Prediction of PID control model on PLC

TELKOMNIKA, Vol.17, No.1, February 2019, pp.529~536
ISSN: 1693-6930, accredited First Grade by Kemenristekdikti, Decree No: 21/E/KPT/2018
DOI: 10.12928/TELKOMNIKA.v17i1.11589  529
Received June 20, 2018; Revised October 1, 2018; Accepted November 5, 2018
Prediction of PID control model on PLC
Erwani Merry Sartika*
1
, T. Rudi Sarjono
2
, Diki Dwi Saputra
3
Universitas Kristen Maranatha (Electrical Engineering Department),
Suria Sumantri St. No.65, 022-2012186, Indonesia.
*Corresponding author, e-mail: erwanimerry@gmail.com
1
, rudi.sarjono@gmail.com
2
,
knight.diki@gmail.com
3
Abstract
PID (Proportional Integral Derivative) is a control algorithm that mostly used in industry. However,
users have never known what the PID model that used inside the PLC. By knowing the PID model that
used in PLC, users will have more choice in determining the more appropriate tuning algorithm. Also,
users can use MATLAB to perform analysis and can implement it to PLC. Through OPC Server (Object
Linking and Embedding for Process Control Server) as a software interface, programs on a windows
operating system can communicate with industry devices universally. PID model prediction method is done
by comparing the output of the plant controlled by PID model in PLC and PID model in SIMULINK
MATLAB using OPC Server intermediaries. Based on comparison result in graph and analysis using
integral error method, PLC M221 using Parallel PID model and PLC S7-1200 using Ideal PID model.
Keywords: MATLAB, PID control, PLC, prediction
Copyright © 2019 Universitas Ahmad Dahlan. All rights reserved.
1. Introduction
PID (Proportional Integral Derivative) is a control algorithm that mostly used in industry
because of its good performance and relatively easy to tune its parameters [1, 2]. There are
three forms of PID models in general, namely series, parallel, and ideal. PLC (Programmable
logic controller) is a control device that is often used in the industry because it is relatively easy
to program, durable and can be integrated with other industrial devices [3, 4]. PID in industry is
implemented using PLC hardware [5-7]. Each PLC brand uses a different PID model [8]. The
differences PID model making each output between different brands PLC not the same although
using the same plant. In practice, the user never knows the PID model used on the PLC. By
knowing the PID model used, the user will have more choice in determining the more
appropriate tuning algorithm. Also, by knowing PID model in PLC, user can use MATLAB to
analyze and implement the analysis results to PLC.
PLC can be integrated with MATLAB application that works on windows operating
system [9-12]. MATLAB (Matrix Laboratory) is a program used to perform engineering and
mathematical computations as well as modeling and simulating the SIMULINK
environment [13-15]. The advantages of integrating PLC and MATLAB directly are reducing
complexity, minimizing manually entering data, simplifying system maintenance, facilitating plant
modeling/simulation processes, no need to install additional hardware on the PC, and cost
savings. In the absence of additional hardware then there is no need to change the I/O analog
to digital or vice versa, since all I/O is in digital form. This paper will explain prediction of the PID
model used in PLC with virtual plant in MATLAB.
Some researcher that uses MATLAB analysis results to be used or compared to the
results in the PLC. Comparative results with MATLAB and PLC provide findings on various
performance parameters in the application of shell and tube type heat exchanger control
systems [16, 17]. Comparison of MPC controls using OPC and MATLAB servers as OPC clients
and PID control on PLC on the implementation of heating water tank systems [18-20]. In the
design of multivariable process control, a tool has been created to convert the Simulink model to
automatically generated code in C/C++ and implementation directly on the PLC [15], [21]. The
conventional SCADA can enhanced further more with PLC as well as NI-OPC server
significantly through the experimental validation procedure of a simple cascade control system
through a number of architectures (PLC, SCADA, OPC, internet) [9]. Through realization in PLC

