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Controlsystem
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Acontrolsystemisadevice,orsetofdevices,thatmanages,
commands,directsorregulatesthebehaviorofotherdevicesor
systems.Industrialcontrolsystemsareusedinindustrialproduction
forcontrollingequipmentormachines.
Therearetwocommonclassesofcontrolsystems,openloopcontrol
systemsandclosedloopcontrolsystems.Inopenloopcontrol
systemsoutputisgeneratedbasedoninputs.Inclosedloopcontrol
systemscurrentoutputistakenintoconsiderationandcorrections
aremadebasedonfeedback.Aclosedloopsystemisalsocalleda
feedbackcontrolsystem.Thehumanbodyisaclassicexampleof
feedbacksystems.

Contents
1Overview
2Logiccontrol
3Onoffcontrol
4Linearcontrol
4.1Proportionalcontrol
4.1.1Underdampedfurnaceexample
4.1.2Overdampedfurnaceexample
4.2PIDcontrol
4.2.1Derivativeaction
4.2.2Integralaction
4.2.2.1RampUP%perminute
4.3Othertechniques
5Fuzzylogic
6Physicalimplementations
7Seealso
8References
9Externallinks

Overview
Theterm"controlsystem"maybeappliedtotheessentiallymanualcontrolsthatallowanoperator,for
example,tocloseandopenahydraulicpress,perhapsincludinglogicsothatitcannotbemovedunless
safetyguardsareinplace.
Anautomaticsequentialcontrolsystemmaytriggeraseriesofmechanicalactuatorsinthecorrectsequence
toperformatask.Forexamplevariouselectricandpneumatictransducersmayfoldandglueacardboard
box,fillitwithproductandthensealitinanautomaticpackagingmachine.Programmablelogiccontrollers
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areusedinmanycasessuchasthis,butseveralalternative
technologiesexist.
Inthecaseoflinearfeedbacksystems,acontrolloop,including
sensors,controlalgorithmsandactuators,isarrangedinsucha
fashionastotrytoregulateavariableatasetpointorreference
Abasicfeedbackloop
value.Anexampleofthismayincreasethefuelsupplytoafurnace
whenameasuredtemperaturedrops.PIDcontrollersarecommon
andeffectiveincasessuchasthis.Controlsystemsthatincludesomesensingoftheresultstheyaretrying
toachievearemakinguseoffeedbackandsocan,tosomeextent,adapttovaryingcircumstances.Open
loopcontrolsystemsdonotmakeuseoffeedback,andrunonlyinprearrangedways.

Logiccontrol
Logiccontrolsystemsforindustrialandcommercialmachinery
werehistoricallyimplementedatmainsvoltageusinginterconnected
relays,designedusingladderlogic.Today,mostsuchsystemsare
constructedwithprogrammablelogiccontrollers(PLCs)or
microcontrollers.Thenotationofladderlogicisstillinuseasa
programmingidiomforPLCs.[1]
Logiccontrollersmayrespondtoswitches,lightsensors,pressure
switches,etc.,andcancausethemachinerytostartandstopvarious
operations.Logicsystemsareusedtosequencemechanicaloperationsinmanyapplications.PLCsoftware
canbewritteninmanydifferentwaysladderdiagrams,SFCsequentialfunctionchartsorinlanguage
termsknownasstatementlists.[2]
Examplesincludeelevators,washingmachinesandothersystemswithinterrelatedstopgooperations.
Logicsystemsarequiteeasytodesign,andcanhandleverycomplexoperations.Someaspectsoflogic
systemdesignmakeuseofBooleanlogic.

