Damping — the series
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The cliff before the fastest settling
Settling time against damping is not a smooth curve with a minimum. It falls by a third in one step of a sweep of five thousandths, and the fastest damping sits on the edge of that step — so a design a hundredth of a damping ratio to the left of the optimum settles forty-eight per cent slower, with a waveform that looks no different.
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Three cliffs, and where they are
The rung below sweeps a second-order step's damping, finds the settling time falling by a third in one step of a five-thousandth sweep, and calls it the cliff. There are three of them between 0.3 and 0.98, one for each excursion that stops leaving the band, and adding a third pole moves all three left and makes all three shallower — so the classic 0.78 for fastest two per cent settling is a second-order number, and at a third pole one and a half times the natural frequency the answer is 0.745 and 0.78 is on the wrong side of the step.
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The best damping is not the one to build
The fastest settling damping is the right-hand limit at a discontinuity, so two thousandths below it costs 41 per cent and two thousandths above it costs 0.34 — a ratio of 120 in the penalty for the same error. With ±2 per cent on the damping ratio the nominal that minimises the worst case is 0.7927 rather than the optimum's 0.7734, and it guarantees 4.243/ωₙ against 5.943. The band moves the optimum by 0.231 of damping ratio and the third pole by 0.047, and 0.78 is exact at ±2% and 55 per cent slow at ±1%.