Introduction to industrial control systems

Industrial control systems are systems used in automation and

supervision of industrial processes. These systems are responsible for regulating and
control variables such as temperature, pressure, flow, and level in various equipment and
processes, with the aim of ensuring efficient and safe operation.

Industrial control systems consist of several components, including

sensors, actuators, controllers, and a user interface. The sensors
they collect information about the process variables, which is then sent to
controller. The controller processes the data and makes decisions to adjust the
actuators, which are the devices responsible for modifying the variables of the
process.

There are different types of industrial control systems, such as the systems of
open loop and closed loop control. In open loop control, the output of
system does not influence the input or adjustment of the controller, which means that it does not
there is feedback. In contrast, in closed-loop control, it uses
feedback to compare the system output with a desired value and
make adjustments accordingly.

Industrial control systems are applied in a wide range of industries,

such as manufacturing, petrochemicals, energy, food and beverages, among others. These
systems allow improving the efficiency and accuracy of processes, reducing the
waste of resources, increase security and facilitate supervision and control
remote operations.

In summary, industrial control systems are fundamental tools in

the automation of industrial processes, allowing for regulation and supervision
efficient key variable management to ensure optimal operation of the
systems.

General concepts

Here are some general concepts related to control systems

industrial

1. Automation: It is the process of using systems and technology to perform

tasks automatically, without direct human intervention. In the
In the industrial context, automation is used to improve efficiency.
precision and security of the processes.
 2. Process variable: It is a quantity or physical property that is measured and
controls in an industrial system. Some common examples include the
temperature, pressure, liquid level, flow rate, velocity, among
others.

3.Sensor: It is a device that converts a physical variable into a signal.

electrical or digital. Sensors are used to measure and monitor the
process variables. They can be temperature, pressure, flow sensors,
level, among others.
4. Actuator: It is a device that receives signals from the controller and performs.
physical changes in the system. Actuators are used to adjust or
control the process variables. Some examples are valves, motors,
relays, among others.

5.Controller: It is the central component of an industrial control system.

Receives information from the sensors, processes the data, and generates signals of
control for the actuators. Its objective is to maintain the variables of
process within desired or predefined ranges.

6. Feedback: It is the process of using information from the output of the

system for adjusting and controlling the input or actions of the controller. The
feedback allows for real-time corrections and improvements
control precision.

7.Open loop vs. closed loop: In an open loop control system, the
controller does not receive feedback information from the output of
system. In contrast, in a closed-loop control system, it is used
feedback to compare the system output with a desired value
and adjust the control accordingly.

8. User interface: It is the part of the industrial control system with which
the operators interact. It can be a touchscreen, a computer
or physical control panels. The user interface allows monitoring the
process, make adjustments and receive information about the system status.

Block diagram representation of control systems

Block diagram representation is a common way to visualize and

represent the control systems. In this type of diagrams, the components
The system is represented as blocks, and the connections between them are shown.
through lines that represent signals or flows of information.
Here are the basic elements used in block diagrams of the
control systems:

Functional blocks: Functional blocks represent the components or

elements of the control system, such as sensors, actuators, controllers,
processors, among others. Each block usually has a specific function in the
system.

Signal lines: The signal lines connect the functional blocks and
they represent the flow of information or signals between them. These lines indicate how
Signals are transmitted between the different components of the system.

Adders: Adders are blocks used to add or combine.

different signals. They are used, for example, to sum the reference signals and
feedback in a closed-loop controller.

Signal take-off points: These points are used to indicate where a signal is taken from.
signal or an external signal is introduced into the system. For example, it can be used
a signal pickup point to indicate the entry of a reference signal in the
controller.

Transfer blocks: Transfer blocks represent the relationships

mathematics or dynamics between the input and output signals. These blocks
they are used to model the behavior of the system components.

Delays: Delays are represented as blocks that indicate a delay in the

time between the input and output of a signal. Delays can be caused
due to the response speed of the components or due to the delay in the
signal transmission.

Points of addition and multiplication: These points are used to indicate

addition or multiplication operations between signals. They are used, for example, to
to combine different input signals or to adjust the gain of a signal.

These are just some basic elements used in diagrams of

blocks of control systems. The structure and complexity of the diagrams
They can vary depending on the specific application and system being used.
representing.

Classification of control systems.

Control systems can be classified in different ways according to various

criteria. Here are some common classifications of control systems:
1. According to the control topology:

Open loop control: In this type of control, the control action

it is based solely on the reference input and there is no
feedback on the system output.

