Industrial AutomationAutomation IndustrielleIndustrielle Automation

1.3 Types of Plants and ControlTipos de plantas y de controlSystèmes contrôlés et contrôleStrecken und Steuerungen

Types of plants and control 1.3 - 2Industrial Automation

1.3 Contents

1 Introduction

1.1 Automation and its importance

1.2 Applications of automation

1.3 Plants and controls

1.3.1 Open loop and closed loop control

1.3.2 Continuous processes

1.3.3 Discrete processes

1.3.3 Mixed processes

1.4 Automation hierarchy

1.5 Control system architecture

Types of plants and control 1.3 - 3Industrial Automation

Plant types

Despite the large diversity of applications, the principles of automation are always the same.

There are a few basic types of plants and the same control system hardware and basic software is shared by most applications.

Distinction is often question of a point of view, profession-specific vocabulary and marketing.

Types of plants and control 1.3 - 4Industrial Automation

Control Tasks

Leiten - die Gesamtheit aller Massnahmen, die einen im Sinne festgelegter Ziele erwünschten Ablauf eines Prozesse bewirken (DIN 19222)

control: el conjunto de medidas que permiten influenciar el estado de un proceso para un propósito dado

Conduite: l'ensemble des mesures qui permettent d'influencer l'état d'un processus dans un but fixé.

messen - steuern - regeln - leiten

mesure - commande - régulation - conduite

measure - command - control

Types of plants and control 1.3 - 5Industrial Automation

Open loop and closed loop

1

23

4

5

temperature

temperature is imprecise,depends on ambient temperature andcooking quantity but time of heating can be modulated.

120

140180

200

220 temperature closely controlled, requires measurement of the output variable (temperature)

+

-higher/lower

temperature sensor

open loop:

closed loop:

on/off

Types of plants and control 1.3 - 6Industrial Automation

Open loop and closed loop

outputcontroller+

-

plant state

display

control variable(analog)

set-point (solicited)valeur de consigneSollwert,

plant

measurement

plant state

sequencer

on/off

plant

display

closed-loop control / regulation(régulation, Regelung)

keywords: feedback, analog variables, continuous processes, "process control"

open-loop control / command(commande / pilotage, Steuerung, )

keywords: sequential / combinatorial, binary variables, discrete processes,"batch control", "manufacturing"

output

error(deviation)

binary

%process value(valeur mesurée,Istwert)

measurement

clock

Types of plants and control 1.3 - 7Industrial Automation

Traditional allocation of function of computers in control systems

open-loop functions

Data acquisition and pre-processing

Sequential control

Data transfer between plant and operator

Display the plant state

Logging and history recording

Simulation and training

closed-loop functions

Protection and interlocking*

Regulation

Process-driven sequential control

Process optimization algorithms

Interlocking*: prevent dangerous actions,such as all lights on green at a crossing(interbloquage, Verriegelung, enclavamiento)

the control system acts directly and autonomously on the plant

Types of plants and control 1.3 - 8Industrial Automation

Discrete and continuous plants

discrete control(binary)

continuous control(analogue)

Types of plants and control 1.3 - 9Industrial Automation

Continuous plants

Examples: Drives, Ovens, Chemical Reactors

F(p)yx

Continuous plants (processes) have states that can be described by a continuous (analog) variable (temperature, voltage, speed,...)

Between plant input and plant output, there exists a fixed relation which can bedescribed by a continuous model (transfer function).

Continuous plants are mostly reversible and monotone: These are the conditions necessary to control them, i.e. impose the value of their output.

The transfer function may be described by a differential equation, simplified to a Laplace or a z-transform when the system is linear.

The principal control task in relation with a continuous process is its regulation (maintain the state on a determined level or trajectory)

Types of plants and control 1.3 - 10Industrial Automation

Discrete plants

ec + ¬d

1

2 3

6 5

4

7

a

bc + d

e

init

A discrete plant is modeled by well-defined, exhaustive and non-overlapping states, and by abrupt transitions from one state to the next caused by events.

Discrete plants are mainly reversible, but not monotone:the removal of the stimulus which caused a state transition will not necessarilybring the plant back to the previous state.

