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Applications/Fuzzy in Appliances
Fuzzy Logic and NeuroFuzzy in Appliances
Citation Reference: This paper was published at the Embedded Systems Conferences in
1994, 1995, and 1996 in Santa Clara.
The first case study shows how an existing product is enhanced with new, intelligent
functions. In home air conditioners, the enhancement of the thermostat by fuzzy logic
control techniques allows for a better adaptation to the requirements of the user. This
results in a higher comfort level. Also, detection of low load situations yields energy
savings.
The second case study covers the replacement of sensors with fuzzy logic state
estimators. In the example of a central heating system control, a $35 outdoor temperature
sensor and its installation were replaced. Comparisons show that the fuzzy logic solution
better adapts to high and low heat demand periods, thus yielding higher comfort and
energy savings at the same time. The presented system is now in production in Germany
(350,000 units per year).
The third case study focuses on the automated generation of fuzzy logic systems or parts
thereof. For laundry load detection in washing machines, neural-fuzzy technologies are
employed that set up a fuzzy logic system using experimental data. The results of washing
experiments, evaluated by experts, form this data base. The introduction of the resulting
fuzzy logic laundry load detector saves an average of 20% on water and energy. The
presented system is now in production in Germany (400,000 units per year).
The following discussion assumes the reader is familiar with basic fuzzy logic design
principles. For a comprehensive hands-on course in practical fuzzy logic design, refer to
[14].
One of the major consumers of the total of all energy produced in the world is the heating
and cooling of homes and office buildings. Hence, increasing efficiency of these systems
has a great effect on energy savings. These savings can be realized either by
constructional improvements, such as better insulation, more efficient heating/cooling
systems or by using more intelligent control strategies for the operation of these devices.
This case study focuses on the application of fuzzy logic control techniques for air
conditioning systems.
Fuzzy logic allows for the formulation of a technical control strategy using elements of
everyday language. In this application, fuzzy logic was used to design a control strategy
that adapts to the individual user needs, thereby achieving both a higher comfort level and
reduced energy consumption at the same time. Using a fuzzy logic software development
system, the entire system, containing both conventional code for signal preprocessing and
the fuzzy logic system, can be implemented on industry standard 8-bit microcontrollers.
Using fuzzy logic on such a low-cost platform enables this solution to be implemented in
most air conditioning systems.
Quite a few air conditioning systems already use fuzzy logic control. In 1990, Mitsubishi
introduced their first line of fuzzy logic controlled home air conditioners. Also, industrial air
conditioning systems in Japan have been using fuzzy logic [7] since 1990. Four years later,
most Korean, Taiwanese, and European AC controllers also use fuzzy logic as a standard
control technique [6, 1, 15].There are different incentives to use fuzzy logic:
The application discussed in this case study falls more into the second category. Each AC
system has a thermostat that measures the room temperature and compares it with the set
temperature that is set on a dial. Figure 1 shows the principle of such a thermostat.
The thermostat compares the set temperature that is selected on the dial by the user with
the actual room temperature. To minimize the number of starts for the AC, a hysterisis is
used. Both mechanical and electronic thermostats are used for this. Figure 1 shows the
principle of an electronic analog AC controller.
This method works well to maintain a certain temperature level in a room. However, the
actual room temperature does not always correspond to the subjective temperature feeling
of the people in the room. A certain comfort level is reached with different room
temperatures, depending on a number of conditions:
1. During the day, the temperature may be higher than during the night.
2. The same room temperature is perceived warmer if the sun shines.
Empirical analysis on how people adjust the temperature dial on their ACs has shown even
more factors:
1. Someone who turns down the set temperature wants a large cooling effect. Due to
this, most people tend to put the temperature dial lower than necessary. Usually,
people forget to turn the temperature dial up again. Before this is corrected, the
increased cooling wastes energy.
2. Someone who turns down the AC just a little bit is not interested in a quick
response but rather in an accurate temperature. Reacting too much to this can
cause an overshoot in the room temperature.
3. If someone changes the room temperature very often, the control should be
sensible.
4. If room temperature varies strongly, the room is often used. Hence, control should
be sensible.
