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CHAPTER 3

MULTIMODEL BASED CONTROL SCHEMES

3.1 INTRODUCTION

The control of nonlinear system using single controller cannot give


the best performance in all the operating points due to the variations process
gain, dead time in different operating points. To improve the performance of
the single controller in nonlinear system for all operating points, Multimodel
controllers are designed to fuse the individual controllers and to combine the
controllers output, weight scheduler is designed. This chapter describes about
the design and implementation of MM-PID, MM-Fuzzy, MM- ANFIS, and
MM-IMC using the models developed in each region. The servo performance
of the proposed control schemes are obtained for pH neutralization process
and Injection Molding process.

3.2 MULTIMODEL CONTROL SCHEMES FOR pH


NEUTRALIZATION PROCESS

For the pH neutralization process, the entire operating region is


divided into six linear regions. Using the data obtained for the steady state
profile of the process, 6 transfer functions are obtained. For the developed
multimodel the PI, Fuzzy, ANFIS, IMC controllers are designed.
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3.2.1 MM- PI Control Design

The PI controller settings are obtained by direct synthesis method.


The transfer function model developed in each region relates the pH and acid
flow rate at all operating points. The transfer function model form is

G(s) = K/ τs+1

The control strategy is

Kc = τp /Kp* τp ; τi=τp

The PI controller parameters for six regions are listed in Table 3.1.

Table 3.1 PI controller parameter for six regions of pH process

Operating points
K Τ
Acid flow rate
pH Gain Time constant
L/hr
19.88 10.6032 1.874 0.01244
19.985 9.7054 0.5 0.012907
20.0013 8.6329 0.3 0.012011
20.0134 7.9109 2.3 0.009344
20.11 7.004 2.8710 0.122355
20.584 6.2795 3.2779 0.009165

3.2.2 MM-Fuzzy Control Design

Seven fuzzy controllers have been designed, one for each of the six
regions (weight scheduler) and seventh one for choosing the weights for the
controllers. Each controller uses two inputs variables: Error- e and Integral of
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error- eint. The output of these controllers are combined using weights to give
net output = (w1*out1) + (w2*out2) + (w3*out3)+ (w4*out4) + (w5*out5) +
(w6*out6).

The proposed fuzzy logic controllers control the pH neutralization


process using conventional triangular membership functions. Furthermore, the
fuzzy inference engine implements a set of IF-AND-THEN rules on the error
e, eint and output ‘out’. All three universe of discourse are divided into five
overlapping fuzzy set values labeled VS (Very Small), S (Small), M
(Medium), L (Large) and VL (Very Large). For weight selection controller,
similar membership functions are defined for the universe of discourse.
Design of the rules are based on heuristic knowledge of the behavior
and based on the theoretical criteria. Twenty five rules are defined for
each controller. The rule base matrix for the Fuzzy controller is given in
Table 3.2.

Table 3.2 Rule Base Matrix for Fuzzy Controller

ie
VS S M B VB
e
VS VS VS S S M
S VS S S M B
M S S M M B
B S M B B VB
VB M B B VB VB

3.2.3 MM- ANFIS Control Design

Adaptive Neuro – Fuzzy Inference System can be used effectively


for tuning the fuzzy membership functions. ANFIS can serve as a basis for
30

constructing a set of fuzzy ‘if – then’ rules with appropriate membership


functions to generate the stipulated input-output pairs.

Fundamentally, ANFIS is taking an initial fuzzy inference (FIS)


system and tuning it with a back propagation algorithm based on
the collection of input-output data. In principle, if the size of available
input-output data is large enough, then the fine-tuning of the membership
functions are applicable. If the data set is too small, then it does not contain
enough information of the system under consideration. The training
parameters used for designing MM- ANFIS controller for six regions are
listed in Table 3.3.

Table 3.3 Training Parameters of ANFIS Controllers at Different


Operating Points

Number of
Region Training method Error tolerance
Epochs Taken
Region 1 Back propagation 0.01 33130
Region 2 Back propagation 0.03 35021
Region 3 Back propagation 0.01 37565
Region 4 Back propagation 0.01 40000
Region 5 Back propagation 0.01 45780
Region 6 Back propagation 0.01 38900

3.2.4 MM- IMC Control Design

The six region transfer function models listed in Table 2.3 is used
to design the Internal Model Controller. The inverse model for corresponding
regions and the IMC controller parameters are listed in Table 3.4. The inverse
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model is multiplied by filter transfer function to find out the IMC parameter, λ
the tuning parameter.

