Automation

I. Introduction

Structure of control system

Control software
actuating
drives
controller

actuating
units
actuator

transducers

Process
or plant

sensors

transmitter
Standard signals
operator desk

Variables

Visualization software
SCADA (Supervisory control and data acquisition)

Material flow

Mathematical software, like Matlab, are used preparation the model of the process.

Variables and signals

action signals
or

manipulated variables

control signals
actuator

controller

measured variables
a part of these

controlled variables

Process
or plant

transducer

operator desk

measured signals or
detecting signals
a part of these

feedback signals
disturbance variables

Dimensionless technique
manipulated
variable

controlled
variable

action
signal

feedback
signal

max

max

20 mA

20 mA
A/D conversion
control task
D/A conversion

Domain of
variability
4 mA

4 mA

min

min

w(t ){dim} wm in{dim}

w(t )
1{dim}

Most frequently used standard signals

On / Off signals: 0 24 VDC

Continuous signals: 4 20 mA

30 V
24 V

Logical 1, or high

20 mA

max
7V
Logical 0, or low

4 mA

0V

Further frequently used continuous signals:

0 20 mA, 0 10 V, 2 10 V, (0.4 2 Bar)
Further frequently used on /off signals:
0 110 / 230 VAC, (0 4 Bar)

Engineering jobs
instrumentation
measurement (temperature, level, pressure, flow, drive, and so on)
final element (control valves, drivers)

safety philosophy of the process

(Safety systems are usually independent from the normal control system)

control philosophy of the process

process control
manufacturing

maintenance

Divide into simpler part

Which variables of the process need control.
All controlled variable is an independent simpler part of the process. *
All simpler part of the process needs a control strategy.

The safety philosophy of the process.

Safety systems are usually independent from the normal control system
and the safety considerations are very dependent on the process.
More often a part of the safety considerations is to monitor of exceptional
conditions or to detect a malfunction of a device or to reach a dangerous
level of a variable.
The failsafe philosophy can also be applied to the actuator and the
transmitter. (power or wiring failure).

Points of view to choose control law

Which manipulated variable can control the controlled
variable.
Is the controlled variable performance on/off or continuous?
Which measured variables are required for developing a
control law (algorithm).
Can one describe the plant between the input manipulated and
disturbances variables and the output controlled variable
by a precise model.
Is this model linear or not, time invariant or not?
Economic efficiency points of view.

Control strategies
Open loop control
One can describe the plant between the manipulated and disturbance
variables and the controlled variables by a precise model and so using the
required measured variables one can develop a control algorithm.
Advantages: There isnt stability problem. This method is so punctual
such as the model, the control action doesnt require an error.
Disadvantages: Sometimes this solution isnt economical.

Closed loop control ( Feedback )

The reference signal represents the required value of the controlled
variable. The controlled variable and the reference signal continuously
compare and if the detecting and the reference signal are not equal, than
an adequate action signal attempt to eliminate the error.
Advantages: Sometimes this solution is economical.
Disadvantages: The key is to appear an error and needs a transient time to
eliminate this error. The controlled variable isn't always punctual. There
is stability problem.

Process requirements
valve

inflow

difference
of pressure

It means which variables depend on other

equipment of process or environment and which
variable can be controlled and which variable
can be manipulated.
pump

tank level

outflow

Controlled variable is the tank level

Manipulated variable is the inflow: In steady-state the inflow equals outflow.
Requirement of other equipment of process gives a control signal the pump changing the outflow.
Manipulated variable is the outflow: In steady-state the inflow equals outflow. Requirement of
other equipment of process gives a control signal the pump changing the outflow.

Controlled variable is the time of stay of inflow mass

Either inflow or outflow can be manipulated variable: In steady-state the time of stay is constant.
Requirements of other equipments cause disturbance the inflow or the outflow.

Classification of control strategies

inflow

valve

difference
of pressure

We assume: The controlled variable is the tank

level. In steady-state the inflow equals the outflow.
Requirement of consumers gives a control signal
for the pump, which changes the outflow. It is an
disturbance of the system. Further disturbance is
the difference pressure of control valve.
pump

tank level

outflow

Open-loop
open loop control: It needs to measure the outflow and the difference pressure know the relation
between the valve position and the actual value of the tank level at an average value of outflow.
feedforward control: It needs to know the relation between the valve position and the actual value of
tank level at different value of outflow, and needs to measure the outflow.

