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Manufacturing Control Technology 2 - Control 1
Manufacturing Control Technology 2 - Control 1
INTRODUCTION TO CONTROL
SYSTEM
Ignatius Agung Wibowo
12/3/2010 IAW 1
DEFINITION
• Control: Regulate, direct or command and ability
to make something do what you want
• System: a group of things, pieces of equipment
that are connected and work together to perform
certain objective
• A control system is an interconnection of
components forming a system configuration that
will provide a desired system response
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CONTROL SYSTEM BASIC
Control system can be described by 3
components:
1. Input/ stimulus/ desired response
2. Control system
3. Output/ response/ actual response
Input Output
Control
system
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CONTROL SYSTEM
OBJECTIVE
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EXAMPLE OF CONTROL
SYSTEM
Controlling the temperature of a furnace
– Input: desired temperature is given by adjusting the
opening of the fuel valve
– Control system: Fuel valve, pipes and the furnace
– Output: the actual temperature of the furnace
Desired Temperature
Actual Temperature
Fuel
Control valve
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ADVANTAGES OF CONTROL
SYSTEM
• Doing tasks which
are impossible for
human being to
control manually
• Examples:
– Point a huge
antenna
– Carry an elevator
and stop at the
right floor
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ADVANTAGES OF CONTROL
SYSTEM
• We build control system for 4 primary reasons:
– Power amplification
– Remote control
– Convenience of input form
– Compensation for disturbances
• All of this primary reason is to make precision
control for a system that impossible for
human to control manually such as motor
speed, etc.
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EXAMPLES
• Power amplification: rotates a knob can rotate a
radar antenna
• Remote control: robot arm can be used to pick
up material in radioactive environment
• Convenience of input form: by adjusting the
position of thermostat yields a desired thermal
output in temperature control system
• Compensation for disturbance: In antenna
pointing system when wind rotates the antenna
the system is able to correct it
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OPEN-LOOP AND CLOSED-LOOP
CONTROL SYSTEM
2 Basic categories of control system:
1. Open-loop control system
2. Closed-loop control system
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OPEN-LOOP CONTROL SYSTEM
Output /
Controlled
Desired Actuating variable, y
output signal, u
response, r
Controller Controlled
process
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OPEN-LOOP CONTROL SYSTEM (cont.)
Open loop control system also can be drawn in the following block
diagram
ACTUATOR
Input signal
(reference)
Output
OUTPUT response
CONTROLLER ELEMENT LOAD
+V
ANTENNA
High Output
Power θO response
Supply power
Input GEARS
signal
AMPLIFIER MOTOR
0V
Low
power
-V
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EXAMPLE OF OPEN-LOOP CONTROL SYSTEM
(CONT.)
Dial Setting
(Desired Actual
temperature) CONTROLLER temperature
(TIMER & ON- HEATER
OFF SWITCH)
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EXAMPLE OF OPEN-LOOP SYSTEM
(CONT.)
3 Electronic typewriter
KEYBOARD µP POWER DC
Print
(Desired CONTROLLER AMP MOTOR
wheel
character)
(Actual
character)
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CLOSED-LOOP SYSTEM
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CLOSED-LOOP SYSTEM (cont.)
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CLOSED-LOOP SYSTEM (cont.)
Output
(C)
Reference + E
OUTPUT
CONTROLLER ELEMENT LOAD
signal
(R) -
MEASUREMENT
Feedback
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EXAMPLE OF CLOSED-LOOP CONTROL
SYSTEM
Error
Output
detector
Ve = Vi - Vo
180°° 0°°
180°° 0°°
+V 0
Vo
Output
Feedback
sensor
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EXAMPLE OF CLOSED-LOOP SYSTEM
(CONT.)
