Control engineering or control systems engineering or Automation engineering is an engineering discipline that deals with control systems, applying control theory to design equipment and systems with desired behaviors in control environments. The discipline of controls overlaps and is usually taught along with electrical engineering, chemical engineering and mechanical engineering at many institutions around the world.
Control 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.
Feedback occurs when outputs of a system are routed back as inputs as part of a chain of cause-and-effect that forms a circuit or loop. The system can then be said to feed back into itself. The notion of cause-and-effect has to be handled carefully when applied to feedback systems:
Simple causal reasoning about a feedback system is difficult because the first system influences the second and second system influences the first, leading to a circular argument. This makes reasoning based upon cause and effect tricky, and it is necessary to analyze the system as a whole. As provided by Webster, feedback in business is the transmission of evaluative or corrective information about an action, event, or process to the original or controlling source.
Instrumentation is a collective term for measuring instruments, used for indicating, measuring, and recording physical quantities. It is also a field of study about the art and science about making measurement instruments, involving the related areas of metrology, automation, and control theory. The term has its origins in the art and science of scientific instrument-making.
A fuzzy control system is a control system based on fuzzy logic—a mathematical system that analyzes analog input values in terms of logical variables that take on continuous values between 0 and 1, in contrast to classical or digital logic, which operates on discrete values of either 1 or 0.
A proportional–integral–derivative 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, hence the name.
Automation describes a wide range of technologies that reduce human intervention in processes, mainly by predetermining decision criteria, subprocess relationships, and related actions, as well as embodying those predeterminations in machines. Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices, and computers, usually in combination. Complicated systems, such as modern factories, airplanes, and ships typically use combinations of all of these techniques. The benefit of automation includes labor savings, reducing waste, savings in electricity costs, savings in material costs, and improvements to quality, accuracy, and precision.
Negative feedback occurs when some function of the output of a system, process, or mechanism is fed back in a manner that tends to reduce the fluctuations in the output, whether caused by changes in the input or by other disturbances. A classic example of negative feedback is a heating system thermostat — when the temperature gets high enough, the heater is turned OFF. When the temperature gets too cold, the heat is turned back ON. In each case the "feedback" generated by the thermostat "negates" the trend.
A thermostat is a regulating device component which senses the temperature of a physical system and performs actions so that the system's temperature is maintained near a desired setpoint.
A 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 have an effect on the process outputs, which is measured with sensors and processed by the controller; the result is "fed back" as input to the process, closing the loop.
In 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.
Industrial process control (IPC) or simply process control is a system used in modern manufacturing which uses the principles of control theory and physical industrial control systems to monitor, control and optimize continuous industrial production processes using control algorithms. This ensures that the industrial machines run smoothly and safely in factories and efficiently use energy to transform raw materials into high-quality finished products with reliable consistency while reducing energy waste and economic costs, something which could not be achieved purely by human manual control.
In cybernetics and control theory, a setpoint 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. A setpoint can be any physical quantity or parameter that a control system seeks to regulate, such as temperature, pressure, flow rate, position, speed, or any other measurable attribute.
Proportional control, in engineering and process control, is a type of linear feedback control system in which a correction is applied to the controlled variable, and the size of the correction is proportional to the difference between the desired value and the measured value. Two classic mechanical examples are the toilet bowl float proportioning valve and the fly-ball governor.
A control loop is the fundamental building block of control systems in general and industrial control systems in particular. It consists of the process sensor, the controller function, and the final control element (FCE) which controls the process necessary to automatically adjust the value of a measured process variable (PV) to equal the value of a desired set-point (SP).
Integral windup, also known as integrator windup or reset windup, refers to the situation in a PID controller where a large change in setpoint occurs and the integral term accumulates a significant error during the rise (windup), thus overshooting and continuing to increase as this accumulated error is unwound.
In control theory, a bang–bang 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. Due to the discontinuous control signal, systems that include bang–bang controllers are variable structure systems, and bang–bang controllers are thus variable structure controllers.
An 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.
The following outline is provided as an overview of and topical guide to control engineering:
Linear control are control systems and control theory based on negative feedback for producing a control signal to maintain the controlled process variable (PV) at the desired setpoint (SP). There are several types of linear control systems with different capabilities.
