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Procedia Computer Science 150 (2019) 208–215

13th International Symposium “Intelligent Systems” (INTELS’18)

13th International Symposium “Intelligent Systems” (INTELS’18)
On Development of Module for Neural Tuner to Adjust D-part of
On Development of Module for Neural Tuner to Adjust D-part of
PID-controller Online
PID-controller Online
A.I. Glushchenko*
A.I. Glushchenko*
Stary Oskol technological institute n.a. A.A. Ugarov (branch) NUST “MISIS”, Stary Oskol, 309516, Russia
Stary Oskol technological institute n.a. A.A. Ugarov (branch) NUST “MISIS”, Stary Oskol, 309516, Russia

Abstract
Abstract
Nowadays nonlinear industrial plants are controlled by linear P, PI and PID-controllers with constant parameters. This results in
Nowadays nonlinear
both transients qualityindustrial
and energyplants are controlled
efficiency by linear
decrease. P, PI and
An adaptive PID-controllers
neural with Pconstant
tuner to adjust and PI parameters. This resultshas
controllers parameters in
both
been transients
proposed to quality
solve and
theseenergy
problemsefficiency decrease.
and tested both forAnheating
adaptive neuraland
furnaces tuner
DCtodrives.
adjustButP and
it isPInotcontrollers parameters
able to adjust a D-parthas
of
been proposed which
the controller, to solveis these
widelyproblems
used forand the tested
heatingboth for heating
furnaces. So thefurnaces and research
aim of this DC drives. But
is to it is not
extend the able to adjust of
functionality a D-part of
the tuner
the
withcontroller, which module
a new software is widelytoused
adjustforKthe heating furnaces.
D parameter online. InSoorder
the aim of this research
to achieve this, a newis to extend the
structure functionality
of the of thefor
neural network tuner
the
with
tuneraisnew software
chosen, module
its rule base to
is adjust
enhancedKD parameter online. Inrules
with the developed orderforto K
achieve
D, and this,
the a new structure
sustainability of the
criterion neural
for the network
system for
with the
the
tuner
tuner isand
chosen, its rule base isisenhanced
the PID-controller developed. withThe
the new
developed
versionrules
of the KD, and
for tuner is the sustainability
applied to controlcriterion
a heating for furnace
the system with the
to keep
tuner andtransients
required the PID-controller is developed.
quality under the conditionTheofnewthe version
furnace of the tuner non-stationarity.
parameters is applied to control a heating
Comparing furnace
to the to keep theit
PID-controller,
required
allows totransients quality time
reduce transients underaveragely
the condition of the
by 11.6% andfurnace parameters
the furnace energynon-stationarity.
consumption by 8.4%. Comparing to the PID-controller, it
allows to reduce transients time averagely by 11.6% and the furnace energy consumption by 8.4%.
© 2019 The Author(s). Published by Elsevier B.V.
© 2019 The Authors. Published by Elsevier B.V.
© 2019
This The
is an
an Author(s).
open Published
access article
article under bythe
Elsevier B.V.
CC BY-NC-ND
BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
(https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is open access under the CC license
This is an open access
under article under
responsibility of the
the CC BY-NC-ND
scientific committee license
Peer-review under responsibility of the scientific committee of the 13th
Peer-review of the (https://creativecommons.org/licenses/by-nc-nd/4.0/)
13th International
International Symposium
Symposium “Intelligent
“IntelligentSystems”
Systems”(INTELS’18)
(INTELS’18).
Peer-review under responsibility of the scientific committee of the 13th International Symposium “Intelligent Systems” (INTELS’18)
Keywords: nonlinear plants; neural tuner; PID-controller; sustainability; rule base.
Keywords: nonlinear plants; neural tuner; PID-controller; sustainability; rule base.

1. Introduction
1. Introduction
Nowadays P, PI and PID control algorithms are widely used in different branches of industry, since they are
Nowadays
simple, robustP,and
PI well-known
and PID control algorithms
to factories are [1].
workers widely used
At the in different
same branches
time, they of and,
are linear industry, since
in most theyhave
cases, are
simple, robust and well-known to factories workers [1]. At the same time, they are linear and, in most cases,
constant parameters values, which have been found as a result of a commissioning, during the whole period of a have
constant parameters values, which have been found as a result of a commissioning, during the whole period of a

* Corresponding author. Tel.:+7-910-22-66-946; fax: +7-4725-45-12-00.