The objective in this case study is to design an "intelligent" thermostat that "understands"
both different environment conditions and the current needs of the user. For this,
knowledge as contained in 1.-2. and A)-D) must be implemented in the thermostat. Since
this kind of knowledge is hard to model mathematically, as well as hard to code in a
conventional algorithm, fuzzy logic has been used for implementation.
Figure 2 shows the structure of the "intelligent" thermostat. To measure the brightness in
the room, a LDR photo sensor is added. The fuzzy logic system corrects the signal before
the threshold unit and sets its hysterisis. For that, the fuzzy logic system uses four input
variables:
When the difference between set temperature and room temperature is very large, the
fuzzy logic system increases the signal so the desired temperature is reached faster (Rule
5 and 6). At the same time, the hysteresis is set to large, so minor disturbances do not
cause unnecessary on/off switches.
This input signal is used to identify a user who tries to set the room temperature very
precisely (Rule 4). To satisfy such a user, the hysterisis is set to small. This variable counts
each time the user moves the dial. Every 6 hours, this variable is counted down until 0 is
reached.
If direct sunlight hits the room, the set temperature is automatically reduced (Rule 2).
During the day or when lights are on in the room, the set temperature is slightly increased
(Rule 1) and the hysterisis is set to small.
Figure 3 shows the structure of the fuzzy logic system as designed with the fuzzyTECH
development system [2]. All input variables have three (3) terms with standard membership
functions. The output variable "Correction" has five (5) terms and uses Center-of-Maximum
defuzzification. The output variable "Hysterisis" has three (3) terms and uses also Center-
of-Maximum defuzzification.
Figure 4: The Fuzzy Logic Rules
Represent the Knowledge That the
Thermostat Uses to Correct the Set
Temperature and the Hysterisis
(large)
Figure 4 shows part of the rule base that defines the strategy of the system. This spread
sheet representation is appropriate for small rule bases. Each row represents a rule. The
left part of the screen under the [IF] button shows all input variables of the rule block; the
right part under the [THEN] button shows all output variables. The column [DoS] that is
displayed for each output variable allows for the association of a weight to this conclusion.
This enables fine tuning of the fuzzy logic system during optimization.
The fuzzy logic system has been tested using data that has been recorded in various
rooms under various conditions. This test data has been preprocessed using the
spreadsheet software MS-Excel™. To test the performance of the fuzzy logic solution,
fuzzyTECH's Excel link has been used. It allows for MS-Excel cells be linked to fuzzy logic
input and output variables. As this link is dynamic, the fuzzy logic system can be monitored
and modified using the fuzzyTECH analyzers and editors while browsing through the data
sets.
As a result, the room temperature as controlled by the fuzzy logic thermostat, results in an
increased comfort level. In addition, the fuzzy logic thermostat detected situations where
less cooling effort suffices. The simulation revealed that in an average residential house,
the average energy consumption was reduced by 3.5%. At the same time, the comfort
level was increased, since, depending on the situation, the fuzzy logic thermostat reduced
the room temperature 5°F more than the conventional thermostat.
The fuzzy logic thermostat does not require any modification of the AC itself. Hence, by
replacing existing temperature controllers, even old ACs can be upgraded. By also
controlling the ventilation, an even more improved performance could be reached.
To maximize both the economics and comfort of a private home heating system, fuzzy-
logic control has been used by a German company in a new generation of furnace
controllers [13]. The fuzzy-logic controller ensures optimal adaptation to changing
customer heating demands while using one sensor less than the former generation. Both
the fuzzy-logic controller and the conventional control system were implemented on a
standard 8-bit microcontroller. Design, optimization and implementation of the fuzzy
controller were supported by the software development system fuzzyTECH.
Most European houses have a centralized heating system that uses a furnace for diesel-
type fuel to heat the water supply (boiler). From the boiler, the hot water is distributed by a
pipe system to individual radiators in the rooms of the house. To meet the different needs
of customer heating habits, the temperature of the furnace-heated water must constantly
be adjusted in relation to the outdoor temperature (heat characteristic). To measure the
outdoor temperature, a sensor is installed on the outside of the house.