Gci(s) = G-1(s) * 1/(λS+1)

Where Gci(s) - IMC controller

G-1(s) - Inverse model

1/ (λS+1) - Filter transfer function

Table 3.4 IMC controller parameter for six regions of pH process

Operating points G(s) Gci(s)=


Acid flow Transfer function G-1(s) * 1/(λS+1)
pH
rate L/hr model Inverse model
0.53336 0.01244 S+1
19.88 10.6032
0.01244 S+1 0.006 S+1
0.48564 0. 012907 S+1
19.985 9.7054
0.012907 S+1 0.00645 S+1
0.43162 0.0.012011 S+1
20.0013 8.6329
0.012011 S+1 0.16923 S+1
0.39528 0.0093448 S+1
20.0134 7.9109
0.0093448 S+1 0.0973 S+1
0.3483 0.122355 S+1
20.11 7.004
0.122355 S+1 0.06117 S+1
0.30507 0.009165 S+1
20.584 6.2795
0.009165 S+1 0.00458 S+1
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3.3 SERVO RESPONSE OF pH PROCESS

3.3.1 Servo Response of MM - PI Controller

In order to observe the performance of proposed controller, set


point variations have been introduced. The MM based PI controllers are
designed and MM -PI performance is shown in Figure 3.1 .The variations in the
controller output is shown in Figure 3.2. Based on the set point variations the
weighting function for the MM-PI is presented in Figure 3.3.

9.5
SP
9 MM PI

8.5

8
pH VALUE

7.5

6.5

5.5
0 500 1000 1500 2000 2500 3000 3500 4000 4500
SAMPLING INTERVAL

Figure 3.1 Servo response of the pH process with MM-PI controller

21.5

21
ACID FLOW RATE (Lt/hr)

20.5

20

19.5

19
0 500 1000 1500 2000 2500 3000 3500 4000 4500
SAMPLING INTERVAL

Figure 3.2 Controller output of the pH process with MM PI controller


(acid flow (L/h))
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1.2
PI1

1 PI 2
PI 3
PI 4
PI 5
0.8 PI 6

0.6
WEIGHT

0.4

0.2

-0.2
0 500 1000 1500 2000 2500 3000 3500 4000 4500
SAMPLING INTERVAL

Figure 3.3 Weights of the controllers for pH process with MM PI

The proposed Multimodel PI controller is able to follow the set


point variations. The ISE and IAE values are calculated to determine the
performance of the proposed controller schemes. The performance criteria for
the proposed MM-based PI controllers for pH process is listed in Table 3.5.

Table 3.5 Performance criteria for MM-PI controller of pH process

Sampling interval Setpoint ISE IAE


-8 -4
0-400 7 1.0551x 10 1.027x 10
-6
400-800 6 2.1800x 10 0.0015
-6
800-1200 7 4.3100x 10 0.0021
-9 -5
1200-1600 8 5.7612x 10 7.5902x 10
-5
1600-3000 9 1.0165x 10 0.0032
-9 -5
3000-4000 8 8.2061x 10 9.0588 x 10
-8 -4
4000-4500 7 1.0551x 10 1.0272x 10
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3.3.2 Servo Response of MM - Fuzzy Logic Controller

The MM based Fuzzy controller is designed and set point variations


have been introduced to observe the response. The servo response of
MM fuzzy is shown in Figure 3.4 and the corresponding controller output is
shown in Figure 3.5. The weighting function for the MM-Fuzzy is shown in
Figure 3.6.

11
SP
MM Fuzzy

10

9
pH VALUE

5
0 50 100 150 200 250 300 350 400
SAMPLING INTERVAL

Figure 3.4 Servo response of the pH process with MM-Fuzzy Logic


controller

21.2

21
ACID FLOW RATE (lt/hr)

20.8

20.6

20.4

20.2

20
0 50 100 150 200 250 300 350 400
SAMPLING INTERVAL

Figure 3.5 Controller output of the pH process with MM FUZZY


controller (acid flow (L/h))
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1.2

0.8 Fuzzy cont 1


Fuzzy cont 2
Fuzzy cont 3
0.6
WEIGHTS

Fuzzy cont 4
Fuzzy cont 5
0.4 Fuzzy cont 6

0.2

-0.2
0 50 100 150 200 250 300 350 400
SAMPLING INTERVAL

Figure 3.6 Weights of the controllers for pH process with MM Fuzzy

In order to assess the tracking capability of the controller, the set


point is varied from 7 to 6, 6 to 7 and 7 to 7.5. The MM-Fuzzy controller is
able to maintain the process output at desired set point. The ISE and IAE
values are calculated to check the performance of the controller.

