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Process contre| and automation involve the use of technology and systems to monitor,
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to-control devices. The twa main types of control systems are:
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feedback from sensorste continuously monitor the process output and adiust the cont
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temperature, pressure, flow rate, level. and oH. They provide real-time data to the contr
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19 valves, motors, switches, or ather components in the process.
control manufacturing processes and machinery. They are programmable and can
handle inputs from sensors, make decisions based on logic, and control actuators
cordingly: PLCs are widely used in industrial automation due to their reliability ancl
eens
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lar to PLCs but are designed for large
‘scale industrial processes that require distributed control acrass multiple control units
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jerconnected controllers, operator stations, and communication
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and interact with the control system. They display real-time dats, alarms, and control
options, allowing operators to make informed decisions and intervene when necessary.
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various sensors, PLCs,and other devices to provide a comprehensive view of the pro
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collection, anelysis, and remote monitoring, improving process efficiency and enabling
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includes techniques like model oredictive control, fuzzv leaic control, and adaotive
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personnel, and mitigate potential risks.Berea eee) ice
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position, velocity, and acceleration of mechanical systems. It is commonly used in robotics,
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control typically involves the following components:
1. Servo Motor: A servo motor is a rotary actuator that converts electrical signals into
precise mechanical motion. It consists of a DC motor, gears, and an encoder for position
feedback. The motor rotates to a specific position based on the: control signals it
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2. Position Feedback: Servo control relies on position feedback to achieve accurate control.
An encoder or a sensor is used to measure the actual position of the system and provide
feedback to the control system. The control system compares the desired position with
the actual position and generates control signals to adjust the motor accordingly.
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. Control Algorithm: The control algorithm used in servo control is typically a closed-loop
control algorithm. It continuously compares the desired position with the actual position
and adjusts the motor's speed and direction to minimize the error and reach the desired
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4. Servo Drive: A servo drive is an electronic device that amplifies and provides power to the
servo motor. It receives control signals from the control system and translates them into
appropriate voltage and current levels to drive the motor.
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. Controller: The controller is responsible for generating control signals based on the
desired position and the feedback from the position sensor. It calculates the error
between the desired position and the actual position and a
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minimize the error and achieve precise control.
Servo control systems are widely used in applications where precise positioning and motion
control are critical, such as robotics, industrial automation, and motion control systems.ieee Rees
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etc.) ata desired setpoint or within a specified range. Regulatory control systems typically
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1. The process variable is the parameter that needs to be controlled, such
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the operator or determined based on process requirements.
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manipulated variable.
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that can change the process conditions.
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the setpoint, calculates the error, and adjusts the manipulated variable to minimize the _
error and maintain the process variable at the desired setpoint.
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represents the desired operating condition or the reference value to which the process
8. Error: The error (E) is the difference between the process variable (PV) and the setpoint
(GP).It indicates the deviation of the process variable from the desired value and is used
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control signal that adjusts a valve position, motor speed, heater power, or any ather
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5. Gain: Gain refers to the sensitivity or responsiveness of the process to changesin the
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the resulting change in the process variable. Gain isa crucial parameter in control system
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dynamics of the process and influences the system's response time and stability.
7. Dead Time: Dead time, also known as transport delay or time lag, is the delay between a
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magnitude of the process response to changes in the control signal and is a critical
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variable exhibits periodic oscillations or fluctuations. It provides insights into the dynamic
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process variable to reach and remain within a specified range around the setpoint after a
change in the contro! output or a disturbance It reflects the process's ability to stabilize
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takes for the PLC to complete one full cycle of executing its program. The scan time is an
important parameter that determines the responsiveness and performance of the control
acne
The PLC scan time consists of several stages, including input scanning, program execution,
and output update. Here's.a breakdown of these stages:
i. Input scanning: The PLC reads the state of its input modules, which are connected to
sensors and other devices in the controlled system. it checks the status of these inputs to
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instructions that define the control logic and behavior of the system. These instructions
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modules. These outputs are connected to actuators, such as motors, valves, or relays,
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‘of the PLC. It typically ranges from microseconds to milliseconds, depending on the
complexity of the program, the processing power of the PLC, and the number of inputs and
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‘The scan time is critical because it affects the system's response time to changes in inputs
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quickly to input changes, enabling faster control actions and higher system throughput. On
the other hand, a longer scan time may introduce delays in the system's response and
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‘specifications. It is important to consider the scan time when designing control systems to
ensure that it meets the required performance criteria and can handle the desired control
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i. Robustness and Retiabitity: PLCsare designed to operate in harsh industrial
environments. They are built to withstand temperature variations, electrical noise,
s, and other challenging conditions. This robustness ensures reliable operation
ea oe ns
2. Modularity and Scalability: PLCs are modular in nature, allowing for flexible system
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‘various modules such as input, output, communication, and special function modules.