Ve = Vi - Vo
Reference + Speed
CONTROLLER LOAD
AMPLIFIER MOTOR
signal
(Vi) -
Antenna
-
Vo
Vo rpm
TACHOMETER
Small generator
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SERVO CONTROL
• Position control
– When the output variable is mechanical position is
called servo-mechanism
– Amplifier is called servo amplifier
• Examples of servo-mechanism applications :
– robotics
– autopilot for an aircraft
– recording devices
– lathe and milling machines
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COMPARISON BETWEEN OPEN-LOOP AND
CLOSED-LOOP CONTROL SYSTEM
• Open-loop system
– The system is simple, makes:
• its price is cheap
• it is more reliable, and
• it is easy to maintain
– It is not accurate; accuracy depends on the calibration
of its elements. If the value of the elements changes,
caused by factors like temperature, age, pressure, or
humidity, then the calibration will change. There is no
error correction by a controller
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COMPARISON BETWEEN OPEN LOOP
AND CLOSED LOOP CONTROL SYSTEM
(CONT.)
• Open-loop system (cont.):
– It does not experience stability problem.
– Its output response is slow.
– Its controller action does not have any
relationship with the output.
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COMPARISON BETWEEN OPEN LOOP
AND CLOSED LOOP CONTROL SYSTEM
(CONT.)
• Closed-loop system
– The system is complex, requires transducer
and error detector, makes:
• it is more expensive,
• it is less reliable, and
• it is difficult to maintain.
– The system is very accurate; because there is
a correcting action by the controller.
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COMPARISON BETWEEN OPEN LOOP
AND CLOSED LOOP CONTROL SYSTEM
(CONT.)
• Closed-loop system
– It may experience stability problem, i.e.
when a positive feedback occurs.
– Its response is fast.
– Its controller action has a relationship with
the output.
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FEEDBACK AND ITS EFFECTS
• A system that maintains a relationship between
the output and some reference input by comparing
them and using the difference as a means of
control is called a feedback control system
• Feedback system = closed loop system
• Feedback effects are:
– Reduction of system error on system
– Effect on performance characteristic, such as:
• Stability
• Bandwidth
• Overall gain
• Impedance
• Sensitivity
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CONTROL SYSTEMS CLASSIFICATION
1. Single-Input-Single-Output (SISO)
Input Output
CONTROL SYSTEM
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
2. Multiple-Input-Multiple-Output (MIMO)
Input Output
. CONTROL SYSTEM .
. .
. .
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
3. Linear
Its components show linear characteristics
(where superposition theorem may apply)
4. Non-Linear
Superposition theorem cannot be used. The
system is difficult to analyze, there is no
theory which can be used for all conditions,
e.g. amplifier.
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
5. Time-Invariant
The parameters of this control system do not
change with time, e.g. R, L, C.
6. Time-Variant
The parameters of this control system change
with time. It is difficult to analyze, e.g.
resistance winding of a DC motor varies when
the temperature rising, fighter aircraft
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
7. Analog (Continuous-Time) Control System
All signals in this system are in the form of analog (continuous)
signal
8. Digital (Discrete-Time) Control System
In this system a digital computer is used as the controller in the
system. Any control law can be applied via programming, e.g.
‘fly by wire’
Input DIGITAL Output
D/A PLANT
COMPUTER
A/D SENSOR
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
9. Process Control
• Variables which are required to be controlled are temperature,
pressure, level, flowrate, pH, or viscosity.
• The terminologies are different although the theories are similar.
For example reference signal is called set point.
Control Valve A
Measured variable
Level detector
Valve B
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
10. Sequential Control
The operations of this control
system are performed in orders
which are already set before. For
example in an automatic washing
machine, the operations of filling
the tube, washing the clothes,
draining the tube, rinsing the
clothes, and spinning the clothes
are already set. Another example is
the use of PLC (Programmable
Logic Controller) in control system.
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CONTROL SYSTEMS CLASSIFICATION
(CONT.)
11. Feed Forward Control System
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CONTROL SYSTEM DESIGN
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DESIGN PROCESS
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DESIGN PROCESS (CONT.)
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DESIGN PROCESS (CONT.)
Step 4: Reduction of block diagram
Initial block diagram might be too complicated.
Therefore, it is reduced to simple block in order to
get simple equations that represent the system
Step 5: Analyze and design
Once the simple representation of the system is
obtained, it is easier to analyze the system. The
system is analyzed to see whether the transient
response specification, steady state error and
stability requirements are met. If the requirements
are not met, then the controller is designed to meet
the specification.
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