E-mail address:author.
* Corresponding Tel.:+7-910-22-66-946; fax: +7-4725-45-12-00.
a.glushchenko@sf-misis.ru
E-mail address: a.glushchenko@sf-misis.ru
1877-0509 © 2019 The Author(s). Published by Elsevier B.V.
1877-0509 © 2019
This is an open The article
access Author(s).
underPublished by Elsevier license
the CC BY-NC-ND B.V. (https://creativecommons.org/licenses/by-nc-nd/4.0/)
This is an open
Peer-review access
under article under
responsibility of the
the CC BY-NC-ND
scientific license
committee (https://creativecommons.org/licenses/by-nc-nd/4.0/)
of the 13th International Symposium “Intelligent Systems” (INTELS’18)
Peer-review under responsibility of the scientific committee of the 13th International Symposium “Intelligent Systems” (INTELS’18)

1877-0509 © 2019 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the 13th International Symposium “Intelligent Systems” (INTELS’18).
10.1016/j.procs.2019.02.042
 A.I. Glushchenko / Procedia Computer Science 150 (2019) 208–215 209
2 A.I. Glushchenko / Procedia Computer Science 00 (2019) 000–000

plant functioning. But almost all industrial plants are nonlinear. Application of the linear controllers without tuning
of their parameters to the nonlinear plants leads to eventual transients quality decrease and increase of the energy
consumption [2].
This problem is especially actual for energy consuming branches of industry, particularly, for the metallurgy. One
of the classes of the plants with the highest consumption of the energy resources in the metallurgy is heating
furnaces. Their parameters are time-varying due to the change of both the furnace load and the setpoint value, and
disturbances. Its possible solution is the optimal or the adaptive control methods application. The optimal ones [3,4]
require an accurate plant mathematical model, which identification is rather a difficult task under the industrial
conditions.
Considering the adaptive control approaches, the highest chances of industrial application have those of them,
which do not change the base control algorithm, but try to adjust its parameters online [1,5,6] – so-called tuners.
Excluding from the analysis all methods based on the plant identification with the help of test signals [2,5,7] due to
the above mentioned reason, such tuner could be based on a reference model [2,8] or intelligent methods [9-11]
application. The reference model allows to obtain equations to tune the parameters of the controller, but one of the
variables in them is the gradient descent step size, which value determination is a nontrivial problem for a real
industrial plant.
As far as intelligent methods are concerned, they allow to take into consideration knowledge (fuzzy logic [10],
expert systems [11]), trainability and ability to generalise (neural networks [9]) of a process automation engineer,
who adjusts the controller without the plant and reference models. The problem is that the solution of the considered
problem should combine all these abilities, while mentioned methods do not follow this requirement. The fuzzy
logic needs an approach to train normalization coefficients of the tuner input and output parameters values. The
knowledge base of the expert system is closely related to a particular plant dynamics due to difficulty of such system
online training. Neural networks can be trained offline and online, but there is a need in: 1) a training set, containing
the controller ideal parameters values for all possible situations, for the offline case, 2) a method to calculate
learning rate value ηk(q) (k is the neuron number, q is the layer number) for the online case.
In order to overcome above mentioned disadvantages of the intelligent methods we have proposed a P and PI
controllers neural tuner [12,13] combining the neural networks (to calculate KP, KI), which are trained online, and a
set of rules to calculate ηk(q) for such training (detailed description is given in Section 3). It was applied to control
both metallurgic electroheating furnaces and DC drives and allowed to keep transients quality under the conditions
of the time-varying plants parameters. But in many cases the heating furnaces are controlled with the help of the
PID-controller, which could not be adjusted with the help of the mentioned tuner due to, particularly, absence of the
rule set for the D-part of the controller and the criterion to estimate the sustainability of the control system with both
the tuner and the PID-controller.
So this research scope is to develop both the mentioned rule set and sustainability criterion and choose the tuner
neural networks structure. This will improve the method under consideration and allow it to adjust PID-controllers
online.

