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04IndustrialRobotic ControlAutomation EWS

The document discusses industrial control systems, including: 1. It defines automation as technology that accomplishes processes without human assistance. 2. It describes the basic elements and levels of automation in industrial control systems, including continuous and discrete control. 3. It distinguishes between process industries, which deal with continuous materials, and discrete manufacturing industries, which deal with discrete parts.

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haikalakhmadsandyasha
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22 views25 pages

04IndustrialRobotic ControlAutomation EWS

The document discusses industrial control systems, including: 1. It defines automation as technology that accomplishes processes without human assistance. 2. It describes the basic elements and levels of automation in industrial control systems, including continuous and discrete control. 3. It distinguishes between process industries, which deal with continuous materials, and discrete manufacturing industries, which deal with discrete parts.

Uploaded by

haikalakhmadsandyasha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Industrial Control Systems

Sections:
1. Basic Elements of an Automated System
2. Levels of Automation
3. Process Industries vs. Discrete Manufacturing Industries
4. Continuous Control
5. Discrete Control
6. Computer Process Control
7. Supervisory Control
8. Enterprise Control
Automation Defined
Automation is the technology by which a process or
procedure is accomplished without human
assistance

Automation has cost-benefits Program


Instructions
Control
System

Transformation Process

Power
Program of Instructions
Set of commands that specify the sequence of steps in the work cycle and the details of each step
• CNC part program, Robot program, AS/RS program, etc.
Work Cycle Program
• Number of steps in the work cycle
• Manual participation in the work cycle (e.g., loading
and unloading workparts)
• Process parameters - how many must be
controlled?
• Operator interaction - does the operator enter
processing data?
• Variations in part or product styles
Control System
Control Architecture
Enterprise
Level 4 Control
Business Information
Plant Control (Business Office)
Level 3 (Production,
Quality, …)

Level 2 Cell Controller


(Supervisory Control)

Level 1 Machine Controller


(Automatic Control) Industrial Automation
(Shop Floor)
Level 0 Device Control
(Sensors/Actuators)

Raw Part or
Material Transformation Process Product

Scrap or
Power Waste
Tools
Machines
Labour
Automatic Control - Level 0 and 1
Input
Parameters Logical
(Level 2) Error Signal

Controller Actuators Inputs

Process

Feedback Signal
Sensors Output
Variables
Sensors – Level 0

Physical Sensing Conditioning Target Signal


Medium Element Handling

Temperature Resistance Voltage Information


Actuators – Level 0

Logical Mechanism
Signal Signal Processing Electric Hydraulic
& Amplification Final Actuation
Pneumatic
Element

Actuator
Sensor
Industrial Control Systems
The automatic regulation of unit operations and their
associated equipment as well as the integration and
coordination of the unit operations into the larger
production system
Process vs. Discrete Industries

• Process industries
• Production operations are performed on amounts of materials
• Liquids, gases, powders, etc.

• Discrete manufacturing industries


• Production operations are performed on quantities of materials
• Parts, product units
Variables and Parameters

• Variables - outputs of the process


• Parameters - inputs to the process
• Continuous variables and parameters - they are uninterrupted as time proceeds
• Discrete variables and parameters - can take on only certain values within a given range
Types of Control

• Continuous control - variables and parameters are continuous and


analog
• Discrete control - variables and parameters are discrete, mostly binary
discrete

• Maintain the value of an output variable at a desired level


• Parameters and variables are usually continuous
• Similar to operation of a feedback control system
• Most continuous industrial processes have multiple feedback loops
• Examples: Chemical reaction (temperature, pressure, etc.); Position control of gripper at end of a
robot arm
Types of Continuous Process
Control
• Regulatory control
• Feed forward control
• Steady-State optimization
• Adaptive control
• On-line search strategies
• Other specialized techniques
• Expert systems
• Neural networks
Regulatory Control
• Objective - maintain process performance at a
certain level or within a given tolerance band of
that level
• Appropriate when performance relates to a quality
measure
• Performance measure is sometimes computed
based on several output variables
• Performance measure is called the Index of
performance (IP)
• Problem with regulatory control is that an error
must exist in order to initiate control action
Regulatory Control
Feedforward Control
• Objective - anticipate the effect of disturbances that
will upset the process by sensing and compensating
for them before they affect the process
• Mathematical model captures the effect of the
disturbance on the process
• Complete compensation for the disturbance is difficult
due to variations, imperfections in the mathematical
model and imperfections in the control actions
• Usually combined with regulatory control
• Regulatory control and feedforward control are more
closely associated with process industries
Feedforward Control
Combined with Feedback Control
Steady-State Optimization
Class of optimization techniques in which the
process exhibits the following characteristics:
1. Well-defined index of performance (IP)
2. Known relationship between process variables and IP
3. System parameter values that optimize IP can be
determined mathematically
• Open-loop system
• Optimization techniques include differential
calculus, mathematical programming, etc.
Steady State (Open-Loop)
Optimal Control
Adaptive Control

• Because steady-state optimization is open-loop, it cannot compensate


for disturbances
• Adaptive control is a self-correcting form of optimal control that
includes feedback control
• Measures the relevant process variables during operation (feedback control)
• Uses a control algorithm that attempts to optimize some index of
performance (optimal control)
Adaptive Control Operates in a
Time-Varying Environment
• The environment changes over time and the changes
have a potential effect on system performance
• Example: Supersonic aircraft operates differently in
subsonic flight than in supersonic flight
• If the control algorithm is fixed, the system may
perform quite differently in one environment than in
another
• An adaptive control system is designed to
compensate for its changing environment by altering
some aspect of its control algorithm to achieve
optimal performance
Three Functions in Adaptive
Control
1. Identification function – current value of IP is
determined based on measurements of process
variables
2. Decision function – decide what changes should
be made to improve system performance
• Change one or more input parameters
• Alter some internal function of the controller
3. Modification function – implement the decision
function
• Concerned with physical changes (hardware rather
than software)
Adaptive Control System
On-Line Search Strategies
• Special class of adaptive control in which the
decision function cannot be sufficiently defined
• Relationship between input parameters and IP is not
known, or not known well enough to implement the
previous form of adaptive control
• Instead, experiments are performed on the
process
• Small systematic changes are made in input parameters
to observe effects
• Based on observed effects, larger changes are
made to drive the system toward optimal
performance

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