Industrial process controlAn industrial process control or simply process control in continuous production processes is a discipline that uses industrial control systems and control theory to achieve a production level of consistency, economy and safety which could not be achieved purely by human manual control. It is implemented widely in industries such as automotive, mining, dredging, oil refining, pulp and paper manufacturing, chemical processing and power generating plants.
Industrial control systemAn industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and interactive distributed control systems (DCSs) with many thousands of field connections. Control systems receive data from remote sensors measuring process variables (PVs), compare the collected data with desired setpoints (SPs), and derive command functions that are used to control a process through the final control elements (FCEs), such as control valves.
Control systemA control system manages, commands, directs, or regulates the behavior of other devices or systems using control loops. It can range from a single home heating controller using a thermostat controlling a domestic boiler to large industrial control systems which are used for controlling processes or machines. The control systems are designed via control engineering process. For continuously modulated control, a feedback controller is used to automatically control a process or operation.
Distributed control systemA distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control. This is in contrast to systems that use centralized controllers; either discrete controllers located at a central control room or within a central computer. The DCS concept increases reliability and reduces installation costs by localising control functions near the process plant, with remote monitoring and supervision.
Proportional–integral–derivative controllerA proportional–integral–derivative controller (PID controller or three-term controller) is a control loop mechanism employing feedback that is widely used in industrial control systems and a variety of other applications requiring continuously modulated control. A PID controller continuously calculates an error value as the difference between a desired setpoint (SP) and a measured process variable (PV) and applies a correction based on proportional, integral, and derivative terms (denoted P, I, and D respectively), hence the name.
Control theoryControl theory is a field of control engineering and applied mathematics that deals with the control of dynamical systems in engineered processes and machines. The objective is to develop a model or algorithm governing the application of system inputs to drive the system to a desired state, while minimizing any delay, overshoot, or steady-state error and ensuring a level of control stability; often with the aim to achieve a degree of optimality. To do this, a controller with the requisite corrective behavior is required.
Statistical process controlStatistical process control (SPC) or statistical quality control (SQC) is the application of statistical methods to monitor and control the quality of a production process. This helps to ensure that the process operates efficiently, producing more specification-conforming products with less waste scrap. SPC can be applied to any process where the "conforming product" (product meeting specifications) output can be measured. Key tools used in SPC include run charts, control charts, a focus on continuous improvement, and the design of experiments.
Control chartControl charts are graphical plots used in production control to determine whether quality and manufacturing processes are being controlled under stable conditions. (ISO 7870-1) The hourly status is arranged on the graph, and the occurrence of abnormalities is judged based on the presence of data that differs from the conventional trend or deviates from the control limit line. Control charts are classified into Shewhart individuals control chart (ISO 7870-2) and CUSUM(CUsUM)(or cumulative sum control chart)(ISO 7870-4).
Open-loop controllerIn control theory, an open-loop controller, also called a non-feedback controller, is a control loop part of a control system in which the control action is independent of the "process output", which is the process variable that is being controlled. It does not use feedback to determine if its output has achieved the desired goal of the input command or process setpoint. There are many open-loop controls, such as on/off switching of valves, machinery, lights, motors or heaters, where the control result is known to be approximately sufficient under normal conditions without the need for feedback.
Angular velocityIn physics, angular velocity (symbol ω, sometimes Ω), also known as angular frequency vector, is a pseudovector representation of how the angular position or orientation of an object changes with time, i.e. how quickly an object rotates (spins or revolves) around an axis of rotation and how fast the axis itself changes direction. The magnitude of the pseudovector, , represents the angular speed (or angular frequency), the rate at which the object rotates (spins or revolves).
Closed-loop controllerA 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.
Angular momentumIn physics, angular momentum (sometimes called moment of momentum or rotational momentum) is the rotational analog of linear momentum. It is an important physical quantity because it is a conserved quantity – the total angular momentum of a closed system remains constant. Angular momentum has both a direction and a magnitude, and both are conserved. Bicycles and motorcycles, flying discs, rifled bullets, and gyroscopes owe their useful properties to conservation of angular momentum.
VelocityVelocity is the speed and the direction of motion of an object. Velocity is a fundamental concept in kinematics, the branch of classical mechanics that describes the motion of bodies. Velocity is a physical vector quantity: both magnitude and direction are needed to define it. The scalar absolute value (magnitude) of velocity is called , being a coherent derived unit whose quantity is measured in the SI (metric system) as metres per second (m/s or m⋅s−1). For example, "5 metres per second" is a scalar, whereas "5 metres per second east" is a vector.
Setpoint (control system)In cybernetics and control theory, a setpoint (SP; also set point) is the desired or target value for an essential variable, or process value (PV) of a control system, which may differ from the actual measured value of the variable. Departure of such a variable from its setpoint is one basis for error-controlled regulation using negative feedback for automatic control. Cruise control The SP-PV error can be used to return a system to its norm.
Functional derivativeIn the calculus of variations, a field of mathematical analysis, the functional derivative (or variational derivative) relates a change in a functional (a functional in this sense is a function that acts on functions) to a change in a function on which the functional depends. In the calculus of variations, functionals are usually expressed in terms of an integral of functions, their arguments, and their derivatives.
Bang–bang controlIn control theory, a bang–bang controller (hysteresis, 2 step or on–off controller), is a feedback controller that switches abruptly between two states. These controllers may be realized in terms of any element that provides hysteresis. They are often used to control a plant that accepts a binary input, for example a furnace that is either completely on or completely off. Most common residential thermostats are bang–bang controllers. The Heaviside step function in its discrete form is an example of a bang–bang control signal.
Angular accelerationIn physics, angular acceleration (symbol α, alpha) is the time rate of change of angular velocity. Following the two types of angular velocity, spin angular velocity and orbital angular velocity, the respective types of angular acceleration are: spin angular acceleration, involving a rigid body about an axis of rotation intersecting the body's centroid; and orbital angular acceleration, involving a point particle and an external axis. Angular acceleration has physical dimensions of angle per time squared, measured in SI units of radians per second squared (rads-2).
Action (physics)In physics, action is a scalar quantity describing how a physical system has changed over time (its dynamics). Action is significant because the equations of motion of the system can be derived through the principle of stationary action. In the simple case of a single particle moving with a constant velocity (uniform linear motion), the action is the momentum of the particle times the distance it moves, added up along its path; equivalently, action is twice the particle's kinetic energy times the duration for which it has that amount of energy.
Model predictive controlModel predictive control (MPC) is an advanced method of process control that is used to control a process while satisfying a set of constraints. It has been in use in the process industries in chemical plants and oil refineries since the 1980s. In recent years it has also been used in power system balancing models and in power electronics. Model predictive controllers rely on dynamic models of the process, most often linear empirical models obtained by system identification.
LinearityIn mathematics, the term linear is used in two distinct senses for two different properties: linearity of a function (or mapping ); linearity of a polynomial. An example of a linear function is the function defined by that maps the real line to a line in the Euclidean plane R2 that passes through the origin. An example of a linear polynomial in the variables and is Linearity of a mapping is closely related to proportionality. Examples in physics include the linear relationship of voltage and current in an electrical conductor (Ohm's law), and the relationship of mass and weight.
