FIC(4311701)
UNIT-2
Fundamentals Of Controls and
Automation
contents
2.1 Concept of control with day to day examples
2.2 Basic block diagram of control instrumentation system with
definition of all terms
2.3 Water tank level control system with all parameters
identification.
2.4 Different methods of linking various blocks of system with
each other.
2.5 Simple linkages and Terminology
2.6 Basics of gears, pulleys
2.7 Basic principles of pneumatics
2.8 Flapper Nozzle Principle
2.9 Force Balance Principle
2.10 Moment Balance
2.11 Motion Balance Principle
2.1 Concept of control with day to day examples
o System: A system is combination or arrangement of
different physical components which act together as
entire unit to achieve certain objective.
o Control: The action to command, direct or regulate a
system.
o Control System : Control System is arrangement of
different physical elements connected in such a manner
so as to regulate, direct or command itself or other
system to achieve a certain goal.
o Man-made control system: It is a control system that
is created by humans, i.e. automobile, power plants
etc.
o Automatic control system: It is a control system that
is made by using basic theories from mathematics
and engineering. This system mainly has sensors,
actuators and responders.
o Combinational control system: It is a control system
that is a combination of natural and man-made
control systems, i.e. driving a car etc
Ceiling Fan Regulator
Automatic washing Machine
Automobile steering control
Mixing hot and cold water
Automatic Electric Iron
Manual Liquid level Control system
Basic block diagram of control
Instrumentation system
Controlled Variable: - A dynamic variable in a process which is
controlled or regulated by process control loop is called controlled
variable.
Controlling variable or Manipulated variable:- To achieve the
control objective there must be one or more variables we can alter
or adjust. These are called manipulated variables or controlling
variable..
Water tank level control system with all
parameters identification.
An example of automatic tank-level control system. The
control system maintains water level in a storage tank. The
system performs this task by continuously sensing the level in
the tank and adjusting a supply valve to add more or less water
to the tank. The desired level is preset by an operator, who is
not part of the system.
The level transducer measures the level within the tank by
using float and potentiometer arrangement. The level
transducer sends a signal representing the tank level feedback
to the level control device (motor drive). This feedback is
compared with a desired level to produce the required control
action that will position the level control as needed to maintain
the desired level. The level control device computes how far to
open the supply valve to correct any difference between actual
and desired tank levels. The block diagram of this system
representing the signal flow to various elements including
feedback.
In this system, the various elements are:
Plant or process – the water storage tank
Controlled variable – the storage tank level
Manipulated variable – the flow rate of the
water supplied to the
tank
Reference input – the desired tank level
Comparison element – the level controller
Error signal – the difference between
the current and
required water level
Controller – the level controller
Correction element – the level control valve
Measuring element – the level transducer
Different Systems for Communication in
Instrumentation
System Standard Output Power Supply Used for
Communication
Mechanical Mechanical Links , Joints,
Motion Gears Pulleys
Pneumatic 3-15 psi Air Compressor Compressed Air
Hydraulic 3-15 psi Hydraulic Pump Hydraulic Oil
Electric 4-20mA Electrical Power Current/ Voltage
Supply
Wireless Electrical Power Wireless Signals /
Supply RF / EM Waves
Simple linkages and Terminology
A mechanical linkage mechanism is
an assembly of bodies connected to
manage forces and movement.
Linkage mechanisms are incorporated
into systems to produce rotating,
oscillating or reciprocating motion
Link
A link is defined as a member or a combination of
members of a mechanism connecting other
members and having relative motion between them.
A link, is an (assumed) rigid body which possesses
at least two nodes which are points for
attachment to other links.
A link may be called as kinematic link or element.
Links can be classified into binary, ternary,
quarternary,etc, depending upon their ends on which
revolute or turning pairs can be placed.
Binary Link: a link which is connected to
two other links is call as binary link . It
has two nodes.
Ternary Link : a link which is connected
to three other links is call as binary link .
It has three nodes.
Quaternary Link: a link which is
connected to four other links is call as
binary link . It has four nodes.
Joints
A joint is a connection
between two or more
links, which allows some
motion, or potential
motion, between the
connected links.
Depending upon the
number of links at the
joint, a joint can be binary,
ternary or quaternary.
Lever
A lever is a simple machine made of a
rigid beam and a fulcrum.
The effort (input force)
and load (output force) are applied to
either end of the beam. The fulcrum is
the point on which the beam pivots.
When an effort is applied to one end
of the lever, a load is applied at the
other end of the lever. This will move
a mass upward.