2. Problem statement

The neural tuner is to be applied to the system depicted in Fig. 1 (e(t) is the control error, r(t) is the setpoint,
y(t) is the plant output, u(t) is the control action). The plant in this scheme is a metallurgic one-zone heating furnace
or one zone of a multizone furnace, which can be described as (1). K is the furnace gain coefficient, T1 is the furnace
time constant, T2 is a thermocouple time constant, τ is the furnace time delay.

Fig. 1. Control system with neural tuner.

210 A.I. Glushchenko
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Science 150 (2019)
00 (2019) 208–215
000–000 3

W ( s )  ( K /(T1s  1))  (1 /(T2 s  1))  e   s (1)

K, T1 and τ are not constants due to the setpoint value change and the furnace loading and unloading. But the
model parameters values are unknown. The schedule of the setpoint value change is stepwise and known, as well as
the required transients quality.
The tuner is applied to the functioning plant controlled with the help of the PID-controller with known constant
KP, KI, KD parameters. They need to be adjusted by the neural tuner to keep the required quality of transients.

3. Neural tuner

A functional chart of the neural tuner is shown in Fig. 2. The tuner is called once in Δt seconds. It obtains data
from the control system and sends them to the neural network, which is active at the moment. Two networks, which
are responsible for the heating and cooling processes respectively, are used since the heating furnaces are
unsymmetrical plants [14], so two processes with different dynamics are to be controlled. For each of them a set of
the controller parameters needs to be found. At the moments of the setpoint change the switch chooses the network
to be used. The rule base determines when and at what learning rate to train an active network online.

Fig. 2. Neural tuner with two neural networks.

3.1. Neural network structure selection

Neural networks structure (see Fig. 3) has been selected in accordance with [12]. The set of the input neurons is
chosen as a result of the analysis of the PID-controller difference equation (2) for the stepwise setpoint schedule. The
tuner must have not less data than the PID-controller has, so its input layer contains five neurons (Ninput = 5)
including two delayed by Δt seconds plant output signals (Ndelay = 2) – the setpoint value r (X1), the plant output
values y(tk) (X2), y(tk – Δt) (X3) and y(tk – 2Δt) (X4), the controller previous output u(tk – Δt) (X5).

u (t k )  ( K I  t )  r  ( K P  K I  t  K D / t )  y (t k ) 
(2)
 (2  K D / t  K P )  y (t k  t )  ( K D / t )  y (t  2t )  u (t k  t ).

Fig. 3. Selected neural networks structure.

 A.I. Glushchenko / Procedia Computer Science 150 (2019) 208–215 211
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The number of hidden neurons Nhidden is calculated using (3). In this research the number of measurements to
average y(t) is three (Nav = 3). So Nhidden is equalled to 15.

N hidden  (2 N input  1)  N av  N delay  1 . (3)

3.2. Neural network training

At the start-up moment the neural tuner is trained with the help of the extreme learning machine method [15] to
make the neural networks outputs be equal to the PID-controller parameters used before the tuner installation. After
that both networks are trained online with the help of the backpropagation method (4). Each output neuron is trained
in accordance with its own error e2(t) = e(t) = r(t) – y(t), e1(t) = e2(t) – e2(t – Δt) and
e3 = e2(t) – 2·e2(t – Δt) + e2(t – 2·Δt) and learning rate η1(2), η2(2), η3(2). η(1) is the same for all hidden neurons and
equalled to 10-5 according to [16]. Oj(1) is the jth hidden neuron output value, dOj(1)/dsj(1) is the sigmoid activation
function derivative. η1(2), η2(2), η3(2) are calculated by the rule base at each call of the tuner.

 kj( 2) (t )   k( 2) ek O (j1) , bk( 2) (t )   k( 2) ek , k  1, 3, j  1, 15

3 3 (4)
 (ji1) (t )   (1) [  ek  kj( 2) (dO (j1) / ds (j1) )] X i , b (j1) (t )   (1) [  ek  kj( 2) (dO (j1) / ds (j1) )], j  1, 15, i  1, 5
k 1 k 1

