INTRODUCTION TO CONTROL SYSTEM

THIS IS AN INTRODUCTORY TOPIC TO CONTROL SYSTEM AND EXPLAINS ITS IMPORTANCE IN INDUSTRY. THIS TOPIC COVERS ARE THREE (3) IMPORTANT ELEMENTS; MEASUREMENT IN A CONTROL SYSTEM, EVALUATION AND CONTROL. OTHER ELEMENTS WHICH WILL BE EXPLAINED IN THIS TOPIC ARE THE OPEN LOOP AND CLOSED LOOP SYSTEM AS WELL AS BLOCK DIAGRAM.

 Definition of control Importance in industry Example of application

Open-loop & closed-loop system

Case studies: ipc-201 system

DEFINATION OF CONTROL
A control system can be thought of a system which

for some particular input or inputs is used to control its output to some particular value, give a particular sequence of events or give an event if certain conditions are met.

Importance in industry
Automatically operating machinery, perhaps in a

production line with robots, which can be used to produce components with virtually no human intervention. Appliances around the home and in the office. Consistency of product Reduced operating costs due to improved utilization of plant and materials and reduction in manpower. Greater safety for operating personnel.

Example of application
Electrical

 Pneumatic Air brake, vacuum pump, air compressor, pneumatic cylinder ext.

 Hydraulic

Open loop & closed loop control system

Open loop control

Input

Of the Temperature Selection

Cooling Process

Output
Of the Room Temperature

Closed loop control

+

Comparison Correction element Input Element

Output Cooling

Of the Set value

Error

Switch

Of the required Room temperature

Temperature Measurement

Feedback of temperature information

 In an open-loop control system the output from the

system has no effect on the input signal to the plant or process. The output is determined solely by initial setting. In a closed-loop control system the output does have an effect on the input signal, modifying it to maintain an output signal at the required value.

Comparison
Open-loop system Closed-loop system

Simple Cheap Good reliability Inaccurate No Feedback system

Complex Costly Greater chance of

breakdown Accurate Feedback system

Basic Elements In Open-loop System

Input Set Value Control Correction Process Output Required Value

Control This determine the action to be taken as a result of the input required value signal to the system. Correction This has an input from the controller and gives an output of some action designed to change the variable being controlled. Process This is the process of which a variable is being controlled.

Basic Elements In Closed-loop System

Comparison Input Element + Of the Set value

Output Control Law Correction Element Process Of the required Room temperature

Error

Measurement Feedback of a signal Which is a measure Of the variable being controlled

 Comparison element

This element compare the required value of the variable being controlled with the measured value of what being achieved and produces an error signal. Thus if the output is the required value then there is no error and so no signal is fed to initiate control. Only when there is a difference between the required value and the actual values of the variable will there be an error signal and so control action initiated. The control law element determines what action to take when an error signal is received. The control law used by the element may be just to supply a signal which switches on or off when there is an error, as in a room thermostat, or perhaps a signal which is proportional to the size of the error so that if the error is small a small control signal is produced and if the error is large a large proportional control signal is produced.

Control law implementation element

 Correction element the correction element produces a change in the process which aims to correct or change the controlled condition. The term actuator is used for the correction element unit that provides the power to carry out the control action. Examples of correction elements are directional control valves which are used to switch the direction of flow of a fluid and so control the movement of an actuator such as the movement of a piston in cylinder. Another example is an electrical motor where a signal is used to control the speed of rotation of the motor shaft.

 Process The process is the system in which there is a variable that is being controlled, e.g. it might be a room in a house with the variable of its temperature being controlled. Measurement element The measurement element produces a signal related to the variable condition of the process that is being controlled. For example, it might be a temperature sensor with suitable signal processing.

CASE STUDIES
THE FOLLOWING ARE EXAMPLES OF CLOSED LOOP CONTROL SYSTEMS TO ILLUSTRATE THE TEMPERATURE CONTROL, LEVEL CONTROL, FLOW CONTROL AND PRESSURE CONTROL USING IPC201C SYSTEM.

IPC 201C SYSTEM

Aluminum profile table (1200 x 720 mm)

Air treatment unit: - Manual valve.

- Filter.
- Pressure regulator with manometer. - Security valve (2 bar) Red lamp.

Button pad: - Push-buttons: start, stop, reset. - Selectors: 0-1, control PLCPID. - Emergency Stop.

