the controller plays with the gains for you, and you walk away.
Note that this approach only works if your needs don't approach what the system would be capable of if it were 'properly' tuned, but often the advantages gained from even a less-than-perfectly-tuned controller are more than enough for the job.
As an intermediate step between having no transfer function and having an explicit, accurate transfer function, you can measure the frequency response of a system and use that for your design. Frequency domain design methods have been with us for decades, they're well known by anyone with gray hair, they work pretty darn well for many kinds of systems, and IMHO the measurement of frequency response gives a more accurate characterization of many systems than the measurement of it's step response.
I would be remiss (and Peter would point it out) if I didn't mention that a frequency domain approach doesn't work for _all_ systems: it is most useful where your system doesn't have any nonlinearities such as backlash or friction that make it's high-frequency behavior unpredictable, and there are some systems where a swept-sine response measurement would be prohibitively expensive.
For systems where swept-sine measurement is a no-go, a step (or other simple time-domain response) measurement followed by an ARMA transfer function fit is probably best -- but the data that you collect has a very poor signal/noise ratio at the higher frequencies, which means that your transfer function is guaranteed to be inaccurate up there, which in turn means that you must restrict your control system bandwidth to a figure that may well be lower than what you could otherwise reliably achieve with frequency domain techniques.
You can measure the response + noise, then you can use that measurement to estimate the transfer function. You'll never get a perfect representation, which is why it's called an 'estimate'.
This measurement works even if the system isn't observable -- you get a reasonable estimate of the end-to-end transfer function, you just don't get an estimate of the internal, unobservable dynamics. If these dynamics are stable and well behaved then it doesn't matter if you don't see them.
By testing for observability. See Kalaith, "Linear Systems".
I very much doubt that even 1/10th of 1% of the control loops in the world get analyzed for their robustness during their design -- even in terms of gain and phase margins. Yet they work, because they are designed so that their tuning falls way short of any dangerous instability, or because they are attached to equipment where instability can either be tolerated or where it can be detected and the equipment shut down.