This regular paper was presented as part of the main technical program at IEEE ETFA'2011

Implementation of Fuzzy Logic Control Based on PLC

Jiri Kocian, Jiri Koziorek, Miroslav Pokorny

VSB - Technical University of Ostrava
Department of Measurement and Control
17. listopadu 15/2172
708 33 Ostrava, CZ
jiri.kocian1@vsb.cz, jiri.koziorek@vsb.cz, miroslav.pokorny@vsb.cz

Abstract The goal of this work is to design own universal

A substantial portion of the literature on fuzzy control
deals with the usage of fuzzy rules to implement PID type
control and also fuzzy supervisory control.
Fuzzy models have received significant attention from
various fields of interest. Especially so called the
Takagi-Sugeno-type fuzzy model which superbly
describes a nonlinear system.
In this paper we present implementation of universal
fuzzy PS/PD function block implemented to the PLC
Simatic S7 300/400. We also present implementation of
universal function block of fuzzy expert system and PID
regulator for PLC Simatic S7 300/400.
Control system with implemented fuzzy expert system
and PID regulator and control system with implemented
PS/PD regulator with visualizations are designed.
1. Introduction
The aim of this work is design and implementation of
universal function block of fuzzy regulator PS/PD and
design of own universal fuzzy expert system function
block for PLC Simatic S7 300/400.
Many papers deal with fuzzy expert systems or fuzzy
supervisors that provide adaptation of PID regulator.
Fuzzy supervisors generally monitor step responses of
closed loop and according measured variables PID
regulator constants are recalculated. This approach is
discussed in [2], [3]. [4], [6], [7]. Practical case studies
of fuzzy gain scheduling as a supervisory control
function implementation are in [5], [8], [9]. Online
stochastic analysis approach of closed loop and case
study of adaptive bioreactor control is given in [1].
Generally, there are also a lot of implementations of
fuzzy control to the PLC. [11]
Nearly all PLC producers offer fuzzy control
functions in their portfolio. But a lot of these solutions
do not cover all possibilities that may occur when using,
e.g. dead band for regulation error, manipulated value
limitation, manual control mode etc. Therefore, if you
need to apply these functions you have to program it
yourself.
fuzzy control function block and own universal fuzzy
expert system function block which cover all necessary
industrial functions and possibilities mentioned above.
Chapter 2 contains a description of the designed
control system with fuzzy PS/PD regulator and with the
visualization made in Intouch.
Chapter 3 contains a description of the designed
control system with fuzzy expert system in PID control
and with the visualization made in Intouch.
Description of implementation details of with fuzzy
expert system function block and PID regulazor function
block is in chapter 3.3.
2. Control system with fuzzy regulator
Control system with fuzzy PS/PD/PSD regulator is
designed.
Block diagram of the control system is shown on
Fig. 1. The control system consists of programmable
controller CPU 315-2 DP which is connected to the
communication processor CP 343-1 Advanced.
Communication processor communicates with the
visualization created in InTouch through an Ethernet
communication interface.
Figure 1. The block scheme of the control
system with fuzzy regulator.
2.1 Implementation of fuzzy regulator PS/PD/PSD
Function block for Siemens Simatic S7 300/400 has
been implemented to be used in described control
system.
Fuzzy controller function block uses auxiliary
function Fuzzification. This function was implemented
for degrees of membership evaluation of the error or

978-1-4577-0018-7/11/$26.00 2011 IEEE

the first difference of the error in order to known sets procedure also checks the coordinates of fuzzy sets so
coordinates. that any bad assignment of fuzzy sets and no fatal impact
Function Fuzzification is called by internal code of to the regulation function should be applied. If errors are
function block. When using fuzzy controller function detected in the coordinates of fuzzy sets during
block, function Fuzzification has to be copied to the initialization procedure, the control is stopped and
project. indication of wrong is appeared in function block output
Fuzzy controller can be PS or PD according to a (can be displayed on the visualization).
logical value of function block input Sel_PS_PD
(Sel_PS_PD in log. 0: PS regulator, Sel_PS_PD in log. Regulation error
1: PD regulator). NB NM NS Z PS PM PB
For regulation error the first difference of regulation NB 1 2 3 4 5 6 7
error and for and manipulated value (in the case of NB NB NB NB NM NS AZ
fuzzy PS regulator the first difference of manipulated