Onoffcontrol
Athermostatisasimplenegativefeedbackcontroller:whenthetemperature(the"processvariable"orPV)
goesbelowasetpoint(SP),theheaterisswitchedon.Anotherexamplecouldbeapressureswitchonanair
compressor.Whenthepressure(PV)dropsbelowthethreshold(SP),thepumpispowered.Refrigerators
andvacuumpumpscontainsimilarmechanismsoperatinginreverse,butstillprovidingnegativefeedback
tocorrecterrors.
Simpleonofffeedbackcontrolsystemslikethesearecheapandeffective.Insomecases,likethesimple
compressorexample,theymayrepresentagooddesignchoice.
Inmostapplicationsofonofffeedbackcontrol,someconsiderationneedstobegiventoothercosts,such
aswearandtearofcontrolvalvesandperhapsotherstartupcostswhenpowerisreappliedeachtimethe
PVdrops.Therefore,practicalonoffcontrolsystemsaredesignedtoincludehysteresiswhichactsasa
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deadband,aregionaroundthesetpointvalueinwhichnocontrolactionoccurs.Thewidthofdeadbandmay
beadjustableorprogrammable.

Linearcontrol
Linearcontrolsystemsuselinearnegativefeedbacktoproduceacontrolsignalmathematicallybasedon
othervariables,withaviewtomaintainthecontrolledprocesswithinanacceptableoperatingrange.
Theoutputfromalinearcontrolsystemintothecontrolledprocessmaybeintheformofadirectlyvariable
signal,suchasavalvethatmaybe0or100%openoranywhereinbetween.Sometimesthisisnotfeasible
andso,aftercalculatingthecurrentrequiredcorrectivesignal,alinearcontrolsystemmayrepeatedly
switchanactuator,suchasapump,motororheater,fullyonandthenfullyoffagain,regulatingtheduty
cycleusingpulsewidthmodulation.

Proportionalcontrol
Whencontrollingthetemperatureofanindustrial
furnace,itisusuallybettertocontroltheopeningofthe
fuelvalveinproportiontothecurrentneedsofthe
furnace.Thishelpsavoidthermalshocksandapplies
heatmoreeffectively.
Proportionalnegativefeedbacksystemsarebasedon
thedifferencebetweentherequiredsetpoint(SP)and
processvalue(PV).Thisdifferenceiscalledtheerror.
Powerisappliedindirectproportiontothecurrent
measurederror,inthecorrectsensesoastotendto
reducetheerrorandthereforeavoidpositivefeedback.Theamountofcorrectiveactionthatisappliedfora
givenerrorissetbythegainorsensitivityofthecontrolsystem.
Atlowgains,onlyasmallcorrectiveactionisappliedwhenerrorsaredetected.Thesystemmaybesafe
andstable,butmaybesluggishinresponsetochangingconditions.Errorswillremainuncorrectedfor
relativelylongperiodsoftimeandthesystemisoverdamped.Iftheproportionalgainisincreased,such
systemsbecomemoreresponsiveanderrorsaredealtwithmorequickly.Thereisanoptimalvalueforthe
gainsettingwhentheoverallsystemissaidtobecriticallydamped.Increasesinloopgainbeyondthispoint
leadtooscillationsinthePVandsuchasystemisunderdamped.
Inrealsystems,therearepracticallimitstotherangeofthemanipulatedvariable(MV).Forexample,a
heatercanbeofforfullyon,oravalvecanbeclosedorfullyopen.Adjustmentstothegainsimultaneously
altertherangeoferrorvaluesoverwhichtheMVisbetweentheselimits.Thewidthofthisrange,inunits
oftheerrorvariableandthereforeofthePV,iscalledtheproportionalband(PB).Whilethegainisuseful
inmathematicaltreatments,theproportionalbandisoftenusedinpracticalsituations.Theybothrefertothe
samething,butthePBhasaninverserelationshiptogainhighergainsresultinnarrowerPBs,andvice
versa.
Underdampedfurnaceexample