The basic structure of a controller for this system is shown in Figure 6. The controller itself
realizes an on-off characteristic. If the water temperature in the furnace drops to 2 Kelvin
below the set temperature, the fuel valve opens and the ignition system starts the burning
process. When the water temperature in the boiler itself rises to 2 Kelvin above the set
temperature, the fuel valve closes. This on-off control strategy involving hysterisis
minimizes the number of starts while assuring that the boiler temperature remains within
the desired tolerance.
Figure 5: Schematic of a Centralized
Heating System (large)
Although the structure of this control loop is quite simple, the task of determining the
appropriate set boiler temperature is not. The maximum heat dissipation of the room
radiators depends on the temperature of the incoming water (approximately the boiler
temperature). For that, the set point for the water temperature in the boiler must never be
set so low that it cannot warm the house when necessary. On the other hand, an
excessively high setting of the boiler temperature would result in energy loss in both the
furnace and the piping system. Thus the set boiler temperature needs to be carefully set to
ensure both user comfort and energy efficiency.
In the 1950´s, the German Electrical Engineering Society (VDE) defined a procedure for
this. The assumption is that the maximum amount of heat required by the house depends
on the outdoor temperature (Toutdoor). A parametric function Tsetboiler=f(Toutdoor) adjusts the set
boiler temperature in relation to the outside temperature. This function is also called the
"heat characteristic". Parameters are the insulation coefficient of the house and a so-called
"comfort parameter". The physical model of this is one in which the maximum amount of
available heat equals the amount of heat disposed by the house plus some excess energy
to compensate occasional door and window opening.
The assumption that the amount of energy a heating system has to deliver is largely
outdoor-temperature dependent, was true back in those days when most houses only had
poor thermal insulation. Today, this is obsolete. Due to rising energy costs and
environmental concerns, modern houses are built with improved insulation. Therefore, to
achieve high efficiency, the outdoor temperature is not the only parameter which reflects
the required energy amount. Other factors, such as ventilation, door/window openings and
personal lifestyle, have to be considered as well.
Two approaches for determining the appropriate set boiler temperature for a well-insulated
house exist:
• Extensive use of sensors (that is temperature sensors in every room) and use of a
mathematical model.
• Definition of engineering heuristics to determine the set boiler temperature based
on a knowledge-based evaluation of existing sensor data.
Since the use of extensive sensors is expensive and the construction of a comprising
mathematical model is of overwhelming complexity, the second approach has been chosen
for realizing the new generation of heating system controllers.
The most important criterion about individual customer heat demand patterns comes from
the actual energy consumption curve of the house, which is measured by the on/off-ratio of
the burner. An example of such a curve is given in Figure 7. From this curve, four
descriptive parameters are derived:
These parameters were used to heuristically form rules for the determination of the
appropriate set boiler temperature. To allow for the formulation of plausibility rules (such as
"temperatures below thirty degrees Fahrenheit are rare in August") the appropriate
average outdoor temperature for that season is also a system input parameter. These
curves are plotted in Figure 8. Since the average temperature curves are given, no outdoor
temperature needs to be measured. Hence, the outdoor temperature sensor can be
eliminated.
The structure of the new furnace controller is shown in Figure 9. The fuzzy controller uses
a total of five inputs: four of which are derived from the energy consumption curve using
conventional digital filtering techniques; the fifth is the average outdoor temperature. This
input comes from a look-up table within the system clock. The output of the fuzzy system
represents the estimated heat requirement of the house and corresponds to the Toutdoor
value in the conventional controller (Figure 6).
The objective of the fuzzy controller is to estimate the actual heat requirement of the
house. For this, if-then rules were defined to express the engineering heuristics of this
parameter estimation:
IF current_energy_consumption IS low
AND medium_term_tendency IS increasing
AND short_term_tendency IS decreasing
AND yesterday_average IS medium
AND average_outside_temperature IS very_low
THEN estimated_heat_requirement IS medium_high
In total, 405 rules were defined for the parameter estimation. To develop and optimize such
a large system efficiently, fuzzyTECH's matrix representation was used [9]. This technique
enables rule bases to be viewed and defined graphically rather than in text form. Figure 10
shows a screen shot of such a rule matrix. In this representation, all linguistic labels of two
selected linguistic variables (established heating requirement and yesterday's average
energy consumption) are displayed. All other variables (medium term tendency) are kept at
a selected label. The matrix may be browsed to show the entire rule base by selecting
other terms for these variables.
