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Cascade Control
Cascade Control
1.0
Cascade Control
1.1
Introduction
Cascade Control has a multi-loop structure, where the output of the controller
in the outer loop (the primary or master) is the set point of a controller in
the inner loop (the secondary or slave).
The slave measurement is an intermediate process variable that can be used
to achieve more effective control of the primary process variable. Two
controllers are used, but only one process variable is manipulated.
The primary controller maintains the primary variable at its set point by
adjusting the set point of the secondary controller. The secondary controller,
in turn responds both to set point and to the secondary controlled variable.
Figure 1 shows a cascade loop to control heat exchanger process fluid outlet
temperature by controlling the steam inlet flow.
In most applications, the control loop is not functioning as a cascade loop all
the time. The operator (in the case of batch control, the batch control
program) has the ability to change modes. Following is the typical selection of
modes of operation available for a cascade control loop. Manual and Auto are
usually used during start-up while cascade is used for normal operation.
Manual Mode - The set point of the flow controller tracks the actual
flow variable. Figure 7 shows in (a) the schematic of a Manual mode.
Auto Mode - The output of the temperature controller tracks the set
point of the flow controller. Figure 7 shows in (b)the schematic of an
Auto mode.
a)
Manual
mode
b) Auto
mode
c)
Cascade
mode
Windup
If the secondary controller cannot deliver enough flow, even with its valve
wide open, to bring the primary measured variable to its set point, the primary
controller will "windup" and continue to increase the flow set point above the
maximum flow. Later, when the flow is sufficient to bring the primary
measurement to its set point, the primary controller must take the time to
"wind down" the secondary set point to the actual flow before the valve begins
to close.
The windup problem can be eliminated by connecting the secondary
measurement to the external feedback of the primary.