TOPIC 1 :

INTRODUCTION TO
INDUSTRIAL CONTROL
SYSTEM

INTRODUCTION
The industrial revolution began in England during the
mid-1700s when it was discovered steam-powered
engines.
Further inventions and new ideas in plan-layout in
1850s by United States. Electric motor replaced
steam and water wheels as a power source.

TERM OF INDUSTRIAL CONTROL SYSTEM

The term industrial controls is used to define this
type of system, which automatically monitors
manufacturing processes being executed and takes
appropriate corrective action if the operation is not
performing properly.

CLASSIFICATIONS OF INDUSTRIAL CONTROL

Industrial control systems are often classified

by what they control :

either motion or process.

MOTION CONTROL
is an automatic control system that controls the
physical motion or position of an object.
- One example is the industrial robot arm which
performs welding operations and assembly
procedures

MOTION CONTROL
Motion control is a sub-field of automation, in
which the position or velocity of machines are
controlled using some type of device such as a
hydraulic pump, linear actuator, or electric motor,
generally a servo

Hydraulic pump

Linear actuator

CHARATERISTICS OF MOTION
CONTROL
(i) motion control devices control the position,
speed, acceleration or deceleration of a mechanical
object.
(ii) the motion or position of the object being
controlled is measured.
(iii) motion devices typically respond to input
commands within fractions of a second rather
than seconds or minutes as in process control.

CHARATERISTICS OF MOTION
CONTROL
motion control systems are also referred to

as servos
or
servomechanisms

MOTION CONTROL APPLICATIONS

-

CNC machine tool equipment

printing presses
office copiers
packaging equipment
electronics parts insertion machines that
place components onto a printed circuit
board

MOTION CONTROL APPLICATIONS

CNC Machine

Automation Robotics

Printing machine

PROCESS CONTROL
- one or more variables are regulated during
the manufacturing of a product.
- these variables may include temperature,
pressure, flow rate, liquid and solid level, pH
or humidity.

PROCESS CONTROL

PROCESS CONTROL

Can be divided into 2

categories :
i.batch
ii.continuous

BATCH PROCESS
Definition:
is a sequence of timed operations
executed on the product being
manufactured.

BATCH PROCESS
also known as

sequence
or
sequential process

BATCH PROCESS

CONTINUOS PROCESS
Definition:
one or more operations are being
performed as the product is being passed
through a process
raw materials are continuously entering
and leaving each process step.

CONTINUOS PROCESS
Example: producing paper

CONTINUOUS PROCESS APPLICATIONS

Oil refining

Gas Pipe Lines

Waste water treatment

CONTINUOUS PROCESS
another terms commonly used of process
control is

instrumentation

PRIMARY DIFFERENCE BETWEEN

PROCESS & MOTION CONTROL
In process control
The emphasis is place on sustaining a constant
condition of a parameter such as level, pressure
or flow rate of a liquid
In servo control
The input command is constantly changing. The
emphasis of the system is to follow the changes
in the desired input signal as closely as possible.
Variations of the input signal typically very rapid

ANOTHER TERMINOLOGY
Servomechanism
sometimes shortened to servo, is an automatic
device that uses error-sensing negative feedback
to correct the performance of a mechanism

DEC 2012/JUNE 2013 QUESTION 1 (A)

Briefly explain TWO (2) categories of process
control
(4 marks)

ANSWER
Batch proces
Sequence of time operation on the product
being manufactured
Continuous process
One or more operations are being performed as
the product is being passed through a process

DEC 2012 QUESTION 2 (A)

Briefly explain about the following
terminologies
-controlled variable
-disturbance
(4 marks)

JUNE 2013 QUESTION 2 (A)

Describe the functions of the following
terminology used in closed loop network
-error detector
-disturbance
(4 marks)

OPEN - LOOP SYSTEM

Definition
A type of control system that uses only an input
signal to actuate an output
There is no automatic feedback to adjust the
process, so adjustments must be made manually
by operator

OPEN - LOOP SYSTEMS

OPEN - LOOP SYSTEM

OPEN - LOOP SYSTEM

OPEN - LOOP SYSTEM

Advantages

Simplicity and stability: they are simpler in

their layout and hence are economical and
stable too due to their simplicity.

Construction: Since these are having a simple

layout so are easier to construct.