3.3. Rule base

Rule base for the P and PI-controllers are shown in [12]. Here it is widened to cover the case of KD adjustment.
Main definitions are shown further. Nn is the noise amplitude measured at the steady-state mode. r and rold are the
current and previous setpoint values. KP ↑ is to increase KP, KI ↑ is to increase KI, KD ↑ is to increase KD, KP ↓ is to
decrease KP, KI ↓ is to decrease KI, KD ↓ is to decrease KD, vmax is the maximal speed of y(t) change, σ = 100%  (ymax
– r(t)) / (r(t) – rold) is the overshoot, S% is the required steady-state error, X% is the required σ, ymax is the amplitude
of the transient peak.
The tuner is trained online if u(t) is in allowed range. If the current transient is in progress and |e(t)| ≥ 0.2·|r – rold|
and |e(t)| ≤ 0.9·|r – rold|, and:
1) |y(t) – y(t – Δt)| < Nn, then KP ↑ and KD ↑. η1(2) and η3(2) are calculated as (5).

Sp  r (t )  y (t ) / r (t )  rold  | y (t )  y (t  t ) | / r (t )  rold , 1( 2)  K P (t )  Sp,  3( 2)  K D (t )  Sp. (5)

2) |y(t) – y(t – Δt)|> vmax, then KP ↓ and KD ↓. η1(2) and η3(2) are calculated as (6).

r (t )  y (t ) | y (t )  y (t  t ) | | y (t  t )  y (t  2t ) | ( 2)
Sp    , 1  K P (t )  Sp,  3( 2)  K D (t )  Sp . (6)
N hidden  r (t )  rold r (t )  rold r (t )  rold

If these two rules have not executed and |e(t)| ≤ 0.2·|r – rold|, then:
3) if |e(t)| < (S% / 100%)·|r – rold| at the moment of the setpoint change, and the control system is stable, then the
current control action u is saved to a special array as a calibrated value uet for the current r value. If after that there is
a new transient process to this r value and y(t) curve have just crossed r curve for the first time, then the current
control action signal from the I-part of the controller ui is considered. If ui < uet, then it is decided that KI ↑,
otherwise – KI ↓.
4) if it is decided that KI↑ and σ > X%·|r – rold|, then KP ↓, KD ↓. η1(2) and η3(2) are calculated using (5).
5) if it is decided that KI↑ and σ < X%·|r – rold|, and e(t) > (S% / 100%)·|r – rold|, and |y(t) – y(t – 2Δt)| < Nn, then
KI↑, KD↑. η2(2) and η3(2) are calculated using (7).
212 A.I. Glushchenko / Procedia Computer Science 150 (2019) 208–215
A.I. Glushchenko / Procedia Computer Science 00 (2019) 000–000 5

r (t )  y (t ) | y (t )  y (t  t ) | | y (t  t )  y (t  2t ) | ( 2)
Sp  (  S % / 100%)   ,  2  K I (t )  Sp,  3( 2)  K D (t )  Sp . (7)
r (t )  rold r (t )  rold r (t )  rold

6) if it is decided that KI↓, and e(t) > (S% / 100%)·|r – rold|, and |y(t) – y(t – 2Δt)| > Nn, then KI↓, KD↓. η2(2) and
η3(2)are calculated using (7).
These rules are appropriate for the heating processes. As far as the cooling processes are concerned, the following
set of the rules is developed (rules three, five and six are used from the previous set of rules):
7) if |y(t) – y(t – Δt)| < Nn, and |e(t)| > (S% / 100%)·|r – rold|, and y(t) curve has not crossed r curve yet, then KI↑,
KD↑. η2(2) and η3(2) are calculated using (7).
8) if y(t) curve has already crossed r curve, and y(t) > r, and |e(t)| > (S% / 100%)·|r – rold|, then KP ↓, KD ↓. η1(2)
and η3(2) are calculated using (8).

Sp  ( r (t )  y (t ) / r (t )  rold  S % / 100%) | y (t )  y (t  t ) | / r (t )  rold , 1( 2)  K P (t )  Sp,  3( 2)  K D (t )  Sp. (8)

9) if y(t) curve has crossed r curve once, and |e(t)| > (X% / 100%)·|r – rold|, then KP ↓, KD ↓. η1(2) and η3(2) are
calculated using (9).

