Beruflich Dokumente
Kultur Dokumente
Sections:
1. Process Industries vs. Discrete Manufacturing
Industries
2. Continuous vs. Discrete Control
3. Computer Process Control
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Types of Control
Just as there are two basic types of variables and
parameters in processes, there are also two
corresponding types of control:
Continuous control - variables and parameters are
continuous and analog
Discrete
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Continuous Control
Usual objective is to maintain the value of an output
variable at a desired level
Parameters and variables are usually continuous
Similar to operation of a feedback control system
Most continuous industrial processes have multiple
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Control
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Control
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Regulatory Control
Objective - maintain process performance at a certain
level or within a given tolerance band of that level
Appropriate when performance relates to a quality
measure
Performance measure is sometimes computed based
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action
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Regulatory Control
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Feedforward Control
Objective - anticipate the effect of disturbances that
will upset the process by sensing and compensating
for them before they affect the process
Mathematical model captures the effect of the
disturbance on the process
Complete
compensation
for theSaddle
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Feedforward Control
Combined with Feedback Control
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Steady-State Optimization
Class of optimization techniques in which the process
exhibits the following characteristics:
1. Well-defined index of performance (IP)
2. Known relationship between process variables
and IP
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Open-loop
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Optimization techniques include differential calculus,
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Adaptive Control
Because steady-state optimization is open-loop, it cannot
compensate for disturbances
Adaptive control is a self-correcting form of optimal control
that includes feedback control
Measures the relevant process variables during
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No portion of this material may be reproduced, in any form or by
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Event-Driven Changes
Executed by the controller in response to some event
that has altered the state of the system
Examples:
A robot loads a workpart into a fixture, and the part
is sensed by a limit switch in the fixture
The diminishing
of plastic
in the
hopper
of an
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Time-Driven Events
Executed by the controller either at a specific point in
time or after a certain time lapse
Examples:
The factory shop clock sounds a bell at specific
times to indicate start of shift, break start and stop
times, and
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Interlocks
Safeguard mechanisms for coordinating the activities of
two or more devices and preventing one device from
interfering with the other(s)
1. Input interlocks signal from an external device sent
to the controller; possible functions:
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Interrupt System
Computer control feature that permits the execution of
the current program to be suspended in order to
execute another program in response to an incoming
signal indicating a higher priority event
Internal interrupt generated by the computer itself
Examples:
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events,
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Interrupt Systems:
(a) Single-Level and (b) Multilevel
(a)
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Exception Handling
An exception is an event that is outside the normal or
desired operation of the process control system
Examples of exceptions:
Product quality problem
Process variable outside normal operating range
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(b)
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(c)
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Manufacturing, Third Edition, by Mikell P. Groover.
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Components of a
Direct Digital Control System
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Manufacturing, Third Edition, by Mikell P. Groover.
DDC (continued)
Originally seen as a more efficient means of performing
the same functions as analog control
Additional opportunities became apparent in DDC:
More control options than traditional analog control
(PID control), e.g., combining discrete and continuous
2008control
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Supervisory Control
In the process industries, supervisory control denotes a
control system that manages the activities of a
number of integrated unit operations to achieve
certain economic objectives
In discrete manufacturing, supervisory control is the
control
system
that directs
and Saddle
coordinates
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a manufacturing
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Functions:
efficient
scheduling
of production,
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tracking
tool
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operating
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publisher. For
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Most closely
withbook
the process industries
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No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
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Manufacturing, Third Edition, by Mikell P. Groover.
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reserved. This material is protected under all copyright laws as
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No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
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Manufacturing, Third Edition, by Mikell P. Groover.
DCS Advantages
Can be installed in a very basic configuration, then
expanded and enhanced as needed in the future
Multiple computers facilitate parallel multitasking
Redundancy due to multiple computers
Control cabling is reduced compared to central controller
configuration
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Networking
provides
process under
information
throughout
theyenterprise
currently exist.
for more efficient plant and process
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management
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Enterprise-Wide
Integration of Factory Data
Managers have direct access to factory operations
Planners have most current data on production times
and rates for scheduling purposes
Sales personnel can provide realistic delivery dates to
customers, based on current shop loading
Order
trackers
can provide
current
status
information
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Accounting
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Production personnel can access product design data
the exclusive use of adopters of the book
to clarify ambiguities
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Enterprise-Wide PC-based
Distributed Control System
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