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Applied Mechanics and Materials Vols.

284-287 (2013) pp 2266-2270


(2013) Trans Tech Publications, Switzerland
doi:10.4028/www.scientific.net/AMM.284-287.2266

PID Controller Tuning by Differential Evolution Algorithm


on EDM Servo Control System
Trias Andromeda1,2, a, Azli yahya2,b , Syahrullail Samion3,c
Ameruddin Baharom1,d, Nor Liyana Hashim4,e
1

Faculty of Electrical Engineering, UTM, Skudai 81310, Johor, Malaysia

Department of electrical engineering, Diponegoro University, Semarang 50275, Indonesia


3

Faculty of Mechanical Engineering, UTM, Skudai 81310, Johor, Malaysia

Faculty of Health Science and Biomedical Engineering, UTM, Skudai 81310, Johor, Malaysia
a

triasandromeda@undip.ac.id, bazli@fke.utm.my, csyahruls@fkm.utm.my


d

amer@fke.utm.my, enlsafura88@gmail.com

Keywords: Servo Control System, Electrical Discharge Machining (EDM), Proportional Integral
Derivative (PID), Controller Tuning, Differential Evolution (DE).

Abstract Maintaining gap between Electrode and workpiece in Electrical Discharge Machining
(EDM) is very important since the capability of control system to keep the gap will improve the
performance of this machine. Therefore to maintain the gap, a Proportional Integral Derivative
(PID) controller is designed and applied to EDM servo actuator system. The objective of this work
is to obtain a stable, robust and controlled system by tuning the PID controller using Differential
Evolution (DE) algorithm. The controller for EDM die sinking is verified by simulation of the
control system using MATLAB/Simulink program. Simulation results verify the capabilities and
effectiveness of the DE algorithm to search the best configuration of PID parameters controller to
control the electrode position.
Introduction
PID controller is the most popular ones on dealing with industrial control processes. It is simple
in structure, reliable in operation, robust in performances and up to 90% of all control strategies are
PID. Various applications have implemented using PID controller, such as process control, motor
drives, automotive, flight control. On the contrary, it has been experimentally checked that more
than 30% of the installed controllers are operating in manual mode and 65% of the automatic close
loops is operated in poorly tuned condition[1], so new approaches algorithm to adjust PID constants
controller are very important.
Conventional methods such as Zigler-Nichols[2] and simplex methods are not excellent to be
implemented in digital system. Recently, intelligent approaches such as genetic algorithm, particle
swarm optimization have been proposed for PID optimization. Some tuning methodologies PID
controllers have been proposed in literatures such as auto tuning, self-tuning and computational
intelligence[3-5].
Many researchers have tried to propose a new strategy in order to obtain a good technique to
determine parameters in PID controller. Conventional methods called Zigler-Nichols based on step
response analysis. Kp, Ki and Kd gains of the controller are determined using this response
graph[6]. It means that the accuracy of capturing the step response graph is significantly contributed
to the determination of PID parameters. Artificial Intelligence algorithm tries to find optimum
parameter in PID controller based on fitness function.
It is not easy to find a proper configuration gains of PID controllers because many industrial
plants are often burdened with problems such as high order, time delays, poorly damped,
nonlinearities and time-varying dynamics. Over the years, several authors have proposed the tuning
of PID to control variable processes by optimization methods, such as genetic algorithms[7],
particle swarm optimization[8], tribes algorithm[9], harmony search[10], evolution strategy [11],
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ant colony [12]. In this paper, Differential Evolution as a new Evolutionary Algorithm is used as a
tool for solving the class of multi objective optimization problems that results from a PID design
problem for maintaining the gap between electrode and workpiece in EDM system process.
System Description
Electrical Discharge Machining (EDM) is a controlled metal removal process that is used to
remove metal by means of electric spark erosion. The English scientist Priestley first reported the
erosive effect of electrical discharges in 1770. In this process, an electric spark is used as the
eroding tool to erode the workpiece to produce finished part (moulding). The metal removal process
is performed by applying an electrical discharge of pulsed high frequency direct current through the
electrode to the workpiece. The electrode location is controlled by the machine and is positioned so
as not to contact the workpiece. A precise controlled space is maintained, allowing the spark to
discharge its current from the electrode to the workpiece through an insulated dielectric fluid. This
removes tiny particles of metal, called debris, from the workpiece.

Figure 1. Basic Elements of an EDM system


Fig.1 shows basic elements of an EDM system. When the gap between the electrode and
workpiece is sufficiently small (10 50 m), said gap being controlled by the position control servo
system, an electrical spark occurs in the gap.
Gap Control in EDM System
Machining gap is adjusted using ram servo control system at a critical distance for the continuous
occurrence of electric discharge. At the same power generator settings, machining stability and
productivity depend on performance of this servo control mechanism. Fig. 2 shows block diagram of
EDM servo control unit.