Example: a lift will not go back to the previous floor when releasing the button that called it.

Discrete plants are described by Finite State Machines, Petri Net, State transition tables Grafcet, or Sequential Function Chart diagrams.

The main task of a control system in relation with discrete plants is their command.

Going back to a previous state may require transit through several other states.

Types of plants and control 1.3 - 11Industrial Automation

Continuous and batch processes

Continuous process(processus continus, kontinuierliche Prozesse)

continuous flow of material or energye.g. motor control, cement, glass, paper production,rolling mill for wires, plate or profiles,

newspaper printing: 23 m/s, steel wire 90 m/s

Main task: regulation

Batch process(processus de charge (par lots), Stückgutprozesse)

discrete processes with handling of individual elementse.g. Numerical Controlled machine, packing machines,Bottle-filling, manufacturing, pharmaceutical and chemical processes.

Main task: command

Types of plants and control 1.3 - 12Industrial Automation

Mixed plants

All processes have some continuous and some discrete behavior - a question of point of view.

In reality, all plants consist of discrete and of continuous processes.

Example 1: Motor control of a cable-car with speed control and stop at stations

All parts must de described individually.

Processes can be described as continuous within a discrete state or as non-linear, continuous process.

Example: Time-triggered set-point of an oven temperature.

Mixed plants are the normal case.

Example 2: A bottle-filling line is in principle a continuous process, but each step consists of a sequence of operations

Types of plants and control 1.3 - 13Industrial Automation

Depends on industrial process

Automotive Manufacturing

Electronics

Machinery

Textiles

Pharmaceuticals

Fine Chemical

Food & Beverage

Metals & Mining

Water & Waste

Pulp & Paper

Vehicles

Petrochemicals

Oil & Gas

Electrical Power

discrete

continuous

source: ARC

Types of plants and control 1.3 - 14Industrial Automation

The main categories in industry

industry distinguishes the following categories of applications:

"process control": continuous processes, associated with fluxes, e.g. sewage water treatment, petrochemical process, cement…

"batch control": semi-continuous processes, associated with individual products, e.g. fine chemicals, pharmaceutical, brewery…

"manufacturing": also called “factory automation”discrete processes, associated with transformation of parts,e.g. automobile industry, bottle-filling, packaging

Types of plants and control 1.3 - 15Industrial Automation

Assessment: which answers are correct ?

1. open loop control is only usedwhen the plant can produce indefinitelywhen the plant is operated in on/off modewhen the operator can supervise the plant

2. closed loop control is needed whenthe plant is insufficiently knownthe plant is subject to perturbationsthe plant cannot be described by differential equations

3. the main task of a controller in a continuous process is:to keep the output always at the same valueto keep the output within a certain rangeto bring the output to a specific value in function of time

4. the main task of a controller in a discrete process is:to issue commands depending on the stateto maintain constant speed of productionto measure the state and present it to the operator

5. which of the following is a consistent plant categorization:open loop – continuous – closed loopdiscrete - continuous - hybridprocess - manufacturing- batch

Types of plants and control 1.3 - 16Industrial Automation

Assessment: which answers are correct ?

1. open loop control is only usedwhen the plant can produce indefinitelywhen the plant is operated in on/off modewhen the operator can supervise the plant

2. closed loop control is needed whenthe plant is insufficiently knownthe plant is subject to perturbationsthe plant cannot be described by differential equations

3. the main task of a controller in a continuous process is:to keep the output always at the same valueto keep the output within a certain rangeto bring the output to a specific value in function of time

4. the main task of a controller in a discrete process is:to issue commands depending on the stateto maintain constant speed of productionto measure the state and present it to the operator

5. which of the following is a consistent plant categorization:open loop – continuous – closed loopdiscrete - continuous - hybridprocess - manufacturing- batch

Types of plants and control 1.3 - 17Industrial Automation

Fill in the grid

hydro power plantcar factorypaper millcontainer harborluggage transportelectrical substationprinting machinelocomotivewater treatmentbuilding automationpetrochemical plantpharmaceutical

(continuous) process

batch manufacturing