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Specific requirements of the ap
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the specific needs of the industrial process. The programming can be done using
programming languages like ladder logic, function block diagrams, structured text, or
other high-level languages. This flexibility enables complex control strategies and
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to input changes and execute control actions in a deterministic and predictable manner.
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synchronization are required, such as in motion control or high-speed processes.
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with the external devices and sensors i r Re eas
types of signals, including digital inputs and outputs, analog inputs and outputs, and
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instruments._
6. Communication and Networking: PL€s offer built-in communication capabilities to
connect with other devices and systems. They support standard industrial
communication protocols. such as Modbus, Ethernet/IP, Profibus, and Profinet, allowing
seamless integration with other control systems, human-machine interfaces (HMIs),
supervisory control and data acquisition (SCADA) systems. and enterprise networks.
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system performance, detect faults, and troubleshoot issues. They offer built-in self-
testing functions, error detection mechanisms, and comprehensive diagnostics tools ta
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8. Safety Features: PLCs incorporate safety functionalities to ensure the protection of
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eee de eee ees aDCS, or Distributed Control System, is a type of control system that utilizes various protocols
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1. Modbus: Modbus is a widely used protocol for serial communication between electronic
devices. It is simple, open, and easy to implement, making it popular in industrial
automation ms, including DCS. Modbus allows for t! Ey
master device (usually a supervisory controller) and multiple slave devices (sensors,
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2. Profibus: Profibus is a versatile and robust fieldbus protocol used for communication
between industrial devices in DCS. It supports both digital and analog signals and
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provides high-speed and reliable communication overlong distances, making it suitable
for complex DCS applications.
3. Foundation Fieldbus: Foundation Fieldbus isa digital protocol specifically designed for
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field devices, such as sensors and actuators, and the DCS. Foundation Fieldbus supports
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communication with smart field devices in DCS. It combines traditional analog signaling
with digital communication, allowing for simultaneous transmission of process variables
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access to device configuration, diagnostics, and calibration data.
5. OPC (OLE for Process Control): OPC is not a communication protocol itself but rather a
standard for interoperability between different systems in DCS. OPC allows for seamless
integration and communication between diverse devices, software applications, and data
sources, regardless of the underlying communication protocols. OPC provides a common
interface for data exchange, enabling efficient information sharing in DCS environments.a ees be eee gan eee a
(DCS) that is responsible for performing control functions at a local level.
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integral, and derivative (PID) control, arivanced control strategies, model-based control
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conditions. The acquired datais used for control calculations, trend analysis, alarming,
and reporting.
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actions as necessary to ensure stable and optimal operation.
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LCU can prioritize and escalate alarms based on their severity, allowing operstorsto
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LOU sends process dats, status updates, and alarm information to the HM, enabling
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multiple LCUs work in parallel, sharing the workload and providing backup in case of
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switchover between primary and backup LCUs, ensuring uninterrupted control and
CeesPLC BLOCK DIAGRAM
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"Processor section (CPU)
‘The processor section is brain of PLC which consists of RAN ROM, logic solver and
user memory, The central processing unit is heart of PLC. CPU eontrots monitors and,
supendses ail operation within PLC. The CPU makes decision and executes santrol
instructions based on the program instruction in memory.
© dnputand output module
‘The input module is a mediator between input: ‘and ventral processing unit (CPI
which is used to convert analog signal into signal
‘The cutpit module i a medistor benvesn output devices and central processing unit
{CPU} which is convert digital signal inte analog signal
© Power supply
ower supply is provided ta the processor unit, input and output module unit. Power
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supply may be integral or separately minanied ini
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= Memory section
‘The memory section is the area of the GPU in which data and information is stored and
retrived Dats Memory is used to store numerical dats required in math calculation, bar
code dats eto. User memory contains user's application program.
© Programming device
Programming devices are dedicated devices used for losding the user program into the
program memmry or edit it and to monitor the execution of the program of the PLC: ttis
also used to troubleshoot the PLC ladderlogio program. Hand held terminal (HHT) oF
dedicated tenrinal or personal computer are programming devices commonly wsed in
most of the PLCs.Multidrop DCS, also knewn as multidrop distributed control system, is a variation of
distributed control system (DCS) architecture. Ina traditional DCS, each field device or
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Configuration, where they share a common communication link
Here are some key characteristics and features of a multidrop DCS:
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connected in a series or loop configuration, typically using a digital communication
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or fieldbus protocol, like Modbus RTU.
2 Shared Communication Channet: All field devices or controllers in the multidrop
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addressing scheme ensures that data is correctly routed to the intended devices.
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6. Challenges and Limitations: While multidrop DCS can be cost-effective and provide
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machines for precise positioning of the tooling and werkpiece. They enable accurate
control of the cutting or milling operations.