 ISSN: 1693-6930
TELKOMNIKA Vol. 17, No. 1, February 2019: 529-536
530
can used to prove that improvement performance of traditional PID obtained from parameters
self-tuning PID [22-25]. The system is design in MATLAB/Simulink and the software
communicates with PLC using Kepware OPC which allows communication between
multi-vendor devices without any restrictions [26].
2. PID Control
PID Control is a control loop feedback mechanism that mostly used in industrial control
systems. PID control calculates an error value and applies correction based on proportional,
integral, and derivative terms. There are 3 types of PID controllers; they are series PID, parallel
PID, and ideal PID as shown in (1), (2), and (3). The parameters of each type of PID controller
have an influence on the control signal generated.
𝑃𝐼𝐷𝑠𝑒𝑟𝑖𝑒𝑠 = 𝐾𝑝 (1 +
1
𝑇𝑖 𝑠
)(1 + 𝑇𝑑 𝑠) (1)
𝑃𝐼𝐷 𝑝𝑎𝑟𝑎𝑙𝑙𝑒𝑙 = 𝐾𝑝 +
𝐾𝑖
𝑠
+ 𝐾𝑑 𝑠 (2)
𝑃𝐼𝐷𝑖𝑑𝑒𝑎𝑙 = 𝐾𝑝 (1 +
1
𝑇𝑖 𝑠
+ 𝑇𝑑 𝑠) (3)
The series PID model is usually called the interacting form, because the value of
derivative time affects the integral part, so this part interacts with each other. The
Ziegler-Nichols PID rules tuning were developed for this controller algorithm. The parallel PID
model is one that is commonly used because it has a proportional value, pure integral action. In
the Ideal PID model, proportional, integral, and derivative actions do not interact with each other
in the time domain. The Cohen-Coon and Lambda PID tuning rules were designed for this
algorithm [27].
3. Research Method
PLC is a controller in which there is a PID controller. Each PLC from various vendors
provides PID controllers with different models. In this paper will be compared PID model of two
different PLC brand with intermediary OPC Server and MATLAB. PLC will be used as PID
controller. PID model testing process on PLC will be done by comparing the output of virtual
plant after PID controlled on PLC and output after PID controlled on MATLAB, with the help of
OPC Server. MATLAB SIMULINK is used to create a virtual plant from second order system
and as a comparison of the PID model. After all the testing that had been done, user will have
more choice in determining more appropriate tuning algorithm. Also, by knowing PID model in
PLC, user can use MATLAB to analyze and implement the analysis results to PLC.
The OPC Server application used is KepserverEx v6. For the communication
configuration diagram between PLC, OPC Server, and MATLAB used in the comparison
simulation process shown in Figure 1. For configuration of PID controller on PLC and MATLAB
with OPC Server interface device used in this paper is shown in Figure 2. While the
configuration for PID in MATLAB is shown in Figure 3.
Figure 1. Communication configuration diagram between PLC, OPC Server, and MATLAB

TELKOMNIKA ISSN: 1693-6930 
Prediction of PID control model on PLC (Erwani Merry Sartika)
531
Figure 2. PID configuration block diagram of PLC with OPC Server interface (PLC to MATLAB)
Figure 3. PID MATLAB configuration block diagram with OPC Server interface
(MATLAB to MATLAB)
The two block diagrams shown in Figure 2 and Figure 3, are made similar, because for
the process of comparison between the two systems must have the same state. The process is
the setpoint goes into the OPC, the PID output goes to the OPC, and the outputs (feedback) go
to OPC. Plant made in the form of a virtual plant. In this paper virtual plant created in SIMULINK
application. The second order plant used plant mass-spring-damper.
4. Results and Analysis
This section shows the simulation results in the output graph from the virtual plant after
being controlled by PLC PID and MATLAB PID. For comparison use parallel PID MATLAB and
ideal PID MATLAB to compare result with PLC PID to know PID model used in PLC. For PLC
M221 from Schneider produces a comparison of output graph as shown in Figure 4 using PID
parameters in Table 1. The first PID parameters are obtained by using auto-tune in PLC M221.
Next use the second PID parameter to ensure the simulation results in PLC M221. The
second PID parameter is shown in Table 2 and the results are shown in Figure 5. For PLC
S7-1200 from Siemens produces a graph of output graph as shown in Figure 6, with PID
parameter as in Table 3 obtained by using auto-tune PLC S7-1200. Next result with second PID
parameter on PLC S7-1200. The second PID parameter is shown in Table 4 and the results are
shown in Figure 7.
Table 1. The First PID Parameters used for
Comparison of Mass-spring-Damper Plant
for M221 PLC
Indicator Value
Setpoint 100
Ts 50ms
PID Parameter
Kp: 130
Ti : 16
Td: 4
Table 2. The second PID Parameters used for
Comparison of Mass-spring-damper Plant
for M221 PLC.
Indicator Value
Setpoint 100
Ts 50ms
PID Parameter
Kp: 189
Ti : 27
Td: 1
Setpoint OPC PID OPC Plant
OPC
+-
Output
Feedback
PLC
Setpoint OPC
PID
MATLAB
OPC Plant
OPC
+-
Output
Feedback

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532
Table 3. The First PID Parameters used for
Comparison of Mass-spring-damper Plant
for PLC S7-1200
Indicator Value
Setpoint 100
Ts 50ms
PID Parameter
Kp: 0.1
1/ki: 0.4
Kd: 0.05
Table 4. The second PID Parameters used for
Comparison of Mass-spring-damper
Plant PLC S7-1200
Indicator Value
Setpoint 100
Ts 50ms
PID Parameter
Kp: 1.89
1/ki: 0.758
Kd: 0.308
Figure 4. Comparison of output of M221 and
MATLAB for mass-spring-damper plant with
first PID paramete
second PID parameter
Figure 6. Comparison of output S7-1200 and
the first PID parameter.
second PID parameter
For data analysis, the integral error method is used to indicate the total error difference
between the output plant of PID PLC and output plant of PID MATLAB (parallel PID model and
ideal PID model). The results are shown in Table 5. From the results of data analysis using
integral error method, it is concluded that PLC M221 uses parallel PID model and PLC S7-1200
using Ideal PID model. It is because the total integral error difference when PID PLC M221
compare to parallel PID MATLAB is smaller than the total integral error difference when PID

