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Digital twins & sim-to-real

A twin with an unlimited actuator says a PI step response ignores step size: what does the real loop with a command limit do?

research/windup-twin

A twin with an unlimited actuator is exact for a PI step only while kp·x0 ≤ U; beyond it the integrator winds up to x0²/(2U), overshoot rises from 21% to 97% and settling from 4.9 to 944, loads d ≥ U are never rejected, and the twin-tuned faster gains settle slower (clamping recovers most).

7 tests

What it found

Integrator plant under PI control, real actuator limited to |u|≤U with constant load d; the twin has neither. The twin is exact iff kpx0≤U (zero deviation up to x0=0.714), so gentle step tests certify it. Beyond that the integrator winds up to exactly x02/(2U): overshoot rises from the twin’s 21% to 74%, 93%, 97% and the settling time from 4.9 to 17, 165, 944 (x0/U=5, 20, 50); a load d≥U is never rejected and settling blows up as d→U. “Faster is better” fails: the twin’s settling time falls 32× over ωn=0.25–8 while the real one is best near ωn=1 and rises to 77; conditional integration recovers most of it. Companion to the lag and slew twins. Stylised: one integrator, static limit, noiseless.

A figure from its own output

Figure produced by research/windup-twin: twin_gap
windup-twin/experiments/twin_gap.svg, written by the project's own experiment code.

Paper, code and results

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Produced with AI assistance (Claude). Results are from the code in this repository and are simulated or stylised unless the abstract says otherwise; nothing here implies affiliation with or endorsement by any lab, researcher or company cited. MIT licensed.