Reservoir tank
Volume: 3.12 l. Stainless steel.

Coverless for easy filling.

Draining controlled by the bottom 2/2 single acting solenoid valve. Allows circuit filling.

Left tank
Volume: 3.12 l

Pressurized.
Top fluid input controlled by 2/2 single acting solenoid valve. Bottom fluid output controlled by 2/2 single acting solenoid valve.

Left tank
Minimum and maximum capacitive level sensors. ITV transductor: pressure controller with pressure display. 3 in 1: Controller, actuator and sensor.

Central tank
Volume: 3.12 l

Not pressurized.
Top input and bottom output controlled by 2/2 single acting valves. Bottom cooling / heating system based on Peltier Cells.

Mixer moved by a 24VDC motor.

Central tank
Temperature sensor: PTC with signal amplifier. Level sensor (differential pressure) with display.

Minimum and maximum capacitive level sensors.

Right tank
Volume: 3.12 l Pressurised.

Top filling valve controlled by 2/2 single acting solenoid valve.

Pressure input controlled by 2/2 single acting pneumatic solenoid valve and pressure switch with display. Bottom fluid draining controlled by proportional solenoid valve. Minimum and maximum level capacitive sensors.

Electrical components
- Power supplies 110VAC/24VDC - PLC.

- Industrial PIDs.
- Connection terminals. - Displays: + level & flow.

- Signal conditioners.
- PWM amplifiers.

Other devices
- Faults generation box.

- Pump 24VDC. - Flowmeter.

SCADA applications

- PLC/PID control - Manual mode. - Exercises. - Graphs.

Temperature closed loop control

Setpoint: Environment T + 15 - 10
+ -

REGULADOR (CONTROLLER) PLC/PID

ACTUATOR
PELTIER CELLS

SENSOR PTC

Setpoint: Environment T + 15 - 10
+ -

PLC/PID

PELTIER

PTC

Flow closed-loop control (1/3)

Setpoint: 0,45 2,5l/min

+ -

REGULADOR (CONTROLLER) PLC/PID

ACTUATOR
PUMP

SENSOR
FLOWMETER

Setpoint: 0,45 2,5l/min

+ -

PLC/PID

PUMP

FLOWMETE R

Flow closed loop control (2/3)

Setpoint: 0,45 2,5l/min

+ -

REGULATOR (CONTROLLER) PLC/PID

ACTUATOR
ITV

SENSOR
FLOWMETER

Setpoint: 0,45 2,5l/min

+ -

PLC/PID

ITV

FLOWMETE R

Flow closed-loop control (3/3)

Setpoint: 0,45 2,5l/min

+ -

REGULATOR (CONTROLLER) PLC/PID

ACTUATOR
PROPORTIONAL SOLENOID VALVE

SENSOR FLOWMETER

Setpoint: 0,45 2,5l/min

+ -

PLC/PID

PROPORCIONAL SOLENOID VALVE

FLOWMETER

Level closed-loop control (1/3)

Setpoint: 0 200mm
+ -

REGULATOR (CONTROLLER) PLC/PID

ACTUATOR ITV

SENSOR
DIF. PRESSURE

Setpoint: 0 200mm
+ -

PLC/PID

ITV

DIFFERENTIAL PRESSURE SENSOR

Level closed loop control (2/3)

Setpoint: 0 200mm
+ -

REGULATOR (CONTROLLER) PLC/PID

ACTUATOR
PROPORTIONAL SOLENOID VALVE

SENSOR
DIF. PRESSURE

Setpoint: 0 200mm
+ -

PLC/PID

PROPORTIONAL SOLENOID VALVE

DIFFERENTIAL PRESSURE SENSOR

Level closed loop control (3/3)

Setpoint: 0 200mm
+ -

REGULATOR (CONTROLLER) PLC/PID

ACTUATOR
PUMP

SENSOR
DIF PRESSURE.

Setpoint: 0 200mm
+ -

PLC/PID

PUMP

DIFFERENCTIAL PRESSURE SENSOR

Pressure closed-loop control

Setpoint: 0 1,7 bar

+ -

REGULATOR (CONTROLLER) PLC/PID(ITV)

ACTUATOR
ITV

SENSOR
ITV

Consigna: 0 1,7 bar

ACTUATOR

PID

SENSOR.