Industrial process controlAn industrial process control or simply process control in continuous production processes is a discipline that uses industrial control systems and control theory to achieve a production level of consistency, economy and safety which could not be achieved purely by human manual control. It is implemented widely in industries such as automotive, mining, dredging, oil refining, pulp and paper manufacturing, chemical processing and power generating plants.
Ladder logicLadder logic was originally a written method to document the design and construction of relay racks as used in manufacturing and process control. Each device in the relay rack would be represented by a symbol on the ladder diagram with connections between those devices shown. In addition, other items external to the relay rack such as pumps, heaters, and so forth would also be shown on the ladder diagram. Ladder logic has evolved into a programming language that represents a program by a graphical diagram based on the circuit diagrams of relay logic hardware.
Open-loop controllerIn control theory, an open-loop controller, also called a non-feedback controller, is a control loop part of a control system in which the control action is independent of the "process output", which is the process variable that is being controlled. It does not use feedback to determine if its output has achieved the desired goal of the input command or process setpoint. There are many open-loop controls, such as on/off switching of valves, machinery, lights, motors or heaters, where the control result is known to be approximately sufficient under normal conditions without the need for feedback.
Industrial control systemAn industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.
Control loopA control loop is the fundamental building block of control systems in general industrial control systems and industrial control systems in particular. It consists of the process sensor, the controller function, and the final control element (FCE) which controls the process necessary to automatically adjust the value of a measured process variable (PV) to equal the value of a desired set-point (SP). There are two common classes of control loop: open loop and closed loop.
ComputerA computer is a machine that can be programmed to carry out sequences of arithmetic or logical operations (computation) automatically. Modern digital electronic computers can perform generic sets of operations known as programs. These programs enable computers to perform a wide range of tasks. A computer system is a nominally complete computer that includes the hardware, operating system (main software), and peripheral equipment needed and used for full operation.
Control theoryControl theory is a field of control engineering and applied mathematics that deals with the control of dynamical systems in engineered processes and machines. The objective is to develop a model or algorithm governing the application of system inputs to drive the system to a desired state, while minimizing any delay, overshoot, or steady-state error and ensuring a level of control stability; often with the aim to achieve a degree of optimality. To do this, a controller with the requisite corrective behavior is required.
Setpoint (control system)In cybernetics and control theory, a setpoint (SP; also set point) is the desired or target value for an essential variable, or process value (PV) of a control system, which may differ from the actual measured value of the variable. Departure of such a variable from its setpoint is one basis for error-controlled regulation using negative feedback for automatic control. Cruise control The SP-PV error can be used to return a system to its norm.
CyberneticsCybernetics is a wide-ranging field concerned with circular causal processes such as feedback. Norbert Wiener named the field after an example of circular causal feedback—that of steering a ship where the helmsman adjusts their steering in response to the effect it is observed as having, enabling a steady course to be maintained amongst disturbances such as cross-winds or the tide.
Closed-loop controllerA closed-loop controller or feedback controller is a control loop which incorporates feedback, in contrast to an open-loop controller or non-feedback controller. A closed-loop controller uses feedback to control states or outputs of a dynamical system. Its name comes from the information path in the system: process inputs (e.g., voltage applied to an electric motor) have an effect on the process outputs (e.g., speed or torque of the motor), which is measured with sensors and processed by the controller; the result (the control signal) is "fed back" as input to the process, closing the loop.
Programmable logic controllerA programmable logic controller (PLC) or programmable controller is an industrial computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of programming, and process fault diagnosis. Dick Morley is considered as the father of PLC as he had invented the first PLC, the Modicon 084, for General Motors in 1968.
Perceptual control theoryPerceptual control theory (PCT) is a model of behavior based on the properties of negative feedback control loops. A control loop maintains a sensed variable at or near a reference value by means of the effects of its outputs upon that variable, as mediated by physical properties of the environment. In engineering control theory, reference values are set by a user outside the system. An example is a thermostat. In a living organism, reference values for controlled perceptual variables are endogenously maintained.
Distributed control systemA distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localising control functions near the process plant, with remote monitoring and supervision.
Building automationBuilding automation (BAS), also known as building management system (BMS) or building energy management system (BEMS), is the automatic centralized control of a building's HVAC (heating, ventilation and air conditioning), electrical, lighting, shading, access control, security systems, and other interrelated systems. Some objectives of building automation are improved occupant comfort, efficient operation of building systems, reduction in energy consumption, reduced operating and maintaining costs and increased security.
Process variableIn control theory, a process variable (PV; also process value or process parameter) is the current measured value of a particular part of a process which is being monitored or controlled. An example of this would be the temperature of a furnace. The current temperature is the process variable, while the desired temperature is known as the set-point (SP). Measurement of process variables is essential in control systems to controlling a process. The value of the process variable is continuously monitored so that control may be exerted.
Negative feedbackNegative feedback (or balancing feedback) occurs when some function of the output of a system, process, or mechanism is fed back in a manner that tends to reduce the fluctuations in the output, whether caused by changes in the input or by other disturbances. Whereas positive feedback tends to lead to instability via exponential growth, oscillation or chaotic behavior, negative feedback generally promotes stability. Negative feedback tends to promote a settling to equilibrium, and reduces the effects of perturbations.
ThermostatA thermostat is a regulating device component which senses the temperature of a physical system and performs actions so that the system's temperature is maintained near a desired setpoint. Thermostats are used in any device or system that heats or cools to a setpoint temperature. Examples include building heating, central heating, air conditioners, HVAC systems, water heaters, as well as kitchen equipment including ovens and refrigerators and medical and scientific incubators.
ActuatorAn actuator is a component of a machine that is responsible for moving and controlling a mechanism or system, for example by opening a valve. In simple terms, it is a "mover". An actuator requires a control device (controlled by control signal) and a source of energy. The control signal is relatively low energy and may be electric voltage or current, pneumatic, or hydraulic fluid pressure, or even human power. Its main energy source may be an electric current, hydraulic pressure, or pneumatic pressure.
TransducerA transducer is a device that converts energy from one form to another. Usually a transducer converts a signal in one form of energy to a signal in another. Transducers are often employed at the boundaries of automation, measurement, and control systems, where electrical signals are converted to and from other physical quantities (energy, force, torque, light, motion, position, etc.). The process of converting one form of energy to another is known as transduction.
