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APPLICATION OF COMPUTER IN PROCESS CONTROL

Click to edit shall cover the digital This topic Master subtitle style

and analogue input terminologies, the digital and analogue output, data conversion devices (ADC and DAC), telemetry, multiplex and de-multiplex.

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introduction

The use of digital computers to control industrial processes had its origins in the continuous process industries in late 1950s. that time, the computer technology was in its infancy, and only computers available for process control were large, expensive mainframes. computer that were installed sometimes cost more than the process they controlled. 1960s the digital computer started to replacing the analog controllers in continuous process control application.

At

The

Around

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Example

of process control in a paint factory in which two colors, blue and yellow, are mixed to produce green. keep the output color constant, the exact proportional of blue and yellow must be maintained. setup accomplishes this with flow valves 1 & 2, which are manually adjusted until the desired hue (warna) of green is achieved. problem is that, as the level of paint in the vats (bekas) change, the flow will change and the mixture will not remain constant.

To

The

The

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To

maintain an even flow from the vats, we could add two electrically operated flow valves (and their control). Each valve would maintain a specified flow of paint into mixer, regardless of the upstream pressure. if the blue and yellow are independently maintained, the green should stay constant. practice, however, other factors such as temperature, or humidity may affect the mixing chemistry and therefore the output color.

Theoretically,

In

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better approach might be the system shown in figure (c); a single sensor monitors the output color. If the green darkens, the controller increases the flow of yellow. If the green gets too light, the flow of yellow is increased. system is desirable because it monitors the actual parameter that needs to be maintained. real life, such a straightforward system may not be possible because sensors that can be measure the output directly may not exits and/or the process may involve many

This

In

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In

a large plant such as a refinery, many processes are occurring simultaneously and must be coordinated because the output of one process is the input of another. early days of process control, separate independent controllers were used for each process, as shown in figure (a). problem with this approach was that, to change the overall flow of the product, each controller had to be readjusted manually.

In

The

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DDC
In

the 1960s, a new system was developed in which all independent controllers were replaced by single large computer. Illustrated in figure (b), this system is called DIRECT DIGITAL CONTROL (DDC). advantage of this approach is that all local processes can be implement, monitored, and adjusted from the same place. because the computer can see the whole system, it is in position to make adjustments to enhance total system performance. drawback is that the whole plant is

The

Also,

The

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DCS
The

advent of small microprocessor-based controller has led to a new approach called a DISTRIBUTED CONTROL SYSTEM (DCS). Illustrated in figure (c). this system, each process has its own separate controller located at the site. These local controllers are interconnected via a local area network so that all controllers on the network can be monitored or reprogrammed from a single supervisory computer. programmed, each process is essentially operating independently.

In

Once

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 This

makes for a more robust and safe system, because all the local processes will continue to function even if the supervisory computer or network goes down. example, a local controller whose job it is to keep some material at the critical temperature will continue to function even if the supervisory computer is temporarily disabled. the components of a control system are being interconnected with the business office network in a factory, which allows the status of any process in the factory to be examined by any computer on anyones desk. might be sit down at a PC anywhere in the building and determined whether a particular

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For

Increasingly,

You

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SEQUENTIALLY CONTROLLED SYSTEM

Defined

as a series of tasks to be performed that is, a sequence of operations, one after the other. operation in the sequence is performed either for a certain amount of time, in which case it is a time-driven operation, or until the task finished, in which case it is an eventdriven operation. automatic washing machine (timedriven operation), traffic signal (event-driven operation).

Each

Example:

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Many

automated industrial processes could be classified as sequentially controlled systems. example is a process where parts are loaded into trays, inserted into furnace for 10 minutes, then removed and cooled for 10 minutes, and loaded into boxes in groups of six. the past, most sequentially controlled systems used limit switches, relays and electromechanical timers to implement the control logic. tasks are now performed more and more by small computer known as

An

In

These

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Programmable logic controllers

A

PLCs is a self-contained microprocessorbased unit, designed specifically to be a controller. PLC includes an I/O section that can interface directly to such system components as switches, relays, small motors, and lights. in the late 1960s to replace relay logic controllers, PLCs were originally used in applications where the input and outputs were all on/off type signals, but over the years they have evolved to be able to handle sophisticated motion control applications as well.

The

Developed

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Figure

below shown a selection of PLCs.