Closed loop control: In this type of control, the control action

is based as much on the reference input as on the
feedback from the system output. It is used to reduce
errors and improve control accuracy.
2. According to the nature of the system:

Continuous control: Continuous control systems operate in

continuous time, where the input and output signals are variables
they continue over time. Differential equations are used to
describe the behavior of the system.

Discrete control: Discrete control systems operate in time

discrete, where the input and output signals are samples taken
at specific moments in time. Equations are used in
differences to describe the behavior of the system.
3. According to the type of controlled variable:

Level control: It refers to the control of the height or level of a

liquid in a tank or container.

Temperature control: It refers to the control and regulation of the

temperature in a system or process.

Pressure control: It refers to the control and regulation of pressure.

in a system or process.

Flow control: It refers to the control and regulation of the flow rate.
of a fluid in a system or process.

Position control: It refers to the control and regulation of position

of an object or system.
4. According to the complexity of the system:

Simple control: It refers to control systems that involve a

only control loop and have a relatively simple structure.
 Multivariable control: It refers to control systems that
involve multiple interconnected control loops, where the
controlled and manipulated variables are interrelated.
5. According to the control approach:

Classical control: It is based on traditional techniques and methods.

control, such as proportional-integral-derivative (PID) control and
frequency-based control. It is focused on linear systems and
stationary.
Modern control: It is based on more advanced methods and techniques.
such as optimal control, adaptive control, and robust control.
It is focused on nonlinear systems, time-varying variables and with
uncertainty.

Practical implementation of automatic control.

The practical implementation of an automatic control involves several steps and

considerations. Here is an overview of the steps involved in the
implementation of an automatic control:

Define the objectives and requirements of control: It is important to establish

clearly the objectives of control and the requirements that must be met. This
includes identifying the variables to control, the operating limits, the
performance specifications and any other relevant criteria.

Design the controller: The design of the controller involves selecting a

appropriate control strategy and design the control algorithm. This may include
the choice of a proportional-integral-derivative (PID) controller, a controller
based on a model, an adaptive controller, among others. The design of
controller is implemented based on the system model and the requirements
established.

Implement the hardware and software of the controller: Once designed the
controller, it is implemented in hardware and software. This can
involve the selection and configuration of programmable logic controllers (PLCs),
microcontrollers, embedded systems or other suitable hardware/software for
the application.

Connect the sensors and actuators: The sensors are installed and configured to
measure the process variables that will be controlled. The actuators are connected
and are configured to act on the system according to the instructions of the
controller.
Calibrate and adjust the controller: It is important to calibrate and adjust the controller
to correctly adapt to the system. This involves adjusting the parameters
of the controller, such as the gains of the PID, to achieve optimal performance and
stability in control.
Testing and adjusting the control: Tests and adjustments are carried out under conditions.
operational realities. During this stage, response tests can be conducted.
perturbations, reference tracking and compliance verification of the
established requirements.

Monitor and optimize the control: Once the control is implemented, a

continuous monitoring to ensure its proper functioning. It can be done
additional adjustments if necessary to optimize performance and ensure the
long-term stability.

Maintenance and improvements: The automatic control requires maintenance

regular to ensure its performance and reliability over time.
Furthermore, as conditions or requirements change, they may be
necessary improvements or adjustments in control to adapt to the new ones
circumstances.

Open loop control system

An open-loop control system is one in which the control action does not
based on the feedback from the system output. In this type of system, the
control signal is established in advance without taking into account the actual response of the
system.

In an open-loop control system, the reference signal (or setpoint) is

introduced in the controller and is used to determine the control signal that is
will be sent to the actuators. The control signal is applied directly to the system, without
consider the actual output of the system or its deviation from the reference.

A common example of an open-loop control system is the control of

speed in an electric motor. If a desired speed is established, it is sent
a constant control signal to the actuators so that the motor operates at that
speed. There is no measurement of the actual speed of the engine nor is it carried out
a correction based on the variations or disturbances in the system.
Open-loop control systems are less common in applications.
industries where a higher level of precision and stability is required. These
systems are more susceptible to disturbances and errors due to the lack of
feedback. However, they can still be used in situations where
it has precise control of the system and the disturbances are minimal or can be
tolerate.

It is important to note that, in general, closed-loop control systems

closed, which use feedback from the system output, are more
common in industrial applications where greater precision is sought
stability in control.

Closed-loop system

A closed-loop control system is one in which the output of the system

It is measured and used as feedback to adjust and correct the control signal.
In this type of system, the control signal is continuously adjusted based on
the deviation between the actual output and the desired reference.

