AUTOMATION IN TEXTILE AND

GARMENT ENGINEERING

Chapter 1
AUTOMATIC CONTROL
SYSTEMS

Assoc.Prof. Võ Tường Quân

HCMUT - 2023
 Basic elements

- The basic elements of a control system

1. Set point (References)
2. Feedback
3. Controllers
4. Actuators
5. Processes (Control systems)
6. Sensors – Sensory systems

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 Basic elements – Set points
Set points / References

- What is/are the set points or references?

- How can we get the set points?
- The value set points?
- How can we measure the set points?

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 Basic elements – Feedback
Feedback

- What is feedback? Do we need feedback?

- How many types of feedback?

Negative feedback Positive feedback

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 Basic elements - Controllers
Controllers
- What is controllers:
+ Control algorithms  Software
+ Devices  Hardware

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 Basic elements - Actuators
Actuators?
- What is the role of actuators?
- How about the types of actuators?

Power sources:
DC: Direct current
AC: Alternating current

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 Basic elements - Actuators
DC motors: DC, DC servo, Step, RC servo, BLDC,…

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 Basic elements - Actuators
AC motors: AC 1 phase, AC 3 phases, AC servo

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 Basic elements - Actuators
Cylinders

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 Basic elements - Processes
Processes
The mechanical systems of the robots or systems

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 Basic elements - Sensors
Sensors
- A device that is used to record that something is present or that
there are changes in something.
- A sensor is a device that detects and responds to some type of input
from the physical environment. The input can be light, heat, motion,
moisture, pressure or any number of other environmental
phenomena. The output is generally a signal that is converted to a
human-readable display at the sensor location or transmitted
electronically over a network for reading or further processing.
- A sensor is a device that measures physical input from its
environment and converts it into data that can be interpreted by either
a human or a machine. Most sensors are electronic (the data is
converted into electronic data), but some are more simple, such as a
glass thermometer, which presents visual data. People use sensors to
measure temperature, gauge distance, detect smoke, regulate
pressure and a myriad of other uses.

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 Basic elements - Sensors
The basic steps to choose sensors
Step 1: What exactly is to be measured? Just saying height needs to
be measured is not good enough. Is it height in a particular place,
peak height or possibly an average height across the top of the part?

Step 2: What is the nature of the target? What is it made of? What is
the surface like? How big is it?

Step 3: What tolerances are you trying to hold?

Step 4: Given the tolerance and accuracy needed, is it still in

budget?

Step 5: Is the target moving or stationary?

Step 6: In what environment will the sensor perform?

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 Basic elements - Sensors
Sensors types: passive and active

A passive sensors do not need any additional energy source and

directly generates an electric signal in response to an external
stimulus.

The active sensors require external power for their operation, which is
called an excitation signal. That signal is modified by the sensor to
produce the output signal.

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 Basic elements - Sensors
Sensors classification: Analog and digital
• Analog Sensors measure the external parameters and give an
analog voltage as an output. They produce a continuous output signal
or voltage which is proportional to the quantity being measured.
The output voltage may be from the range of 0 to 5V. Low logic 0 (0V-
3.5V) and High logic (3.5V-5V).
• Digital Sensors act as electronic sensors where data is digitally
converted and transmitted. Digital sensors produce discrete values
(0s and 1s) or ‘binary’ signals.

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 Basic elements – Sensors characteristics
Range/span: The range (or span) of a sensor is the difference
between the minimum (or most negative) and maximum inputs that
will give a valid output.

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 Basic elements – Sensors characteristics
Resolution: The resolution of a sensor is the smallest increment of
input that can be reliably detected.

Resolution: Describes smallest increments of stimulus, which can be

sensed.

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 Basic elements – Sensors characteristics
Sensitivity
Sensor sensitivity is defined as the change in output per change in
input.
The sensitivity of digital sensors is closely related to the resolution.
The sensitivity of an analog sensor is the slope of the output versus
input line.

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 Basic elements – Sensors characteristics
Error of sensors: Sensor error is the difference between a measured
value and the true input value.

Calibration error: This is the inaccuracy permitted by a manufacturer

when a sensor is calibrated in the factory. This error is of a
systematic nature, meaning that it is added to all possible real
transfer functions. It shifts the accuracy of transduction for each
stimulus point by a constant.
This error is not necessarily uniform over the range and may change
depending on the type of error in calibration.

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 Basic elements – Sensors characteristics
• System Error Bias errors are present in all measurements made
with a given sensor, and cannot be detected or removed by
statistical means.
Cause by???

• Random Error Is unpredictable errors.

Cause by:
– Random noise.
– Environment effects …

Noises / Disturbances

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 Basic elements – Sensors characteristics
Repeatability: Repeatability (or reproducibility) refers to a sensor’s
ability to give identical outputs for the same input.

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 Basic elements – Sensors characteristics
Accuracy and Precision
Precision: Low standard deviation, good repeatability
Accuracy: Average measured value is close to true value.

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 Basic elements – Sensors characteristics
Linearity – Non linearity
Nonlinearity error is specified for sensors whose transfer function may
be approximated by a straight line.

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 Basic elements – Sensors characteristics
Hysteresis
A hysteresis error is a deviation of the sensor’s output at a specified
point of the input signal when it is approached from the opposite
directions.

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 Basic elements – Sensors characteristics
Output Impedance is the ratio of voltage and current flow for a
sensor.
Output impedance Zout is important to know to better interface a
sensor with the electronic circuit. The output impedance is
connected to the input impedance Zin of the circuit either in parallel
(voltage connection) or in series (current connection).

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 Basic elements – Sensors characteristics
Output format is a set of the output electrical characteristics that is
produced by the sensor alone or together with the excitation circuit.

The characteristics may include voltage, current, charge, frequency,

amplitude, phase, polarity, shape of a signal, time delay, and digital
codes.

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 Basic elements – Sensors characteristics
Saturation
Every sensor has its operating limits. Even if it is considered linear, at
some levels of the input stimuli, its output signal no longer will be
responsive.
Further increase in stimulus does not produce a desirable output. It is
said that the sensor exhibits a span-end nonlinearity or saturation

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 Basic elements – Sensors characteristics
Deadband The deadband is typically a region of input close to zero at
which the output remains zero.
Dead band is insensitivity of a sensor in a specific range of the input
signals. In that range, the output may remain near a certain value
(often zero) over an entire dead band zone.

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 Some popular sensors

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 Some popular sensors

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 New approachs
The concept of Smart Textile???

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