Closed-loop
on/off feedback control: It needs to measure the tank level. If it is higher than the reference value
the valve is closed and when the tank level is lower than the reference value the valve is opened.
modulating feedback control: It needs to measure the level of the tank. The difference between the
reference and feedback signals determine a continuously action signal for the actuating drive
of valve.

Problems of control strategies

valve

inflow

difference
of pressure

In steady-state the inflow equals the outflow. The

steady-state error means: The actual value of the
pump level and the required level (shown by reference
signal) isnt equal in steady-state.

outflow
tank level
open loop control: The error in the actual value of the tank level is caused by the difference of the
model of process and the real process.
feedforward control: It needs more measuring to know the relation between the valve position and
the actual value of tank level at different value of outflow, and of course it needs a flow transmitter
and an more expensive controller for complicated task.
on/off feedback control: It has a violent fluctuation of tank level caused by valve on/off. Any delay
in the plant response, which is common in more complex plant, means that the level will continue to
rise even after the upper limit is reached. With very sensitive switch and negligible delay the valve
very frequently fully open and closed.
modulating feedback control: There is the stability problem. Other problem at the stable control
loop is, the performance of the time response isnt adequate for requirements of the technology.

Block model (Classical method)

Modern method is the state-variables description
w(t)

y(t)

We assume the variables are within a range and

the output remain in this range in steady-state.
Y

y(t)
WP2
WP1

The dynamic behaviour is describe

by differential equation.
Using the Laplace transform method
the transfer function replace the
differential equation.
t

The steady-state characteristic. When

the transients signals have died a new
working point WP2 is defined in the
steady-state characteristic.
W
w(t)

Performance of a block
Frequency transfer function:

G ( j )

x(t )

y ( j )
x ( j )

y(t)
WP2

y (t )
WP1

x( j )

y( j )
x(t)

All block has frequency transfer function, but

not all time signal - x(t), y(t) - can be converted
t
to frequency form.
Using Laplace transform it is possible.
If the system investigation is started from WP1 in steady-state than the x(t) and y(t) signals
form are such as they are multiplied by 1(t) unit step.

Correlation between frequency and time

domain of linear systems
x(t )

y (t )

Fourier and inverse Fourier transform

F x(t ) x(t )e jt dt x( j )

y( j )

x( j )

x( j ) x( j )e jt d ( j ) x(t )
j

The above is true if:

x(t ) 1(t ) x(t )e t

x(t ) dt K

Laplace and inverse Laplace transform

x(s) x( j )

y (s)

Lx(t ) 1(t ) x(t )e( j )t dt x( j )

1
{ j }t
L1x( j )
x
(

)
e
d ( j ) 1(t ) x(t )

2j j

Laplace transform
Rules of Laplace transform

Laplace transform of standard signals

L{ f (t )} F ( s)

L{ (t )} 1

L{k f (t )} k F (s)
L{ f (t ) g (t )} F (s) G(s)

L{

df (t )
} sF ( s) f (t )t 0 sF ( s)
dt

L{1(t )}

1
s

L{t1(t )}

1
s2

1
L{ f (t )dt} F ( s)
s
0

If pole of sY(s) are in the left half of the s-plane

the final value theorem:

lim y(t ) lim sY (s)

t

s0

is available.

Using Laplace transform

Using the rules of Laplace transform to convert a differential equitation to operator
frequency form.

d 2 f (t )
df (t )
2
L{k2

k
f
(
t
)}

k
s
1
0
2 F ( s ) k1sF ( s ) k0 F ( s )
2
dt
dt
x(t)

y(t)

x(j)

y(j)

d 2 y (t )
dy(t )
dx(t )
k2
k1
k0 y (t ) c1
c0 x(t )
2
dt
dt
dt
y( s)
c1s c0
k2 s 2 y ( s ) k1sy ( s ) k0 y ( s ) c1sx ( s ) c0 x( s )

G ( s)
2
x( s ) k2 s k1s k0

Summary questions

Sketch the main structure of process control. What are the points of view to
choose control strategies?
Classify and characterise the control strategies.
Interpret the block diagram representation technique. What is the steady-state
and the dynamic performance of a block. What is the advantages of the
dimensionless technique?
Define the correlation between frequency and time domain. How we can use
the Laplaces transform method?
Sketch the detailed block diagram of a single loop, compensator in cascade,
closed loop system, and define the blocks, signals, and variables.
Highlight the role of the transmitter in a control system. What are the linearity,
sensitivity, repeatability, and accuracy of a transmitter?