Industrial Systems Control: A Comprehensive Analysis

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Industrial Systems
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Contents
Introduction......................................................................................................................................2
LO1:.................................................................................................................................................4
a....................................................................................................................................................4
b....................................................................................................................................................5
c....................................................................................................................................................5
d....................................................................................................................................................6
LO2:.................................................................................................................................................7
a....................................................................................................................................................7
b....................................................................................................................................................7
c....................................................................................................................................................7
d....................................................................................................................................................8
LO3:.................................................................................................................................................9
a....................................................................................................................................................9
b..................................................................................................................................................11
c..................................................................................................................................................12
d..................................................................................................................................................12
LO4:...............................................................................................................................................13
a..................................................................................................................................................13
b..................................................................................................................................................13
c..................................................................................................................................................14
Conclusion.....................................................................................................................................15
References:....................................................................................................................................16
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List of Figures
Figure 1: Industrial process and configuration picture....................................................................3
Figure 2 output of the dc motor.......................................................................................................7
Figure 3: Control system with unity feedback.................................................................................9
List of Tables
Table 1: Characteristics of PID gain................................................................................................9
2

Introduction
This assignment illustrates the main elements of electronic control system, industrial system and
its configuration, Dc motor and its speed controlling methods, robotic linear motion, and PID
controller. This assignment gives complete idea of control engineering and measurement system.
The industrial system is concerned with optimization of complex system and industrial
engineering creates organization by integrating system for the people.
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LO1:
a.
Industrial System’s Main Components
Industrial system is mostly based on heavy machines and these machines are controlled by smart
electronic device. The devices are used to manipulate the complete industrial system. PLC and
SCADA system is mostly used to run the heavy machinery in industry. The main elements of
industrial control system are configured and executed in a given sequence.
Input sensor
The input transducers are controlled electronically with the input sensors and these sensors are
used according to the given situation. For instance, in the silo process system this electronic
sensor is used as electronic valve.
Industrial system Process
In the process of industrial system, electronic comonents play crucial role and work like other
parts work in industrial system for instance, in cenment manufacturing factory the mixture are
used for mixing the gradients.
Measuring elements
The electronic components measures the scalling parameters of all industrial system like digital
temperature and presure measuring devices. These devices play essential role because of its need
and requirement. For any kind of alarming system these measuring devices are interfaced with
the controller and proper feedback is obtained via programming. For instance fire alarm is also a
measuring device which update the system about the dangour of fire and smoking area.
Feed back
Feedback is major element which plays essential role in whole procedure, feedback not only put
output in operational range but also give information about error in system. The concept of
feedback is used to make the system balance.
Output
In industrial process, the output is the final product which came after executing all the above
procedure success fully. This output should be in linear operating mode and should be run as per
need of system requirement.
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Figure 1: Industrial process and configuration picture
b.
The Key Ideas of Industrial Control Systems
This system is used to increase the productivity and quality of entire procedure of industrial
system. Mostly, advance control strategies are used to manipulate the industrial process. In the
industrial system the controller input signals are obtained from the measurement sensors, for.
The values which are captured by sensors use to make comparison with the reference point in the
controller. The exact value which comes after comparison used to control the actuator. Actuator
is controlled the input process as mentioned in above figure.
c.
DC Motor’s Speed Control Techniques: Pros and Cons
There are three main method of controlling DC motors
Controlling speed through flux
In this method the dc motor speed and flux per pole both are inversely proportional to one
another.
Advantage
The main advantage of this method is rheostat control which is obtained easily by using series
parallel control. It is very convenient way to control the motor.
Disadvantage
There is disadvantage of field control method which used to control the speed of DC shunt
motor.
Armature control method
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Armature control method is synchronized with its resistance. By varying the resistance the
voltage across the armature is controlled due to which the variable resistor and armature are
connected in series.
Advantage
The variation in resistance does not affect the flux of motor.
Disadvantage
This controlling procedure is applied for tiny motors. In this method large amount of power is
wasted.
Controlling through voltage
In this method fixed amount of voltage is given to field winding whereas the variable voltage is
given to armature. PWM signal is used to manipulate the motor’s speed in an efficient way.