Sp  ( r (t )  y (t ) / r (t )  rold  X % / 100%) | y (t )  y (t  t ) | / r (t )  rold , 1( 2)  K P (t )  Sp,  3( 2)  K D (t )  Sp . (9)

10) if it is decided that KI↓ and σ > X%·|r – rold|, and e(t) > (S% / 100%)·|r – rold|, and |y(t) – y(t – 2Δt)| < Nn, then
KP↑, KD↑. η1(2) and η3(2) are calculated using (9).
The learning rate ηk(2) calculated by the rules might be too high for the current state of the control system. This
may cause its instability. This situation is prevented with the help of a developed sustainability criterion (Section 4).

3.4. Time gap between consecutive neural tuner calls

As it has already been mentioned, the tuner is called once in Δt seconds. The method for Δt value calculation is
proposed in [17]. It is based on G.B. Huang’s theorem [15] and the fact that the tuner is applied to a functioning
plant. So the transients time is known for the current PID-controller parameters. This time is averaged for the
sequence of the setpoint values under consideration and divided by Nhidden to obtain Δt.

4. Sustainability criterion

A method to estimate stability of the system in Fig. 1, but in case of PI and P controllers usage, is proposed in
[13] using the Lyapunov’s second method. It calculates selected Lyapunov function and its derivative discretely. As
a result, the maximum allowed value for the learning rate is calculated. In order to apply this method to the PID-
controller based system the Lyapunov function is to be modified and its derivate is to be recalculated. In this case the
Lyapunov function is selected as (10). Its derivative is calculated as (11).

3
V ( E )  0.5   ei 2 (t )  0.5  (e12 (t )  e2 2 (t )  e3 2 (t )). (10)
i 1

1 3 1 3
 ei (t ) . (11)
2
V   ei (t )  ei (t ) 
t i 1 2t i 1

All ei and Δei can be calculated using r(t) and y(t) signals. So (11) is rewritten as (12) for the stepwise setpoint
graph.
 A.I. Glushchenko / Procedia Computer Science 150 (2019) 208–215 213
6 A.I. Glushchenko / Procedia Computer Science 00 (2019) 000–000

1
V (t )  [9 y 2 (t )  30 y 2 (t  t )  16 y 2 (t  2t )  y 2 (t  3t )  y (t )(30 y (t  t )  18 y (t  2t )  4 y (t  3t ))  (12)
2t
 y (t  t )(42 y (t  2t )  10 y (t  3t ))  y (t  2t )(8 y (t  3t ))  2r (t )( y (t  t )  y (t ))]  0.

This equation allows to check the sufficient stability condition each Δt seconds, i.e. at every tuner call. Moreover,
it can be considered as inequality, where y(t) is a variable. Knowing the real y(t) value and solving this inequality,
the desired yst(t) plant output value is found [13] for the current moment. Maximal allowed corrections for KP, KI and
KD are calculated on this basis as ΔKP ≤ (yst(t) – y(t)) · (KP + KD / Δt) / e(t), ΔKI ≤ (yst(t) – y(t)) · (KP + KD / Δt) /
/ (e(t) · Δt / dt), ΔKD ≤ (yst(t) – y(t)) · (KP + KD / Δt) / (e(t) – e(t – Δt)) (dt is the sampling period of a central
processor unit of a programmable logic controller (PLC)).
Using the backpropagation training method and ΔKP (ΔK1), ΔKI (ΔK2), ΔKD (ΔK3), the equation (13) is obtained
to calculate the maximal allowed learning rate value ηk max(2) for the output layer neurons.

15
k(2max
)
 K k /[ek(2) (  ((O(j1) ) 2 )  1)], (k  1, 3). (13)
j 1

If |ηk(2)| ≤ |ηk max(2)|, then ηk(2) is chosen, otherwise, ηk max(2) is applied.