The performance criteria for the proposed MM-based Fuzzy


controllers for pH process are listed in Table 3.6.

Table 3.6 Performance criteria for MM-Fuzzy controller of pH process

Sampling interval Setpoint ISE IAE


0-100 7 0.0466 0.2159
100-200 6 0.2141 0.4627
200-300 7 0.2669 0.5166
300-400 7.5 0.2039 0.4515
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3.3.3 Servo Response of MM -ANFIS Controller

To improve the performance of the multimodel control schemes,


the MM based ANFIS controller is designed and its response and controller
output are shown in Figure 3.7 and Figure 3.8 respectively. The weighting
function for the MM-ANFIS is shown in Figure 3.9.

11
SP
M ANFIS
10

9
pH VALUE

5
0 50 100 150 200 250 300 350 400
SAMPLING INTERVAL

Figure 3.7 Servo response of the pH process with MM-ANFIS controller

21.2

21
ACID FLOW RATE(lt/hr)

20.8

20.6

20.4

20.2

20
0 50 100 150 200 250 300 350 400
SAMPLING INTERVAL

Figure 3.8 Controller output of the pH process with MM ANFIS


controller (acid flow (L/h))
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1.2

0.8 ANFIS 1
ANFIS 2
ANFIS 3
0.6
WEIGHTS

ANFIS 4
ANFIS 5
ANFIS 6
0.4

0.2

-0.2
0 50 100 150 200 250 300 350 400
SAMPLING INTERVAL

Figure 3.9 Weights of the controllers for pH process with MM ANFIS

The set point is varied from 7 to 6 and the controller is able to


maintain the required set point with in minimum duration. The weight
scheduling is also switched from one region to another region without any
oscillation.

3.3.4 Servo Response of MM - IMC Controller

The model based controller is designed using transfer function


model of the each region. The MM based IMC controller performances
are analyzed by introducing variations in set points. The servo response of
MM IMC controller is presented in Figure 3.10. The controller output is
shown in Figure 3.11.The weighting scheduler switching action is shown in
Figure 3.12.
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9.5
SP
MM IMC
9

8.5

8
pH VALUE

7.5

6.5

5.5
0 500 1000 1500 2000 2500 3000 3500 4000 4500
SAMPLING INTERVAL

Figure 3.10 Servo response of the pH process with MM-IMC controller

26

24

22
ACID FLOW(Lt/hr)

20

18

16

14
0 500 1000 1500 2000 2500 3000 3500 4000 4500
SAMPLING INTERVAL

Figure 3.11 Controller output of the pH process with MM IMC


controller (acid flow (L/h))
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1.2

0.8
IMC 1
IMC 2
0.6
WEIGHT

IMC 3
IMC 4
IMC 5
IMC 6
0.4

0.2

-0.2
0 500 1000 1500 2000 2500 3000 3500 4000 4500
SAMPLING INTERVAL

Figure 3.12 Weights of the controller for pH process with MM-IMC

To obtain the model based controller performance, the set point is


varied from 6 to 7, 7 to 8, 8 to 9. The MM -IMC controller is able to follow
the set point variations. The ISE and IAE values are calculated to improve the
performance of the controller. The performance criterion for the proposed
MM-based controllers for pH process is listed in Table 3.7.

Table 3.7 Performance criteria for MM-IMC controller of pH process

Sampling interval Setpoint ISE IAE


0-400 7 0.015325 0.123794
400-800 6 10.39781 3.224563
800-1200 7 9.63759 3.104447
1200-1600 8 8.033124 2.834277
1600-3000 9 3.660635 1.913279
3000-4000 8 0.842826 0.842836
4000-4500 7 0.647811 0.647811
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3.4 MULTIMODEL CONTROL SCHEMES FOR INJECTION


MOLDING PROCESS

For the injection molding process, the entire operating region is


divided into three linear regions. Using the data obtained from the steady state
profile of the process, three transfer function models are obtained. For the
developed multimodel the PID, Fuzzy, ANFIS, IMC controllers are designed.

