Feedback and Control (EST323L-T)

TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES

TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 1 of 10

Members

No Name & Signature Task Assigned Group Grade Individual Overall

(70%) Grade (30%) Grade
1 Analysis of I/O devices
2 Controller device
3 Temperature control
4 Water-level control
5 Pressure & Flow-rate
6 System response analysis

Specific Learning Outcome

1. Enumerate the (input and output) devices and the (flowing) signals within a given multivariable control system.
2. Determine the technical specifications of the controller device that would suit the system’s requirements.
3. Extract and draw the General Block Diagram for the single control loop process variable.
4. Discuss the Output Response according to Controller’s Command and Actuator’s Action.

Materials

Process Control Training modules (Temperature, Level, Pressure and Flowrate)

PLC Modules with ebook PLC manual
Laptop/smart phone, MS Word, online connectivity

Video Lessons
Topic 1 Applications https://youtu.be/PJYaeZd0lOM
Topic 2 Part 1 Open-Loop: https://youtu.be/KQ5yP-meUMA
Topic 2 Part 2 Close-Loop: https://youtu.be/h83cvF-WMNk
Topic 2 Part 3 Multivariate: https://youtu.be/uoYgVO80wFI
Topic 2 Part 4 Assignment: https://youtu.be/jlaF60w9vUg
Topic 3 Nomenclature: https://youtu.be/f2UJ9tA3hMk
Topic 4 IPO Devices: https://youtu.be/6kYbhWExQLg

References
Closed-Loop Control System by Brian Douglas: https://www.youtube.com/watch?v=O-
OqgFE9SD4&list=PLUMWjy5jgHK3j74Z5Tq6Tso1fSfVWZC8L&index=1
Textbook: Control System Engineering by Norman S. Nise

PAGES 1 TO 9 SHOULD BE PRINTED ONE COPY PER GROUP.

1 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 2 of 10

Basic Principle

Analysis and Design of Control Systems

In analyzing control systems, the system’s operation and output performance is being determined. The sequence of
operation is first understood to learn the expected output performance. How the individual device of the system responds to the
command and take action is directed through the step-by-step processes. The technical design and concept of the system is a
requirement to be able to operate and troubleshoot the machine. But if it is not known, system analysis plays a big role in order
to operate and maintain the machine accordingly.

Input-Control-Output System

The basic concept of a system’s block diagram is composed of three major devices for Input-Control-Output concept, as
shown in Figure 1. The input devices are either transducers or sensors that converts a human or physical information into an
electrical signal that a machine understood. This information is then process by a control logic device to make a decision that
commands an output device or actuator. These output devices take action according to the amount of correction needed to
achieve a desired output performance.

Input Control Output Output

Information Device Logic Device Response

Figure 1: Basic System Block Diagram

Source: Control System Engineering by Norman S. Nise

General Block Diagram

This basic block diagram is incorporated in a general block diagram to illustrate the complete control concept of the
system. Figure 2 is a general block diagram of a Feedback Control System, also known as Closed-Loop System. The
feedback element is a sensor device that detects and measures the actual value of the controlled variable, which is then send
back to the control unit for comparison to a reference variable. Sensors are also input devices and also a type of transducers,
that converts a physical quantity into an electrical signal. Automation is achieved thru the design concept of feedback-
controlled systems.

There are systems that does not have a feedback element and is called an Open-Loop System. The accuracy of this
type of system relies on the precision and calibration of the input and output devices, and a very reliable program of the
control unit.

Reference Input Control Actuator Process Controlled

Signal Transducer Logic Variable

Sensor

Figure 2: General Block Diagram of a Closed-Loop System

2 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 3 of 10

Multivariate Control System

When the system has more than one controlled variable, is it so called a multi-variable or simply multivariate control
system. Figure 3 represents a control system that has three controlled variables. When analyzing a control system, it is
necessary to identify the individual control loop for a particular controlled variable.

