Unit 4 Control System

Instrumentation and Control

Prof. Praveen P. Rathod

[email protected]
Department of Mechanical Engineering

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
 Objective`

1. To understand the interdisciplinary applications of Electronics,

Electrical, Mechanical and Computer Systems for the Control of
Mechanical and Electronic Systems.

Learning Outcome/Course Outcome

• Analyze the time and Frequency domain analysis of system model for
control application and PID control system.

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 CONTROL SYSTEM

A system which carry out following functions

1. for particular input the system output can be controlled to a desired
particular value.
2. If some conditions satisfied it can give a particular sequence of events as
output corresponding to given input
Example: 1. House hold central heating system
2. House hold washing machine

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CONTROL SYSTEM continued
Control : Achieving certain desired results
System : group of devices which achieve certain functions
• So we can say group of components which while working together can
achieve a desired results
Examples: 1. speed control system of turbine
2. temp control system
3. washing machine
In 1& 2 output always measured and compared
In 3 process in independent of output

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 Open Loop Control System

A system in which output is dependent on input

but controlling action is totally independent of the
changes in output, is an Open Loop Control
System.
Here, no feedback is used, so the controller must
independently determine what signal to send to
the actuator.

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 Light/Fan Control System

Position Control System

Water Level Control System

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 Closed Loop Control System

A system in which the controlling action is dependent

on the output or changes in output is called a closed
Loop control system.
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 Closed loop control system contd…
• The output of the process is constantly monitored by a sensor.
• The output does have an effect on the input signal, modifying it to
maintain an output signal at the desired value (setpoint).
• The manipulated variable is such that error will approach to zero.
• Feedback is said to be negative, when the signal fed back subtracts from
the input value.

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 The objective is to regulate the level of
liquid in the tank, h, to the value H.

A human can regulate the level using a sight

tube, S, to compare the level, h, to the
objective, H, and adjust a valve to change the
level.

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 An automatic level-control system replaces the
human with a controller and uses a sensor to
measure the level

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 The electric fire closed-loop system

To obtain the required temperature, a person stands in the room

with a thermometer and switches the 1 kW and 2 kW elements on
or off, according to the difference between the actual room
temperature and the required temperature in order to maintain
the temperature of the room at the required temperature.
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 Control of the speed of rotation of a motor shaft

The input of the required speed value is by means of the setting of the position of
the movable contact of the potentiometer. This determines what voltage is
supplied to the comparison element, i.e. the differential amplifier, as indicative of
the required speed of rotation.
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• Consider the liquid level system, as shown.

Control
Valve

• The block diagram of the system can be developed as shown

below:
Forward path Take-off
Setpoint Control point
Controller Tank
Summing Valve
Controlled
Point variable

Float
position
Feedback path
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 Block Diagram Representation

• Block Diagram is a pictorial representation of the given system.

• It explains the cause and effect relationship existing between input and
output of the system through the blocks, arranged in a proper sequence.
• Each block explains the mathematical operation on the input by the
element to produce the corresponding output.
• This mathematical function called as the transfer function of the
element, is inserted in the respective block.

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 Block Diagram Representation contd…

• For closed loop control systems, the function of comparing different

signals is indicated by the summing point.
• A point from which signal is taken for feedback is indicated by the take-
off point in block diagrams.
• An arrow is associated with each and every branch, indicating the
direction of signal transmission.

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 Block Diagram Simplification

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 Block Diagram Reduction Rules

To reduce any complicated system into a simple form and derive the overall
transfer function of the system, it is necessary to reduce the block diagram
such that the output of the system and the value of any feedback signal does
not get disturbed. Following are the mathematical rules for the block diagram
reduction.
Rule 1: Associative Law:
R1-R2 R1-R2+R3
R1

R2 R3
Associative Law holds good for summing points which are directly connected
to each other.

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 Rule 2: Blocks in Series:

R1 (R1+R3)G1-R2
G1

R3 R2
• The transfer functions of the blocks which are connected in series get
multiplied with each other.

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 Rule 3: Blocks in Parallel:

G1

G2
R(s) C(s)
G3

• The transfer functions of the blocks which are connected in parallel get
added algebraically (considering the sign).

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 Rule 4: Shifting a summing point behind the
block:

• While shifting a summing point behind the block, add a block having TF as
reciprocal of the TF of the block before which summing point is to be shifted, in
series with all the signals at that summing point.

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 Rule 5: Shifting a summing point beyond
the block:

While shifting a summing point beyond / after the block, add a block having TF as
same as that of the TF of the block after which summing point is to be shifted, in
series with all the signals at that summing point.

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 Rule 6: Shifting a take-off point behind the block:

R C=RG R C=RG
G G

G
Y=RG
Y=RG
• While shifting a take off point behind the block, add a block having TF
same as that of the block behind which take-off point is to be shifted, in
series with all the signals which are taking off from that point.