3.4.1 MM- PID Control Design

For the proposed Injection molding process the entire operating


region is divided into three linear regions based on the difference in
temperature.

To design the controller based on multiple model concept, the


nonlinear process has been linearized at different operating points and the
linear PI controllers are designed based on the selected linear models. The
operating points are chosen, so that the fused linear model should track the
rigorous nonlinear model without steady state error. The three operating
points are chosen at the temperature of 423.15 K, 433.15K and 443.15K. The
comparison of open loop responses of fused linear model developed at three
operating points with rigorous nonlinear model for the heater current variation
is shown in Figure 3.13 and Figure 3.14 respectively. The mean square error
between the rigorous nonlinear model and the fused linear model can decrease
if more models are used, but to minimize the number of controllers, three
models have been selected.
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Figure 3.13 Open Loop Response of Rigorous Model

Figure 3.14 Open Loop Response of Fused Linear Model

The tuning parameters for the 3 PID controllers are calculated using
Zeigler-Nichols method. Since temperature T is the scheduling variable, the
controller parameters KC (a) and TI (a) are calculated by substituting n=3 and
a=T, in the following equations.

K C (a ) =  w i (a ) k c ,i (3.1)
i= 1
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T I (a ) =  w i (a ) T I,i (3.2)
i= 1

T D (a ) =  w i (a ) T d ,i (3.3)
i= 1

Using KC (T) and TI (T), the global PID controller output is


calculated. In Equations (3.1), (3.2) and (3.3), wi (T) is a weighing factor and
weights are estimated based on the scheduling variable T.

The weights are calculated according to the algorithm as given below.

If T ≤ T1, then

w3 = 0; w2 = 0; w1 = 1

If T1 ≤ T ≤ T2, then

w3 = 0; w2 = (T - T1) / (T2 – T1); w1 = 1 - w2

If T2 ≤ T ≤ T3, then

w3 = (T – T2) / (T3 – T2); w2 = 1 - w3; w1 = 0

If T ≥ T3, then

w3 = 1; w2 = 0; w1 = 0

Based on the weights w3, w2, w1 are obtained and the fused
controller output is decided. The PID controller settings for 3 zones are listed
in Table 3.8.
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Table 3.8 PID controller parameter for three zones of IMM

Zone Number P I D
Zone 1, i=1 0.0954 0.000602 3.777
Zone 2, i=2 0.984 0.00131 4.83885
Zone 3, i=3 0.18336 0.00301 5.7893

3.4.2 MM-Fuzzy Logic Control Design

Four fuzzy controllers have been designed, one for each of the three
zones and another for choosing the weights for the controllers. Each controller
uses two input variables. error : e and integral of error : eint. The output of
these controllers are combined using weights to give net output = (w1*out1) +
(w2*out2) + (w3*out3).

The proposed fuzzy logic controllers control the temperature of the


Injection molding machine using conventional triangular membership
functions. Furthermore, the fuzzy inference engine implements a set of IF-
AND-THEN rules on the error e, eint and output ‘out’. All three universe of
discourse are divided into five overlapping fuzzy set values labeled VS (Very
Small), S (Small), M (Medium), L (Large) and VL (Very Large). For weight
selection controller, similar membership functions are defined for the universe
of discourse. Design of the rules are based on heuristic knowledge of the
behavior and based on the theoretical criteria. Twenty five rules are defined
for each controller. The rule base matrix for the IMM controller is given in
Table 3.9 Same rule base is taken for the weight selection system.
44

Table 3.9 Rule Base Matrix for IMM Controller

ie
VS S M B VB
e
VS VS VS S S M
S VS S S M B
M S S M M B
B S M B B VB
VB M B B VB VB

3.4.3 MM-ANFIS Control Design

Adaptive Neuro – Fuzzy Inference system can be used effectively


for tuning the membership functions. ANFIS can serve as a basis for
constructing a set of fuzzy ‘if – then’ rules with appropriate membership
functions to generate the stipulated input-output pairs.

