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A system for tuning a process control loop includes a tuner module for receiving an error signal representative of the difference between a set point and a process variable, the module generating a first process control signal for controlling the process. The system further includes a controller mod

A system for tuning a process control loop includes a tuner module for receiving an error signal representative of the difference between a set point and a process variable, the module generating a first process control signal for controlling the process. The system further includes a controller module for receiving the error signal and a parameter signal from a nonlinear module to generate a second process control signal for controlling the process, wherein the nonlinear module applies a nonlinear procedure to generate the parameter signal. The system further includes a switching means coupled to the tuner module and the controller module to select the appropriate process control signal for controlling the process. The system provided uses nonlinear techniques in the nonlinear module to approximate the desired controller tuning parameters. The nonlinear techniques include neural network tuning, fuzzy logic tuning and nonlinear functions, including sigmoid tuning. A system also provides that the nonlinear module use nonlinear techniques to approximate the desired process model parameters. According to an embodiment of the present invention, the nonlinear module includes a process model identification module and a controller tuning module that provides controller parameters and model identification parameters using neural networks, fuzzy logic and nonlinear functions, including sigmoid tuning.

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1. A system for tuning a process control loop, the system comprising:a tuner for receiving an error signal representative of a difference between a set point and a process variable to generate a first process control signal for controlling the process and to generate a set of process characteristic

1. A system for tuning a process control loop, the system comprising:a tuner for receiving an error signal representative of a difference between a set point and a process variable to generate a first process control signal for controlling the process and to generate a set of process characteristic signals characterizing the process; a nonlinear module for applying a nonlinear procedure to the set of process characteristic signals to generate at least one controller parameter signal; a controller for receiving the error signal and the at least one controller parameter signal from the nonlinear module, the controller generating a second process control signal for controlling the process; and a switch coupled to the process for coupling one of the tuner and the controller to the process to select the appropriate process control signal for controlling the process. 2. The system of claim 1 wherein the nonlinear module includes a nonlinear controller design module for providing a nonlinear estimation of a plurality of controller tuning parameters.3. The system of claim 2 wherein the controller is further coupled to receive the nonlinear estimation of controller tuning parameters from the nonlinear controller design module.4. The system of claim 2 wherein the nonlinear controller design module allows adjustments to the controller, the adjustments altering a response speed of the controller.5. The system of claim 1 further comprising an analytical controller design module coupled to the nonlinear module, the analytical controller design module capable of providing a plurality of controller parameters to the controller based on a plurality of model identification parameters received from the nonlinear module.6. The system of claim 1 wherein the controller is a proportional, integral, and derivative feedback controller.7. The system of claim 1 wherein the nonlinear module includes at least one neural network module.8. The system of claim 7 wherein the neural network module uses a function selected from the group consisting of a sigmoid function and a radial basis function.9. The system of claim 7 wherein the neural network module uses a sigmoid function wherein a transfer function is given by wherein In is a weighted sum of a plurality of external inputs of the form In=ΣwiIni.10. The system of claim 1 wherein the nonlinear module includes a nonlinear process identification module and a nonlinear controller design module, and wherein an output from the nonlinear process identification module and an output from the nonlinear controller design module are coupled to the controller.11. The system of claim 1 wherein the nonlinear module includes a fuzzy logic module.12. The system of claim 1 wherein the controller parameter signal includes a plurality of control parameters using nonlinear estimators of a plurality of tuning parameters for tuning the process control loop.13. The system of claim 12 wherein the nonlinear module calculates the plurality of control parameters using nonlinear estimators using nonlinear functions to create nonlinear estimators of the plurality of tuning parameters.14. The system of claim 13 wherein the nonlinear function includes a neural network using a sigmoid function.15. The system of claim 14 wherein heuristic coefficients are used with the sigmoid function to provide parameters including an integral time, a gain and a derivative time.16. The system of claim 12 wherein the nonlinear module calculates the plurality of control parameters using nonlinear estimators using neural networks to estimate a set of relay oscillation tuning parameters.17. The system of claim 13 wherein the nonlinear module calculates the plurality of control parameters using nonlinear estimators using fuzzy logic to estimate a set of relay oscillation tuning parameters.18. A method for tuning a process control loop, the method comprising:receiving an error signal representative of a difference between a set point and a process variable; generating a set of process characteristic signals characterizing the process from the error signal; applying a nonlinear procedure to the set of process characteristic signals to generate at least one controller parameter signal and to generate process model identification parameters associated with the at least one controller parameter signal; generating a process control signal for controlling a process based on the error signal and the at least one controller parameter signal; and controlling the process using the process control signal. 19. A system for tuning a process control loop, the system comprising:a computer readable memory; and software stored on the computer readable memory operable to: receive an error signal representative of a difference between a set point and a process variable; generate a set of process characteristic signals characterizing the process; apply a nonlinear procedure to the set of process characteristic signals to generate at least one controller parameter signal and to generate process model identification parameters associated with the at least one controller parameter signal; generate a process control signal for controlling a process based on the error signal and the at least one controller parameter signal; and control the process using the process control signal.