Input-
Reference Control- System Output
Signals Output Process Variables

Sensor

Figure 3: Block Diagram of a Closed-Loop Multivariate Control System

Process Flow Diagram

A Process Flow Diagram is a kind of block diagram that conveys the overall operation of a process control system. The
interconnection of the devices and signals or information are shown to imply the role of each device to the system. The
common industrial applications in the field of process control system involves the four process variables namely, temperature,
level, pressure and flowrate. Systems that involve more than one processed variable are called multivariate control system.
For each process variable, there should be one complete control loop.

The multivariable control system in shown in Figure 4 has the four common processed variables.
a) The Temperature Control Loop is a closed-loop system that has two different actuators: (1) heater coil for increasing
the temperature and (2) the cooling tank arrangement for decreasing the temperature.
b) The Liquid-Level Control Loop is also a closed-loop system, wherein there are two set point levels: (1) minimum liquid
level to be maintained, tank should not be totally empty and (2) maximum liquid level which will be the basis of triggering
the next step in the cycle.
c) The Pressure Control Loop is an open-loop system. Since the tank is closed, the pressure inside it increases due to
increasing level of the water and because of the increase of temperature inside the tank. Therefore, the pressure should
be monitored on a level that will not cause over-pressure inside the tank. There is a fixed set-point pressure according
to the design specification of the process tank.
d) The Flowrate Control Loop is an open-loop system. The flowrate sensor is for monitoring that there is water circulating
from the process tank to the cooling tank thru the water pump. If there is no water flowing while its at “on” state, the
water pump might be damaged.

3 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 4 of 10

Figure 4: Process Flow Diagram of a Four-Variable Process Control System

The System’s Operating Process

1.0 The sequence of operation of the system in Figure 4 are as follows:

1.1 The initial level of water in the tank could be ant any point between minimum and maximum, at room temperature.
1.2 Upon pressing the start button, the sequence begins by filling the tank with water until it reaches a maximum level.
1.3 At maximum water level, the temperature of water needs to be increased until it reaches a specified heat.
1.4 At the correct amount of temperature, the water will start to drain until it reaches the minimum level of water.
1.5 The cycle then repeats continuously until the stop button is pressed, and the whole operation ends.
2.0 Important considerations:
2.1 The start and stop button could be pressed anytime during the entire operation.
2.2 The temperature set point could be adjusted (increased or decreased) anytime during the process operation.
2.3 It is advisable to stop the operation when adjusting the level of water (both minimum and maximum levels).
2.4 The difference between the minimum and maximum water levels should be at least 50% tank capacity.
2.5 The pressure inside the process tank is pre-programmed to have a maximum value and is not advisable to be
changed.
2.6 The flowrate sensor is to ensure that there is water circulating between process tank and cooling tank when water
pump is working.

4 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 5 of 10

Laboratory Procedure

A. Analyzing the System’s Input/Output Devices and Signals

1. Read the System Operating Process of Figure 4 under the Basic Principle. Analyze the concept of the block diagram. Identify
which are the input devices, the output devices and the feedback elements (sensor) if any. Write your answers in Table 1.
Write “Not Applicable” if there is no device for a particular part of the control loop.

Table1
Identification of Hardware Devices used in the Four-Variable Process Control System

Temperature Control Water-level Control Pressure Control Water Flowrate

Loop Loop Loop Control Loop
Input Devices
(input transducers)

Input Devices
(output sensors)

Output Devices Heating:

(actuators)
Cooling:

2. Describe the following signals (information) and output performance of the system in Figure 4. Write your answers in Table
2.

Table2
Identification of Input and Output Signals of the Four-Variable Process Control System

Temperature Control Water-level Control Pressure Control Water Flowrate

Loop Loop Loop Control Loop
Input Signal/Stimulus
(set point)

Desired Response

Output Response

Actual Response

5 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 6 of 10

B. Controller Device Specifications

3. The controller device used in this system is a Programmable Logic Controller (PLC). After identifiying the number of
required input and devices, and understanding the signals flowing through the system, recommend a PLC model that
would meet the requirements. Look in the internet the different models of a PLC. Remember that the input signals to the
system are analog (continuous) signals. Provide the specification of PLC model and describe the purpose in choosing the
values for the given system. Write your answer in Table 3.

