S.H.H.J.

B Polytechnic,Chandwad
Course Name :Control System and PLC Course Code: 22531

Cover Course Outcome:Test the performance of various types of controllers.

Faculty Name: Mr.N.R.Thakre

Syllabus

3.1 Block diagram of process control system &need of controller.

Explanation:
Process control system consists of
i) Process
ii) Sensor (Feedback Elements)
iii)Error detector
iv) Controller
v) Control element.
1) Process:
 Process means some manufacturing sequence for example temperature control system
where process variable is temperature and it is controlled as per the requirement.
2) Sensor/Feedback Elements
 It is the device that converts the current output variable into another Suitable variable
which can acceptable by error detector.
 Sensor is present in feedback path of close loop system in case of temperature control
system RTD sensor used as feedback sensor which sense actual output variable i.e
temperature and convert

3) Error detector

 Error detector is summing point whose output is an error signal.

 Error Signal : It is the difference between the set point and actual output.
 Error signal i.ee(t) = r(t) - b(t) applied to controller corrective action. Because of
corrective action output improvise till the level of set point.
4) Controller
 Controller received error signal and generates appropriate signal for control element in
order to control the process variable according to set point.
 In case of temperature control system Heater is control element which is heating as per
the applied voltage value those send by controller as per error signal.
5) Control element –
 Control element is nothing but Heating Coil or Heater which produces an input to the
plant according to thecontrol signal getting from controller

Need of controller
 1.To reduce human efforts.
 2. To get maximum efficiency from machine and control them with human logic
 3.To reduce complex circuitry of entire system
 4. To eliminate the high costs associated with inflexible, relay-controlled systems.
 5. Replacing Human Operators (Dangerous Environments & Beyond Human
Capabilities)
 3.2 Give classification of control actions

3.2 i) Working principle of ‘ON-OFF’ controllers using one example

 This is one of the most common & simplest mode of controller.

 It controls two positions of control element, either on or off hence this mode is called as ON
OFF controller
 It is the cheapest controller. This controller mode has two possible output states namely 0
%& 100%.
Mathematically this can be expressed as,
P (t) = 0% (OFF) for ep< 0
100% ( ON) for ep> 0
Where p (t) – Controlled output
ep - Error based on % of span
 Hence if the error rises above a certain critical value, the output changes from 0% to100%. If
the error decreases below certain critical value, the output falls from 100%to 0%.
 Example: Room temperature controller: If the temperature goes above 30 ocooler isturned ON.
If the temperature goes below 25o heater is turned ON. Thus thetemperature is maintained
between 25o 30o
Explain in brief ON – OFF control action.

It has only two fixed positions such as on (1) and off (0). The output signal P remains
either 0% or 100% depending upon whether the error is negative or positive.
P = 100% (on) for positive error
P = 0% (off) for negative error .
Consider a practical example of temperature control system with Set Point “x”.
When the temperature is more than “x” the on - off controller will be Off and
when it is less than “x” ,on - off controller will be on.
Example:- Relays, Thermostat

3.2 i-a) Neutral Zone:

 The range of error in which there is no change in the controller output is called neutral zone.
This is designed to reduce excessive cycling of ON-OFFController
 Define the following term:
(i) Neutral Zone·
(ii) Control Action 4M
Ans:

i) Neutral Zone:

 The range of error in which there is no change in the controller output is called neutral zone.
This is designed to reduce excessive cycling of ON-OFF Controller

(ii) Control Action: An automatic controller produces the control signal is called
control action.
There are classified as:
Discontinuous controller (on-off)
Continuous controller (P,I,D)
Composite controller (PI,PD, PID)

3.2 ii) Proportional Controller and Proportional band ,Offset in Proportional Controller

 Controller output is proportional to the error.

 Mathematical Expression of output of proportional Controller is as follow
P= + P0
Where Kp – Proportional Gain
P0- Output of Controller when Error is Zero
 It responds to the presenterror available between Process variable and Set Point at current instant
of time.
 The range of error to cover the 0% to 100% controller outputis called proportional band. It also
specifies the percentage error that results in a100%change in the controller output.
 OFF Set: When the load changes, the output deviates from the set point in theproportional
controller. Such deviation is called as offset

Figure
 Define following term related to control action:
(i) Controller
(ii) Error Signal
(iii) OFF Set
(iv) Proportional Band

(i) Controller :It generates the correct signal which is then applied to the
final control element. Controller output is denoted by “m”.
(ii) Error Signal :It is the difference between the set point and actual output
 (iii) OFF Set When the load changes, the output deviates from the set point in theproportional
controller. Such deviation is called as offset
(iv) Proportional Band: The range of error to cover the 0% to 100% controller output is called
proportional band. It also specifies the percentage error that results in a100%
change in the controller output

Integral controller

 In this type of mode output of the controller is integration of the input error signal.

 The Integral Controller Sums the error term over time. Integral response continuously
increases over a time unless the error is zero.
 Integral controller Response to magnitude of error i.e size and time duration.