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Inthefurnaceexample,supposethetemperatureisincreasingtowardsasetpointatwhich,say,50%ofthe
availablepowerwillberequiredforsteadystate.Atlowtemperatures,100%ofavailablepowerisapplied.
Whentheprocessvalue(PV)iswithin,say10oftheSPtheheatinputbeginstobereducedbythe
proportionalcontroller(notethatthisimpliesa20proportionalband(PB)fromfulltonopowerinput,
evenlyspreadaroundthesetpointvalue).Atthesetpointthecontrollerwillbeapplying50%poweras
required,butstraystoredheatwithintheheatersubsystemandinthewallsofthefurnacewillkeepthe
measuredtemperaturerisingbeyondwhatisrequired.At10aboveSP,wereachthetopoftheproportional
band(PB)andnopowerisapplied,butthetemperaturemaycontinuetoriseevenfurtherbeforebeginning
tofallback.EventuallyasthePVfallsbackintothePB,heatisappliedagain,butnowtheheaterandthe
furnacewallsaretoocoolandthetemperaturefallstoolowbeforeitsfallisarrested,sothattheoscillations
continue.
Overdampedfurnaceexample
Thetemperatureoscillationsthatanunderdampedfurnacecontrolsystemproducesareunacceptablefor
manyreasons,includingthewasteoffuelandtime(eachoscillationcyclemaytakemanyminutes),aswell
asthelikelihoodofseriouslyoverheatingboththefurnaceanditscontents.
Supposethatthegainofthecontrolsystemisreduceddrasticallyanditisrestarted.Asthetemperature
approaches,say30belowSP(60proportionalband(PB)),theheatinputbeginstobereduced,therateof
heatingofthefurnacehastimetoslowand,astheheatisstillfurtherreduced,iteventuallyisbroughtupto
setpoint,justas50%powerinputisreachedandthefurnaceisoperatingasrequired.Therewassome
wastedtimewhilethefurnacecrepttoitsfinaltemperatureusingonly52%then51%ofavailablepower,
butatleastnoharmwasdone.Bycarefullyincreasingthegain(i.e.reducingthewidthofthePB)thisover
dampedandsluggishbehaviorcanbeimproveduntilthesystemiscriticallydampedforthisSP
temperature.Doingthisisknownas'tuning'thecontrolsystem.Awelltunedproportionalfurnace
temperaturecontrolsystemwillusuallybemoreeffectivethanonoffcontrol,butwillstillrespondmore
slowlythanthefurnacecouldunderskillfulmanualcontrol.

PIDcontrol
Apartfromsluggishperformancetoavoidoscillations,
anotherproblemwithproportionalonlycontrolisthat
powerapplicationisalwaysindirectproportiontothe
error.Intheexampleaboveweassumedthattheset
temperaturecouldbemaintainedwith50%power.
Whathappensifthefurnaceisrequiredinadifferent
applicationwhereahighersettemperaturewillrequire
80%powertomaintainit?Ifthegainwasfinallysetto
a50PB,then80%powerwillnotbeappliedunless
thefurnaceis15belowsetpoint,soforthisother
applicationtheoperatorswillhavetorememberalways
tosetthesetpointtemperature15higherthanactually
AblockdiagramofaPIDcontroller
needed.This15figureisnotcompletelyconstant
either:itwilldependonthesurroundingambient
temperature,aswellasotherfactorsthataffectheatlossfromorabsorptionwithinthefurnace.

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Toresolvethesetwoproblems,manyfeedbackcontrolschemesincludemathematicalextensionsto
improveperformance.Themostcommonextensionsleadtoproportionalintegralderivativecontrol,orPID
control.
Derivativeaction
Thederivativepartisconcernedwiththerateofchange
oftheerrorwithtime:Ifthemeasuredvariable
approachesthesetpointrapidly,thentheactuatoris
backedoffearlytoallowittocoasttotherequired
levelconverselyifthemeasuredvaluebeginstomove
rapidlyawayfromthesetpoint,extraeffortisapplied
inproportiontothatrapiditytotrytomaintainit.
Derivativeactionmakesacontrolsystembehavemuch
moreintelligently.Oncontrolsystemslikethetuningof
thetemperatureofafurnace,orperhapsthemotion
controlofaheavyitemlikeagunorcameraona
movingvehicle,thederivativeactionofawelltuned
PIDcontrollercanallowittoreachandmaintaina
setpointbetterthanmostskilledhumanoperatorscould.

