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INDUSTRIAL CONTROL SYSTEMS ENSC 484

Enterprise Manufacturing Supervision (SCADA) Group control Individual control Field Primary Technology

Pyramid of Industrial Automation (Dr. H. Kirmann)

5 4 3 2

Planning, Statistics, Finances Production planning, orders, purchase Workflow, order tracking, resources Supervisory
SCADA = Supervisory Control And Data Acquisition

administration enterprise (manufacturing) execution

Group control Unit control 1 Field Sensors & actuators 0 Primary technology A V T

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Administration

Finances, human resources, documentation, long-term planning Set production goals, plans enterprise and resources, coordinate different sites, manage orders Manages execution, resources, workflow, quality supervision, production scheduling, maintenance.

Enterprise

Manufacturing

Supervision

Supervise the production and site, optimize, execute operations visualize plants, store process data, log operations, history (open loop) Controls a well-defined part of the plant (closed loop, except for intervention of an operator) Coordinate individual subgroups Adjust set-points and parameters Command several units as a whole

Group (Area)

Unit (Cell)

Control (regulation, monitoring and protection) part of a group (closed loop except for maintenance) Measure: Sampling, scaling, processing, calibration. Control: regulation, set-points and parameters Command: sequencing, protection and interlocking data acquisition (Sensors & Actuators), data transmission (no processing except measurement correction and built-in protection).

Field

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Sectors Represented Include:

Chemical Processing Petroleum Refining Food and Beverage Power Pharmaceuticals Process Automation Suppliers IT Suppliers Government Labs Consultants Car manufacturing IC manufacturing Defense Etc.

Levels 4 and 5

Business Planning & Logistics

Plant Production Scheduling, Operational Management, etc

Level 3

Manufacturing Operations & Control

Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

Levels 0, 1, and 2

Batch Control

Continuous control

Discrete Control

SCADA
Level 2

Supervisory Control And Data Acquisition

SCADA

SCADA is Supervisory Control And Data Acquisition. S Real-time industrial process control systems used to centrally monitor and control remote or local industrial equipment such as motors, valves, pumps, relays, sensors, etc. SCADA is Combination of telemetry and Data Acquisition. SCADA is not just a hardware, neither a software. Its a concept, its a system as a combination of special hardware, software and protocols. SCADA is used to control chemical plant processes, oil and gas pipelines, electrical generation and transmission equipment, manufacturing facilities, water purification and distribution infrastructure, etc.

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CONTROL

CONTINUOUS

DISCRETE

Linear

Non-linear

Sequential

Conditional

PID

TEMPORAL

EVENT-BASED COUNTERS

TIMERS MRAC FUZZY

PLC

EXPERT SYSTEMS

BOOLEAN

Discrete Control Systems

Process parameters and variables are changed at discrete intervals The changes are defined in advance by the program of instructions The changes are executed for either of two reasons:
1. The state of the system has changed (event-driven changes) 2. A certain amount of time has elapsed (time driven changes)

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 Parameters and variables = 0 or 1 (OFF or ON)

2. Sequential control controls the execution of time-driven changes

Uses internal timing devices to determine when to initiate changes in output variables

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EventEvent-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 level of plastic in the hopper of an injection molding machine triggers a low-level switch, which opens a valve to start the flow of more plastic into the hopper Counting parts moving along a conveyor past an optical sensor

A control system reduces the flexibility and variation of another system (being controlled system) and forces the controlled system manner. to behave in a predefined manner

Sensor

Process being controlled

Actuator

Controller

Sensors
Sound includes ultrasound, hearing range and sub-sonic Motion Strain Biological agents Vibration Chemical agents Temperature Gases Light Fluids Moisture Solids/metals Pressure . Radio Magnetic Often using Image Analog-To-Digital Converters (ADCs) Video

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Actuators
Turn on/off valves Turn on/off switches Motor control Lights Buzzers/Speakers Alarms Chemical triggers Etc

Often using Digital-to-Analog Converters (DACs)

Nowadays control systems are mostly microprocessor based. (Microcontrollers, PLCs, PC-Based Control systems).