 The output equation of Integral Controller is Pout =

Where,
Pout =Controller output
Ep=Error Percentage
Ki =Integral constant
P0=Controller Output at t=0
1) If the error is zero ,output of the controller is constant at value when error went to zero.
2) If the error is not zero then output will increase or decrease at the rate of integral
Constant.
Figure

Advantages of Integral Mode

1) It reduces steady state error.
2) Sums the error term over time hence provide continuous corrective action.
Disadvantages of Integral Mode
 1) It makes the system unstable.(Oscillatory response)
2) It never used alone but used in combination with proportional controller.

Give the principle of derivative action. Write its standard equation. 4M

Principle of derivative control action:
 The controlled output is proportional to the rate of change of error signal OR The output
of the
 controller is proportional to derivative of the input signal.
Mathematical expression:
P = KD * [dep/ dt]
OR
P(t) = KD * [de(t) / dt]
Where KD = Derivative gain constant and
[dep/ dt] = rate of change of error signal

Figure

1) if error is zero output is zero.

2) If error is constant in time then derivative control action provides no output
3) Positive rate of change of error produces a positive derivative mode output.
4) If the error is changing in time then output is contributed by derivative constant.

Advantages of derivative Mode:

1) It can overcome the overshoot and severe cycling.
2) It produced rapid response against rapid changing errors.
3) It does not affect the steady state error directly , but anticipates error.
4) It increases the stability of the system by initiating an early corrective action.
Disadvantages of derivative Mode
1) It cannot be used alone because cannot give any output for zero or constant error.
2) It is ineffective for slowly changing error.
3) It does not eliminate the steady state error (Offset).
Explain PI control action. State its equation. State advantages of PI control. (any two)

This is composite control mode obtained by combining the proportional mode and the integral
mode
ii) The mathematical expression for such a composite control is

Where, p(0)= Initial value of the o/p at t=0

iii) One important advantage of this control is that one to one correspondence of proportional
mode is available while the offset gets eliminated due to integral mode
iv) As the error changes from zero to positive at that instant t1, the controller o/p changes but
this change due to proportional mode. As the error changes further the controller o/p
increases, but this increase is due to integral mode. And as the error becomes constant,
controller o/p remains as it is equal to
Previous stage.

Advantages of PI mode
1. It eliminates offset error i.e improves the steady state accuracy.
2. It decreases bandwidth of the system.
3. It increases the rise time so response becomes slow.
4. It filters out the high frequency noise.

Explain PD control action. State advantages of PD control.(any two)

Fig- Proportional-Derivative action.

Advantage of PD mode
1. It improves the damping &reduces overshoot.
2. It reduces the rise time.
3. It allows the rise of narrower proportional band with its lesser offset.
4. Increases the controller gain during the error changes.
5. Can compensate the rapidly changing error.
6. Can handle the fast processes.
7. Can compensate some of the lag in a process.
Explain PI control action. State its equation. State limitations of PI controller. 4M

It is the combination of Proportional and Integral controller. The output equation is

where Po is the controller output when time t=0
If the error is not zero, the proportional controller gives correction and integral begins to
change the accumulated value of the error which is initially.Integral controller is rarely used
alone because of its slow response to disturbances. When it is combined with proportional
controller, its slow response can be eliminated. Here, one to one correspondence of the
proportional controller is available and integral controller eliminates offset.
PI mode ensures that when a deviation takes place, prop mode reacts immediately to change
the controller output since there is not a time integral of deviation. Offset error occurs with a
load change but mode provides a new controller output which in turn changes the error to be
zero after a load change.
Characteristics:
i) When error=0, controller output is Po (output when t=0)
When error is not zero, the proportional controller gives correction and integral begins to
change the accumulated value of the error which is initially
Limitations of PI controller: It is slow.

Comparison

Describe PID control action w.r.t. equation and response to error.

PID controller is the proportional-integral-derivative controller. A PID controller calculates an

"error" value as the difference between a measured process variable and a desired set point. The
controller attempts to minimize the error by adjusting the process control inputs

Equation: Pout= KPEp+ KP KI ∫t Ep(t)d(t)+KPKDd/dtEp + P0

KP = proportional gain
Ep = error percentage
KI = integral gain
KD = derivative gain
P0 = controller output at time t = 0
 When an error is introduced to a PID controller, the controller’s response is a combination of
the proportional, integral, and derivative actions.
 Assume the error is due to a slowly increasing measured variable. As the error increases, the
proportional action of the PID controller produces an output that is proportional to the error
signal.
 The integral action of the controller produces an output whose rate of change is determined
by the magnitude of the error.
 In this case, as the error continues to increase at a steady rate, the integral output continues to
increase its rate of change.
 The derivative action of the controller produces an output whose magnitude is determined by
the rate of change.
 When combined, these actions produce an output. The output produced responds
immediately to the error with a signal that is proportional to the magnitude of the error and
that will continue to increase as long as the error remains increasing.
 The proportional action of the controller stabilizes the process. The integral action combined
with the proportional action causes the measured variable to return to the set point. The
derivative action combined with the proportional action reduces the initial overshoot and
cyclic period.