9780130306883

Marrying an academic examination on control system technology with a reference that practicing engineers and technicians can include in their personal libraries, this carefully balanced study covers the terminology, concepts, principles, procedures, and computations used by engineers and technicians to analyze, select, specify, design, and maintain control systems. An accompanying diskette provides computer programs that emulate proven graphical design methods of analysis and design.Basic concepts and terminology, measurement, manipulation, analysis and design.For engineers and technicians interested in a comprehensive addition to their libraries.

PART ONE INTRODUCTION

Basic Concepts and Terminology

1

(35)

Introduction

2

(1)

Block Diagrams and Transfer Functions

3

(4)

Open-Loop Control

7

(1)

Closed-Loop Control: Feedback

8

(7)

Control System Drawings

15

(2)

Nonlinearities

17

(3)

Benefits of Automatic Control

20

(1)

Load Changes

21

(1)

Damping and Instability

22

(1)

Objectives of a Control System

23

(1)

Criteria of Good Control

24

(2)

Block Diagram Simplification

26

(10)

Types of Control

36

(33)

Introduction

37

(1)

Analog and Digital Control

38

(1)

Regulator and Follow-Up Systems

39

(1)

Process Control

39

(5)

Servomechanisms

44

(3)

Sequential Control

47

(2)

Numerical Control

49

(2)

Robotics

51

(4)

The Evolution of Control Systems

55

(2)

Examples of Control Systems

57

(12)

The Common Elements of System Components

69

(44)

Introduction

70

(2)

Electrical Elements

72

(7)

Liquid Flow Elements

79

(10)

Gas Flow Elements

89

(4)

Thermal Elements

93

(7)

Mechanical Elements

100

(13)

Laplace Transforms and Transfer Functions

113

(40)

Introduction

114

(1)

Input/Output Relationships

115

(9)

Laplace Transforms

124

(8)

Inverse Laplace Transforms

132

(4)

Transfer Functions

136

(4)

Initial and Final Value Theorems

140

(1)

Frequency Response: Bode Plots

141

(12)

PART TWO MEASUREMENT

Measuring Instrument Characteristics

153

(28)

Introduction

154

(1)

Statistics

154

(1)

Operating Characteristics

155

(2)

Static Characteristics

157

(5)

Dynamic Characteristics

162

(10)

Selection Criteria

172

(9)

Signal Conditioning

181

(69)

Introduction

182

(1)

The Operational Amplifier

183

(5)

Op-Amp Circuits

188

(15)

Analog Signal Conditioning

203

(21)

Digital Signaling Conditioning

224

(26)

Position, Motion, and Force Sensors

250

(35)

Introduction

251

(1)

Position and Displacement Measurement

252

(18)

Velocity Measurement

270

(3)

Acceleration Measurement

273

(3)

Force Measurement

276

(9)

Process Variable Sensors

285

(36)

Temperature Measurement

286

(17)

Flow Rate Measurement

303

(5)

Pressure Measurement

308

(4)

Liquid Level Measurement

312

(9)

PART THREE MANIPULATION

Switches, Actuators, Valves, and Heaters

321

(42)

Mechanical Switching Components

322

(4)

Solid-State Components

326

(10)

Hydraulic and Pneumatic Valves and Actuators

336

(8)

Control Valves

344

(8)

Electric Heating Elements

352

(11)

Electric Motors

363

(54)

Introduction

364

(6)

AC Motors

370

(7)

DC Motors

377

(19)

Stepping Motors

396

(6)

AC Adjustable-Speed Drives

402

(5)

DC Motor Amplifiers and Drives

407

(10)

PART FOUR CONTROL

Control of Discrete Processes

417

(25)

Introduction

418

(1)

Time-Driven Sequential Processes

419

(2)

Event-Driven Sequential Processes

421

(14)

Time/Event-Driven Sequential Processes

435

(7)

Programmable Logic Controllers

442

(30)

Introduction

443

(3)

PLC Hardwarev

446

(3)

PLC Programming and Operation

449

(5)

PLC Programming Functions

454

(18)

Control of Continuous Processes

472

(43)

Introduction

473

(3)

Modes of Control

476

(24)

Electronic Analog Controllers

500

(4)

Digital Controllers

504

(5)

Advanced Control

509

(4)

