Design and Simulation of Fuzzy-PID Controller Based on

Mixed Injection Molding Machine

Jianming DU

Yixing LUO

College of Mechatronics and Control Engineering

Shenzhen University
Shenzhen Guangdong China
djm33@szu.edu.cn

College of Mechatronics and Control Engineering

Shenzhen University
Shenzhen Guangdong China
batistar007@yahoo.com.cn

Abstract The mixed injection molding machine driven by

PMSM control system was established and a Fuzzy-PID
controller based on the Fuzzy-PID control method was designed
according to the characteristic of melting and plasticizing action.
In the Simulink environment the Fuzzy-PID control system was
simulated. The results of simulation indicated that the FuzzyPID system has the better performance in comparison with
traditional PID control system.

Proportional, Integral and Differential, but the melting plastic

mechanism is so complicated and changeful that model of
system can not be described easily. Therefore the Fuzzy-PID
control method is selected to control plasticizing screw
rotating. The Fuzzy-PID controller not only has the
advantages of traditional PID control method but also has
small overshoot and fast response, and moreover it is not
necessary to know the accurately model of the controlled
object [3]. The model of the melting plastic mechanism based
on the PT160 injection molding machine from L.K Group was
established under the Simulink environment of Matlab. The
dynamic simulations of melting plastic mechanism were
performed using the PID and Fuzzy-PID control method, and
the results of simulation were analyzed.

Keywords- Fuzzy-PID controller; fixed injection molding

machine; PMSM; Simulink

I.

INTRODUCTION

As the main molding equipment, injection molding

machine makes different shapes of plastic products which
made of thermoplastic or thermosetting materials. The
melting plastic process is one of the most important actions in
the injection molding cycle. It impacts the final quality of the
product. Nowadays, the hydraulic driving system was applied
to most of injection molding machines, such as hydraulic
motor that drives the plasticizing screw to melt. However,
there are some disadvantages such as high energy
consumption, slow-response, low-precision, oil leakage, noisy
and so on in hydraulic driving system and every action of
injection molding cycle can only be carried out orderly [1].
Aiming at these problems, a new solution of mixed injection
molding machine driving system was proposed. The main
pump and plasticizing screw are driven by PMSM
respectively. The mixed driven system can not only enhance
the plasticizing quality but also shorten the injection molding
cycle of some product effectively by making the optimization
design and synchronizing some technological actions.
Moreover, especial power transmission technology by
transmitting the breaking energy of two PMSMs can achieve
the goal of further energy saving [2].
The plasticizing screw rotating and shearing with plastic
generates energy which is the main source for melting plastic.
The rotation speed of plasticizing screw can determine the
quality of melting plastic action. Therefore, the plasticizing
screw should be controlled accurately and steadily rotating at
the setting velocity. The traditional PID control method has
been widely used, but the accurate model of the controlled
object should be known firstly. The PID controller controls
the system according to the setting parameters of

II.

MELTING PLASTIC SYSTEM MODELING AND FUZZY-PID

CONTROLLER

Melting plastic action has the characteristics of lowspeed and high-torque. The model of melting plastic of PT160
injection molding machine produced by L-K Group was
established. Hydraulic motor was substituted by PMSM and
motor shaft connects directly with screw by the way of using
splined shaft. The melting plastic mechanism is shown in
Fig.1:

Fig.1 Schematic diagram of melting plastic mechanism

Melting plastic mechanism is the closed-loop system

including the current loop and speed loop. The speed
feedback signal comes from the encoder of PMSM encoder
and the current feedback signal comes from the driver.
System control structure is shown in Fig.2:

Project of Science and Technology Plan of Shenzhen (No.08CXY-47)

978-1-4244-5874-5/10/$26.00 2010 IEEE

Fig.2 Block diagram of melting plastic control system

The mathematical model of PMSM is so complex that

the model was established under the rotor based
synchronously rotating reference frame (d-q-0 coordinate
system). The coordinate transformation from d-q-0 to a-b-c
can make the diagonalization of impedance and eliminate the
rotary coupling between stator and rotor, and thus achieve the
purpose of simplification of the model [4]. The mathematical
model of PMSM under the d-q-0 coordinate system is given
as follow:
di
(1)
u d = R Si d + Ld d Pn m Lq i q
dt
di q
(2)
u q = R Si q + Lq
Pn m L d i d + Pn m f
dt
Tem = Pn (d i q q i d )
(3)

Tem = Pn [ f i q (Ld Lq )i d i q ]

(4)

dm
+ R m + T l
(5)
dt
Where the symbol Ud is d-axis voltage, Uq is q-axis
voltage, id is d-axis current, iq is q-axis current, Ld is d-axis
inductance, Lq is q-axis inductance, Pn is pairs of poles, f is
flux induced by magnets, J is rotor moment of inertia, Te is
electromagnetic torque, and R is coefficient of friction. The
product of m and current of d-axis and q-axis implies that
there are interference and coupling between these parameters.
Therefore, making sure id=0 is the way to eliminate the
interferes between id and iq and achieve steady state
decoupling control [4]. In addition, the d-axis and q-axis have
the same inductance Ld=Lq due to that the permeability of
permanent magnet rotor is close to air.
Te = J

The general expression of traditional PID controller can

be stated as:
t
de(t)
(6)
u(t) = K p e(t) + K i e()d + K d
0
dt
The structure of PID controller is shown in Fig.3, where the
error value e is the deviation of input and feedback values.
The controller regulates the output according to the PID
parameters.

output. Finally, the dynamic control is achieved [5]. The

structure of Fuzzy-PID controller is shown in Fig.4:

Fig.4 Block diagram of Fuzzy-PID controller

According to block diagram of Fuzzy-PID controller, the

fuzzy domain of input is [-300,300], and the fuzzy domain of
output is [-10, 10]. In the output Kp fuzzy control rule table,
the velocity deviation was divided into 8 membership degrees
and the deviation variation rate was divided into 7
membership degrees. The division of input and outputs
membership degrees is shown in Table 1, Table 2 and Table
3:
TABLE 1. OUTPUT Kp FUZZY CONTROL RULE TABLE
e
Kp

ec

Fuzzy-PID controller is the two-dimensional structure.

