Ch 5 Industrial Control Systems

Sections:
1. Process Industries vs. Discrete Manufacturing
Industries
2. Continuous vs. Discrete Control
3. Computer Process Control
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Industrial Control - Defined

The automatic regulation of unit operations and their
associated equipment as well as the integration and
coordination of the unit operations into the larger
production system
Unit operation
Usually
to a manufacturing
operation
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Process Industries vs.

Discrete Manufacturing Industries
Process industries
Production operations are performed on amounts of
materials
Materials: liquids, gases, powders, etc.
Discrete manufacturing industries
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Definitions: Variable and Parameters

Variables - outputs of the process
Parameters - inputs to the process
Continuous variables and parameters - they are
uninterrupted as time proceeds
Also considered to be analog - can take on any value
a certain
range
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Discrete Variables and Parameters

Categories:
Binary - they can take on either of two possible values, ON
or OFF, 1 or 0, etc.
Discrete other than binary - they can take on more than
two possible values but less than an infinite number of
possible
values
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Continuous and Discrete

Variables and Parameters

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Types of Control
Just as there are two basic types of variables and
parameters in processes, there are also two
corresponding types of control:
Continuous control - variables and parameters are
continuous and analog
Discrete
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Continuous Control
Usual objective is to maintain the value of an output
variable at a desired level
Parameters and variables are usually continuous
Similar to operation of a feedback control system
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Types of Continuous Process Control

Regulatory control
Feedforward control
Steady-State optimization
Adaptive control
On-line search strategies
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Regulatory Control
Objective - maintain process performance at a certain
level or within a given tolerance band of that level
Appropriate when performance relates to a quality
measure
Performance measure is sometimes computed based
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Regulatory Control

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Feedforward Control
Objective - anticipate the effect of disturbances that
will upset the process by sensing and compensating
for them before they affect the process
Mathematical model captures the effect of the
disturbance on the process
Complete
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Feedforward Control
Combined with Feedback Control

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Steady-State Optimization
Class of optimization techniques in which the process
exhibits the following characteristics:
1. Well-defined index of performance (IP)
2. Known relationship between process variables
and IP
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Steady State (Open-Loop)

Optimal Control

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Adaptive Control
Because steady-state optimization is open-loop, it cannot
compensate for disturbances
Adaptive control is a self-correcting form of optimal control
that includes feedback control
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Adaptive Control Operates in a

Time-Varying Environment
The environment changes over time and the changes
have a potential effect on system performance
Example: Supersonic aircraft operates differently in
subsonic flight than in supersonic flight
If the control algorithm is fixed, the system may perform
quite
differently
in oneInc.,
environment
than
in another
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Three Functions in Adaptive Control

1. Identification function current value of IP is
determined based on measurements of process
variables
2. Decision function decide what changes should be
made to improve system performance
Change
one or more
input Saddle
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Adaptive Control System

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On-Line Search Strategies

Special class of adaptive control in which the decision
function cannot be sufficiently defined
Relationship between input parameters and IP is
not known, or not known well enough to
implement the previous form of adaptive control
Instead,
areUpper
performed
the process
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Discrete Control Systems

Process parameters and variables are discrete
Process parameters and variables are changed at
discrete moments in time
The changes are defined in advance by the program
of instructions
The
changes
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Event-Driven Changes
Executed by the controller in response to some event
that has altered the state of the system
Examples:
A robot loads a workpart into a fixture, and the part
is sensed by a limit switch in the fixture
The diminishing
of plastic
in the
hopper
of an
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Time-Driven Events
Executed by the controller either at a specific point in
time or after a certain time lapse
Examples:
The factory shop clock sounds a bell at specific
times to indicate start of shift, break start and stop
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Two Types of Discrete Control

1. Combinational logic control controls the execution
of event-driven changes
Also known as logic control
Output at any moment depends on the values of
the inputs
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Computer Process Control

Origins in the 1950s in the process industries
Mainframe computers slow, expensive, unreliable
Set point control
Direct digital control (DDC) system installed 1962
Minicomputer introduced in late 1960s, microcomputer
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Two Basic Requirements for

Real-Time Process Control
1. Process-initiated interrupts
Controller must respond to incoming signals from
the process (event-driven changes)
Depending on relative priority, controller may have
to interrupt current program to respond
2. Timer-initiated
actions
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Other Computer Control

Requirements
3. Computer commands to process
To drive process actuators
4. System- and program-initiated events
System initiated events - communications between
computer and peripherals
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Capabilities of Computer Control

Polling (data sampling)

Interlocks
Interrupt system
Exception handling

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Polling (Data Sampling)