Fundamentally, ANFIS is taking an initial fuzzy inference (FIS)


system and tuning it with a back propagation algorithm based on
the collection of input-output data. In principle, if the size of available
input-output data is large enough, then the fine-tuning of the membership
functions are applicable. If the data set is too small, then it does not contain
enough information of the system under consideration. The training
parameters for ANFIS controller at different operating points are listed in
Table 3.10.
45

Table 3.10 Training Parameters of ANFIS Controllers at Different


Operating Points

Error Number Of
Zone Training Method
Tolerance Epochs Taken
Zone 1 Back propagation 0 33130
Zone 2 Back propagation 0 35021
Zone 3 Back propagation 5 37565

The step response of the system with the proposed


ANFIS controller is nearer to the ideal one. ANFIS configuration provides
best performance over the conventional PID and fuzzy controllers proposed.

3.5 SERVO RESPONSE OF INJECTION MOLDING PROCESS

3.5.1 Servo Response of MM - PID Controller

The process is simulated with the conventional PID controller


structure with multi model approach and the results are presented in
Figures 3.15, 3.17 & 3.19 respectively. The weights assigned for each of the
multimodel PID controllers are shown in Figures 3.16, 3.18 & 3.20.

TIME (s)

Figure 3.15 Servo response of the IMM with MM-PID controller (Zone 1)
46

TIME (s)

Figure 3.16 Weights of the controller for IMM with MM-PID


(Zone 1)

TIME (s)

Figure 3.17 Servo response of the IMM with MM-PID controller


(Zone 2)
47

TIME (s)

Figure 3.18 Weights of the controller for IMM with MM-PID


(Zone 2)

TIME (s)

Figure 3.19 Servo response of the IMM with MM-PID controller


(Zone 3)
48

TIME (s)

Figure 3.20 Weights of the controller for IMM with MM-PID


(Zone 3)

The performance criteria of the PID controller with multi-model are


given in Table 3.11.

Table 3.11 Performance Criteria for MM-PID Controller of IMM

Zone IAE ISE Settling time (s)

Zone 1 (423.15 K) 6.989 x 104 4.885 x 109 3800

Zone 2 (433.15 K) 3.734 x 104 1.394 x 109 2750

Zone 3 (443.15 K) 1.781 x 104 3.171 x 108 1300

3.5.2 Servo Response of MM - Fuzzy Logic Controller

The process is simulated with the MM Fuzzy controller structure


with multi model approach and the results are presented in Figures 3.21, 3.22
& 3.23 respectively.
49

TIME (s)

Figure 3.21 Servo response of the IMM with MM-Fuzzy Logic


controller (Zone 1)

TIME (s)

Figure 3.22 Servo response of the IMM with MM-Fuzzy Logic


controller (Zone 2)
50

TIME (s)

Figure 3.23 Servo response of the IMM with MM-Fuzzy Logic


controller (Zone 3)

The performance criteria of the Fuzzy logic controller with multi-


model is given in Table 3.12.

Table 3.12 Performance Criteria for MM –Fuzzy Logic controller of


IMM

Zone IAE ISE Settling time (s)


Zone 1 (423.15 K) 2.561 x 104 6.556 x 108 2300
Zone 2 (433.15 K) 2.6 x 104 6.759 x 108 2250
Zone 3 (443.15 K) 2.899 x104 8.407 x 108 1300

The MM- Fuzzy controller is designed for the IMM and the
performance of the controller is observed. The settling time of proposed MM-
Fuzzy controller is lower when compared to MM-PID controller.

3.5.3 Servo Response of MM -ANFIS Controller

The MM- ANFIS controller is designed for each zone, the training
error for the each ANFIS controller is set as minimum to get the
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best performance from the ANFIS controller compared to conventional


controller.

The training errors for the MM-ANFIS controllers are presented in


Figures 3.24, 3.26 and 3.28 for 3 zones. The set point is varied for each zones
and the MM- ANFIS controller is able to maintain the process output for
given set point. The servo response of the MM- ANFIS is shown in Figure
3.25, 3.27 and 3.29.

