Design and Implementation of a Torque Control System Based on Siemens S7-200 SMART PLC and Adaptive PID Algorithm

Advancements in computing technologies have significantly enhanced industrial automation, enabling the development of intelligent control systems with real-time adaptability. In this study, a high-performance torque control system integrating the Siemens S7-200 SMART Programmable Logic Controller (PLCs) with an Adaptive Proportional-Integral-Derivative (PID) algorithm is proposed. The system leverages the computational power of modern PLCs to dynamically adjust proportional, integral, and derivative gains in real time, addressing the limitations of conventional PID controllers in nonlinear and dynamic environments. The hardware architecture consists of a torque sensor, servo motor, and PLC, forming a closed-loop control system, while the software incorporates the Adaptive PID algorithm to optimize control performance. Experimental evaluations under static and dynamic load conditions demonstrate the system’s superior performance, achieving a 75% reduction in steady-state error, a 33\% decrease in response time, and enhanced robustness against load disturbances compared to traditional PID controllers. These results validate the system’s ability to provide precise, robust, and real-time torque regulation, making it suitable for applications such as robotic arms, precision machining, and automated production lines. This study not only highlights the effective combination of Adaptive PID algorithms with industrial PLC platforms but also lays a foundation for future research on optimizing real-time control strategies and expanding the system’s applicability to more complex industrial scenarios.