The controller has two inputs. One is denoted by e, i.e. the
deviation of input and feedback values. Another is the change
rate of deviation denoted by ec. The output is the increment of
the controlled value. Firstly, the fuzzy processing of input is
carried on according to the fuzzy membership table.
Secondly, the controller adjusts the PID parameters on-line
according to the fuzzy control rule table and quantifies the

NB

NM

NS

NZ

PZ

PS

PM

PB

PB
PB
PB
PB
PM
PS
Z

PM
PM
PS
PS
PS
Z
Z

PM
PS
PS
Z
Z
NS
NM

PS
PS
Z
Z
Z
NM
NM

NB
NM
Z
Z
Z
PS
PB

NM
NS
Z
Z
PS
PS
PB

Z
Z
PS
PM
PM
PB
PB

Z
PS
PB
PB
PB
PB
PB

TABLE 2. OUTPUT Ki FUZZY CONTROL RULE TABLE

e
Ki

ec

NB
NM
NS
Z
PS
PM
PB

PB

PM

PS

NS

NM

NB

Z
PS
PM
PB
PB
PB
PB

Z
Z
PS
PM
PM
PB
PB

NM
NS
Z
PS
PS
PM
PB

NM
NS
Z
Z
Z
NS
NM

PB
PM
PS
PS
Z
NS
NM

PB
PB
PM
PM
PS
Z
Z

PB
PB
PB
PB
PM
PS
Z

TABLE 3. OUTPUT Kd FUZZY CONTROL RULE TABLE

e
Kd

ec

Fig.3 Block diagram of PID controller

NB
NM
NS
Z
PS
PM
PB

NB
NM
NS
PS
PM
PB

III.

NB

NM

NS

PS

PM

PB

PB
PM
PS
NM
NB
NB

PM
PS
Z
NB
NS
Z

PB
PM
PS
PS
PM
PB

PB
PM
PS
PS
PM
PB

PB
PM
PS
PS
PM
PB

Z
NS
NM
Z
PS
PM

NB
NB
NM
PS
PM
PB

SIMULATION MODEL AND RESULTS

The dynamic simulation model of melting plastic

mechanism based on Fuzzy-PID control system was
established under the Simulink environment of Matlab. The
close-loop control system consists of the internal current loop
and external speed loop. The difference value of setting speed
and feedback speed is processed by Fuzzy-PID controller, and
the control current based on the d-q-0 coordinate system is
output. Then the coordinate converter module outputs the

three-phase control current based on a-b-c coordinate system.

Finally, PWM inverter module outputs the three-phase control
voltage to PMSM and melting plastic mechanism is driven by
PMSM.
Parameter settings for simulation are as follows: the
setting speed 300rmp, the initial values of Kp, Ki and Kd are
1.2, 9.1 and 0.01, the practical quantization factors are 0.5,
0.5, and 0.001. PMSM parameter settings are as follows:
phase resistance 0.0918ohm, d-q inductance 0.000975H, flux
induced by magnets 0.1688wb, rotor moment of inertia
0.003945kgm2, friction factor 0.0004924, pairs of poles 4, the
variable step-size ode23s (stiff/Mod.Rosenbrock) algorithm,
simulation time 0.06s. The simulation results are shown in
Fig.5 and Fig.6.
In Fig.5 and Fig.6 the solid line represents the speed
curve controlled by Fuzzy-PID control method and the dashed
line represents the speed curve controlled by traditional PID
control method. Simulation results show that the Fuzzy-PID
controller has faster response ability, lower overshoot and
steady state error in comparison with traditional PID control
method.

Fig.5 The simulate output of speed curve

Fig.6 The partial enlarged view of speed curve

IV.

CONCLUSION

The new plan of mixed injection molding machine has

been proposed in order to implement precision injection, the
better control ability saving energy. The main pump motor and
hydraulic motor was replaced by two PMSM. The model of
melting plastic system is complex and changeful. Therefore

the Fuzzy-PID controller based on parameter self-tuning was

designed to control the melting plastic mechanism. The
controller can adjust the PID parameters real-timely according
to parameter estimation and accomplish the accurate control to
complex system. The results of dynamic simulation by
Simulink indicate that the Fuzzy-PID control method can
improve the working performance of melting plastic
mechanism in comparison with traditional PID control method.
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Injection Molding Machine Creating Together The New Development
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[2]

QUAN Long, Wang Cheng-bin. Research on the electro-hydraulic

control system driven by AC servo motor and constant pump used in
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[3]

LOU Lei, YANG Feng-yu, WANG Shun, WANG Qi-lei, CHEN Junhui. Fuzzy PID Control on Electro-hydraulic Servo System [B].
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[4]

GUO Qing-bing, SUN Yi-biao. Modern permanent magnet AC servo

motor system [M]. Beijing: China Electric Power Publishing House
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YIN Yun-hua, FAN Shui-kang, CHEN Min-e. The Design and

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