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A new on-line automatic tuning method for PID controllers is presented to solve the problem that PID parameters can not adapt to the change of system characteristics. Firstly, on basis of the internal model control (IMC), the optimal integrated absolute error (IAE) is estimated by the operating data of control system when the set values are changing. Then performance index is established to evaluate the controller. If the performance does not meet the requirements, the PID tuning algorithm is triggered. The critical information can be identified from the oscillating curve which is caused by the relay. Then, the optimized PID parameters are obtained according to the improved Z-N rules. Finally, the effectiveness of the proposed method is verified by a simulation example and an actual level control system.