Within the matrix, a white square indicates rule plausibility whereas a black square
indicates rule implausibility (not existent in the rule base). For instance, the highlighted rule
in Figure 10 is valid. Its textual representation (in the lower part of the window) can be read
as:
IF medium_term_tendency IS stable
AND yesterday_avg IS medium
THEN est._heat_req. IS medium.
For the formulation of these IF-THEN rules, an initial systems prototype was built. During
system optimization, however, it became apparent that some rules were more important
than others and that mere rule addition/deletion was too inexact of a system-tuning
method. Thus the inference strategy had to be extended to allow rules to be associated
with a "degree of support". Such a degree of support is a number between 0 and 1 that
expresses the individual importance of each rule with respect to all other rules. The degree
of support for each rule is indicated in the matrix by a gray-shaded square. This allows for
the expression of rules like:
IF medium_term_tendency IS stable
AND yesterday_avg IS very_high
THEN est_heat_req IS between high and very_high, rather more high.
The entire structure of the fuzzy controller is shown in Figure 11. In this screen shot, the
large block in the middle represents the previously described rule base while the small
blocks represent input and output interfaces. The icons show the
fuzzification/defuzzification methods used in the respective interfaces.
After completion of the design of the fuzzy controller and the definition of linguistic
variables, membership functions and rules, the system was compiled to the assembly
language of the target microcontroller. With this technology, the fuzzy controller only uses
2 KB ROM on a standard 8-bit microcontroller. Once the fuzzy controller had been linked to
the entire furnace controller code, the system was optimized.
To achieve the most efficient system optimization, fuzzyTECH's online module was used
and the target hardware using an 8-bit microcontroller was connected to the developer's
workstation (Windows-PC). The online technique allows for the graphical visualization of
the information flow while the system is running. All fuzzification, defuzzification and rule
inference steps can be graphically cross-debugged in real-time. In addition, the fuzzy
controller can be modified and optimized "on-the-fly" during run-time using the graphical
editors [8, 9].
During optimization, the fuzzy logic controller was connected to a real heating system. This
enabled the optimization of the system robustness against process disturbances such as:
Performance
To evaluate system performance, both the conventional controller and the fuzzy controller
were connected to a test house. One such example is shown in Figure 13. Over a period of
48 hours, three graphs were plotted:
The result of the comparative performance tests showed that the fuzzy controller was
highly responsive to the actual heat requirement of the house. It was very reactive to
sudden heat demand changes like the return of house inhabitants from vacation. Besides
this, the elimination of the outdoor temperature sensor saved about $30 in production costs
and even more in installation costs that average about $120. By setting the set boiler
temperature beneath the level typically used by a conventional controller in low load
periods, the fuzzy controller saves energy. Long-term studies collecting statistical data for
quantifying exactly how much energy per house could be saved annually are currently
being investigated. In addition to this, the two knobs parameterizing the heat characteristic
for the individual house (confer Figure 6) used by conventional heating systems, are no
longer necessary with the fuzzy logic controller. This eases the use of the heating system,
since setting the parameters of the heating curves requires an expertise most home
owners do not have.
• Improved energy efficiency, since the fuzzy controller reduces heat production at
low heat demand periods.
• Improved comfort, due to the detection of sudden heat demand peaks.
• Easy setup, since the heat characteristic does not need to be parameterized
manually.
• Savings both in production and installation cost.
Taking into account the benefits of introducing engineering heuristics, formulated using
fuzzy logic technologies, the price was rather low. In the product, the fuzzy logic controller
only requires 2 KB of ROM. Using matrix rule representation and online development
technology, the optimization of a complex fuzzy logic system containing 405 rules was
done efficiently. Click here to view the Fuzzy Logic Viessmann Heating System Controller.
