Abstract
In industrial control systems, high-order inertial systems widely exist. However, how to design suitable control methods for these systems are facing many challenges, such as slow dynamic characteristics and weak anti-interference ability. This paper emphasizes the theoretical analysis and applications of modified active disturbance rejection control (MADRC) for high-order inertial systems. The stability analysis of MADRC is carried out by separating the high-order transfer function and using the dual-locus diagram method. Then, a simple and quantitative semi-empirical parameter tuning rule based on the expected adjustment time is provided. The effectiveness of the high-order inertial system with MADRC compared to other ADRCs and PIs is then verified by tracking and disturbance suppression simulations. MADRC with the proposed parameter tuning rule is applied to both primary and secondary superheated steam temperature systems of a 660 MW power plant. The running data show that the cascade control system with MADRC can obtain better control performance than the original control method, and show great application potential for more complex industrial control systems.
Keywords
Introduction
Active disturbance rejection control (ADRC), proposed by Prof Han, 1 is becoming an important control technique to deal with external disturbance and internal uncertainties. ADRC is an important technique for dealing with external interference and internal uncertainty. The extended state observer (ESO) is a core part of ADRC, which estimates internal uncertainties and external disturbance as total disturbance and then compensates in real-time by control actions. ADRC has been widely used in many fields. 2
Compared with simple first-order systems, high-order systems3,4 have more complex dynamic characteristics and more state variables, which is the common feature of the industrial field. 5 The most commonly used control methods for high-order systems are proportional-integral-derivative (PID), 6 model predictive control, 7 adaptive control, 8 and so on. However, when high-order systems are faced, it is not easy to analyze the control performance, implement control algorithms, and adjust their parameters. 9
ADRC has satisfactory anti-interference ability and flexibility in various fields. 10 Elbouchikhi et al. 11 proposed ADRC to improve the system’s resilience to load changes, power uncertainties, and faults. Wang et al. 12 proposed a method combining ADRC and vector resonance controller, which can effectively suppress harmonics and improve the anti-interference ability of the system. However, it needs to pay attention to parameter adjustment, 13 robustness and stability analysis 14 and real-time requirements in application, which should be comprehensively considered according to the characteristics and control objectives of specific systems. Therefore, on the basis of ADRC, a series of improvements are proposed. Tian et al. 15 proposed an adaptive ADRC to suppress uncertain current ripples under complex conditions. Sun et al. 16 presented a method combining feedforward and ADRC, applied to non-minimum phase systems, using a model-assisted observer to handle unknown disturbance and uncertainties. Wu et al. 17 proposed an improved gain-scheduling based ADRC that shows promising application potential in the energy and chemical industries. Sun 18 suggested a quantitative tuning method for the time-delay ADRC (TDADRC), utilizing a standard first-order plus delay (FOPTD) model. In order to improve the ability to suppress current interference, Luo 19 proposed an embedded discrete-time repeated ADRC. Chen 20 proposed a predictor-based ADRC with delay robustness based on a wet flue gas desulfurization system. A Smith-like active disturbance rejection control (SLADRC) is proposed, 21 its stability is analyzed theoretically, and a simple yet effective parameter tuning method is provided.
In summary, ADRC features a simple structure, but it has issues with input asynchrony in ESO and bandwidth limitation in high-order inertial systems. TDADRC simplifies the control logic and is suitable for time-delay systems, yet its application relies on an accurate mathematical model. SLADRC improves the control structure and is applicable to high-order inertial systems. However, its tracking performance and anti-disturbance capability are relatively poor.
In view of the limitations of the aforementioned control methods, as well as the problems commonly faced by high-order inertial systems, including difficulties in parameter tuning and the lack of rigorous stability analysis. This paper takes high-order inertial systems with modified active disturbance rejection control (MADRC) as the starting point, conducts in-depth research on its stability analysis, and proposes a simple, quantitative semi-empirical parameter tuning rule. The specific contributions of this paper are as follows.
A relatively novel stability theory is adopted to prove that superheated steam temperature systems (SST) controlled by MADRC can operate safely and stably.
A simple parameter tuning method is proposed, which only requires adjusting one parameter, reducing the operational complexity of SST controlled by MADRC.
The operation data indicates that control performance is satisfactory and can effectively improve the efficiency of SST controlled by MADRC.
The remaining sections of this paper are organized as follows. First, the design of MADRC is introduced. Subsequently, the system stability is derived by decomposing higher-order inertial transfer functions, and the system robustness is analyzed using maximum sensitivity (
MADRC design and tuning for a high-order inertial system
MADRC for a high-order system
A regular first-order ADRC schematic diagram is shown in Figure 1. State feedback control law (SFCL), the high-order inertial element
where

