Vietnam National University-Ho Chi Minh City

Ho Chi Minh City University of Technology

Faculty of Mechanical Engineering
Department of Mechatronics

Subject:
Control System Technology

Process Control

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Introduction

Industrial processes can be divided into two types:

• Discrete process: is a group of discrete stages with clear starting conditions (each
stage). When groups of steps have a defined start point, end point, and control form,
the process is called a sequential process.
• Continuous process: is a process with continuous input/output signals (without
interruption). At least one input signal (controller) is varied so as to maintain a
desired output signal. The output signal is determined by one/more control modes.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Discrete Process Control

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Discrete Process Control
Most discrete processes are sequential

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Form of Process Description
To describe the behavior of a discrete process, we can use :
• Statement list

▪ Step 1: Put noodles, seasoning powder and oil in a bowl

▪ Step 2: Pour about 400cc of boiling water, cover for 3 minutes

▪ Step 3: Then you can use it immediately

• Timing diagram

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Form of Process Description
• Sequential function chart

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Form of Process Description
• State chart

Step No. Sol. A Sol. B Sol. C Sol. D Motor

1 

2  

3   

4   

5 

6  

7 

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Form of Process Description
• Ladder diagram circuit

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Relay In Logic Control Circuit

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Relay In Logic Control Circuit

Relays can be configured to form multiple contact pairs.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Relay In Logic Control Circuit

Relays can perform logic functions.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Relay In Logic Control Circuit
Example:

In a bank, there are 3 employees responsible for

opening the safe. Each person holds a unique
key (i.e. 3 different keys). According to bank
regulations, 2 out of 3 employees must be
present to open the safe. Draw a circuit diagram
of the ladder used to open the safe door and
light up a light bulb when 2 of the 3 keys are
used.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Sequence Control Circuit Design
The basic idea for the design is:
• Use a control relay for each step of the process.
• When the process is working on a certain step, only the control
relay associated with that step will be activated.
• The number of steps of the process will correspond 1-1 to the
number of states of the controller. Each state of the controller is
represented as a branch in the ladder control circuit.

Suppose the process has 3 consecutive steps: step i, step j, and step k.
The jth branch in the control circuit has the following general form:

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Sequence Control Circuit Design
The typical design process includes the following steps:
• Step 1: Process definition (using dynamic diagram / equipment
diagram)
• Step 2: Define steps (states)
(Use a functional sequence diagram / state flow chart)
• Step 3: Determine the status of the input/output signal (Use a time
chart)
• Step 4: Determine transition conditions (Use a time chart)
• Step 5: Determine the function of the output signal (Use Boolean
algebra tools)
• Step 6: Build a ladder control circuit
• Step 7: Build a ladder diagram of the output signal
• Step 8: Create design documents

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Automatic Drilling Machine System

• Step 1: Define the process

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Automatic Drilling Machine System

• Step 2: Define the step

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Automatic Drilling Machine System
• Step 3: Identify the state of input signal / output signal

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Automatic Drilling Machine System
• Step 4: Identify the condition of transition state

C0.1 Reset

C1.2 Start

C2.3 LS4 • Step 5: Identify the function of output signal

C3.4 LS2
Sol. A Step 3
C4.5 LS1
Sol. B Step 4
C5.6 LS3
Sol. C Step 2 OR Step 3 OR Step 4
C6.7 LS6 Sol. D Step 6

Motors 1

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Automatic Drilling Machine System

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Automatic Drilling Machine System
• Step 6:

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Automatic Drilling Machine System
• Step 7: Build the ladder diagram of output signal

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Pick & Place Robot

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Component Spinning System

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Component Bending System

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Component Positioning System

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 PLC
PLC is designed to replace the traditional control method using relays. It creates easy
and flexible device control based on programming on basic logic instructions. In addition,
PLC can also perform other tasks such as timing and counting …

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

PLC & Peripheral Device

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Connect the Input Signal

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Connect the Output Signal

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Module of Analog Signal Processing

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

PLC Programming

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Continuous Process Control

Three main action:

- Measure
- Make a decision
- React

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Continuous Process Control
When there is a change in load or adjustment value, the control system must ensure the
following 3 goals :

• Minimize the maximum deviation value.

Transition stage
• Minimize setup time.

• Minimize residual deviation. Steady-state stage

The set error value is caused by

friction, load, and the accuracy of
the feedback sensor.

Implement appropriate control mode

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 2-Position Control Mode
Depending on the error signal, the controller output signal has only two values.

This control mode is only suitable for processes with relatively large capacity, for
example: heating systems, water level control, air conditioning systems.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 3-Position Control Mode
The output signal of this controller has 3 states (up-off-down, hot-off-cold …)

This control mode is used in systems without a specific stop state.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 3-Position Control Mode
If the control system is not properly designed, the system fluctuations will gradually
increase, leading to system instability.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Ratio Control Mode
With P control mode, the output signal at the controller is proportional to the error signal

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

Ratio Control Mode
P control mode is simple and is the basis
for most controllers. However, this mode
always has a basic problem: the existence
of a set error value.

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Integral Control Mode
With control mode I, the output signal at the controller is proportional to the integral of the
error signal

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

 Proportional-Integral Control Mode

Control mode I overcomes the steady-state error but reduces the stability and response
speed of the system
Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn
 Derivative Control Mode
With control mode D, the output signal at
the controller is proportional to the rate of
change of the error signal

Control mode D creates an initial impulse

for the system to respond faster, then
creates a braking force when the system
approaches the desired position.

The output signal of mode D does not

depend on the error value → mode D
should never be used separately

Associate Prof. Dr. Ngo Ha Quang Thinh, nhqthinh@hcmut.edu.vn

The End

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