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MICROPROCESSOR
The

digital integrated circuit (IC) called a microprocessor [figure (a)], has ushered in a whole new era for control system electronics. revolution has occurred because the microprocessor brings the flexibility of program control and the computational power of computer to bear on any problem. control applications are particularly well suited to take advantage of this technology, and microprocessor-based controllers system are rapidly replacing many older control systems based on analog circuit or electromechanical relays.

This

Automatic

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Microprocessor

by itself is not a computer; additional components such as memory and input/output circuit are required to make it operational. microcontroller [figure (b)], which is a close relative of the microprocessor, does contain all the computer functions on a single IC. lack some of the power and speed of the newer microprocessor, but their compactness is ideal for many control applications; most so-called microprocessorcontroller devices, such as vending machines,

However,

Microcontrollers

Some specific reason for using a digital microprocessor design in control system:
Low-level

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signals from sensors, once converted to digital, can be transmitted long distances virtually error-free. memory is available to keep track of parameters in slow-moving system. the control strategy is easy by loading in a new program; no hardware changes are required. controlled are more easily connected to the computer network within an organization. This allows designers to enter the program changes and read current system status from their desk

Long-term

Changing

Microprocessor-based

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Microprocessor system hardware

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Central

processing unit (CPU)

Does the actual computing and is composed of two subparts: the arithmetic logic unit (ALU) and control sections. performs the actual numerical and logic calculations such as addition, subtraction, AND, OR and so on. control section manages the data flow, such as reading and executing the program instructions. data require calculations, the control section hands it over to the ALU for processing.

ALU:

The

If

Memory

INTERFACING TO A MICROPROCESSOR CONTROLLER

In

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important part of any control system is the link between the controller and the real world. a digital controller, data enter and exit through:

For

a parallel interface or serial interface.

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Parallel interface
Transfers

data 8 bits (or more) at the same time, using eight separate wires. parallel interface is ideal for inputting or outputting data from devices that are either on or off. other applications, the controller may use a parallel interface to connect to an analog device for example, driving a variable-speed dc motor. such a case, the binary output of the controller must first be converted into an analog voltage before it can drive the motor.

The

In

In

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DIGITAL-TO-ANALOG DAC

CONVERSION (DAC)

is a circuit that converts a digital word into an analog voltage.

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ANALOG-TO-DIGITAL ADC A

CONVERSION (ADC)

is a circuit that converts an analog voltage into a digital word. typical ADC consists of a single IC with few support components. is more complicated process than DAC.

ADC

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A control system using parallel port

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Serial interface
The

data are sent 1 bit after the other on a single wire. are a number of good reason for doing this.

There

1st

the cabling is simpler because only two wires are needed (at minimum), those being data and return. shielding a small group of wires, which necessary in an electrically noisy industrial environment, is easier. , serial data can make use of existing single-channel data lines such as the

2nd

3rd

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Because

data always exits in a parallel form inside the computer, it must be converted to serial data before coming out the serial port. is accomplished with a special parallel-toserial converter IC called a universal asynchronous receiver transmitter (UART). the other end of the line, a receiver must convert the serial data back to parallel data, which is done by another UART. Next Figure shown the basic serial data circuit

This

On

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Rs 232
In

order to make the serial interface practical, a set of specifications called RS 232 standard was established. the RS 232 standard specifies the serial data interface between DATA TERMINAL EQUIPMENT (DTE) and DATA COMMUNICATION EQUIPMENT (DCE). common application of RS 232 is the interface between a PC and the modem, in which case the computer is the DTE and the modem is the DCE as shown in next figure.

Officially,

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networking
Probably

the most common use of serial data is in networking. and more, networking are being used to interconnect all the units and devices in the control system. cabling differs depending on the type of LOCAL AREA NETWORK (LAN), but many, such as Ethernet, use the generalized bus system diagrammed in figure in next slide.

More

Network

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Quiz
1.

Give TWO reason for using a digital microprocessor design in control system [4 marks] State TWO type of parallel interface. [2 marks] Give TWO type of microprocessor hardware [ 2 marks] What is the different between DDC and DCS? [2 marks]

2.

3.

4.

 W.Bolt

Referrences

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on. Contro l Engine ering, 2nd Edition . Prentic e hall. 1998 K, Christo pher. Moder n control

T.