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Digital Control and PID Control of Industrial Processes Assignment

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Digital Control and PID Control of Industrial Processes Assignment

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rodneymandizvidza
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© © All Rights Reserved
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Digital Control and PID

Control of Industrial
Processes
Digital Control

 Digital control is a method of controlling industrial processes using digital


devices such as microcontrollers, digital signal processors (DSPs), or
programmable logic controllers (PLCs). Instead of using continuous
analog signals, digital control discretizes inputs, processes them using
algorithms, and outputs control signals in discrete steps.
 Key aspects of digital control include:
 Sampling is the process of converting a continuous-time signal (analog)
into a discrete-time signal (digital). This is a crucial step in digital control
as the controller operates on discrete data.
 Control Algorithm processes the sampled data to calculate the output
required to control the system. It is the "brain" of the digital control
system.
 Output is the signal generated by the control algorithm to influence the
system. It typically drives an actuator or a process device.
Sampling

 Steps in Sampling:
1. Signal Measurement: A sensor measures the process variable
(e.g., temperature, speed) continuously.
2. Sampling: At regular intervals (TsT_sTs​, the sampling period),
the signal is sampled.
3. Analog-to-Digital Conversion (ADC): Each sampled value is
quantized into a digital format for processing.
Control Algorithm

 Common Control Algorithms:


1. Proportional-Integral-Derivative (PID):
1. Most common due to its simplicity and effectiveness.
2. Discrete version implemented using methods like finite differences.
2. State-Space Control:
1. Uses a mathematical model of the system in state-space form.
2. Suitable for multivariable systems and systems requiring optimal control.
3. Model Predictive Control (MPC):
1. Predicts future behavior of the system and calculates the control actions to optimize
performance over a time horizon.
4. Logic-Based Controllers:
1. Include ON/OFF controllers or programmable logic-based algorithms.
2. Simpler but less precise compared to PID or advanced methods.
 Algorithm Implementation:
• The algorithm runs on a digital platform (e.g., microcontroller,
PLC).
• Processing involves arithmetic operations, filtering, and decision-
making based on the system state.
• The algorithm’s response time must align with the system
dynamics and sampling rate.
 Challenges:
• Stability and precision depend on correct tuning and design.
• Computational delays (e.g., due to complex algorithms) can
degrade performance.
Output

 Steps in Output Processing:


1. Digital-to-Analog Conversion (DAC):
1. Converts the digital control signal into an analog form for the actuator.
2. The resolution of the DAC affects output precision.
2. Actuator Control:
1. The analog signal drives devices such as motors, valves, heaters, or
pumps.
2. In some cases, the output remains digital (e.g., PWM signals for motor
control).
3. Signal Conditioning:
1. The control signal may need scaling, filtering, or amplification to match
the actuator's requirements.
Interrelation of Sampling, Control
Algorithm, and Output
1. Sampling captures the real-time state of the system and
converts it into a form the control algorithm can process.
2. The Control Algorithm computes the required correction based
on the system's current and desired states.
3. The Output translates this computation into actionable signals
that directly influence the system, closing the loop.
 This sequence—Sampling → Processing → Output—is repeated at
every sampling interval, ensuring real-time system control. If any
part of this loop is poorly designed (e.g., low sampling rate, slow
processing, or imprecise output), the system performance will
degrade.
Applications of Digital Control

