INTRODUCTION TO CONTROL SYSTEM

CHAPTER 1: INTRODUCTION TO CONTROL SYSTEM

Learning Outcomes: At the end of this chapter, student should be able to: i. define the general terms in control system ii. recognize the elements of control system iii. describe the differences of open loop and closed control system iv. list the advantages of control system v. describe some examples of control system

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INTRODUCTION TO CONTROL SYSTEM

1.1 Introduction History of control system began since 17th century. From time to time until now, control systems become an important and integral part of modern society. Control systems is an interdisciplinary subject and cut across all engineering and non-engineering fields such as electrical, mechanical, aeronautical, chemical, nuclear, economics, management, biological, biomedical and other related fields.

Control system play major roles in human live everyday. Air-conditioning system, washing machine, dryers, elevators, traffic lights, manufacturing plants, robotics system, navigation system, autopilot system, missile-guidance system, satellite system and many more examples are utilize control system application.

Generally, control system can be classified into three categories: nature control system created by Almighty God (example human body immunization) ii. automatic control system created by human (example auto pilot flight operation, satellite system, space shuttle, robotic system) iii. combination between nature and automatic control system (example car driven by human)

i.

In manufacturing industries, control system is used to achieve the increase of productivity and improved performance of production system. The control of manufacturing or production by automatic control system rather than manual workers called as automation. Modern manufacturing utilize automation in order to improve productivity and obtain high-quality products. Automatic control system and computer control has become important elements for better production process and quality. For example, automatic control is essential in the numerical control of machine tools. With programmable control system for robotics arm, repetitive production line operations can be increased and operate for many hours without fatigue.

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INTRODUCTION TO CONTROL SYSTEM

To implement control system for those applications above, many competence and skill persons needed such as control engineers, technology specialists and technicians. Control engineer responsible to plan and design an entire automatic or process control system. Good and deep knowledge about control system characteristics, system stability, computing software, and project management skills are necessarily. Technology specialists may responsible and expert for any specific elements or certain parts in control system where good knowledge in electrical and electronics components, measurement, pneumatic and hydraulic system is essential while technicians will carry out the installations, testing and trouble shooting which require high skills of using tools and equipments.

1.2 General Terms in Control System The term of control system can be defined in many ways. Control system can be defined as: a system that consist of subsystems and processes assembled for purposes of control the output of process or interconnection of components forming a system configuration that will provide a desired response

There are many additional terms that are necessary to understand in studying control system. The following are common terms that usually found in control system:

i.

Automatic control system: a control system that is self regulating or self control without human intervention

ii.

Process control system:

an automatic regulating system in which the

output is a variable such as temperature, pressure, flow, liquid level or pH is called process control system

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INTRODUCTION TO CONTROL SYSTEM

iii.

Feedback control system: a system that maintains a prescribed relationship between the output and input by comparing them and using the difference

iv.

Controlled variable: the quantity or condition that is measured and controlled. Normally controlled variable is the output of the system.

v.

Manipulated variable:

the quantity or condition that is varied by the

controller so as affect the value of the controlled variable.

vi.

Plants: a piece of equipment/set of a machine functioning together, which perform a particular operation.

vii.

Process: progressively continuously operation that consists of a series of controlled action to achieve a particular result.

viii.

Systems: a combination of components that act together and perform a certain objective

ix.

Servo Systems: is a feedback control system in which the output is some mechanical position, velocity or acceleration

x.

Disturbance: a signal that tends to adversely affect the value of the output of the system

Learning Activities: Define the term of manipulated variable

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INTRODUCTION TO CONTROL SYSTEM

1.3 Elements of Control System

The basic elements of a control system consist of: i. Objectives of control system (input / stimulus / actuating signal) ii. Control system components (process) iii. Output of control system (output / controlled variable)

The relationship of these elements can be illustrated in Figure 1.1.

objectives / input Control System Components

output / controlled variable

Figure 1.1: Elements of Control System In technical terms, the objectives can be identified as inputs/stimulus or actuating signal. The results of control system called as output or controlled variables. The components of control system may consist of controller, plant, sensor or transducer and it is depending on type or configuration of control system. It is also called as a process. In general, the purpose of control system is to get the output of the system as per desired input and the specific objective of the control system is to control the outputs in some prescribed manner by the inputs through the elements of the control system. Learning Activities: Name the components of control system

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INTRODUCTION TO CONTROL SYSTEM

1.4 Control System Configuration In control system, there are two types of configurations i.e open loop control system and closed control system. These two types of control system are described in the following section. 1.4.1 Open Loop Control System Open loop control system describe as a control system in which the control or regulating action is independent of the output where output has no effect on the control action. Its also can be defined as a system operates without feedback and directly generates the output in response to an input signal. In general, the output of open loop control system is not compared with the reference input. Figure 1.2 shows the open loop control system block diagram.