Figure 3.24 Training error of ANFIS controller for IMM (Zone 1)

TIME (s)
Figure 3.25 Servo response of the IMM with MM-ANFIS controller
(Zone 1)
52

Figure 3.26 Training error ANFIS controller for IMM (Zone 2)

TIME (s)

Figure 3.27 Servo response of the IMM with MM-ANFIS controller


(Zone 2)
53

Figure 3.28 Training error of ANFIS controller for IMM (Zone 3)

TIME (s)

Figure 3.29 Servo response of the IMM with MM-ANFIS controller


(Zone 3)

The performance criterion of the MM-ANFIS controller is given in


Table 3.13.
54

Table 3.13 Performance Criteria for MM ANFIS Controller for IMM

Zone IAE ISE Settling time (s)


Zone 1 (423.15 K) 121.8 1.483 X 104 30
Zone 2 (433.15 K) 131.8 1.738 X 104 35
Zone 3 (443.15 K) 140.3 1.967 X 104 40

The MM -ANFIS controller gives the best result compared to other


proposed controllers. The IAE and ISE values are reduced and settling time is
also reduced.

3.5.4 Comparison of the Servo Response of MM based Controllers

The closed loop responses of the MM-PID, MM-Fuzzy, MM-


ANFIS for all the 3 zones are compared in Figures 3.30, 3.31& 3.32.

TIME (s)

Figure 3.30 Comparison of Servo responses of the IMM with MM-PID,


MM-Fuzzy, MM-ANFIS controller (Zone 1)
55

TIME (s)

Figure 3.31 Comparison of Servo responses of the IMM with MM-PID,


MM-Fuzzy, MM-ANFIS controller (Zone 2)

TIME (s)

Figure 3.32 Comparison of Servo responses of the IMM with MM-PID,


MM-Fuzzy, MM-ANFIS controller (Zone 3)

The performance criteria of the MM-ANFIS, MM-Fuzzy and MM-


PID controller with multi-model are given in Table 3.14.
56

Table 3.14 Performance criteria for three controller of IMM

Settling time
Zone Controller IAE ISE
(s)
Zone 1 PID 6.898 x 10^4 4.855x 10^9 3800
(423.15 K) FUZZY 2.561x 10^4 6.556x 10^8 2300
ANFIS 121.8 1.483x 10^4 30
Zone 2 PID 3.734 x 10^4 1.394x 10^9 2750
(433.15 K) FUZZY 2.6x 10^4 6.7556x 10^8 2250
ANFIS 131.8 1.738x 10^4 35
Zone 3 PID 1.781 x 10^4 3.171x 10^8 1300
(443.15 K) FUZZY 2.899x 10^4 8.477x 10^8 1300
ANFIS 140.3 1.96x 10^4 40

Among the proposed controllers for IMM, MM-ANFIS


controller provides best performance in terms of IAE,ISE and settling
time.

3.5.5 Servo Response of MM -IMC

The Model based controller is designed using the transfer


function model of the each zone. The process is simulated with the
Internal Model controller and the results are presented in Figures 3.33,
3.34 and 3.35.
57

TIME (s)

Figure 3.33 Servo response of MM-IMC for IMM of Set point 423.15k
(Zone 1)

TIME
TIME (s)(s)

Figure 3.34 Servo response of MM-IMC for IMM of Set point 443.15k
433.15k (Zone 2)
58

TIME (s)

Figure 3.35 Servo response of MM-IMC for IMM of Set point 443.15k
(Zone 3)

The performance criterion of the Internal Model Controller is given


in Table 3.15.

Table 3.15 Performance criteria for MM -IMC controller of IMM

Zone IAE ISE Settling time (s)


Zone 1 (423.15 K) 1.698 x 104 2.884 x 108 1120
4 8
Zone 1+2 (433.15 K) 1.241 x 10 1.54 x 10 1035
Zone 2+3 (443.15 K) 2.544 x 104 6.472 x 108 1265

3.6 CONCLUSION

In this chapter the design of MM- PI, Fuzzy, ANFIS and IMC for
pH neutralization process are carried out. The set point variations have been
introduced for all the proposed control schemes. The process output is
maintained for different set point by the controllers. The servo responses of
the proposed control schemes are obtained. The IAE and ISE values are
59

calculated. It is observed that, the MM -ANFIS controller gives the best


performance compared to other controllers.

The MM- PID, Fuzzy, ANFIS and IMC controllers are designed for
the Injection molding process. The controllers are able to follow the set point
for each zone. The IAE and ISE values are calculated. It is observed that, the
MM -ANFIS controller gives the best performance compared to other
controllers.

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