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Lec 35 Misc Topics in Ind Control Systems 26 03 2025

The document discusses various components and functionalities of industrial control systems, focusing on Human Machine Interfaces (HMIs) and PID control for continuous processes. It outlines the structure of control systems, the role of motion control in applications like pick and place machines, and the tuning methods for controllers. Additionally, it describes the components involved in motion control systems, including programmable logic controllers, motion modules, servo drives, and motors.

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8 views15 pages

Lec 35 Misc Topics in Ind Control Systems 26 03 2025

The document discusses various components and functionalities of industrial control systems, focusing on Human Machine Interfaces (HMIs) and PID control for continuous processes. It outlines the structure of control systems, the role of motion control in applications like pick and place machines, and the tuning methods for controllers. Additionally, it describes the components involved in motion control systems, including programmable logic controllers, motion modules, servo drives, and motors.

Uploaded by

tharunsanjaymts
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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You are on page 1/ 15

ICPC25 – Logic And Distributed Control Systems

Jan 2025 Session – VI Sem. B.Tech (ICE)

Lecture-35: Miscellaneous topics in Industrial Control


Systems

26-March-2025
Dr. Sri Ram Shankar R.
Assistant Professor, Dept. of ICE,
Chamber No. 204-A, First Floor, Dept. Main Building
NIT-Tiruchirappalli.
E-mail: srir@nitt.edu, +91-431-250 3366
Structure of Control Systems
• Sensors
• Actuators
• Signal Conditioning
• Controller
• Human Machine Interface

Allows human inputs through various types of programmed switches, controls,


and keypads to set up the starting conditions or alter the control of a process

Human machine interface (HMI) equipment provides a control and visualization


interface between a human and a process.
HMIs allow operators to control, monitor, diagnose, and manage the application.
Human Machine Interface
Depending on the requirements and complexity of the process, the operator may be
required to:
• Stop and start the process.
• Operate the controls and make the adjustments required for the process and monitor
its progress.
• Detect abnormal situations and undertake corrective action.

Graphic HMI terminals offer electronic interfacing in a wide variety of sizes and
configurations. They replace traditional wired panels with a touch screen with graphical
representations of switches and indicators. Types of graphical display screens include
the following:
Operational Summary —used to monitor the process.
Configuration/ Setup —textual in nature used to detail process parameters.
Alarm Summary —provides a list of time-stamped active alarms.
Event History —presents a time-stamped list of all significant events in the process.
Human Machine Interface …
Trend Values —displays information on process variables, such as flow,
temperature, and production rate, over a period of time.
Manual Control —generally available only to maintenance personnel and
meant to bypass parts of the automatic control system.
Diagnostics —used by maintenance personnel to diagnose equipment failure

Graphic terminals come fully packaged with hardware, software, and


communications.

In general, the tasks required to develop an HMI application include:


• Establish a communication link with the PLCs
• Create the tag addresses database
• Edit and create graphical objects on the screens
• Animate the objects
PID Control for Continuous processes
• During setup, the set-point, proportional
band, reset (integral), rate (derivative), and
output limits are specified.
• All these can be changed during operation to
tune the process.
• The integral term improves accuracy, and
the derivative reduces overshoot for transient
upsets.
• The output can be used to control valve
positions, temperature, flow metering
equipment, and so on.
• PID control allows the output power level to
be varied.
• The process variable (pressure) is measured and feedback is generated.
• The PLC program compares the feedback to the setpoint and generates an error
signal.
• The error is examined by the PID loop calculation in three ways: with proportional,
integral, and derivative methodology.
• The controller then issues an output to correct for any measured error by
adjustment of the position of the variable flow outlet valve.
Controller Tuning
Depending on the characteristics of the deviation of the process variable from the
set-point, the tuning parameters interact to alter the controller’s output and
produce changes in the value of the process variable.
In general, three methods of controller tuning are used:

Manual
• The operator estimates the tuning parameters required to give the desired
controller response.
• The proportional, integral, and derivative terms must be adjusted, or tuned,
individually to a particular system using a trial-and-error method.
Semiautomatic or Autotune
• The controller takes care of calculating and setting PID parameters.
- Measures sensor output
- Calculates error, sum of error, rate of change of error
- Calculates desired power with PID equations
- Updates control output
Controller Tuning …
Fully Automatic or Intelligent
• This method is also known in the industry as fuzzy logic control.
• The controller uses artificial intelligence to readjust PID tuning parameters
continually as necessary.
• Rather than calculating an output with a formula, the fuzzy logic controller
evaluates rules.

The first step is to “fuzzify” the error and change-in-error from continuous variables
into linguistic variables, like “negative large” or “positive small.” Simple if/then rules
are evaluated to develop an output. The resulting output must be de-fuzzified into a
continuous variable such as valve position.

The PID programmable controller output instruction uses closed-loop control to


automatically control physical properties such as temperature, pressure, liquid level,
or flow rate of process loops.
Motion Control
• A motion control system provides precise positioning, velocity, and torque
control for a wide range of motion applications.
• PLCs are ideally suited for both linear and rotary motion control applications.
Pick and Place machines are used in the consumer products industry for a
wide variety of product transfer applications.

The machine takes a product from one point


to another.
One example is the transfer of a product to a
moving conveyor belt

Motion Control – Pick And Place task


Motion Control module
A basic PLC motion control system consists of a
controller, a motion module, a servo drive, one or
more motors with encoders, and the machinery
being controlled.
Each motor controlled in the system is referred to
as an axis of motion.

This application requires two axes of motion: the


motor operating the bottle filler mechanism
and the motor controlling the conveyor speed.
Role of components in a motion control application
Programmable Logic Controller
• The controller stores and executes the user program that controls the process.
• This program includes motion instructions that control axis movements.
• When the controller encounters a motion instruction it calculates the motion
commands for the axis.
• A motion command represents the desired position, velocity, or torque of the servo
motor at the particular time the calculations take place.

Motion Module
• The motion module receives motion commands from the controller and transforms
them into a compatible form the servo drive can understand.
• In addition it updates the controller with motor and drive information used to
monitor drive and motor performance.
Servo Drive
• The servo drive receives the signal provided by the motion module and translates this
signal into motor drive commands.
• These commands can include motor position, velocity, and/or torque.
• The servo drive provides power to the servo motors in response to the motion
commands.
• Motor power is supplied and controlled by the servo drive.
• The servo drive monitors the motor’s position and velocity by use of an encoder
mounted on the motor shaft. This feedback information is used within the servo drive
to ensure accurate motor motion.
Servo Motor
• The servo motors represent the axis being controlled.
• The servo motors receive electrical power from their servo drive which determines
the motor shaft velocity and position.
• The filler motor must accelerate the filler mechanism in the direction the bottles are
moving, match their speed, and track the bottles.
• After the bottles have been filled, the filler motor has to stop and reverse direction to
return the filler mechanism to the starting position to begin the process again.
Robotic system
A robot is simply a series of mechanical links driven by servo motors. The basic
industrial robot widely used today is an arm or manipulator that moves to perform
industrial operations.
Each axis of the robot arm is fundamentally
a closed-loop servo control system. The wrist is
the name usually given to the last three joints on
the robot’s arm.

Going out along the arm, these wrist joints are


known as the pitch joint, yaw joint, and roll joint.
Six axis Robot arm
Two types of controller setups that can be used
to control an industrial robot—PLC- and PC-based systems.
Thank you ! ☺
Ref:
Ch. 14 – PLCs by Petruzella

08/04/2025 Lecture-37: Communication in Industrial Control systems 15

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