Chapter 1

Introduction to Industrial Control Systems

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Introduction
The Industrial Revolution represented the change from manufacturing processes based upon one-at-a-time production to mass production because of the advent of the steam engine. Eventually, the electric motor and hydraulic systems replaced steam and Industrial Controls were developed to automate the manufacturing process.
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Industrial Control Classifications

Motion and Process Control
Motion control: position or velocity Process control: temperature, pressure, flow, level, pH, humidity, or chemical composition
Batch processing Continuous processing
Industrial Control Systems automatically monitor manufacturing processes being executed and take appropriate corrective action if the operation is not performing properly.
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Motion Control
Automatic control system that controls the physical motion or position of an object. Motion control is also referred as servos or servo mechanisms. Example: robot arm performing welding, CNC machine tool equipment Three characteristics: 1- control position, speed, acceleration 2- measurement of motion or position 3- instant response to commands (faster than process control

One or more variables are regulated during the manufacturing of a product. This can include temperature, pressure, flow rate, liquid or solid levels. Response time of PC is typically slow varies from seconds to minutes and is the type of industrial control used in manufacturing Two Categories: batch and continuous 1- Batch Processing aka sequential process is a sequence of timed operations. Ex. Machine producing cookies. See P5 in book 2 Continuous Process aka instrumentation: one or more operations are being performed as the product is being passed through a process. The raw materials enters and leaves several stations in each process step. It can hours, days or weeks. Ex. Nuclear pwr distribution, waste water treatment, oil refining, natural gas distribution
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Process Control

Typical Industries
Process industries
Petroleum Chemical Power Pulp and paper Food and beverage Textile Pharmaceutical Waste Treatment Water Treatment

Discrete parts
Automotive Electrical/electronic manufacturing Instrument/parts manufacturing Toys Sporting Goods Appliances

Tools

Open- and Closed-Loop Systems

How systems are controlled can also define the control process Open-loop systems depend upon a (manual) command signal to inform the output device what to do. Has no comparator. Closed-loop systems are self-correcting and allow for continuous operation without interruption.

Open- and Closed-Loop Level Control

Open-loop level control requires manual operation to maintain proper level with no automatic feedback. It is the simplest way to control a system. Has to reach a steady state or balance condition.

Closed-loop level control allows for unattended continuous level 8 control with feedback

Closed-loop level control allows for unattended level control. Feeback control systems were developed between WWI and WWII.
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Elements of Open- and Closed-Loop Systems

PP 8 9 in book Controlled Variable Measurement Device Feedback Signal Set Point Error Detector Error Signal Controller Actuator Manufacturing Process Disturbance

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More feedback control references

An error can develop in 3 ways in feedback control 1. The set point is changed 2. A disturbance appears 3. The load demand varies See p. 12 for good example There is Positive and Negative feedback. Ex. A home thermostat uses negative feedback to keep its temperature correct, a uses positive feedback to get/find the stronger signal
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Process Lag Time

Describes the time it takes for a corrective action to be reflected in the process. It takes time to re-establish a balanced condition. This is referred to a pure lag and is proportional to the amount of its mass. Factors influencing lag time are: Inertia - mass Capacity physical quantity Resistance type of material Dead-time ex. liquid temperature in a pipe
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Feed-Forward Control
takes corrective action after an error develops

Two factors can make feedback control ineffective:

Large magnitude disturbances Large process lag times

Feed-forward control prevents errors from occurring; however, feed-forward control is seldom used alone, typically in conjunction with feedback systems.
Not perfect due to other disturbances and used only for critical apps.
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Examples of Feed-Forward Controls

Feed-forward control of level

Feed-forward control loop

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