Input Controller Process / plant

output

Figure 1.2: Open Loop Control system

From the Figure 1.2, the controller is functioning only to drives the process or plant. The input can be called as reference or set point and the output can be called as controlled variable. The advantages and disadvantages of open loop control system can be listed as follows: Advantages: i. ii. iii. iv. simple construction easy maintenance no stability problem convenient when output is hard to measured & not economy to produced

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INTRODUCTION TO CONTROL SYSTEM

Disadvantages: i. the output may different from desired input if there is calibration error causes by disturbance/changes ii. re-calibration is required from time to time to maintain the required output

Any control systems that operated on a time basis such as washing machine, toaster, and electric fan are examples of open loop control system and system stability is not a major problem.

1.4.2 Closed Loop Control System Closed loop control system can be described as a control system in which the control action is influence by the output where the actual output is feedback to the desired input or reference for comparison. It is also can be define as a system that uses a measurement of the output and compares it with desired input. Figure 1.3 shows the block diagram of closed loop control system.
error / actuating signal desired input Controller Process / plant actual output

summing junction Output transducer / sensor

Figure 1.3: Closed Loop Control System

In Figure 1.3 above, output transducer/sensor is functioning as measurement device to measure the controlled variable or actual output response. This path or loop called as a feedback path. At the summing junction, the error or actuating signal which is the difference between desired input and the actual output is fed into the controller. The controller will make corrective action and drive the

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INTRODUCTION TO CONTROL SYSTEM

process or plant to the output as the desired input. If no error signal, plants response is already the desired response. Feedback control systems are often referred to as closed loop control system. Any system that maintains a prescribed relationship between output and input and using the difference by comparing them is called feedback control system. There are numerous examples of closed loop or feedback control system and not limited to engineering but also can be found in various non-engineering fields. The advantages and disadvantages of closed loop control system can be listed as follows:

Advantages: i. ii. iii. greater accuracy less sensitive to noise and disturbances convenient control of transient response and steady state error

Disadvantages: i. ii. iii. more complex and expensive stability problem higher cost

The differences between closed-loop control system and open loop control system can be summarized as shown in Table 1.1.

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INTRODUCTION TO CONTROL SYSTEM

Table 1.1 Open Loop Control System Closed Loop Control System

Does not have the feedback path.

Have the feedback path.

Low accuracy.

Greater accuracy

Sensitive to noise, disturbances and changes in the environment.

Less sensitive to noise, disturbances and changes in the environment.

The system cannot compensate and correct disturbance

The system can compare the output response with the input and make a correction if there is any difference

Simple and inexpensive

Complex and expensive

Learning Activities: 1. Describe the open loop control system 2. List the disadvantages of closed loop control system

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INTRODUCTION TO CONTROL SYSTEM

1.5 Advantages of Control system Control system has build for four primary reasons and it is become advantages in real applications: Power amplification control system can produce the needed power for amplification called as power gain such as huge radar antenna is positioned by low-power rotation of small knob ii. Remote control control system useful in remote or dangerous location such as remote controlled robot used to handle radioactive material iii. Convenience of input form control system used to provide convenience by changing the form of input iv. Compensation for disturbances control system able to compensate disturbances in order to achieve the correct output 1.6 Examples of Control System There are lots and numerous of control system application in various fields. The following are examples that easy to understand the application of control system in daily life and industrial sector. 1.6.1 Car Speed Control The car speed is controlled by pressed or depressed the accelerator pedal, which is, controls the fuel quantity to car engine. Figure 1.4 shows the equivalent block diagram for car speed control;
i/p reference (desired speed) controller (human driver) plant (car engine) o/p response (actual speed)

i.

transducer (speedometer)

Figure 1.4: Car Speed Control

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INTRODUCTION TO CONTROL SYSTEM

The following terms can be identified from the block diagram in Figure 1.4; Process/plant car engine Controller driver Sensor/transducer speedometer Input reference desired speed (example: 110 km/h) Controlled variable actual speed Manipulated variable fuel quantity

The controller (driver) measures the car speed through speedometer. When the speed of the car exceed than desire speed, the driver will depress the accelerator pedal to slow down the car. The car speed control is classified as closed loop or feedback control system. 1.6.2 Liquid Level Control Figure 1.5 shows the simple liquid level control system.

