A Differential Evolution-based autotuning strategy for 2-DOF PI controllers implemented on a PLC
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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
Corresponding author
Tomasz Kłopot
Department of Automatic Control and Robotics
Silesian University of Technology
44-100 Gliwice
Akademicka 16
Poland
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ABSTRACT
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.