5. Experimental results

The tuner has been implemented as a function block FB using Structured Text programming language. This
language is supported by most of the PLC producers, particularly, by Siemens. Their controller S7-300 with central
processor unit 314-2DP was used in this research. The above mentioned function block with the tuner was integrated
into the controller memory and took only 32 Kb of it. A standard block FB58 was used to implement the PID-
controller. The tuner outputs were written into such memory cells, from which FB58 took KP, KI, KD values.
An electroheating furnace SNOL-1,6.2,5.1/11-I4 has been used for experiments. Its control system was arranged
as it is shown in Fig. 4.
A cycle of the setpoint value change was from 5900C to 6400C, then to 5050C and back to 5900C. There were 36
transients during each experiment – twelve transients for the unloaded furnace, then twelve transients for the furnace
loaded by a steel cast to fill 20-25% of the furnace inner volume, after that – twelve transients for the unloaded
furnace. The required transients quality was determined as σmax = 100%  (ymax – r(t)) / (r(t) – rold) = 5%, X% ≤ σmax,
S% ≤ σmax. If current S% had been lower than σmax for 30 minutes, then the setpoint value was changed following the
above described cycle.

Fig. 4. Implementation of furnace control system.

Initial values for KP, KI and KD were found for the transient from 5050C to 6900C for the empty furnace to comply
with X% value – KP = 1.2, KI = 0.0024, KD = 18.
The results obtained for the systems with the PID-controller and the neural tuner are depicted in Fig. 5A and
Fig. 5B respectively (line one – the furnace loading, line two – the furnace unloading). The overshoot was higher
214 A.I. Glushchenko / Procedia Computer Science 150 (2019) 208–215
A.I. Glushchenko / Procedia Computer Science 00 (2019) 000–000 7

than X% for the system with the PID-controller (Fig. 5A) when the furnace was loaded. This resulted in longer
transients in comparison with the neural tuner based system (Fig. 5B1). The tuner adjusted KP (Fig. 5B2), KI
(Fig. 5B3), KD (Fig. 5B4) parameters to keep the required transients quality. The curves of the learning rates
calculated by the rules ηk (2) and the maximal learning rates ηk max(2) (k = 1, 2, 3) for the output neurons are shown in
Fig. 5B5, Fig.5B6 and Fig. 5B7. Most of the time all these values equalled to nil. Excluding all such moments from
these figures, curves were obtained, which are shown in Fig.5C. Having analyzed them, it was concluded that ηk (2)
and ηk max(2) were quite close to each other for all values of k = 1, 2, 3. In most cases |ηk max(2)| > |ηk (2)|. In other cases
ηk max(2) value was used for training instead of ηk (2). That allowed to keep the control system stable.
All results of the experiments are also shown in Table 1.

Table 1. Results of experiments

Performance indexes PID-controller Neural Tuner
Time of experiment, h 28.66 27.42
Time reduction, % 0 4.3
Time of transients, h 10.66 9.42
Time of transients reduction, % 0 11.6
Energy consumption, kW · h 17.48 16.02
Energy consumption reduction, % 0 8.4

Fig. 5. (A) Results of PID-controller application; (B) Results of tuner application; (C) Absolute values of learning rate for output neurons.
 A.I. Glushchenko / Procedia Computer Science 150 (2019) 208–215 215
8 A.I. Glushchenko / Procedia Computer Science 00 (2019) 000–000

6. Conclusion

The functionality of the neural tuner was extended in order to allow it to adjust PID instead of PI-controllers. In
order to achieve that, the new neural network structure (5-15-3) for the tuner was chosen using the PID-controller
difference equation. The rule base was also added by the new rules to adjust the D-part of the controller. In addition
to this, the stability criterion was recalculated for the PID-controllers under the condition of the stepwise setpoint
change.
The new version of the tuner was implemented with the help of the Structured Text language, integrated into the
Siemens Simatic S7 controller, and applied to control the heating furnace, which was loaded with different amount
of steel. It allowed to reduce time of the transients by 11.6% and the energy consumption by 8.4% comparing to the
PID-controller with constant KP, KI, KD.

Acknowledgements

This research was financially supported by the Ministry of education and science of the Russian Federation, grant
#14.575.21.0133 (RFMEFI57517X0133).

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