533
PLC M221 compare to ideal PID MATLAB. As well as the total integral error difference when
PID PLC S7-1200 compare to ideal PID MATLAB is smaller than the total integral error
difference when PID PLC S7-1200 compare to parallel PID MATLAB.
Table 5. The Results of Data Analysis using Integral Error Method (mass-spring-damper plant)
Total integral
error
difference
PID PLC M221
compare to parallel
PID MATLAB
PID PLC M221
compare to ideal
PID MATLAB
PID PLC S7-1200
compare to parallel
PID MATLAB
PID PLC S7-1200
compare to ideal
PID MATLAB
First PID
parameter
(auto-tune)
808.30232 1391.07528 2619.8851 341.7901
Second PID
parameter
632.74384 1870.73432 1910.2448 1287.3413
To further convince the conclusion of PID control method prediction on PLC then tested
at real plant. The real plant used in the simulation is the third order RLC plant. The RLC circuit is
realized in the PCB as shown in Figure 8. The equation of the transfer function of the real plant
is as show in (4)
Figure 8. Realization of 3
rd
order RLC circuit on PCB
𝑉𝑜(𝑠)
𝑉𝑖(𝑠)
=
𝑠𝐿 + 𝑅2
𝑠3[(𝐿𝐶1𝐶2𝑅4)(𝑅1 + 𝑅3)]
+𝑠2[𝐶1𝐶2(𝑅1𝑅2𝑅4 + 𝑅1𝑅3𝑅4 + 𝑅2𝑅3𝑅4) + 𝐿(𝐶1 + 𝐶2)(𝑅1 + 𝑅3) + 𝐿𝐶2𝑅4]
+𝑠[(𝐶1 + 𝐶2)(𝑅1𝑅2 + 𝑅1𝑅3 + 𝑅2𝑅3) + 𝐶2𝑅1𝑅4 + 𝐶2𝑅2𝑅4 + 𝐿]
+(𝑅1 + 𝑅2)
(4)
with R1 = R2 = 56kΩ, R3 = R4 = 100kΩ, C1 = 100μF, C2 = 10μF, and L1 = 5mH then the
transfer function is shown in Equation (5)
𝑉𝑜(𝑠)
𝑉𝑖(𝑠)
=
0.005𝑠 + 56000
0.0033𝑠3 + 4.256 × 104 𝑠2 + 4.794 × 105 𝑠 + 112000
(5)
For simulation results using PLC M221 with real plant results output comparison graph
as show in Figure 9 with parameter of PID used as show in Table 6. The result of integral error
method between PLC M221 and parallel PID is 274.178 whereas with ideal PID is 292.736.
These results are increasingly assured that the PID model on the PLC S7-1200 use the
parallel PID model. As for the simulation results using PLC S7-1200 with real plant results the
output comparison graph as in Figure 10 with parameter PID used as in Table 7.
Table 6. PID Parameters used for Comparison
of Real Plant for M221 PLC
Indicator Value
Setpoint 3000
Ts 50ms
PID Parameter
Kp: 1.26
Ti: 1.8
Td: 0.1
Table 7. PID Parameter used for comparison
of real plant for PLC S7-1200
Indicator Value
Setpoint 100
Ts 50ms
Parameter PID
Kp: 0.1
1/ki: 0.4
Kd: 0.05
R1
R2
R3 R4
C1 C2
L1Vi Vo

 ISSN: 1693-6930
534
MATLAB for real plant with PID parameter
MATLAB for real plant with PID parameter
The result of integral error method between PLC S7-1200 with parallel PID is 519.638
whereas with ideal PID is 407.065. These results are increasingly assured that the PID model
on the PLC S7-1200 use the ideal PID model. For the results of the whole analysis is shown in
Table 8.
Table 8. The Result of Data Analysis using Integral Error Method (Real Plant)
Total integral
error
difference
PID PLC M221
compare to
parallel PID
MATLAB
PID PLC M221
compare to ideal
PID MATLAB
PID PLC S7-
1200 compare
to parallel PID
MATLAB
PID PLC S7-
1200 compare
to ideal PID
MATLAB
Real Plant 274.178 292.736 519.638 407.065
4. Conclusion
PID model predictions method have been successfully used by comparing the output of
the plant controlled by PID model in PLC and PID model in SIMULINK MATLAB using OPC
Server intermediaries. Based on comparison result in graph and analysis using integral error
method, PLC M221 is predicted using Parallel PID model and PLC S7-1200 using Ideal PID
model. By knowing the PID model used, user will have more choice in determining the more
appropriate tuning algorithm. By knowing PID model in PLC, user can use MATLAB/Simulink to
analyze and implement the analysis results to PLC.
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