The block diagram of regular first-order ADRC.
where
The system’s state space can be described as
where
The mathematical expression of the ESO is designed as
where
The SFCL is defined as
where the input signal is
The bandwidth parametric method proposed by Gao simplifies the design process of the controller. 22 Therefore, the observer gain and the controller gain can be set as
where
The block diagram of MADRC is shown in Figure 2, it is used to improve the control performance of a high-order inertial system, where

The block diagram of MADRC.
A class of a high-order inertial element can be defined as
where
To achieve the purpose of synchronizing the control signal applied to the ESO with the system output, it is necessary to delay the control signal, that is, to add a compensation part before entering the ESO. It is defined as
Slightly different from the regular ADRC, MADRC has no additional parameters to adjust, and is as simple and easy to implement as ADRC. The ESO portion of the MADRC transforms into the following form
where
Equivalent transformation
The MADRC structure in Figure 2 needs to be converted into a two-degree-of-freedom (2-DOF) structure for subsequent stability analysis and stability analysis, as shown in Figure 3.

Regular equivalent 2-DOF structure of MADRC.
By applying an appropriate Laplace transform to the function, equation (9) can be derived as follows
Through proper transformation of the control system, the transfer function of each controller can be converted to
where polynomials
Stability analysis
Without considering interference, equations (7) and (8) can been converted to
As shown in Figure 4, it is the same as a first-order control object and an equivalent 2-DOF structure of MADRC can be derived as

Another equivalent 2-DOF structure of MADRC.
Through the above three formulas, the closed-loop characteristic equation of the system can be transformed into equation (18).
Based on the above equivalent transfer functions, the following stability analysis will be made.
The compensation link of the system is separated, 23 that is, equation (18) can be obtained as
where polynomials
Define
When the frequency
The following lemma and stability theorem can be derived as
If there are intersections between
Lemma 1 expresses that the intersections of
where all coefficients
Polynomial coefficients in equation (22).
Since the part of
where
Let
Define
If
Under the control of MADRC, the high-order system studied in this paper exhibits no intersection points within the parameter adjustment range. This characteristic, which aligns with Lemma 1–1), will be verified in the subsequent simulation section. Reference 23 conducts an in-depth analysis of the stability conditions when intersection points emerge, providing significant support for the interpretation of Lemma 1–2).
Tuning procedure and robustness analysis
Tuning procedure and numerical simulation
MADRC has a slightly different structure than ADRC, hence, its parameters also behave differently in a high-order inertial system. This section analyzes the control performance of MADRC through simulations, so as to better summarize the parameter tuning process of MADRC.
In the parameter tuning process, parameter
In this section, the tuning method of a first-order MADRC is presented, which can be easily and conveniently applied in actual systems. As an improvement of the method presented, 22 this method has a wider range of applications and is still simple.
When ESO is able to achieve
Under the unit step input, the output Laplace transform of equation (28) is
Therefore, the unit step response of the system is
According to the definition of setting time
where
With equation (32), the control parameter
To make ESO obtain better observation speed even when
With equation (2) and (4), the mathematical relationship between
where
The lag time of
When
When the adjustment time
To sum up, the tuning rules for the first-order MADRC controller of high-order inertial systems can be obtained as
When the adjustment time
Numerical simulation
Without considering the inner-loop of SST, taking the control object of the outer-loop of SST as an example, it is a typical high-order inertial system, as shown in equation (7). Set
Next, a simulation verification will be conducted on the stability analysis proposed above. Figure 5 presents a detailed stability analysis through graphical interpretation, considering specific numerical conditions. In this figure, the black curve represents