Basic parts of a lever showing the locations of the beam, fulcrum, effort and load
First Class Levers
In first class lever, the fulcrum is located between the load and
the effort. When the fulcrum is closer to the load, then less effort is
needed to move the load a
Second Class Levers
In a second class lever, the load is located between the effort
and the fulcrum. When the fulcrum is closer to the load, then
less effort is needed to move the load
Third Class Levers
In a third class lever, the effort is located between the load
and the fulcrum. If the fulcrum is closer to the load, then
less effort is needed to move the load
Degree of freedom(DOF) in plane
The degrees of freedom (DOF) of
a rigid body is defined as the
number of independent movements
it has. Figure shows a rigid body
in a plane. To determine the DOF
of this body we must consider how
many distinct ways the bar can be
moved. In a two dimensional plane
such as this computer screen, there
are 3 DOF. The bar can
be translated along the x axis,
translated along the y axis,
and rotated about its centroid.
Degree of freedom(DOF) in space
A rigid body in space
has six degrees of
freedom: three
translating motions
along
the x, y and z axes and
three rotary motions
around
the x, y and z axes
respectively.
Basics of gears and pulley
Pulleys and gears are used to transfer rotary motion from one
place to another.
Both are wheels.
Pulleys are wheels with grooves in the rims, in which a belt or
rope can run. Pulleys can transfer rotary motion from one shaft
to another or can be used to lift heavy loads.
Gears are wheels with teeth evenly spaced around the rims.
Several gears can be placed, so that their teeth interlock, or
mesh. When two or more gears are used together, they form
what is called a gear train.
Gears can be used to change the speed and direction in which
something rotates. When chains are used to connect the “gears”,
a chain and sprocket system is formed, for example on bicycles
and motorcycles
Types of pulleys
1. Fixed pulley
Fixed pulley system in
which blocks of pulley is
fixed onto a structural
platform.
An extensible string passes
over the groove where
it’s one end is attached to
the object or body to be
lifted while the other end
is kept free.
2. Movable Pulley:
In this case of moveable
pulley system block of the
pulley is not fixed but it
carries some load.
An extensible string is tied
around the groove where
it’s one end is fixed to
support thus other end is
kept free to apply the effort
3. Compound Pulley:
In this class of pulley
system several pulley
are attached to some
fixed pulley with the
help of single or
multiple ropes. As the
number of wheel
increases so lees
amount of effort
needed or applied to
lift the heavy loads of
body during operation.
Types of Gears
Basic principles of pneumatics
Flapper Nozzle Principle
Force Balance Principle
Moment Balance
Motion Balance Principle
Flapper Nozzle Principle
Pneumatic systems are still used in process control
industries even after the penetration and dominance of
electrical signals, electronic and digital systems.
The flapper-nozzle is a basic component of pneumatic
measurement, control and transmission systems.
It works as a pneumatic secondary transducer, by
translating a very small displacement into a pressure
signal.
Construction
The flapper or baffle is a movable flat metal and is attached to the
member whose displacement is to be detected.
The flapper is placed in front of the nozzle in such a way as to
cover or expose the nozzle and to replace the gap between them
when moved.
The nozzle includes a variable nozzle restriction in series with a
fixed orifice restriction.
A constant supply of pressurized air (typically 20 psi or 1.4
kg/cm2) is applied to the nozzle through an orifice restriction.
The pressurized air comes out of the nozzle through the gap
between the nozzle and the flapper.
In order to generate sufficient back pressure and proper functioning
of the system, the diameter of the nozzle should be 1.5 to 2.5 times
the diameter of the orifice.
In general, the diameter of the orifice is of the order of 0.25 mm
and the diameter of the nozzle is of the order of 0.625 mm.
Working principle
When the flapper is moved towards the nozzle, the gap between the
nozzle and the flapper is reduced.
This increases the restriction on the outflow of air through the
nozzle and also increases the pressure behind the nozzle.
Once the flapper completely covers the nozzle, there is no outflow
of air through the nozzle. The nozzle back pressure is at its
maximum and is equal to the supply air pressure.
When the flapper is moved away from the nozzle, the gap between
the nozzle and the flapper increases.
The restriction on the outflow of air through the nozzle is reduced
and the nozzle back pressure is also reduced.
The minimum value of nozzle back pressure is 2-3 psi.
With an input supply of 20 psi (1.4 kg/cm2), an output pressure of 3–15 psi (0.2–1.0
kg/cm2) can be generated via the flapper nozzle system.
The output pressure produced by a flapper nozzle system is proportional to the input
displacement and can be directed to operate an indicator device or another system.
The above diagram shows the typical graph plotted between the nozzle back pressure
(Pb) and the flapper-nozzle gap (x).
The slope dPb/dx at any point on the curve is called the tip sensitivity or gain of the
system. The curve indicates that the system exhibits a nearly linear behavior in the
range between 3 and 15 psi.
Insort
Connect the Air supply at 20 PSI pressure
Keep the flapper at the center.
Then a constant volume of air is bleeds through the
nozzle.
When you move flapper to left side then the bleeding
decreases and the back-pressure increases as read at the
gauge.
Similarly when you move flapper to the right the
bleeding increases and the back-pressure decreases as
read at the gauge
