COMPUTER CONTROL AND

INDUSTRIAL INFORMATICS
BAB 2A

Dr. Ir. Ari santoso, DEA santoso@kemdikbud.go.id

Hady Moh Abdul
 TUJUAN
• LIST THE CLASSIFICATIONS OF INDUSTRIAL CONTROL SYSTEMS
• DESCRIBE THE DIFFERENCES AMONG INDUSTRIAL CONTROL SYSTEMS AND PROVIDE EXAMPLES OF
EACH TYPE
• DEFINE COMMON TERMS ASSOCIATED WITH INDUSTRIAL CONTROL SYSTEMS
• DESCRIBE THE DIFFERENCES BETWEEN OPEN- AND CLOSED-LOOP SYSTEMS
• DEFINE COMMON TERMS ASSOCIATED WITH OPEN- AND CLOSED-LOOP SYSTEMS
• LIST THE FACTORS THAT AFFECT THE DYNAMIC RESPONSE OF A CLOSED-LOOP SYSTEM
• DESCRIBE THE OPERATION OF FEED-FORWARD CONTROL
• LIST THREE FACTORS THAT CAUSE THE CONTROLLED VARIABLE TO DIFFER FROM THE SETPOINT
 KLASIFIKASI

• MOTION CONTROL
• AUTOMATIC CONTROL SYSTEM THAT CONTROLS THE PHYSICAL MOTION OR POSITION OF AN OBJECT

• PROCESS CONTROL
• ONE OR MORE VARIABLES ARE REGULATED DURING THE MANUFACTURING OF A PRODUCT
• TWO CATEGORIES:
• BATCH PROCESSING
• CONTINUOUS PROCESS
 OPEN- AND CLOSED-LOOP SYSTEMS

• OPEN LOOP SYSTEM

• SIMPLE
• MUST BE MANUALLY BALANCED
• EXAMPLES

• CLOSED LOOP SYSTEM

• SELF-CORRECTING AND SELF-REGULATING
• USED BY MOST AUTOMATED PROCESSES
 OPEN- AND CLOSED-LOOP SYSTEMS
Open-Loop Control Systems utilize a controller or
control actuator to obtain the desired response.

Closed-Loop Control Systems utilizes feedback to

compare the actual output to the desired output
response.

Multivariable Control System

 ELEMENTS OF OPEN- AND CLOSED-LOOP SYSTEMS

• COMMON TERMS:
• CONTROLLED VARIABLE
• MEASURED VARIABLE
• MEASUREMENT DEVICE
• FEEDBACK SIGNAL
• SETPOINT
• ERROR DETECTOR
ELEMENTS OF OPEN- AND CLOSED-LOOP SYSTEMS

FIGURE 1-5 CLOSED-LOOP BLOCK DIAGRAM THAT SHOWS ELEMENTS, INPUT/OUTPUT SIGNALS,
AND SIGNAL DIRECTION
ELEMENTS OF OPEN- AND CLOSED-LOOP SYSTEMS

FIGURE 1-6 Open-loop block diagram that shows elements, input/output signals, and signal direction
 FEEDBACK CONTROL

• ERROR MUST EXIST BEFORE SOME CORRECTIVE ACTION CAN BE MADE

• CAUSES OF ERRORS:
• THE SETPOINT IS CHANGED
• A DISTURBANCE APPEARS
• THE LOAD DEMAND VARIES

• SIGNALS MAY BE POSITIVE OR NEGATIVE

 PRACTICAL FEEDBACK APPLICATION
• HEAT EXCHANGER

FIGURE 1-8 Closed-loop temperature control system

 DYNAMIC RESPONSE OF A CLOSED-LOOP SYSTEM

• DYNAMIC RESPONSE:
• MEASURE OF LOOP’S CORRECTIVE ACTION

• FACTORS:
• RESPONSE TIME
• TIME DURATION
• STATIC INERTIA OF CONTROLLED VARIABLE
• LEADS TO PURE LAG
• DEAD TIME
 FEED-FORWARD CONTROL

• PREVENT ERRORS FROM OCCURRING

• MINIMIZE NOT PREVENT
• ALSO USE FEEDBACK CONTROL
• TYPICALLY USED ONLY IN CRITICAL APPLICATIONS WITHIN THE PLANT
 FEED-FORWARD CONTROL

FIGURE 1-9 Feed-forward control of a temperature control system

 FEED-FORWARD CONTROL

FIGURE 1-10 Feed-forward control loop with a feedback control loop

 MATERI

• BASIC CONCEPT
• DATA COMMUNICATION IN INDUSTRIALS
• SYSTEM BASED ON PLC, SCADA AND DCS
• HUMAN MACHINE INTERFACE
• INFORMATION SYSTEM IN INDUSTRIAL
 BASIC CONCEPT
FİG. 4-1

©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.
 BASIC CONCEPT
Supervisory (host)
Computer

Operator Main Operator Archival

Control Control Control Data
Panel Computer Panel Storage

Data highway
To other Processes To other Processes

Local data acquisition and Local Local Local

control computers Computer Computer Computer
Local Display Local Display

PROCESS

©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.
 BASIC CONCEPT
ANALOGUE DIGITAL