Graphical interpretation of stability analysis.
Then, by exhaustively searching

The gain margin and phase margin of the system with fixed

The gain margin and phase margin of the system with fixed
Lastly, set the initial value of

The influences on output and control signal with different
Robustness verification
The model of the controller is usually not accurate enough, and parameters of the target object will change with the change of operating conditions and time. Therefore, it is necessary to verify whether the robustness of the system can meet the requirements in the case of parameters perturbation.
To better analyze the robustness, a typical measure of sensitivity to process change is proposed, namely the maximum sensitivity (
where
By equations (9) and (39),
where polynomials
To verify the maximum sensitivity constraint of the control object,

Three-dimensional data diagram of
Simulation verification and field application
The model description of SST
Figure 10 is the schematic of the cascade control system of the SST. The system is composed of a low-temperature superheater (LTS), a platen superheater (PS), a high-temperature superheater (HTS), a first desuperheater and a second desuperheater, where

The schematic diagram of the SST system with the cascade control.

The block diagram for SST with the cascade control.
Simulation verification
To thoroughly evaluate the control performance of the MADRC-ADRC controller, a comprehensive comparison is made with several other controllers in the cascade control system. In addition to the commonly used PI-PI controller, the performance of DADRC-ADRC, Smith-like ADRC-ADRC (SLADRC-ADRC), and the standard ADRC-ADRC controllers are also simulated. This multi-faceted comparison aims to highlight the unique advantages and potential limitations of the MADRC-ADRC controller under various operating conditions. To facilitate these simulations, the transfer function of the system’s inner-loop
Based on the tuning method described in Section IV, the parameters for the MADRC controller are computed. It should be noted that the following principles apply to the system’s parameter tuning: first, the control output should be kept as smooth as possible, with the system’s overshoot reduced to as small a level as possible; second, on the premise of meeting the first principle, the dynamic tracking speed of the system for the target signal should be improved to as fast a rate as possible. All the parameters for each of the different controllers are systematically summarized in Table 2. The results of the simulations for the SST system are presented in Figures 12 to 14, offering a detailed comparison of control performance under various conditions in this cascade control system.
Parameters of five control methods.

The control performance of the cascade control system without any disturbance.

The control performance of the cascade control system with

The control performance of the cascade control system with
Figure 12 illustrates the control performance when the input is provided without any external disturbance. The input signal is represented by the solid black line, which is followed by the system’s response. The red line, corresponding to the MADRC-ADRC controller, shows the fastest response, reaching a steady-state value more quickly than the other controllers. This demonstrates the superior speed and efficiency of the MADRC-ADRC in handling the input signal. Figure 13 demonstrates the control performance when a unit step input is applied, and an inner-loop disturbance
From the results shown in Figures 12 to 14, it is evident that the MADRC-ADRC controller in the cascade control system outperforms the other four control methods in several key aspects. Specifically, the MADRC-ADRC exhibits the smallest overshoot and demonstrates the significantly strongest ability to resist disturbance. This indicates its superior dynamic performance and robustness when compared to the other controllers under various conditions.
The statistical indices presented in Table 3 further reinforce these observations. Among all the controllers, the MADRC-ADRC achieves the smallest Integral of Absolute Error (IAE), which serves as a clear indication of its exceptional disturbance immunity. The low IAE value highlights the controller’s ability to maintain better accuracy and stability, even in the presence of external and internal disturbances. This further underscores the MADRC-ADRC’s superiority in terms of both steady-state accuracy and resilience to interference, making it the most reliable choice among the methods evaluated.
Data indicators of the SST system under different controllers.
To perform a Monte Carlo experiment for this high-order inertial system, the parameters
The cascade system’s performance is evaluated over a period of 2400 s. Specifically, the Integral of Absolute Error (IAE) for the setpoint, denoted as
In this Monte Carlo simulation, the order
For the analysis, data graphs illustrating