In a closed-loop control system, a reference or setpoint is established that

represents the desired value of the system output. The reference signal is
compare with the actual output of the system using a comparison element,
like a summator. The difference between the reference and the actual output, called error, is
used to generate a control signal that is applied to the actuators.

The controller in a closed-loop system uses information from

feedback to calculate the control signal in such a way that it reduces or
eliminate the error between the actual output and the reference. The controller can use
different strategies and algorithms, such as proportional-integral control
derivative (PID), to adjust the control signal.

The main advantage of closed-loop control systems is that they allow for a
greater precision and ability to correct disturbances and variations in the
system. By using feedback, the system can continuously adjust itself
to keep the output as close as possible to the desired reference.

Closed-loop control systems are used in a wide range of

applications, from temperature and pressure control in industrial processes
up to speed and position control in robotic systems. They provide a
greater stability, accuracy, and adaptability to conditions
system changes compared to open loop systems.
Characteristics of open-loop systems

Open-loop control systems have several distinctive characteristics. Here

Here are some of the most common characteristics of open-loop systems:

1. Absence of feedback: In an open-loop system, it is not used.

the feedback of the system output to adjust the control signal.
This means that the system cannot make automatic corrections in
function of the actual operating conditions.
2. There is no compensation for errors: Given that it is not used
feedback, open-loop systems cannot correct errors or
deviations from the desired output. Any disturbance or variation in the
System can affect the output without being detected or compensated.

3. Sensitivity to disturbances: Open-loop systems are more

susceptible to external disturbances, as they have no mechanisms
to counteract them. Any change in the system's conditions
it can directly affect the output without being compensated.

4.Lower precision and stability: Due to the lack of feedback and

error compensation, open loop systems tend to have a
lower accuracy and stability compared to closed-loop systems
closed. Variations in system conditions can cause
significant deviations in the desired output.

5. Simpler design and adjustment: An advantage of open-loop systems is

that their design and fit are generally simpler compared to
closed-loop systems. It is not necessary to consider stability and the
characteristics of closed-loop response, which can simplify the
control design.

6. Lower cost and complexity: Open-loop systems are usually less

costly and less complex than closed-loop systems, since they do not
they do not require sophisticated sensors or control algorithms for the
feedback and continuous adjustment.

Open-loop systems are suitable in situations where disturbances

are minimal, the system is stable and the deviations in the output do not have a
significant impact on the operation or desired outcome. For example, in
industrial process control systems where the conditions are constant
and predictable, open-loop systems may be sufficient. However, in the
In most industrial applications, closed-loop systems are preferred.
due to its ability to adapt and correct system variations.

Characteristics of closed-loop systems

Closed-loop control systems have several distinctive characteristics that

they are widely used in various applications. Here are some of
the most common characteristics of closed-loop systems:

1. Feedback: Closed-loop systems use feedback

from the system output to compare it with the desired reference. This
feedback allows for continuous adjustments and corrections of the
deviations between the actual output and the reference.

2.Error compensation: Due to feedback, the systems are

closed loops have the ability to correct errors and deviations in the
output. The controllers in these systems can take measures to
minimize and eliminate errors, achieving greater precision and accuracy
in the system output.

3. Stability and robustness: Closed-loop systems tend to be more

stable compared to the systems a open loop. The
feedback allows for dynamically adjusting the control signal and
keep the output close to the reference, even in the face of disturbances and
changes in the system conditions.

4. Rejection of disturbances: Closed-loop systems are designed

to reject external disturbances. By using feedback, the
controllers can detect disturbances and adjust the signal of
control to counteract its effects and maintain stable and accurate output.

5. Adaptability: Closed-loop systems can adapt to the

variations and changes in the system. Feedback allows
continuously monitor the output and adjust the control signal in
consequence, which allows an efficient and precise response to
changing conditions.

6. Greater precision and control: Due to the feedback and the ability to
error correction, closed-loop systems tend to achieve a greater
precision and control over the system output. They can maintain the output
close to the desired reference and significantly reduce errors.
 7. More complex design: Closed-loop systems tend to be more
complex in terms of design and adjustment compared to the systems
open loop. It is necessary to consider the response characteristics in loop.
closed, like stability and robustness, and use control algorithms
more sophisticated.

In summary, closed-loop control systems offer greater precision,

stability and adaptability compared to open-loop systems. These
characteristics make them suitable for a wide range of applications where
a precise control and a robust response to disturbances is required
changes in system conditions.