In some applications, the knowledge about the system solution is contained in sample
data. In these cases, NeuroFuzzy is the method of choice. The following case study is a
good example to show the potential of NeuroFuzzy technologies. The German home
appliance manufacturer AEG used the fuzzyTECH NeuroFuzzy Module to design an
environment-friendly washing machine. The NeuroFuzzy system analyzes the signal of an
existing sensor to estimate the laundry volume and type. This information is used to
optimize the washing program. In an average home, this technology saves about 20% on
water and energy [12]. Click here for a picture of the AEG NeuroFuzzy washing machine or
its presentation at the INFORM Fuzzy Logic User's Conference.
Washing machines in Europe are different from those used in the U.S. and in Japan. The
washing process is much more complicated and takes about 2 hours. On the other hand,
water consumption is much lower. A typical water consumption ranges from 50 to 60 liters
(13 - 18 gallons). White laundry, such as underwear, tableware, and bed sheets, is washed
at temperatures up to 95°C (203°F). Hence, washing machines do not use the hot water
from the house but rather heat up the water electrically.
The complex washing process consists of multiple wash, process, bleach, rinse and spin
steps. To control this, today's washing machines use microcontroller hardware and multiple
sensors:
To determine the optimal washing program, actual laundry load (type and volume) of the
washing machine must be known. Sensors that could measure these parameters directly
are expensive and unreliable. Hence, the objective for AEG was to design a system that
estimates the actual laundry load only from the existing sensors.
• The water intake valve opens at T0. At T1, the water level reached set value. This
duration does not depend much on the laundry load since the laundry in the non-
rotating drum does not absorb much water.
• At T1, the drum starts to rotate in a certain rhythm, causing the laundry to absorb
water. Since the weight of the laundry is held by the drum, the water pressure
measured by the sensor decreases. At a later time T2, the new pressure is stored
and the difference to the pressure at T1 gives an indication of the absorption
speed.
• At T2, the current water pressure is stored again. It gives an indication of the
absorption volume, as the laundry is mostly saturated at this time. At T2, the water
valve is opened again to fill up the water level to the set point.
As there is no mathematical model on the relation of the water absorption curves to the
laundry load, AEG decided to use fuzzy logic to design a solution based on the knowledge
of their washing experts. Figure 16 shows the structure of the fuzzy logic system that
estimates the water requirement in washing and rinse steps. The input variables of the
fuzzy logic system stem from the water absorption curve.
The upper fuzzy logic rule block estimates the water requirement during washing
(WaterLev1) from absorption speed (AbsorbSp) and absorption volume (AbsorbVol). Both
these input variables are calculated from T1 - T0 and T2 - T1. The two lower fuzzy logic
rule blocks estimate the water requirement during rinse (WaterLev2). Inputs to the
intermediate rule block are water requirement during washing, as determined by the upper
rule block, and total absorption volume. These are combined to describe the total
absorption characteristic (AbsorbChar). This variable is not an output of the fuzzy logic
system, but only used as one input for the lower fuzzy logic rule block.
The lower rule block estimates the water requirement during the rinse step (WaterLev2).
Other inputs are the ration of the bounded soap, the number of rinse steps given by the
selected washing program, and the selected intensity of the spin step. All membership
functions are of Standard type (Z, Lambda, S) and the defuzzification employs Center-of-
Maximum (CoM) method.
The approach of interpreting the water absorption curve to estimate the laundry load is
innovative, and hence, not much engineering "know-how" on the interpretation of the
curves exists. As engineering "know-how" on the application is essential to building a
solution with fuzzy logic, the first try of AEG to find a satisfying set of fuzzy logic rules
failed.
On the other hand, AEG already recorded water absorption curves for various known
laundry loads. The optimal water requirement for these laundry loads can easily be
determined by the washing experts. Using these experimental results as training examples,
AEG's next try was to use NeuroFuzzy techniques [4]. Figure 17 shows some of these
training examples. The left column (Laundry load) lists the materials used for this washing
experiment, the next two columns (Water absorption speed and volume) give parameters
from the water absorption curve. AEG showed the washing experts the first columns with
the actual known load and asked them to recommend the optimum water requirement for
this load.