Display

A/D converter Sample-andSample-and-hold

Controller

D/A converter

sensors

Process

actuators

DESIGN OF CONTINUOUS TIME CONTROLLERS

Parameter optimized controllers

Structure optimized controllers

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Zero order

First order

Second order

High order

Tuning rules

Performance criterion

Pole assignment

PI, PD, PID

General linear

Performance Criterion

Pole Assignment

Prescribed behaviour

Finite settling time

Performance Criterion

Pole Assignment

Linear Controller

Minimum Variance controller

Cancellation controller

Deadbeat controller

State controller

Modal state controller

Process V GPV Feedback Controller w GR e

Uv GPU

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Process Uin

GPV GR

Feed-forward controller

n GPU y

Cascade control Process V2 GPV2 Uin w1 e1 GR1 e2 GR2 U n2 GPU2 y2 GPU1 n1 y1 V1 GPV1

Plant Characteristics
Non-self regulating capacitance (i.e. integral or pure capacitance) Self-regulating capacitance Non-interacting capacitance Interacting multi-capacitance Time delay (dead-time) Non-minimum phase Unstable

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NonNon-self regulating capacitance

Fi

H ( s) 1 = Fi ( s) As

SelfSelf-regulating capacitance

H ( s) R = Fi ( s) ARs + 1

NonNon-interacting multi-capacitance multiqin

H 2 (s ) R2 = Qin ( s) ( A1 R1 s + 1)( A2 R2 s + 1)

h1
A1

R1

q1

h2

A2 R2

qout

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Interacting multi-capacitance multiqin h2

A1 A2 R1 R2

h1

qout

H 2 (s ) R2 = Qin ( s) ( A1 R1 s + 1)( A2 R2 s + 1) + A1 R2 s

Time delay (Dead-time) (DeadTime delay is an important problem in process control and many systems exhibit significant time delay.

u(t)

Delay

y(t)

Time delay (Dead-time) (Deadu(t)

Delay

y(t)

y (t ) = u (t )
Taking Laplace Transform with zero initial conditions:

Y ( s) = e s U ( s)

Y ( j ) = e j = 1 U ( j )

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Time delay (Dead-time) (DeadIf a system contains some delay, then the transfer function can be shown as:

Delay

System

e so

K s + 1

G (s ) =

Y ( s) K = e s U ( s) s +1

Time delay (Dead-time) (DeadHistorically, there has been some incentive to find a rational approximation to e-s . The presence of time delay implies that the process transfer function cannot be represented by simple poles and zeros. Polynomial approximation to e-s 1. Truncated Taylor Series

e s = 1 s +

s 2 2 s3 3 + ... 2! 3!

Time delay (Dead-time) (Dead2. All pass filter and truncated Taylor Series
s 2

e s =

s 1 + 2 =

e2

s 2 s3 2 2 L 2! 3! 2 3 s 2 s3 s 2 2 1+ + + L 2 2! 3!

A simple rational approximation which is valid for small time delay (1/): s
1e s 1+ 2

s
2

Note that this all pass power series expansion cannot be used Beyond the fourth order as poles with real positive parts will then occur.

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Time delay (Dead-time) (Dead3. Pad approximation This is the best known approximation; it is an all pass filter and is represented as:
e sT T ( s ) T (s ) = 1 a 1s + a 2 s2 2 + LL + a n ( s ) m + L 1 + a 1s + a 2 s + LL + a m ( s ) m + L
2 2 m m

where:

ai =

(2m i )!m! (2m)!i! (m i )!

m: Pad order (approximation) i: the coefficient of the polynomial

Time delay (Dead-time) (DeadExample: A second-order Pade approximation is: e s

1 s + s2 2 12 1 + s + s2 2 12

Time delay (Dead-time) (Dead4. Multiple lag approximation:

e s 1 s 1 + N
N

This approximation is valid for large N.

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NonNon-minimum phase systems

If the open loop transfer function of a system has zeros at the right hand side of the s-plane or outside unit disc in z-plane sz-plane; the system is said to be non-minimum phase. Note : 1. Approximations 2 and 3 are non-minimum phase. 2. Some minimum phase systems in s-domain become 3. Non-minimum phase when converted to z-plane.

Unstable systems
If the open loop transfer function of a system has poles at the right hand side of the s-plane or outside unit disc in z-plane; the system is said to be unstable. Example:
Ke s (1 + 2s )(1 s )

G (s ) =

Homework
Read section 2.2 of Process Identification and PID control Use MATLAB to simulate the step response for open-loop and closed-loop response of a firstorder system with time delay and comment on the results Approximate the time delay with Pade approximation and compare the results

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