EffectsofvaryingPIDparameters(Kp,Ki,Kd)on
thestepresponseofasystem.

Ifderivativeactionisoverapplied,itcanleadtooscillationstoo.AnexamplewouldbeaPVthatincreased
rapidlytowardsSP,thenhaltedearlyandseemedto"shyaway"fromthesetpointbeforerisingtowardsit
again.
Integralaction
Theintegraltermmagnifiestheeffectoflongterm
steadystateerrors,applyingeverincreasingeffortuntil
theyreducetozero.Intheexampleofthefurnaceabove
workingatvarioustemperatures,iftheheatbeing
applieddoesnotbringthefurnaceuptosetpoint,for
whateverreason,integralactionincreasinglymovesthe
proportionalbandrelativetothesetpointuntilthePV
errorisreducedtozeroandthesetpointisachieved.
RampUP%perminute

Somecontrollersincludetheoptiontolimitthe"ramp
up%perminute".Thisoptioncanbeveryhelpfulin
stabilizingsmallboilers(3MBTUH),especiallyduring
thesummer,duringlightloads.Autilityboiler"unit
mayberequiredtochangeloadatarateofasmuchas5%perminute(IEACoalOnline2,2007)".[3]

Othertechniques
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ItispossibletofilterthePVorerrorsignal.Doingsocanreducetheresponseofthesystemtoundesirable
frequencies,tohelpreduceinstabilityoroscillations.Somefeedbacksystemswilloscillateatjustone
frequency.Byfilteringoutthatfrequency,more"stiff"feedbackcanbeapplied,makingthesystemmore
responsivewithoutshakingitselfapart.
Feedbacksystemscanbecombined.Incascadecontrol,onecontrolloopappliescontrolalgorithmstoa
measuredvariableagainstasetpoint,butthenprovidesavaryingsetpointtoanothercontrolloopratherthan
affectingprocessvariablesdirectly.Ifasystemhasseveraldifferentmeasuredvariablestobecontrolled,
separatecontrolsystemswillbepresentforeachofthem.
ControlengineeringinmanyapplicationsproducescontrolsystemsthataremorecomplexthanPID
control.Examplesofsuchfieldsincludeflybywireaircraftcontrolsystems,chemicalplants,andoil
refineries.Modelpredictivecontrolsystemsaredesignedusingspecializedcomputeraideddesignsoftware
andempiricalmathematicalmodelsofthesystemtobecontrolled.

Fuzzylogic
Fuzzylogicisanattempttoapplytheeasydesignoflogiccontrollerstothecontrolofcomplex
continuouslyvaryingsystems.Basically,ameasurementinafuzzylogicsystemcanbepartlytrue,thatisif
yesis1andnois0,afuzzymeasurementcanbebetween0and1.
Therulesofthesystemarewritteninnaturallanguageandtranslatedintofuzzylogic.Forexample,the
designforafurnacewouldstartwith:"Ifthetemperatureistoohigh,reducethefueltothefurnace.Ifthe
temperatureistoolow,increasethefueltothefurnace."
Measurementsfromtherealworld(suchasthetemperatureofafurnace)areconvertedtovaluesbetween0
and1byseeingwheretheyfallonatriangle.Usually,thetipofthetriangleisthemaximumpossiblevalue
whichtranslatesto1.
Fuzzylogic,then,modifiesBooleanlogictobearithmetical.Usuallythe"not"operationis"output=1
input,"the"and"operationis"output=input.1multipliedbyinput.2,"and"or"is"output=1((1input.1)
multipliedby(1input.2))".ThisreducestoBooleanarithmeticifvaluesarerestrictedto0and1,instead
ofallowedtorangeintheunitinterval[0,1].
Thelaststepisto"defuzzify"anoutput.Basically,thefuzzycalculationsmakeavaluebetweenzeroand
one.Thatnumberisusedtoselectavalueonalinewhoseslopeandheightconvertsthefuzzyvaluetoa
realworldoutputnumber.Thenumberthencontrolsrealmachinery.
Ifthetrianglesaredefinedcorrectlyandrulesarerighttheresultcanbeagoodcontrolsystem.
Whenarobustfuzzydesignisreducedintoasingle,quickcalculation,itbeginstoresembleaconventional
feedbackloopsolutionanditmightappearthatthefuzzydesignwasunnecessary.However,thefuzzylogic
paradigmmayprovidescalabilityforlargecontrolsystemswhereconventionalmethodsbecomeunwieldy
orcostlytoderive.
Fuzzyelectronicsisanelectronictechnologythatusesfuzzylogicinsteadofthetwovaluelogicmore
commonlyusedindigitalelectronics.