Figure 2. Block Diagram of Existing EDM Servo Control System


There are three components which constructs EDM servo control system. Kc is applied at the
controller block. The servo system block consist of model of dc motor and its accessories including
ram and leadscrew. EDM process is a model for EDM discharge phenomenon. At this model, gap
between electrode and workpiece is converted to voltage which represents voltage drop occurred
during discharge state. Control system takes only the average gap voltage (Vg) as a feedback signal
and then comparing it with a servo reference voltage (Vs). The differences between Vg and Vs, known
as error, is fed to amplifier Kc, denoted by Vsd, drives the servo ram to adjust the gap distance so as to

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keep Vg at a level determined by Vs. The control gain Kc and the level of Vs are manually preset
according to the operator's experiences. Conventional servo system does not effectively respond to
either gap state parameters or process dynamic and stochastic features[13]. With this type of control
system, therefore, the machining process is not optimal.

Figure 3. Practical gap control system of an EDM[13]


Fig. 3 shows a practical gap control system of EDM process. The dynamic relationship between
the feed rate fr(s) and the speed V(s) can be expressed as,
=

(1)

where is a magnification constant. The terms and


is damping ratio and natural frequency of
the servo system. Considering to the foregoing analysis, the system is a type 1 system when the gap
controller y(s) is a pure proportional controller. A PD controller is applied to the system to improve
the transient responses. Accordingly, fr(s) can be expressed as:
=

(2)

Differential Evolution (DE)


Differential Evolution (DE) can be used in optimization problems and a variant of evolutionary
computation algorithm[14]. DE has three main advantages (1) able to locate the accurate global
optimum irrespective of the initial parameter values (2) has rapid convergence (3) utilizes few
control parameters, thus easy and simple to use. This algorithm is similar to Genetic Algorithm
(GA) and Particle Swarm optimization (PSO). During optimization step, mutation,
crossover/recombination, and selection operators are involve in this computation. Initially,
population is given randomly. DE utilize mutation operator as a search mechanism and selection
operation to find directly based on prospective regions on search space.
Implementation of DE-PID Controller
Contribution of this paper is to apply the DE method in order to search an optimize
configuration of PID parameters controller. A new control system optimization called DE-PID
control system is proposed. Fig. 4 shows the proposed controller block diagram.

Figure 4 DE-PID controller block diagram


The Differential Evolution (DE) algorithm will be used to search an optimize parameters value
in PID controller. At the first process, EDM model is controlled by initial PID parameters value.
IAE is computed by Simulink software, it is used as an Objective target value in the DE algorithm.

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The DE will compute a new population based on this IAE value. In this work, DE is applied using
matlab m.files coding. DE will propose a new population and then will be used as a new PID
parameters value for the next generation.
Simulation Results
Simulation is conducted for several combinations. PID is configured to construct four types of
controller, i.e. P, PD, PI and PID controller. The results can be seen in Table 1.
Table 1 Experimental result for P, PI, PID and PD controller
No
Kp
Ki
Kd
IAE
1. 26.3956
0.6059
2. 20.2434
-0.4618 0.5893
3. 26.3228 0.1808
0.6057
4. 20.1720 0.1262 -0.4657 0.5884
Table 1 reveals value of each PID parameters for each type of controller. The values are
achieved automatically using DE algorithm. PID controller has the lowest IAE value at 0.5884.
Experimental results in Fig. 5 shows that all combination of PID parameters can be used to obtain
optimum gap required in the EDM process. It is also shown zoomed graph from 450 until 650 mili
seconds. It can be seen that gap response of P similar to PI controller whereas PD similar to PID
controller. The excellent work of PID combination tuned by DE provides the best results in gap
optimization.
Gap Response

Gap Response

240

90
P
PD
PI
PID

220

88
Gap distance (micro meter)

200
Gap distance (micro meter)

P
PD
PI
PID

89

180
160
P and PI
140
PD and PID
120

87
86
85
84
83

Zoomed

100

82
80

81
60
0

100

200

300

400
500
600
time(mili seconds)

700

800

900

1000

80
450

500

550
time(mili seconds)

600

650

Figure 5 Result DE-PID


Conclusion
In this paper, the PID controller parameters have been tuned by Differential Evolution. The
simulation results reveal that determination of each parameter, Kp, Ki and Kd, is achieved
automatically. Gap between electrode and workpiece can be maintained satisfactory. Differential
Evolution successfully tune all combination of P, I and D parameters. The response of all
combination of PID shows that the optimum gap can be achieved. However every combination has
different response and time to reach the setting value. PID controller shows the best performance to
reach the setting with minimum IAE value.
Acknowledgements
The authors are grateful for the financial support from Research Management Centre (RMC) of
Universiti Teknologi Malaysia.

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