OPEN - LOOP SYSTEM

Disadvantages
Accuracy and Reliability: since these systems
do not have a feedback mechanism, so they are
very inaccurate in terms of result output and
hence they are unreliable too.
Due to the absence of a feedback mechanism,
they are unable to remove the disturbances
occurring from external sources.

CLOSED-LOOP SYSTEM
Definition
A type of control system that automatically
changes the output based on the difference
between the feedback signal to the input signal

CLOSED-LOOP SYSTEM
In closed loop control, the system is self
adjusting. Ex: Solar water heating

CLOSED-LOOP SYSTEM
Data does not flow one way, it may pass back
from a specific amplifier (such as velocity or
position) to the start of the control system,
telling it to adjust itself accordingly.

CLOSED-LOOP SYSTEM

CLOSED-LOOP SYSTEM

A closed-loop system that uses a linkage

mechanism as a feedback device to provide selfcorrecting capabilities

CLOSED-LOOP SYSTEM
Advantages
Accuracy: They are more accurate than open loop
system due to their complex construction. They
are equally accurate and are not disturbed in the
presence of non-linearities.
Noise reduction ability: Since they are composed
of a feedback mechanism, so they clear out the
errors between input and output signals, and
hence remain unaffected to the external noise
sources.

CLOSED-LOOP SYSTEM
Disadvantages:
Construction: They are relatively more complex
in construction and hence it adds up to the cost
making it costlier than open loop system.
Since it consists of feedback loop, it may create
oscillatory response of the system and it also
reduces the overall gain of the system.

ELEMENTS OF CLOSED LOOP SYSTEMS

Closed-loop block diagram that shows elements, input/output

signals, and signal direction

TERMINOLOGIES USED IN CLOSED-LOOP SYSTEMS

Controlled Variable :
The controlled variable is the actual variable being monitored
and maintained at a desired value in the manufacturing
process.
Examples in a process control system may include
temperature, pressure, and flow rate.
Another term used is process variable

Measured Variable :
To monitor the status of the controlled variable, it
must be measured.
One method of determining a controlled variable such
as the level of water,

Measurement Device :
The measurement device is the eye of the system.
It senses the measured variable and produces an
output signal that represents the status of the
controlled variable. Examples in a process control
system may include a thermocouple to measure
temperature or a humidity detector to measure
moisture.
Other terms used are detector, transducer, and sensor.

Feedback Signal:
The feedback signal is the output of the measurement
device.
Other terms used are measured value, measurement
signal, or position feedback if in a position loop, or
velocity feedback if in a velocity loop.

Set Point :
The set point is the prescribed input value applied to
the loop that indicates the desired condition of the
controlled variable.
The set point may be manually set by a human
operator, automatically set by an electronic device, or
programmed into a computer.
Other terms used are command, or reference.

Error Detector :
The error detector compares the set point to the
feedback signal.
It then produces an output signal that is proportional
to the difference between them.
Other terms used are comparator or comparer and
summing junction

Error Signal :
The error signal is the output of the error detector. If
the set point and the feedback signal are not equal, an
error signal proportional to their difference develops.
When the feedback and set point signals are equal,
the error signal goes to zero.
Other terms used are difference signal and deviation

Controller :
The controller is the brain of the system.
It receives the error signal (for closed-loop control) as
its input, and develops an output signal that causes
the controlled variable to become the value specified
by the set point.
Most controllers are operated electronically, although
some of the older process control systems use air
pressure in pneumatic devices.

Actuator :
The actuator is the muscle of the system.
It is a device that physically alters some type of
energy or fuel supply, causing the controlled
variable to match the desired set point.
Examples of energy or fuel are the flow of steam,
water, air, gas, or electrical current.
Other terms used are the final control element,
or final correcting device. Common types of
actuators are hydraulic cylinders, pumps, and
motors.

Manipulated Variable :
The amount of fuel or energy that is physically
altered by the actuator is referred to as the
manipulated variable.

The amount at which the manipulated variable is

changed by the actuator affects the condition of the
controlled variable.

Manufacturing Process :
The manufacturing process is the operation
performed by the actuator to control a physical
variable, such as the motion of a machine or the
processing of a liquid.

Disturbance :
A disturbance is a factor that upsets the
manufacturing process being performed, causing a
change in the controlled variable.

DEC 2012 QUESTION 2 (A)

Briefly explain about the following
terminologies:
i. Controlled variable
Ii. Disturbance