Engineering Science

Introduction to Systems

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 System Diagrams

INPUT PROCESS OUTPUT

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Control Systems

All systems require some form of control to make them work properly. This can be
done by people (Manual Control) or by technological devices (Automatic Control).
There are two main ways of controlling systems—Open Loop Control and Closed
Loop Control.

Open Loop Control

Open loop control is the simplest type of control and it is the most common type.
It is widely used in the home and industrial systems because it is simple to
operate and cheap to install.

For example, domestic lighting systems usually have open loop control. The input
is the action of pressing a light switch and the output is the light from the
filament of the bulb.

As the action and the decision to put on the light would be done by a human
being, this is fully described as Manual, Open Loop Control.

A sub-systems diagram of a room lighting system is shown below.

Manual Light Switch Electric Wiring Light Bulb Light

Input

System Boundary

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Assignment 1 - Open Loop Control

Redraw the systems diagrams shown below, filling in the missing inputs, processes
and outputs into your jotter.

Torch

Cash Machine

Gas Fire

DVD Player

Microwave

Vending Machine

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Sub-Systems

The Universal System can be broken down into a number of sub-systems. For
example, a sub-systems diagram of a washing machine could look like this.

Dirty Clean
On/Off Switch Water Heater Drum Motor
Clothes Clothes

System Boundary

A systems boundary is drawn with a broken line. It represents the limits of the
system. Note that the inputs and outputs are the only things that cross the
system boundary.

A full sub-systems diagram of the washing machine could be a bit more

complicated.
Electricity Electricity Dirty Clothes Clean Water

Programme Water
Selector Pump

Clean
Manual On/Off Control Water Drum Clothes
Control Drum
Switch Unit Heater Motor
Waste
Water
Door
Closed
Powder
Dispenser

System Boundary
Washing
Powder

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Closed Loop Control

Closed Loop Control is more complicated and more expensive than Open Loop
Control but it is more accurate at controlling domestic and industrial systems.

Closed Loop Control systems are capable of making decisions and adjusting their
performance to suit changing output conditions. A good example is a
thermostatically controlled fan heater.

A sub-systems diagram for the fan heater is shown below. A sensor is used to
measure the temperature of the room. Once the desired output is achieved, this
type of heater will automatically switch off. Equally, if the room temperature
falls too low, the heater will come on automatically.

Feedback Loop
Thermostat

On/Off Control Motor Heater Desired

Manual Fan
Temperature
Input

System Boundary

Feedback Loops
Automatic Closed Loop Control
The heater is a good example of this. The sensor measures the temperature
output and sends a signal back to the input—this is called a feedback loop. This is
fully described as Automatic, Closed Loop Control.

Manual Closed Loop Control

There may or may not be a physical link between the output and the input. Both
the monitoring and the control unit operation may be done manually.
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For example, the light level in a room could be controlled with a dimmer switch.
The light level in the room can be measured by a human eye and the switch
adjusted manually to give exactly the light level required. This is fully described
as Manual, Closed Loop Control.

Feedback Loop
Manual Observation

Set Light level Electric Wiring Light Bulb Desired Light

Manual
Level
Input

System Boundary

A Closed Loop Control system can always be identified by the presence of a

feedback loop. The feedback and control can either be Manual or Automatic. An
Open Loop Control system never has a feedback loop.

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Assignment 2 - Closed Loop Control

Redraw the systems diagrams shown below, filling in the missing sub-systems into
your jotter.

Fridge

_________________

Manual ______
____ Control Unit Fridge Coolant
Input

Central Heating

Temperature Sensor

_______ Temperature Desired

_________ Boiler _______
Setting Temperature

Stadium Roof

Limit Switch

Manual ___________
___________ Control Unit Driver ______
Input

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Sprinkler System

_____________

Manual Control Valve Open/ Water

Set Level _____
Input Unit Closed On/Off

_______

Tumble Dryer

_________

Moisture Sensor

Door Sensor
Manual
Input
Program _________ Heater Heat
_______
Selection
Driver _____ Drum
_____ Movement
Wet
Clothes
Electricity Waste
Water

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Homework

1. A) Draw the Universal Systems Diagram.

B) Draw a systems diagram for the cement mixer
shown. Show all inputs and outputs.

2. A manufacturer wants to use a cruise control system to keep a car’s speed

constant even when it goes up and down hills. The system should allow a
driver to take their foot off the accelerator once the desired speed has been
set.
A) Complete the systems diagram below for the cruise control system.

B) This control systems makes use of a feedback loop. State the type of
control produced by this automatic system.

3. Give 3 further examples of Open Loop Control. Draw a systems diagram for
each, showing all inputs and outputs.

4. Give 3 further examples of Closed Loop Control. Draw a systems diagram for
each, showing all inputs and outputs.

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Problems—From past papers

1. A petrol driven mini-moto is shown below.

(a) Complete the system diagram below for the mini-moto by adding the
main input energy and the main output energy.

………………………… Energy ………………………… Energy

Mini-moto

(b) The main parts of a mini-moto drive system are shown in the diagram
below.
B

Input Output
Engine Gearbox Chain Drive
Energy Energy

(i) (A) separates the system from the outside world. State the name of
this part of the diagram.

(ii) The whole system can be broken down into several parts labelled
above as (B). State the name given to these parts.

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2. A hand held games console is shown.

A simplified diagram of the main parts of the games console is shown below.

(a) Complete the diagram by adding:

(i) the missing input (A);
(ii) output (B);
(iii) the system boundary.

(b) The system consists of six parts shown above. These parts of the system
are called __________________________.

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3. Hair straighteners are shown below.

(a) Complete the system diagram below for the hair straighteners by adding
one main input energy and one main output energy.

………………………… Energy ………………………… Energy

Hair
Straighteners

(b) The main parts of the hair straighteners are shown below.

ON/OFF Heating Ceramic

Switch Element Plates

(i) (A) separates the system from the outside world. State the name of
this part of the diagram.

(ii) The whole system can be broken down into several parts labelled
above as (B). State the name given to these parts.

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4. A CD player is shown below.

(a) Complete the diagram below for the CD player by adding one main input
and one main output. One input has been provided for you.

Switch ON (Electricity)
…………………………
…………………………. CD Player

(b) Draw the Universal System Diagram.

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5. A manufacturer wants to use a cruise control system to keep a car’s speed
constant even when it goes up and down hills. The system should allow a
driver to take their foot off the accelerator once the desired speed has been
set.

(a) Complete the diagram below for the cruise control system.

____________________

____________ Constant
Control Unit Engine Wheels
Speed

(b) This system makes use of a feedback loop. State the type of control
produced by this automatic system.

6. The moisture level in a greenhouse is controlled automatically.

(a) Complete the diagram below.

Moisture Sensor

Set moisture Output Desired

___________ Water valve
level Driver moisture
level

(b) State the type of control produced by this automatic system.

(c) State a suitable electronic device which could be used for the output
driver sub-system. 15
7. An air conditioning system is operated by closed loop control.

(a) Complete the diagram below.

__________________

Set Output _______

Control Unit ___________
temperature Driver

(b) State a suitable electronic component which could be used for the
output driver sub-system.

8. The temperature of a steam room in a leisure centre is controlled

automatically.
A valve opens to release steam when the temperature is below the set level.
When the temperature of the room is hot enough, the valve is closed.

(a) State the type of control produced by this automatic system.

(b) Complete the diagram.

Temperature Sensor

Set Desired
Control Unit ___________ Valve
temperature temperature

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