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 Rule 7: Shifting a take-off point beyond
the block:
R C=RG
G

R C=RG
G 1/G

Y=R
Y=R
• While shifting a take off point beyond the block, add a block in series with
all the signals which are taking off from that point, having TF as reciprocal
of the TF of the block beyond which the take off point is to be shifted.

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 Rule 8: Removing minor feedback loop

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Block Diagram Simplification

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 Block Diagram Simplification

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 Components of Block
Diagram

• Subsystem is represented as a
block with an input, an output,
and a transfer function

• When multiple subsystems are

interconnected, a few more
schematic elements must be
added to the block diagram

• These new elements are

summing junctions and pickoff
points.

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 Cascaded System

• Each signal is derived from the product of the input times the transfer
function (output Laplace transform divided by the input Laplace
transform)

which is the product of the subsystems’ transfer functions.

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 Parallel Form

• Parallel subsystems have a common input and an output

formed by the algebraic sum of the outputs from all of the
subsystems
• which is the algebraic sum of the subsystems transfer functions;

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 Moving Blocks to Create Familiar Forms

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 Moving Blocks to Create Familiar Forms

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 Example 1

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 Example

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 Example

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 Example 2

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 Example 3

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 Example 3

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 Example 3

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 Example 4

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 Example 5

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 Example 6

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 Why is Controller Necessary?
 Blue response resembles an un-controlled system. This response is
oscillatory as well as it takes much longer to settle down.
 Inertia effect, friction, backlash etc
 The red response is of a controlled system. This response contains no
oscillations and it settles to equilibrium / steady state in lesser time.
 Job of a control system is to “generate a control input / effort that can
be used to drive the un-controlled system, albeit externally, to achieve
the desired performance”.

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 What does Controller do?

-imaginary

X Undesirable Open Loop Pole Location

X
u X Desired Closed Loop Pole Location

-real X +real

Control is all about shifting of system

u poles from un-desirable to desirable
X location.

This shifting is done by the control

signal, u, provided the system allows it
+imaginary i.e. it is “controllable”

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Analysis of Response: Transient Specifications

Unit Step Response of Second Order System

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 Transient Response Specifications
 Percentage Overshoot (% O.S): It is the amount that the
response overshoots the steady state, or final, value at the peak
time, expressed as a percentage of the steady-state value.

 Rise Time (Tr): Time required for the step response to rise from
10% to 90% of its final value.

 Delay Time (Td): Time required for the step response to reach
50% of final value

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 Transient Response Specifications
 Settling Time (Ts): Time required for the step response to
decrease and stay within a specified percentage of its final
value
 Within ±2% / ±5% / ±10% of final value

 Steady State Error (ess): It is the difference between the output

and the reference input after the steady state has reached

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 Feedback Controller

Block Diagram of Feedback Controller

 Feedback controller generates an control signal / effort / external

disturbance based on the input signal it receives.
 The input signal is error; difference between measured value and
desired value, or set point.
 Feedback counters disturbance as well as variation in process

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 Proportional Integral Derivative Control

+ e u
Input ∑ PID Plant Output

Block Diagram of PID Controller

 PID stands for Proportional Integral Derivative Control.

 Being robust & easy to implement, it is one of the most widely used

closed loop control for precise operation of industrial applications and

processes.
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 Proportional Control

ut   uP t   K Pe  Offset

 In Proportional Control, the control signal, u, is directly

proportional to the error, e.

 As the gain is increased the system responds faster to changes in

set-point but becomes progressively under damped and eventually

unstable.
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 Proportional Control
 The proportional controller produces an output, which is
proportional to error signal.
u(t)∝e(t)
⇒u(t)=Kpe(t)

Apply Laplace transformation on both side

U(s)=KPE(s)
U(s)/E(s)=KP
Therefore, the transfer function of the proportional controller
is KP

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Where,
U(s) is the Laplace transform of the actuating signal u(t)
E(s) is the Laplace transform of the error signal e(t)
KP is the proportionality constant
The block diagram of the unity negative feedback closed loop
control system along with the proportional controller is shown in
the following figure.

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 Proportional Control
Advantages:
 Simple and easy to design and tune

 Rapid Response / Reduces Rise Time

 Reduces Steady State Error

Disadvantages:
 Not possible to eliminate Steady State Error / Offset

 Could lead to instability / rise in overshoot/ oscillations

Applications:
 Float Valve, Thermostat etc

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 Derivative Control
ut   u D t   K D de  dt

 Derivative control produces a control signal proportional to the
rate at which the error is changing.
 Also known as rate controller.
 While sudden/rapid change in error leads to a control signal of
larger magnitude, gradual change leads to small magnitude.
 Even if the error is huge, the derivative control will generate no
signal if the error is constant
 Thus, not used alone; used with P control

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 Derivative Control Action
The derivative controller produces an output, which is derivative of
the error signal.
u(t)=KD de(t)/dt

Apply Laplace transform on both sides.