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movement of the print head or the positioning of the build plate, ensuring precise layer-
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Robotics: Stepper motors find extensive use in robotics for controlling the movement of
robot joints, robotic arms, and other components that require precise positioning and
motion control
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‘surgical systems, infusion pumps, and lab automation, where precise and controlled
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them suitable for applications that require high precision.
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allowing them to drive loads with high inertia or resistance. They are capable of holding
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Disadvantages of Stepper Motors:
1. _ited Speed and Torte Rance: Stepper motors are most efficient at low speeds, and
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acceleration/deceleration profiles may require more complex control algorithms or
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Despite these limitations, stepper motors are widely used in various industries due to their
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facturing. Here's an overview of remote I/O systems:
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rol system or supervisory control
and data acquisition (SCADA) system. Similarly, they receive control commands from the
central system and execute them on the field devices:
The architecture of a remote I/O system typically includes the following components:
EI s: These modules serve as the interface between the field devices and
the communication network. They are usually installed near the field devices and contain
input and output channels to connect to sensors and actuators.
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Ge sec (RS-485, Modbus, Profibus, etc), or
wireless protocols (Wi-Fi, cellular, etc), to transmit data between the remote I/O modules
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the data collected by the remote I/O modules and provides control commands to operate
the field devices. It typically includes a human-machine interface (HMI) for visualization,
monitoring, and control purposesaCe aero ea url el a Lee E-ULs)
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communication networks, remote I/O systems reduce the amount of wiring required,
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Remote I/O systems enable efficient data acquisition
from distributed field devices. The collected data can be integrated into higher-level
systems, such as SCADA or enterprise resource planning (ERP) systems, for advanced
analysis, reporting, and decision-making.
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devices. This enables proactive maintenance, troubleshooting, and quick response to
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Overall, remote I/O systems play a crucial role in industrial automation, allowing for efficient
and reliable control and monitoring of field devices in remote or challenging environments.
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‘executing control logic and coordinating the operation of other components. Itperforms
tasks such reading input values, See tee ceca Rar
values based on the programmed logic.
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a. Program Memory: This memory holds the control program or logic written by the
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b. Data Memory: The data memory stores variables, timers, counters, and other data used
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¢. Retentive Memory: Some PLCs have a separate area of memory called retentive
memory, which retains data even when power is lost. Retentive memory is used to store
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actuators and provide electrical isolation and signal conditioning. They convert input
signals from the field davicas into digital or analog data that the CPU can process.
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4. Communication Interfaces: PLCs often have communication interfaces in the processor
section to enable communication with external devices or other PLCs. These interfaces
may include Ethernet ports, serial ports, or specialized fieldbus interfaces (such as
Profibus, Modbus, or DeviceNet). Communication interfaces allow PLCs to exchange data
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required voltage levels for the internal components of the PLC.
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audThere are different types of Distributed Control Systems (DCS) used in industrial c
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1. Integrated DCS: This is the mast common type of DCS, where both control and
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control processors, and I/O modules in a unified architecture.
2. Hybrid DCS: A hybrid DCS combines elements of traditional DCS and Programmable
Logic Controllers (PLCs). It may have a centralized control system similar to a DCS but
also include local PLC-like controllers for specific subsystems or processes.
3. Component DCS: In a component DCS, the control system is composed of separate
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operator workstations, independent controllers, and I/O modules, which communicate
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4. PC-based DCS: This type of DCS utilizes standard personal computers (PCs) as the
hardware platform for the control system. The control software runs on these PCs, which
are connected to I/O modules and field devices through communication interfaces
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‘control and menitoring functions into. single integrated system. Below, Il expisin the
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‘They consist of computer-based workstations equipped with Human-Machine Intertaces
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(Communication Network The communication network connects all the components. of
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stations and the /O modules. These processors process the data, execute control
a‘such as Ethernet, fieldbus protocols, or wireless communication, depending on the
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stations and the I/O modules. These processors process the data, execute control
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from the field devices into digital data that can be processed by the control processors.
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them into appropriste snelog or digital signals to control the field devices.
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Deets eRe ems rem eet Re Bee ares sees stg recl Reta eRe eso
Fee ee eet nee ete the tel ee ees eet eee eee ol
re ee ese Eas
Cer Tee st etre ee ge Re eet ee eae ee et tars
eet ieeccemen ete Rte ne eS tee ice pee ceed
peti Feces t eM ee Te emt tt a een eet se one ea emcee
and control purposes.
Cer etel ere Len iene Peso eg tree ate enn
Fee eae eR et ee eee ee eater eee Pans
Pee Tuo e ha tee cts tran eh el Me tt sure ce iy
Peele See Ee ike steer gee Pete ieee Pee re et ee er
eda nem
ie) ee ele een nate ee an tae eae)
Sr ee eae bat ie eee es eg eta meer)
reenter turd