Comparative Analysis of IAE, ISE, and ITSE Performance in IoT-Based ZN-PID Air Heater Temperature Control
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Precise air temperature control remains a critical yet challenging task in modern industrial and agricultural systems due to high thermal inertia and heater non-linearity. Furthermore, implementing intelligent control on low-cost Internet of Things (IoT) devices is often hindered by digital conversion resolution and quantization errors. These limitations can induce thermal oscillations and energy waste if tuning criteria are sub optimally selected. Therefore, this study comparatively evaluates actual thermal performance using Integral Absolute Error (IAE), Integral Squared Error (ISE), and Integral Time Weighted Squared Error (ITSE) as objective functions for Ziegler Nichols (ZN) Type 1 Proportional-Integral-Derivative (PID) tuning. A key contribution of this work is mitigating quantization errors by integrating a 5x analog amplifier circuit with an LM35 sensor and utilizing high frequency (1000Hz) Pulse Width Modulation (PWM) via a custom-built Solid-State Relay (SSR) on an ESP32. The system was evaluated through physical closed loop testing on a 650 Watt air heater, monitored in real time the MQTT protocol. To ensure robustness, tests were cross validated at 50°C and 60°C setpoints with three replications. Experimental results demonstrate that IAE tuning offers the most balanced performance at the moderate target (50°C), achieving the fastest rise time (5.58s), minimal overshoot (0.42%), high precision (Steady-State Error/SSE: -0.11), and optimal control effort (average PWM: 52.61). Conversely, at the higher target (60°C) which presents a massive initial error deficit ISE tuning proved significantly more robust. It suppressed overshoot to 0.86% while achieving a superior settling time of 15.35 seconds. In conclusion, the IAE criterion is recommended for efficient heating applications with stable loads, whereas ISE is critical for regulating high-inertia thermal loads to prevent extreme overshoot in IoT control actuators.
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