liquid inflow control valve

controller

level sensor liquid tank liquid outflow

Figure 1.5: Liquid Level Control System The objective of this control system is to maintain/control the liquid level in the tank at desire value. This process diagram can be converted into block diagram as shown in Figure 1.6;

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INTRODUCTION TO CONTROL SYSTEM

error /actuating signal set point (desired level) controller control valve liquid tank

actual level

actual level level sensor

Figure 1.6: Block diagram of Liquid Level Control System From the block diagram in Figure 1.6, the following terms can be identified; Controlled variable liquid level Manipulated variable liquid flow Transducer level sensor Process/plant liquid tank

The fluid level in the tank can not be directly controlled. It can be controlled only by changing or manipulating the water flow into the tank The differences between input reference (set point) and output signal will generate an error or actuating signal. If the error signal is positive, it indicates to controller that actual level is lower than desired level. Then controller will open the control valve to allow a higher flow rate into the tank. If the actual level is higher than desired level, the control valve turn close to reduce the inflow rate The liquid level control can classify as closed loop or feedback control system.

1.6.3 Robotic Arm Control System Industrial robots are frequently used in manufacturing company to improve productivity. Robot can work in an extreme environment, handle monotonous jobs without error and perform special task that human cant do.

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INTRODUCTION TO CONTROL SYSTEM

At production line, an example of industrial robot task is pick and place where robot must handle or move parts from one station to another station. Figure 1.7 shows an example of industrial robot for pattern recognition process.

vision sensor

robotic arm

part work station part station actuator computerized controller

Figure 1.7: Robotic Arm Control System

In this example, vision sensor act as a feedback element. It recognizes the pattern and determines the presence and orientation of the part or object. The vision signal then is feedback into computerized controller to actuate the robotic arm. Bar code reading is one of an example of the pattern recognition process. Then the robot will pick up the part and place it at the work station for work process.

1.6.4 Temperature Control System In manufacturing industries, the heater may use to heat the electric furnace. Figure 1.8 shows the schematic diagram of temperature control system of an electric furnace.

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INTRODUCTION TO CONTROL SYSTEM

Electric Furnace heater

thermometer

A/D converter

interface controller

Relay

Amplifier

interface

Figure 1.8: Temperature Control of Electric Furnace Thermometer is used as a sensor to measure the temperature in electric furnace. The analog signal from thermometer than converted into digital signal by A/D converter and fed into digital controller in computer through interface module. The actual temperature then compare with input temperature. If any error occurs, the digital controller sends a signal to the heater through an interface module, amplifier, and relay to bring the temperature of electric furnace to desired value. 1.6.5 Manufacturing Business System A manufacturing business system is a closed loop system. The input and output of the system is the products that want to produce. The manufacturing company may consist of few processes or department such as management, research & development, preliminary design, experiments, product design & drafting, fabrication & assembling, and testing. Disturbances in this system may be lack of personnel or material, interruption of communication, human errors and etc. Figure 1.9 may illustrates the closed loop system of manufacturing business system.

required products

management

research & development

preliminary design

experiments

product design & drafting

fabrication & assembling

testing

products

Figure 1.9: Closed Loop System of Manufacturing Business

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INTRODUCTION TO CONTROL SYSTEM

1.6.6 Industrial Control System The industrial control system is another example of application of feedback control system. It consists of an automatic controller, an actuator, plant and sensor. Figure 1.10 illustrates the general industrial control system.

automatic controller

ref. i/p (set point) amplifier actuator plant

o/p response

sensor

Figure 1.10: Industrial Control System

Automatic controller such as PID controller will detects the actuating or error signal that is usually at very low power level and amplifies it to a sufficiently high level by using amplifier. Then, the output of an automatic controller is fed to an actuator. Actuator is a power device that produces the input to the plant accordingly to control signal so that the output signal will approach the reference input. The examples of actuator are electric motor, hydraulic motor, pneumatic motor, valve and etc.

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INTRODUCTION TO CONTROL SYSTEM

Learning Activities: 1. Recognize and list the components of car speed control 2. Identify the type of control system for car air conditioning temperature control

Summary In this chapter, the concept, general terms and elements of control system has been discussed. Control system configuration which is open loop and closed loop system has been recognized and the advantages of control system are explained for real application. Some of examples of control system in human life and industrial sector has been describes in order to enhance the understanding the concept of control system. Exercise 1. Define the terms of: i. ii. iii. automatic control system feedback control system controlled variable

2. List the elements of control system 3. Describe the main difference between open loop and closed loop system. List the differences of both systems in table form. 4. Relate the advantages of control system with real application. 5. Car air conditioning temperature control can be open loop or closed loop system. Illustrate the block diagram for both types control system

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