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Simulation of Temperature Controller for an Injection Mould Machine using Fuzzy

Logic

Article · January 2013

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 Journal of mathematics and computer Science 7 (2013) 33 - 42

Simulation of Temperature Controller for an Injection Mould Machine using

Fuzzy Logic
Seyed Kamaleddin Mousavi Mashhadi
Iran University of Science and Technology, school of Electrical Engineering, Tehran, Iran
[email protected]

Mehdi Zahiri Savzevar

Khorasan Institute of Higher Education, Mashhad, Iran
[email protected]

Jamal Ghobadi Dizaj Yekan

Khorasan Institute of Higher Education, Mashhad, Iran
[email protected]
Article history:
Received February 2013
Accepted March 2013
Available online April 2013

Abstract
This research introduces a method for designing a linear fuzzy controller to control the temperature in an
injection mould machine. First, a time-delay system is introduced as the temperature control system. The fuzzy
controller system is composed of a heater transfer function controller and a decision maker. Both the controller
and the decision maker are designed using fuzzy logic, and simulated in MATLAB. For facilitating the
implementation of the fuzzy circuit, a linear equation is estimated from fuzzy equations using regression
method, and its response is compared to that of the fuzzy controller. Finally, a PID controller is designed and
its response is compared to the response of the fuzzy system.
Keywords: Fuzzy-PID, Temperature Control, Fuzzy Controller, PID Controller.

1. Introduction.
Fuzzy logic plays such a special role in control issues that it is considered as an intelligent controlling
method. In this paper the fuzzy method is used to control the temperature and as we see the response
gets better in this method. Three articles are used as basic references to complete this paper. In [1],
Prabha has modeled the heater of injection mould machine as a transfer function with time delay as
follow:
Ke−τs
G(S) =
TS+1
In this paper the same transfer function has been used to model the heater. In [2], Zhou has considered
input/output membership functions of the fuzzy controller in terms of temperature and of triangle type.

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

The same method has been used to design the fuzzy controller system described in section. in
[3],hanamane, has implemented a controller using microprocessor to control the injection mould machine
temperature. In aforementioned paper the implementation of this controller using fuzzifier and defuzzifier
has been argued and a flowchart algorithm with a fuzzy controller has been proposed. In this paper we
have used the same algorithm to simulate the fuzzy controller.
Implementing fuzzy rules in integrated circuits has some difficulties such as complex input/output rules
and computing decimal numbers. In this paper a linear time invariant equation has been estimated from
fuzzy rules using regression method. This equation facilitates modeling the fuzzy system and
implementation of fuzzy rules in integrated circuits [4].

2. System transfer function

The system transfer function in general is as follow:
Ke−τs
G(s) = TS+1
(1)
Where, k represents the gain,τ system delay and T time constant.
Analyzing injection mould machine concludes that the transfer function possesses one degree of freedom
and a time delay as follow:
0.92
G(s) =144s+1 e−3s (2)
The open loop system is stable and tracks the set point after a time constant, which is about 560 seconds.
To see the advantages of the fuzzy controller, the close loop system results of a pid compensator is
compared with that of the fuzzy compensator. Then a fuzzy controller and a switch as a controller are
designed and the results are compared to analyze now fuzzy logic act as a controller.

3-Controller design

For aforementioned system a fuzzy and a pid controller are designed in MATLAB and the step results are
plotted for each system.

3-1-PID compensator design

The pid compensator is designed so that the setting time of close loop system is reduced. The closed loop
system with pid compensator is shown in fig 1.

Figure1. closed loop system with pid compensator

System specifications with PID compensator are:

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

PID compensator specifications are:

The closed loop system output whit PID compensator is shown in fig 2.

Figure2. closed loop system output whit PID compensator

According to fig 2, the setting time is reduced to approximately 300 seconds and overshoots is 35% for this
system.

3-2-Fuzzy compensator design

In a closed loop system with step inputs, the compensator outputs are 0 and the plant outputs are 1 ideally.
Therefor, the input variable set point of compensator is assumed 0 and the output variable set point of
compensator is assumed 1.

The membership functions are considered triangle type. Inputs/Outputs membership functions of fuzzy
compensator are specified as follow:

Table1. Inputs/Outputs membership functions

VN Very negativ

LN Low negativ

Z zero

LP Low positiv

VP Very positiv

Inputs/Outputs membership functions are shown in fig 3 and fig 5, and their rules are shown in fig 4.

Figure3. Inputs membership functions

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

Figure4. Outputs membership functions

Figure5. surface controller in the state mamdani

The closed loop system with fuzzy compensator is simulated in MATLAB. The schema of simulation is shown
in fig 6.

Figure6. schema of simulation

The step response of the close loop system with fuzzy compensator is shown in fig 7

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

Figure7. step response of the close loop system with fuzzy compensator

Comparing the step results of close loop system with pid and fuzzy compensator we can see that the setting
time is reduced from 300 seconds to 60 seconds and overshoot is reduced to 0.06.