Table3
PLC Model and Specifications

No. Feature Values Purpose

1. PLC Brand and Model Number

2. AC Power supply (power source) _________VAC, _________Hz

3. DC Power supply VDC

(terminal inputs)
4. External Power supply _________mA, _________VDC

5 Input Terminal Block Word I, from _____ to _____

Word I, from _____ to _____
6 Output Terminal Block Word O, from _____ to _____
Word O, from _____ to _____
7 Number of Analog inputs
8 Input signal range Volts
9 Number of Analog outputs
10 Output signal range Volts

4. Draw the Input-and-Output terminal blocks of the PLC model you have selected in Figure 5.

Figure 5 PLC I/O Terminal Block

6 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 7 of 10

C. Individual General Block Diagram

5. Separate the four control loops (Temperature, Level, Pressure and Flowrate) into separate general block diagrams. Make
sure to identify which are the open-loop and the closed-loop connections.
6. Draw the general block diagram for Temperature Control Loop in Figure 6.

Figure 6 Temperature Control Loop Block Diagram

7. Draw the general block diagram for Level Control Loop in Figure 7.

Figure 7: Water-Level Control Loop Block Diagram

7 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 8 of 10

8. Draw the general block diagram for Pressure Control Loop in Figure 8

Figure 8: Pressure Control Loop Block Diagram

9. Draw the general block diagram for Flowrate Control Loop in Figure 9.

Figure 9: Flowrate Control Loop Block Diagram

8 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 9 of 10

D. System Performance

10. Describe how the Controller will command the Actuator’s action according to the actual response. And how will the output
response be afftected. Write your answers in Table 4.

Table 4
Identification of Input and Output Signals of the Four-Variable Process Control System

Controlled Actual Response Controller’s Command Actuator’s Action Output Response

Variable (Sensor measurement) (due to error value)
Temperature Below set point
(+ error)

Equal to set point

(zero error)

Above set point

(-error)

Water level Reached maximum level

(error = level 2)

Between min and max

levels
(L2 > error > L1

Reached minimum level

(error = level 1)

Pressure Below set point

(- error )

Equal to set point

(zero error)

Above set point

(+ error)

Flowrate With flowrate reading

(+ error)

Zero flowrate
(error = 0)

9 Note: You may delete the blue boxes once you pasted your figures, and this note as well.
 Feedback and Control (EST323L-T)
TECHNOLOGICAL UNIVERSITY OF THE PHILIPPINES
TAGUIG CITY
The Technological University of the Philippines shall be the premiere state Laboratory Tile: Nomenclature of a Control System
university and the model of excellence in technology education in the country Laboratory No: 1
in a knowledge-based economy of the 21st century.
Faculty: Engr. Rica Jane Y. Kosca Date Submitted: Week No.:
Section: Electronics Section Group No.: Term No:
Department: Electrical & Allied Department Section: Page 10 of 10

Individual Interpretation of Data and Conclusion

Name: ______________________________________ Date: _______________________________

Section: ____________________________________ Grade: __________x0.3_______________

A. Interpretation of Data
Input / Output Devices

Controller specifications

Multivariable system

Process Control Variables

1. Controller’s Command
versus error signal
2. Actuator’s Action
versus Controller’s
Command
3. Output Response
versus Actuator’s
Action

B. Conclusion
Outcome 1
Devices & Signals

Outcome 2
Controller Requirements

Outcome 3
Control Loop Block Diagram

Outcome 4
System Performance

This page should be printed as template and write your individual interpretation and conclusion in handwritten.

10 Note: You may delete the blue boxes once you pasted your figures, and this note as well.