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A Differential Evolution-based autotuning strategy for 2-DOF PI controllers implemented on a PLC
 
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Ukryj
1
Department of Automatic Control and Robotics Silesian University of Technology 44-100 Gliwice Akademicka 16 Poland
 
2
Adam Mickiewicz Third General Secondary School 40-092 Katowice Mickiewicza 11 Poland
 
3
Department of Measurements and Control Systems Silesian University of Technology 44-100 Gliwice Akademicka 16 Poland
 
4
Department of Computer Science, Electrical Engineering and Mathematical Sciences Western Norway University of Applied Sciences, Campus Førde 6812 Førde Svanehaugvegen 1 Norway
 
 
Autor do korespondencji
Tomasz Kłopot   

Department of Automatic Control and Robotics Silesian University of Technology 44-100 Gliwice Akademicka 16 Poland
 
 
 
SŁOWA KLUCZOWE
DZIEDZINY
STRESZCZENIE
Despite the continuous development of advanced control algorithms, PID-based controllers, including two-degree-of-freedom proportional-integral (2-DOF PI) structures, dominate in industrial practice. However, obtaining optimal tuning parameters remains a significant application challenge. Contemporary metaheuristic approaches typically offload computations to higher-level supervisory layers, which introduces non-deterministic communication delays and cybersecurity vulnerabilities. Addressing this issue, this paper presents a fully autonomous, Differential Evolution (DE)-based autotuning strategy executed natively on a Programmable Logic Controller (PLC) at the field level. By explicitly accounting for strict memory and cycletime constraints, a universal, hardware-optimized function block was developed. This libraryconformant solution preserves deterministic controller operation and compatibility with standard industrial workflows. Resource analysis on standard PLCs confirmed the implementation feasibility. Furthermore, industrial validation through the virtual commissioning of a heat generation and distribution system demonstrated that the proposed algorithm outperforms commercial autotuning functions and the widely adopted Skogestad Internal Model Control (SIMC) strategy. This work proves that metaheuristics can be safely, effectively, and natively deployed in the field-level process control layer, eliminating the need for external computing units.
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