Fuzzy Logic Controllers

513

(2)

PART FIVE ANALYSIS AND DESIGN

Process Characteristics

515

(50)

Introduction

526

(1)

The Integral or Ramp Process

527

(4)

The First-Order Lag Process

531

(11)

The Second-Order Lag Process

542

(13)

The Dead-Time Process

555

(3)

The First-Order Lag Plus Dead-Time Process

558

(7)

Methods of Analysis

565

(48)

Introduction

566

(1)

Overall Bode Diagram of Several Components

567

(3)

Open-Loop Bode Diagrams

570

(1)

Closed-Loop Bode Diagrams

571

(4)

Error Ratio and Deviation Ratio

575

(3)

Computer-Aided Bode Plots

578

(9)

Stability

587

(1)

Gain and Phase Margin

588

(4)

Nyquist Stability Criterion

592

(3)

Root Locus

595

(18)

Controller Design

613

(40)

Introduction

614

(1)

The Ultimate Cycle Method

615

(1)

The Process Reaction Method

616

(3)

Self-Tuning Adaptive Controllers

619

(1)

Computer-Aided PID Controller Design

620

(17)

Example Design of a Three-Loop Control System

637

(5)

Control System Compensation

642

(11)

APPENDIX A Properties of Materials

653

(3)

Properties of Solids

653

(1)

Melting Point and Latent Heat of Fusion

654

(1)

Properties of Liquids

654

(1)

Properties of Gases

654

(1)

Standard Atmospheric Conditions

655

(1)

APPENDIX B Units and Conversion

656

(3)

Systems of Units

656

(1)

Conversion Factors

657

(2)

APPENDIX C Binary Codes

659

(3)

Powers of 2

659

(1)

Octal and Binary Equivalents

659

(1)

Decimal, Hexadecimal, and Binary Equivalents

660

(1)

One's and Two's Complements

660

(1)

The Gray Code

660

(1)

Binary Codes for Decimal Digits

661

(1)

Seven-Bit ASCII Code

661

(1)

APPENDIX D Instrumentation Symbols and Identification

662

(7)

Purpose

662

(1)

Scope

662

(1)

Definition

663

(1)

Outline of the Identification System

663

(6)

APPENDIX E Complex Numbers

669

(7)

Introduction

669

(1)

Rectangular and Polar Forms of Complex Numbers

670

(1)

Conversion of Complex Numbers

671

(1)

Graphical Representation of Complex Numbers

671

(2)

Addition and Subtraction of Complex Numbers

673

(1)

Multiplication and Division of Complex Numbers

673

(1)

Integer Power of a Complex Number

674

(1)

Roots of a Complex Number

674

(2)

APPENDIX F Communications

676

(15)

Communication Interfaces

676

(6)

Local Area Networks

682

(4)

Communication Protocols

686

(5)

References

691

(2)

Answers to Selected Exercises

693

(9)

Index

702

What is included with this book?

