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Title: Electronics and Electrical/Instrumentation/Data Acquisition and Control - Industry automatic control fundamentals Explanation of automatic control fundamentals and their applications in production processes.
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Industry automatic control fundamentals .The concepts and terminology described here are intended to provide a general explanation of automatic control fundamentals and their applications in the production processes of the industry , including  a brief view of related  instruments characteristics . The following document is intended for training purposes only for industry workers or students  . Specific process conditions may require considerable variation from procedures and specifications described herein. INDUSTRY AUTOMATIC CONTROL FUNDAMENTALS   Industrial controllers , basic theory Function of automatic control . The feedback loop. The measurement . The process . General technical terms The automatic controller . Controlling the process .  Selecting controller action Upsets . Process characteristics and controllability . Controller responses . Proportional action .  Integral action (reset ).  Derivative action . Cascade control  Conclusion . Información en Español . Technical English - Spanish Vocabulary  The most fundamental element of any automatic control system is the basicfeedback control loop. The concept of feedback control is not new; the firstsuch industrial loop was applied in 1774 by James Watt for controlling the speedof an early steam engine. Although understanding of feedback control. loopsdeveloped slowly at first , pneumatic transmission systems did not become commonuntil the 1940's -the past few years have seen extensive study and developmentin the theory and application of feedback control loops and relative instrumentsto measure , record , indicate , transmit , analyze , and control processvariables ( among them : flow , temperature , pressure , level , moisture ,acidity , composition and  more)  . Today the applicationof feedback control loops is an essential element in successfully andeconomically manufacturing virtually every industrial product from steel tobreakfast foods. Yet this feedback control loop which is so important toindustry is based on a few very simple and easily understood principles. Thisarticle discusses this control loop, its basic elements, and the basicprinciples of its application.     Function of automatic control .The basic idea of a feedback control loop is most easily understood byimagining what an operator would have to do if automatic control did not exist. Figure I shows a common application of automatic control found in manyindustrial plants, a heat exchanger which uses steam to heat cold water. Inmanual operation, the amount of steam entering the heat exchanger depends on theair pressure to the valve which is set on the manual regulator. To control thetemperature manually, the operator would watch the indicated temperature, and bycomparing it with the desired temperature, be would open or close the valve toadmit more or less steam . When the temperature had reached the desired value,the operator would simply hold that output to the valve to keep the temperatureconstant. Under automatic control, the temperature controller performs the samefunction. The measurement signal to the controller from the temperaturetransmitter is continuously compared to the set point signal entered into thecontroller. Based on a comparison of the signals, the automatic controller cantell whether the measurement signal is above or below the setpoint and move thevalve accordingly until the measurement (temperature) comes to its final value.The feedback loop .This simple feedback control loop serves to illustrate the four majorelements of any feedback control loop(figure 2). The measurement Measurement must be made to indicate the current value of the variable controlled by the loop. Common measurements used in industry include flow rate, pressure, level, temperature, analytical measurements such as pH, ORP and conductivity and many others particular to specific industries. The final actuator For every process there must be some final actuator, which regulates the supply of energy or material to the process and changes the measurement signal. Most often this is some kind of valve, but it might also be a belt or motor speed, louver position, etc. The processThe kinds of processes found in industrial plants are as varied as thematerials they produce. They range from the simple and commonplace, such asloops to control flow rate, to the large and complex such as distillationcolumns in the petro-chemical industry.The automatic controllerThe last element of the loop is the automatic controller. Its job is tocontrol the measurement. To "control" means to keep the measurementwithin acceptable limits. In this article, the mechanisms inside the automaticcontroller will not be considered. Therefore, the principles to be discussed canbe applied equally well to both pneumatic and electronic controllers and to thecontrollers from any manufacturer. All automatic controllers use the samegeneral responses, although the internal mechanisms and the definitions givenfor these responses may be slightly different from one manufacturer to another.One basic concept is that for the automatic feedback control to exist, theautomatic control loop must be closed. This means that information must becontinuously passed around the loop. The controller must be able to move thevalve, the valve must be able to affect the measurement, and the measurementsignal must be reported to the controller. If this path is broken at any point,the loop is said to be open. As soon as the loop is opened, as for example, whenthe automatic controller is placed on manual, the automatic unit in thecontroller is no longer able to move the valve. Thus signals from the controllerin response to changing-measurement conditions do not affect the valve andautomatic control does not exist.CONTROLLING THE PROCESSIn performing the control function, the automatic controller uses thedifference between the set point and measurement signals to develop the outputsignal to the valve. The accuracy and responsiveness of these signals is a basiclimitation on the ability of the controller to correctly control themeasurement. If the transmitter does not send an accurate signal, or if there isa lag in the measurement signal, the ability of the controller to manipulate theprocess will be degraded. At the same time, the controller must receive anaccurate set point signal. In controllers using pneumatic or electronic setpoint signals generated within the controller, miscalibration of the set pointtransmitter will necessarily result in the automatic control unit in thecontroller bringing the measurement to the wrong value. The ability of thecontroller to accurately position the valve is yet another limitation. If thereis friction in the valve, the controller may not be able to move the valve to aspecific stem position to produce a specific flow and this will show up as adifference between measurement and set point. Repeated attempts to exactlyposition the valve may lead to hunting in the valve and in the measurement. or,if the controller is only able to move the valve very slowly, the ability of thecontroller to control the process will he degraded. One way to improve theresponse of control valves is to use a valve positioner, which acts as afeedback controller to position the valve at the exact position correspondingthe controller output signal. Positioners, however, should be avoided in favorof volume boosters on fast responding loops such as flow arid liquid pressure.To control the process, the change in output from the controller must be insuch a direction as to oppose any change in the measurement value.Figure 3 shows a direct connected valve to control level in a tank atmidscale. As the level in the tank rises, the float acts to reduce the flow ratecoming in thus, the higher the liquid level the more the flow will be shut off.In the same way, as the level falls, the float will open up the valve to addmore liquid to the tank. The response of this system is shown graphically. As the level goes from 0% to 100%, the valve goes from fully open to fullyclosed. The function of an automatic controller is to produce this kind ofopposing response over varying ranges; in addition, other responses areavailable to more efficiently control the process. >> Next >> Function of automatic control .  - The feedback loop. - The measurement .  - The process .  General technical terms  The automatic controller .  -  Controlling the process .  -  Selecting controller action - Upsets .   Process characteristics and controllability . - Controller responses . - Proportional action . - Integral action (reset ).  Derivative action . - Conclusion . Other topics : Stepping motors , widely used in industry , basic theory . Need to convert English units to SI International System ? , click here .  Gaining traction control on your truck is easier than gaining control in industrial manufacturing. Luckily, you can outfit your truck with chrome accessories to improve performance, like K&N air filters or a new exhaust system, so you can have control of your vehicle at all times. Shop : Visit the World's Online Marketplace . - Buy Music : Buy in the World's Online Marketplace . @Contact thewebmaster@   -  
 

Explanation

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Explanation of automatic control fundamentals and their applications in production processes.

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