Chapter 6

Process control

 C.B. Pham 6-1

 Introduction

An industrial process could be:

• A discrete process consists of a series of distinct
operations with a definite condition for initiating each
operation.
• A continuous process has uninterrupted inputs and
outputs.
 C.B. Pham 6-2
 1. Control of Discrete Processes

 C.B. Pham 6-3

 Sequential process

When the series of operations has a beginning, an end,

and a definite controlled form, the process is called a
sequential process or a batch process.

Time-driven operation Event-driven operation

 C.B. Pham 6-4
 Pick-and-place robot control

 C.B. Pham 6-5

 Automatic rotation system

 C.B. Pham 6-6

 Bending system

 C.B. Pham 6-7

 Positioning system

 C.B. Pham 6-8

 Describe sequential processes

Statement list
Microwave Instructions
• STEP 1. Remove tray from carton and peel back film
from one end to vent.
• STEP 2, Place tray in microwave oven.
• STEP 3. Cook 10 min on medium power (50%) or
defrost.
• STEP 4. Rotate 1/2 turn.
• STEP 5. Cook 4 min on full power.
• STEP 6. Let stand for 1 min.
• STEP 7. Remove film and serve.
 C.B. Pham 6-9
 Describe sequential processes

Timing diagram

 C.B. Pham 6-10

 Describe sequential processes

Sequential function chart

 C.B. Pham 6-11

 Describe sequential processes

State chart
Step No. Sol. A Sol. B Sol. C Sol. D Motor

1 

2  

3   

4   

5 

6  

7 
 C.B. Pham 6-12
 Describe sequential processes

Ladder diagram circuit

 C.B. Pham 6-13

 Relay Logic Control

 C.B. Pham 6-14

 Multiple-contact relays

 C.B. Pham 6-15

 Logic functions from relays

 C.B. Pham 6-16

 Sequential Circuit Design

Basic concept of the design:

• Use of a control relay for each step in the process.
• When the process is in a given step. the control relay
associated with that step is energized and all other
relays are deenergized  each control relay represents
a "state" of the controller.
• There is a one-to-one correspondence between steps in
the process and states of the controller, and the step
numbers are used to identify the states.
• Each state in the controller consists of one rung in the
controller ladder diagram.
 C.B. Pham 6-17
 Sequential Circuit Design

Assume that the process has three consecutive steps: step

i, step j, and step k. The rung that establishes step j in a
sequential control circuit has a general form:

 C.B. Pham 6-18

 Sequential Circuit Design

The design process consists of the following steps:

• Step 1: Define the process
• Step 2: Define the step (states)
• Step 3: Define the input and output conditions
• Step 4: Define the transition conditions
• Step 5: Define the output functions
• Step 6: Construct the controller ladder diagram
• Step 7: Construct the output ladder diagram
• Step 8: Document the design

 C.B. Pham 6-19

 PLC - Programmable Logic Controller

A PLC is a small, self-contained, rugged computer

designed to control processes and events in an industrial
environment – that is, to take over the job previously done
with relay logic controllers.

 C.B. Pham 6-20

 PLC and its related components

 C.B. Pham 6-21

 Ladder diagram programming

 C.B. Pham 6-22

 2. Control of Continuous Processes

 C.B. Pham 6-23

 Performance criteria

After a load or setpoint change, the control system should:

(1) Minimize the residual error steady-state
(2) Minimize the settling time
transient
(3) Minimize the maximum error

This error is the result of

friction, loading, and
feedback-sensor accuracy.

A sophisticated
 C.B. Pham
controller 6-24
 Two-Point Control

Two-point control (also called on–off control) is the simplest

type of closed-loop control strategy. The actuator can push
the controlled variable with only full force or no force.

This has only limited applications, mostly on slow-moving

systems where it is acceptable for the controlled variable to
move back-and-forth between the two limit points.
 C.B. Pham 6-25
 Three-Position Control

Three-position control is similar to two-point control, except

in this case the controller has three states, such as
forward–off–reverse, (or up–off–down, hot–off–cold …).

This strategy would be used in a

system that has no particular
self-seeking rest state.
 C.B. Pham 6-26
 P Mode (Proportional)

With proportional control, the actuator applies a corrective

force that is proportional to the amount of error.

 C.B. Pham 6-27

 P Mode (Proportional)
P mode control is simple,
makes sense, and is the
basis of most control
systems, but it has one
fundamental problem: steady
-state error

 C.B. Pham 6-28

 I mode (Integral)

Integral control creates a restoring force that is proportional

to the sum of all past errors multiplied by time:

 C.B. Pham 6-29

 PI mode

The addition of integral feedback eliminates the steady-

state-error problem, however it reduces the overall stability
of the system. The problem occurs because integral
feedback
 C.B. Pham tends to make the system overshoot. 6-30
 D mode (Derivative)

• One solution to the

overshoot problem is to
include derivative control.
• Derivative control “applies
the brakes,” slowing the
controlled variable just
before it reaches its
destination.

• Derivative control is never

used by itself.
 C.B. Pham 6-31
 PID controller

 C.B. Pham 6-32

 PID controller

 C.B. Pham 6-33