UNIT-3

CONTROL SYSTEM COMPONENT AND

PROCESS CONTROL

Prepared By
Sravan Kumar Sudabathula,
Lecturer,
Dept of Marine Engg,
Maritime Academy of Nigeria.
 UNIT-3 TOPICS

3.1 State the components of a simple control system.

3.2 Describe and sketch a simplified data logger system.
3.3 Name some commonly used parameter sensing
instruments and describe their modes of operation.
3.4 Define process control and describe servo-
mechanism(kinetic-control)
3.5 Name and describe some recording and display
equipment.
 Components of a simple control system
i. Controlled variable
ii. Measured variable
iii. Set point
iv. Error signal
v. Controller output
vi. Manipulated variable
 Components of a simple control system
i. Controlled variable: It is a process parameter being controlled.
Ex: water level in the tank is the controlled variable.
• Controlling this variable is the primary function of process
control.
ii. Measured variable: this measured variable is the electronic
(or) pneumatic representation of the value of the controlled
variable.
• It comes from the transmitter, which measures the controlled
variable and produces an output.
iii. Set point: The measured variable is sent to the controller in the
loop, where it is compared to a desired value called the setpoint.
• The setpoint is often manually entered by an operator, but it can
also be automatically obtained from other systems.
iv. Error signal: the error signal is the difference between the
measured level and the setpoint. It can either a negative or positive
value.
• The error signal is then added to the base signal level of the
controller to create the controller output.
Ex: The base or initial output, value of the controller may be
50%with a zero error signal. Any error signal developed by the
controller is then added or subtracted to this 50% base level.
v. Controller output: the controller output is simply the total
output of the controller. With the controller in automatic, the
output is calculated by the controller itself.
vi. Manipulated variable: The manipulate variable is the
parameter that is adjusted to bring the process back to the
desired setpoint.
Ex: the manipulated variable in this case is the water entering the
tank. The water flow is manipulated in order to keep the level
constant as the output demand changes.
 Data logger
• A data logger is an electronic device that records data over
period of time.
• Typically a compact, battery powered device equipped with an
internal microprocessor, data storage and one or more sensors.
• Can be used in indoors, outdoors or underwater.
• Can record data for up to years at a time, unattended.
• Time stamping each ping for study.
• Anything that can be measured can be logged for future and
deeper studies.
• Data logger can measure the following :

Ex: tracking electricity usage in facilities to define energy profiles

and manage peak demand.
• Data loggers are either standalone or wireless.
• Standalone- store data which can be reviewed later on a PC.
• Wireless- transmit data in real-time to connected devices.
 3 types of main data collection difference

i. State: how long can event lasts.

Ex: state data loggers are ideal for monitoring event duration.
ii. Event: when an event occurs.
Ex: event loggers only record when events initiate.
iii. Pulse: number of events in a time interval.
Ex: pulse data loggers indicate a total number of events within
a reading interval.
STATE EVENT PULSE
Heating/Cooling systems Rainfall monitoring Wind speed

Power supply(ON/OFF) Traffic studies Energy monitoring

 Advantages of Data logger:

• Simplicity & ease of use.

• Can run unattended.
• Record different data types.
 Applications of data loggers

i. Monitoring medicine storage in container.

ii. Monitoring machinery.
iii. Monitoring meat temperature in food industry.
 Difference between Sensor and Transducer.
SENSOR TRANSDUCER
Sensor is a device which sense physical Transducer is a device which converts one
variables like temperature/ pressure/ light form of energy into another form mainly
etc., output is in electrical format.

Sensor consist of sensing element only. Transducer consist of sensing element and
transduction element which helps in
conversion of energy.

Ex: smoke detector, automatic door Ex: loud speaker takes electrical signal and
opening converts into sound waves(voice).
Mic takes voice as input converts into
electrical.
Pressure transducer: can converts pressure
in bike/car tires into an analog electrical
signal.
 Servo Mechanism (Kinetic control)

A servo system mainly consists of 3 basic components

- Controlled device
- Output sensor
- Feedback system
This is an automatic closed loop control system.
 Here instead of controlling a device by applying the variable
input signal, the device is controlled by a feedback signal
generated by comparing output signal and reference
input signal.
Block Diagram
Cont.
• When reference input signal or command signal is applied
to the system, it is compared with output reference signal of
the system produced by output sensor, and a third signal
produced by a feedback system. This third signal acts as an
input signal of controlled device.
• Servomechanism most probably applies to the systems
where position and speed is to be controlled.
• This input signal to the device presents as long as there is
a logical difference between reference input signal and
the output signal of the system. After the device achieves
its desired output, there will be no longer the logical
difference between reference input signal and reference
output signal of the system.
Cont.
• Then, the third signal produced by comparing these above
said signals will not enough to operate the device further
and to produce a further output of the system until the next
reference input signal or command signal is applied to the
system.
• The primary task of a servomechanism is to maintain
the output of a system at the desired value in the
presence of disturbance.
 Servo motor Application
• Remote controlled toy cars for controlling the direction of
motion.
• Commonly used as the motor which moves the tray of a CD
or DVD player.
• Servo motors in conveyors.
• Servo motor in robotic vehicle.
• Servo motor in solar tracking system.
Recording and Display equipment
 Recording and Display equipment
• A recorder or display unit is the component that provides the results of
measuring process of an instrument. It is the last element in the measuring
system.
• Ex: Physical quantity is what is going to be measured (Temperature).
• Temp is sent to the sensor & sensor will be producing electrical output
signal.
• The electrical signal will be further sent to signal conditioning(reduce noise)
to get signal with acceptable limit.
• Need to use suitable recorder/display equipments.
• The difference between a recorder and a display unit is that the recorder
produces a permanent record of the signal, while the display unit does not.
• Examples of recorders are U.V. recorders, pen recorders, X-Y plotters and
tape recorders.
• Examples of display are speedometers in cars, the mercury level scale in
thermometer.
• In developing field, there exists a large number of sophisticated recording
equipment which uses microprocessors and semiconductor memories to
THANK
YOU!