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GOAL The goal of Introduction to Control System Technologyis to provide both a textbook on the subject and a reference that engineers and technicians can include in their personal libraries. This text can help students master the concepts and language of control and help engineers and technicians analyze and design control systems. The text covers the terminology, concepts, principles, procedures, and computations used by engineers and technicians to analyze, select, specify, design, and maintain control systems. Emphasis is on the application of established methods with the aid of examples and computer programs. EVOLUTION OF TEXT The writing of this text began 34 years ago when I faced the challenge of developing and teaching a control systems course in a 2-year engineering technology program. I had just entered the teaching profession after 10 years as a research engineer at General Mills, where I had become fascinated with control systems. I was especially intrigued by the combined electrical, mechanical, thermal, liquid, and gas elements in the mathematical models used to analyze and design control systems. This fascination led to the completion of an evening MSEE program with a major in control systems and a hands-on design course at Brown Institute in Philadelphia. In my course work, we used straight-line Bode diagrams to design control systems. This method works very well for processes with dead-time lags. The graphical approach gives the designer an "intuitive feel" of the way the controller changes the frequency response of the system. I found that this "feel" was very helpful working on plant start-ups. Indeed, the greatest benefit from learning the frequency-response design method was the understanding and judgment it imparted. It made me a much better engineer. You can imagine the excitement with which I approached the teaching of my favorite subject. I wanted my students to feel that excitement. I wanted to impart some of the feeling and judgment that I acquired from frequency-response design of a control system. There was one major obstacle, however. There was no suitable text for my students. So I wrote 100 pages of notes on control fundamentals with emphasis on graphical design using straight-line Bode diagrams. These notes were the genesis of this text. The thrust of the notes was to bring students to the point where they could complete frequency-response design of control systems under my direction. My role was that of a control engineer, and my students were my engineering technicians. Those 100 pages of notes have grown to become the seventh edition of a 700-page textbook, but the thrust has not changed. The thrust of this text is to bring students to the point where they can complete computer-aided, frequency-response design of control systems under the direction of their instructor or control engineer. Frequency-response graphs are constructed from the transfer functions of the system components. The chapters on common elements and Laplace transforms were written to give students the foundation required to determine these transfer functions. Analogies were used to develop common elements for modeling and analyzing electrical, thermal, mechanical, and fluid flow elements. These analogies helped students translate their knowledge of one type of component to components of other types. The parts on measurement, manipulation, and control extended the students'' mastery of transfer functions and developed their ability to select, specify, and design measuring and manipulating systems. Finally, we reached the point where the students actually began the graphical design process. The frequency-response (or Bode) design method worked very well, but constructing and reconstructing Bode diagrams is very tedious and time consuming. By the time the students learned how to construct Bode diagrams, there was little time or energy left to learn how to design the controller. My goal was unfulfilled. Then I had a dream. My dream was a computer program that would construct the Bode diagrams so that students, technicians, and engineers could concentrate on the design of the controller. The first attempt to realize my dream was a FORTRAN program that generated frequency-response data from the open-loop transfer function. The program made all the design decisions, and all the student had to do was input the transfer function. As an engineering tool, it was great, but as a teaching tool, it failed. Students could complete the design very well, but they did not understand the results. When design exceptions required an override of the program''s results, students had no idea what to do--no pain but no gain. The first program did too much, and the students did too little. The next program generated tables of frequency-response data that the students used to draw the Bode diagrams. It was not as good an engineering tool but was a much better teaching tool. Drawing the graphs took time, but the students did understand the design process. The third version of the program uses the graphing capabilities of the QuickBASIC programming language. The program DESIGN is an interactive program that plots frequency-response graphs on the screen and accepts user inputs of the control modes. This program emulates the classical Bode design method with precise plots based on the transfer functions of the system components. The designer observes how each control mode changes the shape of the open-loop frequency response of the system. On-screen design decision data allow the designer to determine PID control mode values, which can be easily changed in a "what-if analysis. This enables the designer to use a "design-by-trial" procedure to search for the best possible control system design. It worked; my dream was fulfilled. DESIGN is both a good engineering design tool and a good teaching tool. This text was developed to facilitate the education of engineering technicians. Its purpose is to train technicians who understand the language and methods used by engineers, technicians who can use established methods to complete engineering design work under the direction of a control engineer. I believe an essential part of the education of the engineering technician is to develop the ability to communicate with engineers using their language. Mathematical terms are an essential part of this language. The engineering technician must understand and be comfortable with terms such as derivative, integral, transfer function, frequency domain, and Laplace transform--not at the theoretical level, of course, but certainly at the applied level. A goal of this text is to develop an understanding of the language of control, including the mathematical terms mentioned. COMPUTER DISK ANCILLARY The disk packaged with this text contains QuickBASIC and executable versions of the four programs used in the text. No knowledge of QuickBasic is required to use the executable versions of the programs. They can be executed directly from DOS on any IBM-compatible computer. You may make copies of these programs and distribute them as you wish.I hope you enjoy using the programs as much as I enjoyed creating them. CHANGES TO THIS EDITION The primary emphasis for the seventh edition was a complete rework of the exercises at the end of each chapter. Every section was examined, and every question was reviewed. Numerous exercises were added to provide students with multiple opportunities to develop their grasp of the material. The review also provided ample opportunities to improve the clarity and accuracy of the text. Example 16.3, a walk-through of a run of program Design, was revised to provide better integration of the text and figures. Most of the material in Appendix C, "Binary Codes," was deleted because most reviewers felt the material was covered in other cou

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Introduction to Control System Technology

Introduction to Control System Technology

0130306886

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