CONTROL TECHNOLOGIES

IN AUTOMATION

Industrial Control System

Industrial Control is defined as the automatic regulation of
unit operations and their associated equipment, as well as the
integration and coordination of the unit operations in larger
production system.
 CONTROL TECHNOLOGIES
IN AUTOMATION

Process Industries and Discrete Manufacturing Industries

 Process industries perform their production operations on

amounts of materials, because the materials tend to be liquids,

gases, powders, and similar materials.
 Discrete manufacturing industries perform their operations

on quantities of materials, because the materials tend to be

discrete parts and products.
 CONTROL TECHNOLOGIES
IN AUTOMATION

Process Industries Discrete Manufacturing

Industries
Chemical Reactions Casting
Comminution Forging
Chemical vapor Extrution
deposition
Distillation Machining
Mixing and Blending of Plastic molding
Ingredients
Separation of ingredients Sheet metal stamping
CONTROL TECHNOLOGIES
IN AUTOMATION
CONTROL TECHNOLOGIES
IN AUTOMATION
 CONTROL TECHNOLOGIES
IN AUTOMATION

Device Level:
• At the device level, there are differences in the types
of actuators and sensors used in the two industry
categories, simply because the processes and
equipment are different.
• In process industries the devices are mostly used for
the control loops in chemical, thermal, or similar
processing operations.
• Whereas in discrete manufacturing, the devices
control the mechanical actions of the machines.
 CONTROL TECHNOLOGIES
IN AUTOMATION

• At level 2, the difference is that unit operations are

controlled in the process industries, and machines are
controlled in discrete manufacturing operations.
• At level 3, the difference is between control of
interconnected unit processing operations and
interconnected machines.
• At the upper levels (plant and enterprise), the
control issues are similar, allowing for the fact that the
products and processes are different.
 CONTROL TECHNOLOGIES
IN AUTOMATION
Variables and Parameters in the Two Industries
Continuous Variable:
• A continuous variable (or parameter) is one that is uninterrupted as
time proceeds, at least during the manufacturing operation.
• A continuous variable is generally considered to be analog, which
means it can take on any value within a certain range. The variable is
not restricted to a discrete set of values.
• Production operations in both the process industries and discrete
parts manufacturing are characterized by continuous variables.
• Examples include force, temperature, flow rate, pressure, and
velocity. All of these variables (whichever ones apply to a given
production process) are continuous over time during the process, and
they can take on any of an infinite number of possible values within a
certain practical range.
 CONTROL TECHNOLOGIES
IN AUTOMATION
Discrete Variable:
• A discrete variable (or parameter) is one that can take on only
certain values within a given range.
• The most common type of discrete variable is binary, meaning it can
take on either of two possible values, ON or OFF, open or closed, and
so on.
• Examples of discrete binary variables and parameters in
manufacturing include limit switch open or closed, motor on or off,
and work part present or not present in a fixture.
CONTROL TECHNOLOGIES
IN AUTOMATION
CONTROL TECHNOLOGIES
IN AUTOMATION
 CONTROL TECHNOLOGIES
IN AUTOMATION
Continuous Control Systems
• In continuous control, the usual objective is to maintain the value of
an output variable at a desired level, similar to the operation of a
feedback control system.
• However, most continuous processes in the practical world consist of
many separate feedback loops, all of which have to be controlled and
coordinated to maintain the output variable at the desired value.
• There are several ways to achieve the control objective in a
continuous process-control system.
 Regulatory Control
 Adaptive Control
 Feedforward Control
 On-Line Search Strategies
 Steady-State Optimization
 Other Specialized Techniques
 CONTROL TECHNOLOGIES
IN AUTOMATION
 Regulatory Control
• In regulatory control, the objective is to maintain process
performance at a certain level or within a given tolerance band of that
level.
• This is appropriate, for example, when the performance attribute is
some measure of product quality, and it is important to keep the
quality at the specified level or within a specified range.
 CONTROL TECHNOLOGIES
IN AUTOMATION
 Feed forward Control
• The strategy in feed forward control is to anticipate the effect of
disturbances that will upset the process by sensing them and
compensating for them before they affect the process.
 CONTROL TECHNOLOGIES
IN AUTOMATION
Steady-State Optimization
• Optimization techniques in which the process exhibits the following
characteristics:
(1)there is a well- defined index of performance, such as product cost,
production rate, or process yield;
(2) The relationship between the process variables and the index of
performance is known; and
(3) The values of the system parameters that optimize the index of
performance can be determined mathematically.
(4) When these characteristics apply, the control algorithm is designed to
make adjustments in the process parameters to drive the process toward
the optimal state.
 CONTROL TECHNOLOGIES
IN AUTOMATION
Adaptive Control
• Adaptive control combines feedback control and optimal control by
measuring the relevant process variables during operation (as in feedback
control) and using a control algorithm that attempts to optimize some index
of performance (as in optimal control).
 CONTROL TECHNOLOGIES
IN AUTOMATION
On-Line Search Strategies
• On-line search strategies can be used to address a special class of
adaptive control problem in which the decision function cannot be
sufficiently defined; that is, the relationship between the input
parameters and the index of performance is not known, or not known well
enough to use adaptive control as previously described.
• Therefore, it is not possible to decide on the changes in the internal
parameters of the system to produce the desired performance
improvement.
• Instead, experiments must be performed on the process.
• Small systematic changes are made in the input parameters of the
process to observe the effect of these changes on the output variables.
• Based on the results of these experiments, larger changes are made in
the input parameters to drive the process toward improved performance.

Other Specialized Techniques

• Other specialized techniques include strategies that are currently
evolving in control theory and computer science.
• Examples include learning systems, expert systems, neural networks,
CONTROL TECHNOLOGIES
IN AUTOMATION
CONTROL TECHNOLOGIES
IN AUTOMATION
CONTROL TECHNOLOGIES
IN AUTOMATION