Introduction to the computer-based

process control
• The idea of ​using digital computers
as components in control systems
emerged around 1950.
• Applications with missiles and
automatic control of aircrafts were the
first to be investigated.
• In those days computers were very
large and did not allow real
applications.

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 Historical periods of computer control

• The first serious work began in

1956 when the aerospace
company TRW (Thomson Ramo
Woolridge) contacted TEXACO to
conduct a feasibility study.
• After preliminary discussions, it
was decided to investigate a
polymerization unit in Port Arthur,
Texas refinery.

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 Historical periods of computer control

• The digital control system was based on

a RW-300 computer, and was launched
on March 12, 1959.
• The system was able to control 26
flows, 72 temperatures, 3 pressures,
and 3 mixtures.
• The main function was
– to minimize the pressure in the reactor,
– to determine the optimal distribution of flows
in 5 reactors,
– to control the flow of hot water, and
– to determine the optimal recirculation. 3
 Historical periods of computer control

Features of the first systems:

• Slow systems, expensive and with low reliability.
• Addition time = 1ms
• Multiplication time = 20ms
• MTBF –Mean Time Between Failures– for the
unit process of 50-100hrs.
• Computers were operating in supervisor mode
only:
– generating instructions for the operator
– changing the references of the analog controllers.
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 Historical periods of computer control

• In the era of the 60's there was a strong

development in digital computers, which also
brought a development in computer-based
process.
• Already had computers with:
– MTBF of 20,000hrs
– Addition time = 3 microseconds
– Multiplication time = 7 microseconds

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Historical periods of computer control

It was in the early 70's

(growth of the aerospace
industry and space
exploration) when the
development of the
theory of digital control
systems and sampled-
data lived its most
prolific time.

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 Historical periods of computer control
Microcomputer period:
• The low prices of computers caused that the
computer-based control were a real
alternative.
• The digital systems were included even in the
loops in the lowest level.
• Analog technology was replaced by digital.
• The computer had effect directly on the
process
• Improved communication with the operator. A
computerized panel can replace a wall of
instruments.
• Ease of redesign (reprogramming VS rewiring)
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 The present and future

• More recently, the application

of computer control has made
possible:
– the “smart“ motion of industrial
robots,
– optimizing the use of fuel in
cars,
– improvements in the operation
of electric appliances,
– improvements in measurement
technology (smart sensors), etc.
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 Problem definition of computer-based
control

• To control a process (plant) by using digital

computers so it can have a "satisfactory" behavior.
• “Satisfactory” means that the plant output y(t) is
forced to follow a reference input r(t) despite
disturbances in the plant and in spite of errors in
sensing.
• It is also necessary that the reference tracking is
good enough although the plant dynamics varies
slightly.
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 Closed-loop digital-control system
w

r e Digital u Plant or y
D/A
Computer Process

Synchronization
Pulse v

y*
A/D Sensor

Notation:
• r = reference
• u = control signal
• y = process variable
• y* = sampled process variable
• e = r – y*
• w= disturbance in the process
• v= disturbance in the sensor
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 Advantages
• Low susceptibility to environmental conditions
• Immunity to electrical noise
• No parameter deviation
• Reliability (100,000 hrs. → MTBF –Mean Time
Between Failures–)
• Complex tasks at low cost
• Flexibility in the program of control
(reprogramming)
• Ease-of-use human man interfaces
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 Disadvantages
• Limited precision (finite representation in the
computer)
→ errors around the zero
→ lost of information
• Limitation in processing speed → delays
• System design → total discretization

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 Applications
Flight control
Modern
medicine Automotive
industry

Robotics Numerical
Aeronautics control machines
Hard disk
control

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