First difference of regulation error

NM 8 9 10 11 12N 13 14P
value ) are implemented weighting factors ( , , NB NB NB NM S AZ S
, ). When selecting the type of fuzzy PD regulator NS 15 16 17 18 19 20 21
the error is multiplied by factor and the first NB NB NM NS AZ PS PM
difference of the error by factor. On the other Z 22 23 24 25 26 27 28
hand when selecting a fuzzy PS regulator the error is NB NM NS AZ PS PM PB
multiplied by factor and the first difference of the PS 29 30 31 32 33 34 35
error by factor. NM NS AZ PS PM PB PB
Structure (1) is generally applied for fuzzy PD PM 36 37 38 39 40 41 42
regulator and structure (2) is generally applied for fuzzy NS AZ PS PM PB PB PB
PS regulator.
PB 43 44 45 46 47 48 49
(1) AZ PS PM PB PB PB PB

(2) Table 1. Fuzzy rules.

Manipulated value calculation for the fuzzy PD
regulator is in (3) and for the fuzzy PS regulator in (4).
(3)
(4)
The range of control error and the first difference of
the error is divided to seven fuzzy sets (NB -
Negative Big, NM - Negative Medium, NS - Negative
Small, AZ - Approximately Zero, PS - Positive Small,
PM - Positive Medium, PB - Positive Big).
Manipulated value is expressed by crisp numbers
and also takes seven values (NB, NM, NS, AZ, PS, PM,
PB).
Fuzzy rules used for fuzzy PS/PD regulator are shown
in Tab. 1. Takagi-Sugeno method was used for inferring
the manipulated values (5).
, where (5)
Crisp valu in accordance with the rule at the table
rules.
- Degree of membership. It is given as a minimum
degree of membership of members of the antecedent
(corresponding to the logical AND in the antecedent).
- Calculated manipulated variable.
Fuzzy regulator is inserted into the program and
instance data block is generated.
Fuzzy regulator contains an initialization procedure
that will get the coordinates of fuzzy sets , and crisp
numbers of manipulated value from input structures into
static structures of the fuzzy controller. Initialization
To suppress a small constant oscillation due to the
manipulated value quantization (for example due to a
limited resolution of the manipulated value by the
actuator valve) a dead band is applied to the error signal
of the controller.
Regulation error and the first difference of
regulation error are then fuzzified by function
Fuzzification.
After fuzzy inference defuzzification procedure starts.
Manipulated value is calculated according (5) and then
limited to the Hi_Lim and Lo_Lim limits and the
resulting control value is then sent to the output. The last
step is to determine the dominant rule and the value of
dominant rule (degree of membership of dominant
value). Dominant rule number and value of dominant
rule is copied to the output (and displayed on the
visualization).
It is possible to switch over two modes: an automatic
and a manual mode. The set point is taken from block
input to fuzzy calculation procedure in automatic mode.
The manipulated value is in manual mode directly
copied from the block input through manipulated value
limitation to manipulated value output.
The block scheme of implemented function block is
on Fig. 2. The scheme of fuzzy PS/PD regulator in
control system is on Fig. 3. Fuzzy PS/PD regulators can
be also connected as shown on Fig. 4 to make complete
fuzzy PSD regulator.

Figure 2. The block scheme of fuzzy PS/PD
regulator.
Figure 3. The scheme of fuzzy PS/PD regulator.
Figure 4. The scheme of fuzzy PSD
regulator.
The interface of the implemented function block is
shown on Fig. 5.
Figure 5. Fuzzy PS/PD regulator.
2.2 Visualization
Visualization system was created in InTouch.
The visualization application consists of several
windows, which are logically arranged. The main
window of visualization (Fig. 7) is a central window that
displays key information.
Setpoint switch switches automatically generated and
manual setpoint. There is also a fuzzy controller switch
between manual and automatic mode of fuzzy regulator.
In the middle part of the window are switches for
initialization procedure and fuzzy regulator type: PS or
PD type. Number of dominant rule and its value are
displayed in the right panel. From the main window, you
can get to the window with real time trend or to the
window with historical trend. In addition there are also
other windows: window for users access, window for
fuzzy regulator settings, window for simulated control
system setting and window with information about the
application.
Many controlled systems were tried to control.
Simple example is shown on Fig. 6. This controlled
system has transfer function (6). All tried controlled
systems are simulated in PLC by mathematical functions
and function blocks.
(6)
Figure 6. Real time trend.
3. Control system with PID control and
fuzzy expert system
Many controlled systems are nonlinear systems.
Successful control of system with nonlinear
characteristic is very difficult. Linearization around
working point has to be made. If the nonlinear system
has to be operated in several different operating points or
regulated system has significantly nonlinear behaviour
then constant values of PID regulator parameters cannot
lead to good control quality in required operating range.
 Figure 7. The main visualization window of fuzzy control system.