Inputs
I
Sensors N
T
Computer +
E
processing
R
software
F
A
C
Outputs
E

©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.
 BASIC CONCEPT

Enterprise

Manufacturing Execution

Supervision (SCADA) Automation Hierarchy

Group Control

Individual Control

Field

Primary technology

©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.
 LARGE CONTROL SYSTEM HIERARCHY (1)
5 Planning, Statistics, Finances administration

4 Production planning, orders, purchase enterprise

3 Workflow, order tracking, resources (manufacturing) execution

SCADA =
2 Supervisory Supervisory Control
And Data Acquisition

Group control

Unit control
1
Field

Sensors A V T
& actors

0 Primary technology
 LARGE CONTROL SYSTEM HIERARCHY (2)
Administration Finances, human resources, documentation, long-term planning
Enterprise Set production goals, plans enterprise and resources, coordinate
different sites, manage orders
Manufacturing Manages execution, resources, workflow, quality supervision,
production scheduling, maintenance.
Supervision Supervise the production and site, optimize, execute operations
visualize plants, store process data, log operations, history (open loop)
Group (Area) 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
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
Field .
data acquisition (Sensors & Actors*), data transmission
no processing except measurement correction and built-in protection.
(*capteurs et moteurs, Messfühler & Stellglieder)
FIELD LEVEL

the field level is in direct

interaction with the plant's hardware
(Primary technology, Primärtechnik)
 GROUP LEVEL
unit controllers the group level coordinates the
activities of several unit controls

the group control is often hierarchical, can be

also be peer-to-peer (from group control to
group control = distributed control system)

Note: "Distributed Control Systems" (DCS)

commonly refers to a hardware and software
infrastructure to perform Process Automation
 SUPERVISORY LEVEL: SCADA
(SCADA = Supervisory Control and Data Acquisition)

- displays the current state of the process (visualization)

- display the alarms and events (alarm log, logbook)
- display the trends (historians) and analyse them
- display handbooks, data sheets, inventory, expert system (documentation)
- allows communication and data synchronization with other centres
 PLANT MANAGEMENT

- store the plant and product data for further processing in a

secure way (historian), allowing to track processes and
trace products
-> Plant Information Management System (PIMS)

- make predictions on the future behaviour of the processes

and in particular about the maintenance of the equipment,
track KPI (key performance indicators)
-> Asset Optimisation (AO)
 ANSI/ISA 95 STANDARD CLASSIFICATION
the ANS/ISA standard 95 defines terminology and good practices

Level 4
Business Planning & Logistics Enterprise Resource Planning
Plant Production Scheduling
Operational Management, etc.

Level 3 Manufacturing
Operations & Control Manufacturing Execution System
Dispatching Production, Detailed Product
Scheduling, Reliability Assurance,...

Levels
2,1,0
Batch Continuous Discrete Control & Command System
Control Control Control

Source: ANSI/ISA–95.00.01–2000
 RESPONSE TIME AND HIERARCHICAL LEVEL
Planning ERP
(Enterprise Resource
Level
Planning)

MES
Execution (Manufacturing
Level Execution System)

SCADA
(Supervisory Control
Supervisory and Data Acquisition)
Level
DCS
(Distributed
Control System)
Control
Level PLC
(Programmable
Logic Controller)

ms seconds hours days weeks month years

DATA QUANTITY & QUALITY AND HIERARCHICAL LEVEL
Higher Levels
• When ascending the control hierarchy, data are reduced:
higher level data are created (e.g. summary information)
• Processing and decisions becomes more complicated (requires using models).
• Timing requirements are slackened. Historical data are stored
SCADA level
• Presentation of complex data to the human operator,
help to make decisions (expert system) and maintenance.
• Requires a knowledge database in addition to the plant's database

Lower Levels
• Lowest levels (closest to the plant) are most demanding in response time.
• Quantity of raw data is very large.
• Processing is trivial (was formerly realized in hardware).
• These levels are today under computer control,
except in emergency situations, for maintenance or commissioning.
 COMPLEXITY AND HIERARCHICAL LEVEL
Complexity Reaction Speed
ERP months

Command level MES

Sys. d'exécution days
Führungsebene, Ausführungssystem
Supervision
Prozessleitung minutes
étage de conduite
Conduite de processus
Group Control
Gruppenleitung seconds
Conduite de groupe

Individual Control
0.1s
Einzelleitung, Conduite individuelle

Field 0.1s
Feld, terrain

Site
Anlage, usine
 OPERATION AND PROCESS DATA BASE
Consideration of human intervention breaches this hierarchy.
Normally, the operator is only concerned by the supervisory level,
but exceptionally, operators (and engineers) want to access data of the lowest levels.
The operator sees the plant through a fast data base, refreshed in background.
This database is key for logging and simulation.

knowledge base man-machine

communication

operator

history logging process simulation

data base

instructor

maintenance Update
engineer
process data

plant