Periodic sampling of data to indicate status of process
Issues:
1. Polling frequency reciprocal of time interval
between data samples
2. Polling order sequence in which data collection
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Interlocks
Safeguard mechanisms for coordinating the activities of
two or more devices and preventing one device from
interfering with the other(s)
1. Input interlocks signal from an external device sent
to the controller; possible functions:
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Interrupt System
Computer control feature that permits the execution of
the current program to be suspended in order to
execute another program in response to an incoming
signal indicating a higher priority event
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Interrupt Systems:
(a) Single-Level and (b) Multilevel

(a)

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Exception Handling
An exception is an event that is outside the normal or
desired operation of the process control system
Examples of exceptions:
Product quality problem
Process variable outside normal operating range
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Forms of Computer Process Control

1. Computer process monitoring
2. Direct digital control (DDC)
3. Numerical control and robotics
4. Programmable logic control
5. Supervisory control
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Computer Process Monitoring

Computer observes process and associated equipment,
collects and records data from the operation
The computer does not directly control the process
Types of data collected:
Process data input parameters and output
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(a) Process Monitoring, (b) Open-Loop

Control, and (c) Closed-Loop Control
(a)

(b)

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Direct Digital Control (DDC)

Form of computer process control in which certain
components in a conventional analog control system
are replaced by the digital computer
Circa: 1960s using mainframes
Applications: process industries
Accomplished
on a time-shared,
sampled-data
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A Typical Analog Control Loop

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Manufacturing, Third Edition, by Mikell P. Groover.

Components of a
Direct Digital Control System

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DDC (continued)
Originally seen as a more efficient means of performing
the same functions as analog control
Additional opportunities became apparent in DDC:
More control options than traditional analog control
(PID control), e.g., combining discrete and continuous
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Editing of
control programs
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Numerical Control and Robotics

Computer numerical control (CNC) computer
directs a machine tool through a sequence of
processing steps defined by a program of instructions
Distinctive feature of NC control of the position
of a tool relative to the object being processed
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Manufacturing, Third Edition, by Mikell P. Groover.

Programmable Logic Controller (PLC)

Microprocessor-based controller that executes a program of
instructions to implement logic, sequencing, counting, and
arithmetic functions to control industrial machines and
processes
Introduced around 1970 to replace electromechanical
relay
controllers
in discrete
product
manufacturing
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and
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currently
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portion of this material may be reproduced, in any form or by
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Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.

Supervisory Control
In the process industries, supervisory control denotes a
control system that manages the activities of a
number of integrated unit operations to achieve
certain economic objectives
In discrete manufacturing, supervisory control is the
control
system
that directs
and Saddle
coordinates
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NJ. All rights
activities
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interacting
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of equipment
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a manufacturing
system
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Functions:
efficient
scheduling
of production,
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Most closely
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Automation, Production Systems, and Computer-Integrated
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Supervisory Control Superimposed on

Process Level Control System

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Distributed Control Systems (DCS)

Multiple microcomputers connected together to share and
distribute the process control workload
Features:
Multiple process control stations to control individual
loops and devices
Central
room
where
supervisory
control
is rights
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Pearsoncontrol
Education,
Inc.,
Upper
Saddle River,
NJ. All
accomplished
reserved.
This material is protected under all copyright laws as
theycurrently
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Local operator
No portion
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Communications
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Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.

Distributed Control System

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights
reserved. This material is protected under all copyright laws as
they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.

DCS Advantages
Can be installed in a very basic configuration, then
expanded and enhanced as needed in the future
Multiple computers facilitate parallel multitasking
Redundancy due to multiple computers
Control cabling is reduced compared to central controller
configuration
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Networking
provides
process under
information
throughout
theyenterprise
currently exist.
for more efficient plant and process
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management
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Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.

PCs in Process Control

Two categories of personal computer applications in
process control:
1. Operator interface PC is interfaced to one or more
PLCs or other devices that directly control the
process
PC performs
certain
monitoring
supervisory
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2. currently
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Enablers of PCs for Direct Control

Widespread familiarity of workers with PCs
Availability of high performance PCs
Cycle speeds of PCs now exceed those of PLCs
Open architecture philosophy in control system design
Hardware and software vendors comply with
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Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.

Enterprise-Wide
Integration of Factory Data
Managers have direct access to factory operations
Planners have most current data on production times
and rates for scheduling purposes
Sales personnel can provide realistic delivery dates to
customers, based on current shop loading
Order
trackers
can provide
current
status
information
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Production personnel can access product design data
the exclusive use of adopters of the book
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Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.

Enterprise-Wide PC-based
Distributed Control System

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights
reserved. This material is protected under all copyright laws as
they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
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Manufacturing, Third Edition, by Mikell P. Groover.