4-temperature controller design

Command circuit designed based on oven temperature which is red bye tristor (sensor). This output fed
info command circuit. The temperature controller specifies the system input based on oven temperature to
simulate this system. It is assumed that the desired oven temperature is 5 degree. To model the noise of the
system we assume that the oven temperature variate alternatively between zero and 10 degrees. To simulate
this noise a sinous wave with an average of 5, amplitude of 5and a frequency of 0.1 rad/s is added to system
outputs as shown in fig 8. When the oven temperature is higher than 5 degrees, the temperature controller
feeds a negative signal to the system to reduce the temperature and vice versa. The temperature controller is
designed using a switch and fuzzy logic and the results are compared.

4-1-Tempeature controller design using a switch

Here an on-off switch is used as the temperature controller. So that when the oven temperature is higher
than 5 degrees (u>5), the switch applies a signal with a value of -4.9 to the system input and vice versa. It is
expected that this negative value is compensate the oven temperature variations and a constant
temperature of 5degrees (the desired temperature) is achieved. The simulated temperature controller circuit
with a switch is shown in fig 8.

Figure8. simulated temperature controller circuit with a switch

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

To relay the system output a voltage gain is used. The oven temperature variations using a pid compensator
and a switch as the controller is plotted and show in fig 9.

Figure9. pid compensator and a switch as the controller

The oven temperature variates between 3.3 and 6.8 degrees. It means that the tolerance is 1.8 degrees. But
in critical situation, it needs to be almost constant or with a tolerance less than 0.5 degrees.

4-2-Temperature controller design using fuzzy logic

Here a temperature controller is design using the fuzzy logic. So that when the oven temperature rises, the
fuzzy temperature controller applies a negative signal to reduce the temperature and vice versa. The value of
the output signal of the controller computes according to fuzzy rules. Input and output variable membership
functions are nominated as follow:
Table2.parameter of membership

vvl Very very low

vl Very low

l low

ll About low

lh About High

h High

vh Very High

vvh Very very High

The fuzzy rules bank is shown in table 3.

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

Table3. fuzzy rules bank

Then If

vhh vll

vh vl

h l

lh ll

ll lh

l h

vl vh

vll vvh

The degree of input and output member ship function and the relation of input-output rules are respectively
shown in fig 10, 11, 12.

Figure10. Inputs membership functions

Figure11.output membership functions

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

Figure12. surface controller in the state mamdani

The system with fuzzy controller is simulated in MATLAB and shown in fig 13.

Figure13. with fuzzy controller is simulated in MATLAB

To modeling the noise of the system a sinous wave whit an average of 5, amplitude of 5 and a frequency of
0.1 rad/s is added to system output as shown in fig 14.

Figure14. amplitude of 5 and a frequency of 0.1 rad/s is added to system output

The oven temperature variates between 4.55 and 5.45 degrees. It means that the tolerance is 0.45 degree.

5-Implimentation of fuzzy system using regression

Here a linear equation is obtained from complicated fuzzy equation using regression method and compared
with fuzzy methods response.

The linear equation is formulated as:

y = p0 x + p1

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

MATLAB is used in order to obtain coefficients of regression equation. The regression equations are:

p0 = −0.9318

p1 = 4.6591

In fig 15, obtained equation is ploted. It is obvious that the regression, estimates the fuzzy rules, truly.

Figure15. obtained equation is ploted

To compare the results of fuzzy system and regression equation the system is simulated using a polynomial
block as the temperature controller, shown in fig 16.

Figure 16. polynomial block as the temperature controller

The oven temperature as results of fuzzy controller and regression equation are shown in fig 17.

Figure17. as results of fuzzy controller and regression equation

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 S.K. Mousavi, M. Zahiri, J. Ghobadi/ J. Math. Computer Sci. 7 (2013) 33 - 42

Comparing the output of fuzzy and it’s regression we conclude that the regression of fuzzy system can be
used instead of fuzzy rules with comfort implementation and almost well respons.

References:
[1] Dr. I Santi Prabha, K Durga Rao, D Siva Rama Krishna “Fuzzy Logic Based Intelligent Controller Design
for an Injection Mould Machine Process Control” Department of ECE, EOW&G Director of University, Vol
No. 10, Issue No. 1, 098 – 103 (2011).
[2] H. Zhourll “Simulation on Temperature Fuzzy Control in Injection Mould Machine by Simulink”
IMechanical School in South China U. of Technology, Guangzhou 510641(2008).
[3] M.D. Hanamane “Implementation of fuzzy temperature control using microprocessor” journal of scientific.
Journal of scientific & industrial researchVol.65, February, pp.142-147 (2006).
[4] Curve Fitting Toolbox™ User’s Guide© COPYRIGHT 2001–2010 by The MathWorks, Inc.
[5] C.F. Juang, An automatic building approach to special Takagi-Sugeno fuzzy network for unknown
plantmodeling and stable control, Asian J. Control 5 (2), pp. 176-186 (2003).
[6] C.F. Juang and C.T. Lin, “An on-line self-constructingneural fuzzy inference network and its applications”,
IEEE Trans. Fuzzy Systems 6, pp. 12-32 (1998).
[7] P.J. King, E.H. Mamdani, the Application of Fuzzy Control Systemto Industrial Processes. in IFAC world
Congress.MIT.Boston (1975).
[8] K. Tanaka, M. Sugeno, “Stability analysis and design of fuzzy control systems” Fuzzy sets and systems,
(1992).

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