Advantages
This method provides the speed control in desirable range.
Disadvantage
This method is little expensive because dc drives are used to run the dc motor.
d.
Critical Analysis and Evaluation of DC Motor Control
The controlling methods can be improve by using optimized method, for instance, controlling the
speed of DC motors by using PID parameters and genetic algorithm. In this method there are
three parameters KP, KI, KD which can control speed of dc motor in more efficient way.
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LO2:
a.
Mechanical, Electrical and Electronics Transducers and Controllers
Transducers are used to convert energy of one kind into the energy of another kind. There are
different types of transducer like electrical transducer, mechanical transducers, and electronic
transducers. These transducers are selected according to the given scenario for instance,
mechanical transducers are used where we need to convert physical quantity into the mechanical
quantity like below is the mechanical transducer. it is used to convert the air pressure into
displacement. There is another famous example of a spring which is used to measure the force.
Electrical transducers are used where we need to convert the physical quantity into electrical, for
instance, solar cells which are used to convert the physical quantity into electrical. The sun
energy is converted into electrical energy by photovoltaic cells. The utilization of transducers is
totally depended upon the requirement.
b.
Transducer in Robotic Linear Motion
For robotic linear motion, there are of plethora of transducers which can refer any number of
sensors such as rotary position, and tachometer which is used to detect the speed of object. The
selection of transducer depends upon how much quality we need which is being measured or
controlled. The right transducer could be a simple potentiometer. A displacement transducer
belongs to electrical transducer which is used to measure the liner displacement.
c.
Robotic Behavior of Control System
Transducers play important role in robot and due to these transducers the working efficiency of
control system is improved. For instance, the position sensors are used to measure the position of
robot’s joint.
In the position sensor if we interface encoder which is the digital optical device that converts the
motion into the digital pulses.
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Potentiometer is another transducer that expresses linear or angular displacement in form of
voltage. This sensor is very necessary to detect the motion of robot.
These sensors are controlled by the micro controllers which are effectively operating the robot.
For small robots microcontroller like arduino can be used to run the robot.
The best solution for making efficient robot is PLC and SQADA system which can manipulate
the transducers in efficient way. The transducers and microcontrollers give precise values but
these types of transducers are expensive.
d.
Robotic Behavior of Control System and Comparison Between The Approaches
There are lots of control systems which manipulate the controlling section of robot like
controlling motion through the servo motor. Consider the simple car robot which uses
microcontroller, input and output sensors having proper feedback. The behavior of robot and
robotic motion is controlled via dc gear motor. But the difference between the both motor is that
the servo motor works on the steps and give precise motion but dc gear motor does not give
precise values moreover, dc motors need special kind of drivers to run because the motion can
only control through the pulse width modulation externally.
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LO3:
a.
Matlab Code for Controlling DC Motor Process, Including Tolerance, Repeatability,
Stability and Error in Systems
Matlab is software used to resolve the analytical and technical problems, which are related
programming. For instance, the controlling of dc motors and this software also provides the
output behaviors of different responses like rising time, settling time and overshoot etc.
In this program the PID controller is used to control the different responses of system including
settling time, rising time, overshooting etc. PID controller is used to make the system stable and
by using these controllers error of controlling system is also minimized. In this program the KI
gain is used to decrease the rise time and steady state error. Kp is used is use to increase the
settling time period of the dc control system.
Code of Possible Responses and Controlling DC Motors: In This Code The PID Control Is
Used To Check The Response Of Entire System.
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Figure 2 output of the dc motor
b.
The Practical and Analytical Method of Creating and Testing the Measurement System
Measurement system analytical method follows the following steps
1. Selecting correct measurement and approach
It is very necessary to follow the exact measurement approach and check the availability of
suitable analytical method.
2. Assessing the measuring device
Check the procedure of measuring device and get update from all transducers.
3. Assessing procedure of system and handing its operators
After checking the measurement device and check the procedure of system and handle its
operators.
4. Handing the uncertainty of individual measurement device
Monitor the system continuously and check the uncertainty error if come.
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