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Physicalimplementations
Sincemodernsmallmicroprocessorsaresocheap(oftenlessthan
$1US),it'sverycommontoimplementcontrolsystems,including
feedbackloops,withcomputers,ofteninanembeddedsystem.The
feedbackcontrolsaresimulatedbyhavingthecomputermake
periodicmeasurementsandthencalculatefromthisstreamof
measurements(seedigitalsignalprocessing,sampleddatasystems).
Computersemulatelogicdevicesbymakingmeasurementsof
switchinputs,calculatingalogicfunctionfromthesemeasurements
andthensendingtheresultsouttoelectronicallycontrolled
switches.
Logicsystemsandfeedbackcontrollersareusuallyimplementedwithprogrammablelogiccontrollers
whicharedevicesavailablefromelectricalsupplyhouses.Theyincludealittlecomputerandasimplified
systemforprogramming.Mostoftentheyareprogrammedwithpersonalcomputers.
Logiccontrollershavealsobeenconstructedfromrelays,hydraulicandpneumaticdevicesaswellas
electronicsusingbothtransistorsandvacuumtubes(feedbackcontrollerscanalsobeconstructedinthis
manner).

Seealso
Controltheory
Perceptualcontroltheory
Distributedcontrolsystem
Programmablelogiccontroller
PIDcontroller
HVACcontrolsystem
Droopspeedcontrol
Controlengineering
Sampleddatasystems
Buildingautomation
VisSim
EPICS
SCADA
Coefficientdiagrammethod
Educationandtrainingofelectricalandelectronicsengineers
Industrialcontrolsystems
Processcontrol
Processoptimization
Networkedcontrolsystem
Hierarchicalcontrolsystem
Motioncontrol
Cybernetics
GoodRegulator
Numericalcontrol
BehaviorTrees(ArtificialIntelligence,RoboticsandControl)
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References
1. Kuphaldt,TonyR."Chapter6LADDERLOGIC"
(http://openbookproject.net//electricCircuits/Digital/DIGI_6.html).LessonsInElectricCircuitsVolumeIV.
Retrieved22September2010.
2. Brady,Ian."Programmablelogiccontrollersbenefitsandapplications"(http://www.optimacs.com/wp
content/uploads/2012/03/PLCreport.pdf)(PDF).PLCs.Retrieved5December2011.
3. http://www.seeei.org.il/prdFiles/2702_desc3.pdfABB:PowerGenerationEnergyEfficientDesignofAuxiliary
SystemsinFossilFuelPowerPlants,Page262,Section:LoadFollowing

Externallinks
SemiautonomousFlightDirectionReference
Wikibookshasabookon
unmannedaircraft.org
thetopicof:Control
(http://www.unmannedaircraft.org/f/pat6460810.pdf)
Systems
ControlSystemToolbox
(http://www.mathworks.com/products/control/)fordesignandanalysisofcontrolsystems.
ControlSystemsManufacturer(http://www.trminternational.com/)DesignandManufactureof
controlsystems.
Mathematicafunctionsfortheanalysis,design,andsimulationofcontrolsystems
(http://reference.wolfram.com/mathematica/guide/ControlSystems.html)
Retrievedfrom"https://en.wikipedia.org/w/index.php?title=Control_system&oldid=666800734"
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