Data recording of the perturbed cascade control system under different control methods.
Statistical indexes of Figure 15.
From Figure 15, it can be seen that the integral error data of the cascade control system are concentrated in the lower left corner under the control of MADRC-ADRC, and the dense distribution indicates that the control method has strong robustness. At the same time, a smaller index indicates better tracking and interference suppression performance. In Table 4, the maximum values and minimum values of
Field application
The potential application of MADRC-ADRC in the industrial cascade control system has been demonstrated through both simulation and experimental verification. Specifically, MADRC-ADRC was applied to both the primary and secondary SST systems of a 660 MW power plant, showcasing its effectiveness in improving system performance under complex operating conditions.
To accurately acquire the operating temperature data of the superheater and ensure the reliable execution of subsequent control algorithms in this experiment, a sampling period of 0.25 s is adopted for data sampling. On-site temperature signals are first transmitted directly to the distributed control system (DCS) via hardwiring. Subsequently, the DCS uploads the standardized temperature data to the industrial personal computer (IPC) through the Modbus TCP protocol, and the IPC finally runs the relevant control methods.
To meet the requirements of safe unit operation and precise control, clear standards for temperature measurement accuracy are established: as the core control parameter of the unit, the measurement accuracy error of the main steam temperature is strictly controlled within ±
For a start, Figure 16 shows the operation of the primary SST system under the two control methods for 24 h, first running MADRC-ADRC and then switching to PI-PI. When switching from MADRC-ADRC to PI-PI, a corresponding bump less transfer method is required. This switching process has no additional requirements on external conditions and can be flexibly implemented according to the actual operating conditions of the system. The core goal is to ensure the smooth transition of control variables during the switching process, and thereby guarantee the safety and reliability of the industrial control system. Specifically, before switching from MADRC-ADRC to PI-PI, this bump less transfer method requires PI-PI to first track the current operating state, calculate and initialize the initial value of its own integrator, and then execute the control method switching from MADRC-ADRC to PI-PI. This ensures that the control output remains continuous without sudden changes before and after the switch, keeping the system within a stable range. The statistical indicators in this figure are recorded in Table 5, including average deviation

Field applications of the primary SST system under switching conditions.
Statistical indexes of Figure 16.
In the next part, the comparisons of the operating conditions of the primary SST system for 24 h under the MADRC-ADRC and PI-PI control methods are shown in Figures 17 and 18. And the statistical indicators in this figure are documented in Table 6. The load capacity of MADRC-ADRC is (205.40, 507.16) MW, while the load range of PI-PI is (295.30, 521.19) MW.

Field applications of the primary SST system with MADRC-ADRC.

Field applications of the primary SST system with PI-PI.
Statistical indexes of Figures 17 and 18.
In the end, Figures 19 and 20 are the operating conditions of the secondary SST system for 24 h under the MADRC-ADRC and PI-PI control methods. Table 7 records their data and statistical indicators. Also, the load range of MADRC-ADRC is (205.40, 507.16) MW, and the load range of PI-PI is (295.30, 521.19) MW, because it is collected in the same time period as the working condition of the primary SST system.

Field applications of the secondary SST system with MADRC-ADRC.

Field applications of the secondary SST system with PI-PI.
Statistical indexes of Figures 19 and 20.
In Table 7, under the MADRC-ADRC control method, there is a large negative deviation on the Side B of the secondary SST system, because the setpoint suddenly changes greatly around the 16th hour of operation. In addition, under the PI-PI control method, the average deviation
Conclusions
This paper mainly studies SST controlled by MADRC, with a focus on introducing the relevant contents of stability analysis. The stability is deeply analyzed by separating higher-order transfer functions and using the dual-locus diagram method. This method proves that SST under MADRC control can operate safely and effectively. In addition, a simple and practical first-order MADRC parameter tuning method is proposed, and the robustness of SST is analyzed through the
Footnotes
Ethical considerations
The research does not involve any human or animal experiments.
Consent to participate
Obtained.
Consent for publication
Obtained.
Funding
The authors disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This work was supported in part by supported by Natural Science Foundation of Henan Province under Grant No. 252300421954, Zhengzhou University Professor Team for Enterprise Innovation-Driven Development Project under Grant No. JSZLQY2022016 and Zhongyuan Scientific and Technological Innovation Leading Talent of Henan Province under Grant No. 254200510010.
Declaration of conflicting interests
The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.
Data availability statement
The data used to support the findings of this study are available from the corresponding author upon request.
