Control system

Feedback control systems

A closed-loop controller or feedback controller is a control loop which incorporates feedback, in contrast to an open-loop controller or non-feedback controller. A closed-loop controller uses feedback to control states or outputs of a dynamical system. Its name comes from the information path in the system: process inputs (e.g., voltage applied to an electric motor) have an effect on the process outputs (e.g., speed or torque of the motor), which is measured with sensors and processed by the controller; the result (the control signal) is "fed back" as input to the process, closing the loop.

In the case of linear feedback systems, a control loop including sensors, control algorithms, and actuators is arranged in an attempt to regulate a variable at a setpoint (SP). An everyday example is the cruise control on a road vehicle; where external influences such as hills would cause speed changes, and the driver has the ability to alter the desired set speed. The PID algorithm in the controller restores the actual speed to the desired speed in an optimum way, with minimal delay or overshoot, by controlling the power output of the vehicle's engine. Control systems that include some sensing of the results they are trying to achieve are making use of feedback and can adapt to varying circumstances to some extent. Open-loop control systems do not make use of feedback, and run only in pre-arranged ways.

Closed-loop controllers have the following advantages over open-loop controllers:

• disturbance rejection (such as hills in the cruise control example above)
• guaranteed performance even with model uncertainties, when the model structure does not match perfectly the real process and the model parameters are not exact
• unstable processes can be stabilized
• reduced sensitivity to parameter variations
• improved reference tracking performance
• improved rectification of random fluctuations

In some systems, closed-loop and open-loop control are used simultaneously. In such systems, the open-loop control is termed feedforward and serves to further improve reference tracking performance.

A common closed-loop controller architecture is the PID controller.

Logic control

Logic control systems for industrial and commercial machinery were historically implemented by interconnected electrical relays and cam timers using ladder logic. Today, most such systems are constructed with microcontrollers or more specialized programmable logic controllers (PLCs). The notation of ladder logic is still in use as a programming method for PLCs.

Logic controllers may respond to switches and sensors and can cause the machinery to start and stop various operations through the use of actuators. Logic controllers are used to sequence mechanical operations in many applications. Examples include elevators, washing machines and other systems with interrelated operations. An automatic sequential control system may trigger a series of mechanical actuators in the correct sequence to perform a task. For example, various electric and pneumatic transducers may fold and glue a cardboard box, fill it with the product and then seal it in an automatic packaging machine.

PLC software can be written in many different ways – ladder diagrams, sequential function charts or statement lists.

On–off control

On–off control uses a feedback controller that switches abruptly between two states. A simple bi-metallic domestic thermostat can be described as an on-off controller. When the temperature in the room (PV) goes below the user setting (SP), the heater is switched on. Another example is a pressure switch on an air compressor. When the pressure (PV) drops below the setpoint (SP) the compressor is powered. Refrigerators and vacuum pumps contain similar mechanisms. Simple on–off control systems like these can be cheap and effective.

Linear control

Linear control are control systems and control theory based on negative feedback for producing a control signal to maintain the controlled process variable (PV) at the desired setpoint (SP). There are several types of linear control systems with different capabilities.

Fuzzy logic

Fuzzy logic is an attempt to apply the easy design of logic controllers to the control of complex continuously varying systems. Basically, a measurement in a fuzzy logic system can be partly true.

The rules of the system are written in natural language and translated into fuzzy logic. For example, the design for a furnace would start with: "If the temperature is too high, reduce the fuel to the furnace. If the temperature is too low, increase the fuel to the furnace."

Measurements from the real world (such as the temperature of a furnace) are fuzzified and logic is calculated arithmetic, as opposed to Boolean logic, and the outputs are de-fuzzified to control equipment.

When a robust fuzzy design is reduced to a single, quick calculation, it begins to resemble a conventional feedback loop solution and it might appear that the fuzzy design was unnecessary. However, the fuzzy logic paradigm may provide scalability for large control systems where conventional methods become unwieldy or costly to derive.

Fuzzy electronics is an electronic technology that uses fuzzy logic instead of the two-value logic more commonly used in digital electronics.

Physical implementation

The range of control system implementation is from compact controllers often with dedicated software for a particular machine or device, to distributed control systems for industrial process control for a large physical plant.

Logic systems and feedback controllers are usually implemented with programmable logic controllers. The Broadly Reconfigurable and Expandable Automation Device (BREAD) is a recent framework that provides many open-source hardware devices which can be connected to create more complex data acquisition and control systems.