A method of switching sets of parameter values is one

of possible solutions which can be used in these
situations. Several approaches can be used to switch
values sets of the PID regulator depending on the
operating point.
The contribution shows an example of a fuzzy expert
system for the adaptation of PID regulator based on the
selected operating point. The suggested sets of PID
regulator parameters are placed into a function block of
Figure 8. The block scheme of the control
an expert system. Sets of PID regulator parameters are
system with fuzzy expert system.
then send to PID regulator depending on current working
point of the controlled system. This allows a constant
adjustment of PID regulator constants when process
value is moving between operating points.
Block diagram of the control system is shown on
Fig. 8. The control system consists of programmable
controller CPU 315-2 DP which is connected to the
communication processor CP 343-1 Advanced.
Communication processor communicates with the Figure 9. The principal scheme of fuzzy
visualization created in InTouch through an Ethernet expert system with PID regulator.
communication interface.
The control loop scheme of fuzzy expert system with 3.1 Configuration of fuzzy expert system and
PID regulator is shown on Fig 9. Controlled system PID regulator
transfer function is simulated by mathematical blocks of Stable static system with a transfer function (7) is
standard library in Step 7 software. Process value is chosen as a controlled system.
except PID regulator also input to the fuzzy expert
system function block.
 (7) 3.2 Visualization

Visualization system is created in InTouch. The
Transfer function with changing static gain is selected
visualization application consists of several windows,
to achieve the desired characteristics of the controlled
which are logically arranged. The main window of
system suitable for testing the fuzzy expert system. The
visualization (Fig. 13) is a central window that displays
static gain depends on the process variable as is shown in
key information. The main part of the window is control
Tab. 2.
loop with control loop value: Set Point, Manipulated
Value, Manipulated Value in Test/Direct Mode, Process
Process Value Controlled system parameters Value and PID regulator constants set by fuzzy expert
KS T1 T2 system to PID regulator: K P , TI and TD .
<0; 30> 2,0 16,0 2,0 Set Point switch switches automatically generated and
<30; 50> 1,0 16,0 2,0 manual Set Point. There is also a fuzzy expert system
<50; 70> 0,75 16,0 2,0 switch between manual and automatic mode.
<70; 100> 0,5 16,0 2,0 In the middle part of the window there is a switch for
initialization procedure of fuzzy expert system. Number
Table 2. Controlled system parameters.
of dominant operation point and its value (degree of
Operation points of regulation are set according membership) are displayed in the right panel. From the
Tab. 2: 20.0, 40.0, 60.0 and 80.0. main window, you can get to the window with real time
Coordinates of fuzzy sets and corresponding PID trend or to the window with historical trend.
regulator constants dedicated from Tab. 2 are shown in In addition there are also other windows: window for
Tab. 3 and Tab. 4. Coordinates of fuzzy sets are also on users access, window for fuzzy expert system settings,
Fig. 10. PID regulator constants are calculated according window for simulated control system setting and
Ziegler-Nichols tuning rules from step response for window with information about the application. Fig. 11
every value of K S in transfer function (7). (real time trend window) shows sample regulation over
Implemented PID regulators have purely parallel different operation points in regulation range.
form with filtration of derivation part (8). Detailed
information of implemented PID regulator function
block are in Chapter 3.4.

(8)

Fuzzy sets
1. 2. 3. 4.
WP 1 0,0 0,0 20,0 40,0
WP 2 20,0 40,0 40,0 60,0
WP 3 40,0 60,0 60,0 80,0
WP 4 60,0 80,0 100,0 100,0
Figure 11. Real time trend.
Table 3. Working points with fuzzy sets.
3.3 Implementation details of fuzzy expert system
PID regulator constants The interface of the implemented fuzzy expert system
KP TI TD function block is shown on Fig. 12.
WP 1 8,9274 0,2730 5,2219
WP 2 17,2548 0,1412 10,0929
WP 3 22,8065 0,1069 13,3402
WP 4 33,9097 0,0719 19,8348

Table 4. Working points and PID constants.