 1. Industrial Automation
• Process Control:
• Temperature, pressure, flow, and level control in chemical plants, refineries,
and manufacturing.
• Example: Digital PID controllers for maintaining precise conditions in reactors.
• Motion Control:
• Speed and position control in conveyor belts, robotic arms, and CNC machines.
• Example: Digital controllers in servo systems for precision machining.
• Machine Automation:
• PLCs (Programmable Logic Controllers) using digital control algorithms to
automate industrial machines.
• Example: Automated bottling plants, assembly lines.
 Automotive and Transportation
• Engine Control:
• Digital Engine Control Units (ECUs) regulate fuel injection, ignition timing, and
emissions.
• Example: Adaptive cruise control and idle speed control.
• Vehicle Dynamics:
• ABS (Anti-lock Braking Systems), ESC (Electronic Stability Control), and traction
control systems.
• Example: Ensuring safe vehicle operation under various road conditions.
• Electric and Hybrid Vehicles:
• Battery management systems (BMS) and motor controllers for efficient energy
usage.
• Example: Digital control of inverters in electric drivetrains.
 Consumer Electronics
• Home Appliances:
• Control systems in washing machines, air conditioners, and
refrigerators.
• Example: Temperature control in smart HVAC systems.
• Audio and Video Devices:
• Digital equalizers, filters, and amplifiers in home entertainment
systems.
• Example: Active noise-canceling headphones.
• Smart Devices:
• Digital control in IoT-enabled devices for automation and monitoring.
• Example: Smart lighting systems and thermostats.
PID Control

 PID (Proportional-Integral-Derivative) control is one of the most


commonly used control strategies in industrial automation. It is
based on three components:
1. Proportional (P): Acts on the current error by applying a control
signal proportional to the error magnitude.
Limitation: Proportional control alone cannot eliminate steady-
state error (offset).
2. Integral (I): Addresses accumulated past errors by summing
them over time, eliminating steady-state errors. It enhances the
controller's ability to reach the setpoint precisely.
Limitation: Excessive integral action can lead to oscillations or
overshoot (integral windup).
3. Derivative (D): Predicts future errors by considering the rate of change of
the error, improving system response and stability.
Improves stability by damping the system's response.
Reduces overshoot and oscillations, providing a "smoother" control action.
Limitations: Highly sensitive to noise in the error signal, requiring filtering.
Advantages of PID Control

1. Simplicity: Easy to understand and implement in hardware or


software.
2. Effectiveness: Provides accurate control for a wide range of
systems.
3. Flexibility: Can be adapted to various applications by adjusting
the gains.
4. Robustness: Handles system disturbances and maintains
performance.
Disadvantages/Limitations of PID
Control
1. Noise Sensitivity: The derivative term is highly sensitive to
measurement noise.
2. Integral Windup: Accumulated error can cause overshoot or
instability.
3. Tuning Challenges: Finding optimal gains for complex systems
can be time-consuming.
4. Inability to Handle Nonlinearities: Struggles with highly
nonlinear or time-varying systems.
Applications of PID Control

• Industrial Automation:
• Controlling temperature in furnaces or chemical processes.
• Speed and position control in motors.
• Aerospace:
• Stabilizing aircraft autopilots.
• Consumer Electronics:
• Maintaining temperature in air conditioners or refrigerators.
• Process Control:
• Flow, pressure, and level control in pipelines and tanks.
Relationship Between Digital
Control and PID Control
 Integration: PID controllers are a subset of digital control
algorithms used for systems requiring precise and robust control.
Digital controllers can also implement more advanced algorithms
(e.g., predictive or adaptive control), but PID remains popular for
its simplicity and effectiveness.
 Industrial Use: Digital controllers running PID algorithms are
widely used in applications like temperature regulation, motor
speed control, and process automation due to their reliability and
ease of tuning.
 Flexibility: Digital implementations allow for modifications like
auto-tuning, filtering (to reduce noise), or adaptive gain
adjustment, enhancing the basic PID control.
 RODNEY MANDIZVIDZA BEIE C23154047V
 TARIRO BUSU BEIE C23153939C
References

 Sampling Definition: Kumar, Anand. (2022-03-27.) https://


www.numerade.com/ask/question/how-do-signal-processing-tech
niques-such-as-sampling-and-quantization-affect-the-accuracy-of-
digital-representations-of-analog-signals-and-what-are-their-impli
cations-for-data-transmission-a-35054/
 https://fiveable.me/key-terms/introduction-to-scientific-
computing/adaptive-filtering

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