U(s)=KDsE(s)

U(s)/E(s)=KDs

Therefore, the transfer function of the derivative controller

is KDs
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 Derivative Control Action
Where, KD is the derivative constant.
The block diagram of the unity negative feedback closed loop
control system along with the derivative controller is shown in
the following figure.

The derivative controller is used to make the unstable control

system into a stable one.
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 Derivative Control
Advantages:
 Reduces Settling time; Adds lead

 Reduces Overshoot; Adds more stability

Disadvantages:
 Not possible to eliminate Steady State Error / Offset

 Not possible to use alone

 Excessive use may make the system slow

 Amplifies Noise

Applications:
 In conjunction with P Control

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 Integral Control

u t   u I t   K I  edt

 Rate of change of integral control signal is proportional to

error.
 Control signal proportional to integral of error.

 When the error is zero, the control signal is a constant value.

 When the error is constant, the control signal varies at constant

rate.
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 Integral Control
The integral controller produces an output, which is integral of the
error signal.

u(t)=KI ∫e(t)dt

Apply Laplace transform on both the sides –

U(s)=KIE(s)/s
U(s)/E(s)=KI/s

Therefore, the transfer function of the integral controller is KI/s.

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 Integral controler

 The block diagram of the unity negative feedback closed loop control system along

with the integral controller is shown in the following figure.

The integral controller is used to decrease the steady state error.

Let us now discuss about the combination of basic controllers.

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 Integral Control
Advantages:
 Eliminates steady state error/offset
 Decreases Rise Time
Disadvantages:
 Causes Integral Wind Up
 Leads to minor increase in overshoot
 Could make the system less stable
 Increases Settling time
Applications:
 In conjunction with P Control

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 Parallel Form: PI Control

H s   K P 
KI
s
Where,
K P  Proportion al Gain, K I  Integral Gain

u t   u P t   u I t   K P e  K I  edt

 Proportional Integral (PI) Control helps minimise rise time,

settling time as well as eliminate steady state error.

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 PI Control

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 PI Control

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 Parallel Form: PD Control

H s   K P  K D s
Where,
K P  Proportion al Gain, K D  Derivative Gain


u t   u P t   u D t   K P e  K D de
dt

 Proportional Derivative (PD) Control helps reduce rise time,

settling time as well as minimize overshoot.

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 Parallel Form: PD Control

 Proportional Derivative (PD) Control helps reduce rise time, settling time as well as

minimize overshoot.
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Parallel Form: PD Control

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 PID Controller

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 Applications of PID Control
90% processes are controlled using PID.

1. Regulation of Processes in Industry

1. Flow

2. Temperature

3. Pressure etc

2. Servo / DC motor Control

3. Linear Position Control

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 PID: Stepwise Procedure for Manual Tuning
1. Obtain an open-loop response and determine what needs to be
improved
2. Add a proportional control to improve the rise time
3. Add a derivative control to improve the overshoot
4. Add an integral control to eliminate the steady-state error
5. Adjust each of P, I & D until you obtain a desired overall
response referring to the table shown previously to find out
which controller controls what characteristics.
6. It is not necessary to implement all three controllers (P, I & D)
into a single system. For example, if a PI controller gives a good
enough response, then you don't need to add D control to the
system. Simple is better.

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 PID: Series / Interacting Form
D I

+ +
e + + u
P

 Derivate Action interacts with Integral Action

 Modification in derivative time constant affects integral action

 Commercially used controller

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 Transfer Function of Series Form
Transer Function of PID in series : P  PD 1  I 
where,
P  Proportion al Controller , I  Integral Controller
D  Derivative Controller

TF  P  PD  PI  PID

The term PID  0 since Ti  4Td

where,

Ti  Integral Time Constant, Td  Derivative Time Constant

 TF  P  PI  PD
 Transfer Function of Series Form

Control Signal for PID in series :

u t   u P t   u P t u I t   u P t u D t 

 K P e  K P K I  edt  K P K D de  dt

Where,
e  Error  Difference between reference & measured signal
 PID: Parallel / Non-Interacting Form
ud
Kds

Ki ui
s
+
ysp + e +
y
 Kp up
+
 u
plant
-

 Ideal Form

 Derivative Action does not Interact with Integral Action

Proportional Derivative Control
Response of P, I & D w.r.t Error
Effect of P, I & D on Transient Specifications

Action Rise Overshoot Settling SS

Time Time Error

KP Decrease Increase Small Decrease

Change

KI Decrease Increase Initially Eliminate

Decrease then
Increase

KD Small Decrease Decrease Small

Change Change
PID: Stepwise Procedure for Manual Tuning
NOTE

It is not necessary to implement all three controllers (P, I & D)

into a single system.

For example, if a PI controller gives a good enough response,

then you don't need to add D control to the system. Simple is
better!
P, I & D Control Action