WESCHLER INSTRUMENTS

Process Control
Most industrial processes require that certain variables such as commonly used with proportional control. This is known as two mode PI
temperature, flow, level or pressure, remain at or near some reference value control (see Process Control Modes chart on next page). In processes
(setpoint). Closed-loop control is used to achieve this. The process controller requiring relatively low gain, the integral mode continues to drive the output
looks at a signal representing the process value, compares it to the desired even when the proportional error is zero. This combination generates a
setpoint and acts on the process to minimize the difference (error). smaller total error than either mode operating alone.
The method used by the controller to correct the error is the control mode.
The derivative mode is commonly called rate control because its output is
The four most popular control modes are on/off, proportional, integral
based on the rate of change of the measured variable. This mode is rarely
and derivative.
used alone. It is typically combined with proportional control to form PD
Control Modes control or with proportional and integral control in a three mode PID
controller. The derivative term anticipates changes to reduce overshoot. A
On /off control activates an output until the measured value reaches the variant of the derivative mode uses the derivative of the measured variable
reference value. A common example is the household thermostat. No control rather than the derivative of the difference signal. This can speed response
action takes place until the measured value deviates from the setpoint by a to large process shifts but slows the response to a setpoint change.
minimum amount (deadband). The output then goes from full off to full on,
turning off again when the setpoint is reached. While simple and low cost, Although most PID controllers use proportional outputs, PID control can also
this mode of control has a tendency to overshoot the desired value. A digital be used with on/off outputs by incorporating duty cycle modulation. For
panel meter with relay output and adjustable setpoint can be used for on-off each time interval (cycle time), the controller adjusts the on time in response
process control. to the control signal magnitude. Since this generates frequent on/off
operations, solid state outputs are recommended over mechanical relays.
A more refined control method is proportional control. Here the difference
between the setpoint and measured value generates a continuous, linear Non-linear controllers may be preferred for processes that are highly
control output. The control gain K sets the system response as a function non-linear, such as pH. The standard control modes of proportional,
of time: Output(t) = K • [Setpoint - Measured(t)] + Bias. integral and derivative are superimposed on a non-linear function.
Non-linear controllers can also be used to filter noise or pulsations, while
The bias term creates a non-zero output when the error term is driven to zero. permitting effective control over large disturbances.
This allows bi-directional control. The proportional band is the span of the
measured variable that causes a full range output. A single loop controller handles one process input. Multi-loop controllers
can simultaneously control more than one process variable. Controllers with
The higher the gain, digital communication capability are often called distributed controllers.
the more the output Some controllers can also retransmit the process variable or error signal in
will change for a given analog form for display on a remote indicator.
change in
measurement or
Tuning
setpoint. High K
(narrow band) Tuning is a critical but often confusing aspect of proper controller
provides more precise application. Many reference books and on-line forums are dedicated to
control, but can create tuning issues. Tuning can be optimized for load changes, setpoint changes
stability problems. or other factors. Open loop tuning involves breaking the feedback path and
Low K (wide band) characterizing the system response. Closed loop characterization can be
controls over a wider done with the feedback loop intact, by introducing a known disturbance and
input span, but may monitoring the response. The controller can then be manually adjusted for
be slower to respond. In proportional control, if system loading requires a the signal ranges, time constants and delays of the process. This can be a
shift in operating point, a complex and lengthy task. Fortunately controllers often include automatic
difference between the tuning capabilities to learn a process and set the appropriate
measurement and set point control loop parameters.
will exist at equilibrium. The
higher the system gain, the Signal conditioning
lower the offset will be for a
given load change. Many process controllers can be connected directly to the process sensor,
such as a thermocouple or RTD. In some cases, an additional transducer
Controllers with reset or signal conditioner is required to convert the physical parameter to an
(integral) action will electrical signal that can be handled by the controller. Many of the new
automatically recenter the 'smart' sensors include this signal conditioning, eliminating the need for
proportional band around an additional module. Transducers are also needed to convert some
the offset bias level. An integral mode controller responds to the integral of electrical parameters, such as AC power, into a signal compatible with
the difference between the setpoint and measured value. The adjustable the controller's input.
parameter for integral control is the integral time T, or the reset rate 1/T.
The integral mode is sometimes used as a single mode of control but is more

181
WESCHLER INSTRUMENTS • www.weschler.com • 800-903-9870 • fax: 800-903-9590 • [email protected]