Figure 10. Working points and fuzzy sets. Figure 12. Implemented function block of
fuzzy expert system.
 Figure 13. The main visualization window of fuzzy expert system.
The implemented fuzzy expert system processes
Process Value in its fuzzy algorithm. Process Value
can cover the operating range of up to eight fuzzy sets
representing up to eight working points. Two fuzzy
sets representing two working points are minimum
number of fuzzy sets. Fuzzy sets names have general
meaning: from Working point 1 to Working point 8.
Each fuzzy set is determined by four coordinates and
can be form as trapezoid fuzzy set or triangular fuzzy
set.
PID constants are calculated (8) - (10) by Takagi-
Sugeno defuzzification method.
,
,
(8)
,
, (9)
, fuzzy sets coordinates etc.) of fuzzy sets can have a
, (10)
fatal impact to manipulated value calculation. If any
, - Value of the PID proportional part of i-
th fuzzy set (working point).
, - The calculated proportional part of PID
controller.
, - Value of the PID integral part of i-th
fuzzy set (working point).
, - The calculated integral part of PID
controller
, - Value of the PID derivative part of i-th
fuzzy set (working point).
, - The calculated derivative part of the
PID controller
- Number of fuzzy sets (number of working
points).
- The degree of membership of the
controlled variable of i-th fuzzy set.
Coordinates of the fuzzy sets and sets of PID
regulator parameters are inputs of fuzzy expert system.
Fuzzy expert system includes an initialization
procedure (input InitFuzzy) that will get the
coordinates of fuzzy sets and sets of PID regulator
parameters from input structures into static structures
of the function block of fuzzy expert system.
Coordinates of fuzzy sets and sets of PID regulator
parameters are also checked during the initialization
procedure because wrong coordinates (wrong order of
errors are detected during initialization procedure these
errors are then indicated at the output of function block
outputs InSetsOK, PIDConOK, NmbrOfPntsOK (and
shown on visualization).
The input value is fuzzificated by the function
Fuzzification degrees of membership of Process
Value are calculated depending on coordinates of fuzzy
sets.
 Furthermore, on the basis of (8) - (10) PID constant
calculated and transmitted to the PID regulator
function block.
So-called manual control mode is also implemented
to expert fuzzy (input Man). Fuzzy expert system can
be switched to manual control mode and PID regulator
parameters from function block input are directly
copied to the output (to the PID regulator).

3.4 Implementation details of PID regulator

PID algorithm of designed PID regulator operates as

a position algorithm. Proportional, integral and
derivative actions are connected in parallel form and
can be activated or deactivated individually by setting
zero to K P and/or TI and/or TD constants. This
allows P, PI, PD, and PID regulator to be configured.
Pure I and D regulators are also possible but not
recommended.
Implemented PID regulators have purely parallel
form with filtration of derivation part (8). Although
transfer function (8) is not so often implemented in
commercial PLC it brings some advantages.
To suppress a small constant oscillation due to the
manipulated value quantization (for example due to a
limited resolution of the manipulated value by the
actuator valve) a dead band is applied to the error
signal of the controller. Transfer function of PID
regulator is in a component recursion form with
filtration of derivate action value by a discrete analogy
of continuous low pass filter. The PID regulator
implements the control law with two degrees of
freedom and anti-wind up.
The simplified function block scheme of the
implemented PID regulator is on Fig. 8. The interface
of the implemented function block of PID regulator is
shown on Fig. 9.
Figure 14. The simplified function block
scheme of the implemented PID
regulator.
Figure 15. The simplified function block
scheme of the implemented PID
regulator.
4. Conclusion
With the development of PLC, improving the
operation speed and function unceasing enhancement,
PLC has been applied in many fields, and achieved
many functions modular.
The main goal of this work is design and
implementation of universal function block of fuzzy
regulator PS/PD and design and implementation of
universal function block of fuzzy expert system for
PLC Simatic S7 300/400.
Implementation details of fuzzy regulator PS/PD
function block and description of the designed control
system with fuzzy PS/PD regulator and with the
visualization made in Intouch is introduced.
The contribution shows an example of a fuzzy
expert system for the adaptation of the PID regulator
parameters based on the selected working point. This
approach can be appropriate for systems with nonlinear
characteristic which have to be controlled in several
operating points. The suggested sets of PID regulator
parameters are placed into the function block of the
expert system. Sets of the PID regulator parameters are
then send to the PID regulator depending on current
working point of the controlled system and according
degree of membership of process value to coordinates
of fuzzy sets. This allows a constant adjustment of PID
regulator constants when process value is moving
between operating points.
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and also by the company of Ingeteam a.s. Ostrava. Development Methods for Low Cost Industrial Control
by WinPAC Controller and Measurement Cards in
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