The NeuroFuzzy training used the right column as the desired output and the middle two
columns as the respective inputs. The training cannot use the left column as the actual
load is not known to the washing machine during operation. The aim of this training is that
after training, the fuzzy logic system, which the NeuroFuzzy Module trains, responds with
the appropriate water level recommendation determined of the actual values of the input
variables [4].
Figure 17: The Sample Data for the NeuroFuzzy Training Has Been Gained Through
Extensive Washing Experiments. In Each Experiment, Different Laundry Types and
Volumes Were Used. For Each Experiment, the Washing Expert Gave His
Recommendation for the Amount of Water to Be Used in Subsequent Washing Steps.
The NeuroFuzzy learning process created 159 rules in the fuzzy logic system shown in
Figure 16. The solution was able to estimate the water requirement with a maximum
difference from the optimum value of 0.35 liters (0.09 gallons). In an average home, this
saves about 20% of the water consumption. As most of the electricity consumed by the
washing machine is used to heat up water, 20% of energy is saved too. The fuzzy logic
system that the NeuroFuzzy learning process generated, was implemented on a standard
8 bit microcontroller.
4. Literature
[1] Katayama, R., "Neuro, Fuzzy and Chaos Technology and its Application to (Sanyo)
Consumer Electronics", Japanese-European Symposium on Fuzzy Systems (1992).
[2] N.N., "fuzzyTECH 4.2 MCU Edition Manual", INFORM GmbH Aachen / Inform
Software Corp., Chicago (1996).
[3] N.N., "Fuzzy Logic Benchmarks for Standard MCUs",
http://www.fuzzytech.com/e_ftedbe.htm (1998).
[4] N.N., "fuzzyTECH 4.2 NeuroFuzzy Module Manual", INFORM GmbH Aachen / Inform
Software Corp., Chicago (1996).
[5] N.N., "fuzzyTECH 4.2 DataAnalyzer Module Manual", INFORM GmbH Aachen / Inform
Software Corp., Chicago (1996).
[6] Terai, H. et. al., "Application of fuzzy logic technology to home appliances", IFES'91 -
Fuzzy Engineering toward Human Friendly Systems, p.1118-1119.
[7] Tobi, T. and Hanafusa, T., "A practical application of fuzzy control for an air-
conditioning system", International Journal of Approximate Reasoning 5 (1991), p. 331
- 348.
[8] von Altrock, C., Krause, B. and Zimmermann, H.-J. "Advanced fuzzy logic control of a
model car in extreme situations", Fuzzy Sets and Systems, Vol 48, Nr 1 (1992), p. 41 -
52.
[9] von Altrock, C. and Krause, B., "On-Line-Development Tools for Fuzzy Knowledge-
Base Systems of Higher Order", 2nd Int'l Conference on Fuzzy Logic and Neural
Networks Proceedings, IIZUKA, Japan (1992), ISBN 4-938717-01-8.
[10] von Altrock, C., Krause, B. and Zimmermann, H.-J., "Advanced Fuzzy Logic Control
Technologies in Automotive Applications", IEEE Conference on Fuzzy Systems (1992),
ISBN 0-7803-0237-0, p. 831-842.
[11] von Altrock, C., Franke, S., and Froese, Th., "Optimization of a Water-Treatment
System with Fuzzy Logic Control", Computer Design Fuzzy Logic '94 Conference in
San Diego (1994).
[12] von Altrock, C., "Fuzzy Logic Technologies in Automotive Engineering", Computer
Design Fuzzy Logic '94 Conference in San Diego (1994).
[13] von Altrock, C., Arend, H.-O., Krause, B., Steffens, C., and Behrens-Rommler, E.,
"Customer-Adaptive Fuzzy Control of Home Heating System", IEEE Conference on
Fuzzy Systems in Orlando (1994).
[14] von Altrock, "Fuzzy Logic and NeuroFuzzy Applications Explained", ISBN 0-1336-
8465-2, Prentice Hall 1995.
[15] Wakami, N. "Engineering Application of Fuzzy Systems - Fuzzy Control and Neural
Networks: Applications for (Matsushita) Home Appliances", Japanese-European
Symposium on Fuzzy Systems in Berlin (1992).