CHAPTER 1 : FUNDAMENTAL CONCEPTS

OF INDUSTRIAL SYSTEMS
T/615/1513 INDUSTRIAL SYSTEMS
MARSHAL GREYNER,
LECTURER IN ELECTRICAL AND ELECTRONICS ENGINEERING

MARSHAL 1
 Upon completion of this chapter, students should be
LEARNING able to:

OUTCOMES 1. Identify and describe fundamental concepts of

industrial systems, open and closed loop systems
and working principles of AC and DC motors

MARSHAL 2
 i. Control systems are an integral part of modern society.

ii. Numerous applications are all around us: The rockets fire, and the space shuttle lifts off to
earth orbit; in splashing cooling water, a metallic part is automatically machined; a self-
guided vehicle delivering material to workstations in an aerospace assembly plant glides
along the floor seeking its destination.

iii. These are just a few examples of the automatically controlled systems that we can create.

a. Within our own bodies are numerous control systems, such as the pancreas, which

CONTROL regulates our blood sugar.

SYSTEM b. In time of “fight or flight,” our adrenaline increases along with our heart rate, causing
more oxygen to be delivered to our cells.

c. Our eyes follow a moving object to keep it in view; our hands grasp the object and place it
precisely at a predetermined location.

MARSHAL 3
OPEN AND CLOSED LOOP SYSTEM

Systems can operate under an open or closed loop system, the difference between the two is what is
happens to the data after the transfer functions take place. We consider all actions and processes as a
function of time.

Any idea what is open loop? What is closed loop system too?

MARSHAL 4
DESIGN OF
CONTROL
SYSTEM

MARSHAL 5
 A generic open-loop system is
shown in Figure. It starts with a
subsystem called an input
transducer, which converts the
form of the input to that used by
the controller. The controller
drives a process or a plant. The
input is sometimes called the
reference, while the output can
be called the controlled variable.
Other signals, such as
disturbances, are shown added to
the controller and process
outputs via summing junctions,
which yield the algebraic sum of
OPEN LOOP their input signals using
associated signs.

SYSTEM
MARSHAL 6
 OPEN LOOP SYSTEM
An open loop system does not use the collected data to feed back into the system and will just
display the current status for manual intervention to fix any problems.

The control action is not performed automatically by a processing unit within the system.

Let’s say we are using a cheap fan to cool something down, we press a button which give a
varying fan speed, the button completes the circuit and starts the motor. We model systems
with a block diagram. When drawing the block diagram for an open loop system, we have a
linear path between the input and the output, with transfer function blocks in between.

MARSHAL 7
 OPEN LOOP SYSTEM
•Sistem open loop (sistem terbuka) adalah sistem kontrol yang tidak memiliki umpan balik (feedback)
dari output ke input.

•Dalam sistem ini, input diterapkan pada sistem dan menghasilkan output, tanpa memperhatikan atau
mengevaluasi hasil output tersebut untuk mengubah input selanjutnya.

•Contohnya adalah pengendalian suhu ruangan dengan menggunakan termostat. Termostat akan
mematikan atau menghidupkan sistem pendingin atau pemanas ketika suhu mencapai ambang tertentu.

•Sistem ini tidak mengevaluasi suhu aktual ruangan dan hanya mengandalkan pengaturan suhu yang
sudah diatur sebelumnya.
MARSHAL 8
 OPEN LOOP SYSTEM
A block diagram for a fan can be found in Fig.1.2 below. The main characteristics of an open loop system can be
simplified to:
•desired and real values are not compared,
•no self-control or regulation,
•input is a fixed operating position for the controller,
•external disturbances do not result in a direct output change, unless manual alteration takes place.

MARSHAL 9
 EXAMPLE OF OPEN LOOP
SYSTEM
1. Open-loop systems, then, do not correct for disturbances and are simply commanded by the input.

2. For example, toasters are open-loop systems, as anyone with burnt toast can attest. The controlled variable (output) of a

toaster is the color of the toast. The device is designed with the assumption that the toast will be darker the longer it is

subjected to heat. The toaster does not measure the color of the toast; it does not correct for the fact that the toast is rye,

white, or sourdough, nor does it correct for the fact that toast comes in different thicknesses.

3. Other examples of open-loop systems are mechanical systems consisting of a mass, spring, and damper with a constant

force positioning the mass. The greater the force, the greater the displacement. Again, the system position will change

with a disturbance, such as an additional force, and the system will not detect or correct for the disturbance.

MARSHAL 10
MARSHAL 11
EXERCISE
Determine the control system type and sketch the diagram of control system
of an electric toaster based on the following Figure.

MARSHAL 12
 The disadvantages of open-
loop systems, namely
sensitivity to disturbances
and inability to correct for
these disturbances, may be
overcome in closed-loop
systems. The generic
architecture of a closed-loop
system is shown in Figure.

CLOSED LOOP
SYSTEM
MARSHAL 13
 CLOSED LOOP SYSTEM
The input transducer converts the form of the input to the form used by the controller. An output

transducer, or sensor, measures the output response and converts it into the form used by the controller.

For example, if the controller uses electrical signals to operate the valves of a temperature control system,

the input position and the output temperature are converted to electrical signals. The input position can be

converted to a voltage by a potentiometer, a variable resistor, and the output temperature can be converted

to a voltage by a thermistor, a device whose electrical resistance changes with temperature.

MARSHAL 14
CLOSED LOOP SYSTEM
The closed-loop system compensates for disturbances by measuring the output response, feeding that
measurement back through a feedback path, and comparing that response to the input at the summing
junction. If there is any difference between the two responses, the system drives the plant, via the actuating
signal, to make a correction. If there is no difference, the system does not drive the plant, since the plant’s
response is already the desired response.

MARSHAL 15
 CLOSED LOOP SYSTEM
•Sistem closed loop (sistem tertutup) adalah sistem kontrol yang menggunakan umpan balik (feedback) dari
output ke input untuk memodifikasi atau mengoreksi input berikutnya.

• Dalam sistem ini, output dievaluasi dan dibandingkan dengan nilai yang diinginkan atau target, kemudian
informasi ini digunakan untuk mengubah input selanjutnya.

•Contohnya adalah sistem kendali suhu pada oven yang menggunakan termokopel dan pengontrol PID.
Termokopel akan mengukur suhu oven dan memberikan informasi ini ke pengontrol PID.

•Pengontrol PID akan membandingkan suhu aktual dengan suhu target dan menghasilkan sinyal kontrol untuk
mengubah input pada elemen pemanas atau pendingin.

MARSHAL 16
 EXAMPLE OF CLOSED LOOP SYSTEM
A closed loop system will collect data while it runs and will feedback into the system to correct to compensate for
any disturbances without any external intervention. A closed loop system basically has its own element of control.
Let’s say our fan is now monitoring the temperature of the item we are cooling; the input is no longer the manual
operator pressing the button, it is the desired temperature of the item. Fig.1.3 shows the block diagram for the
closed loop fan.

MARSHAL 17
AUTOMATIC DRYER

MARSHAL 18
When you adjust a Gas Stove Burner

MARSHAL 19
 EXERCISE

ANSWER:

MARSHAL 20
COMPARISON
BETWEEN
OPEN AND
CLOSED LOOP

MARSHAL 21
 Find 6 HIDDEN
WORDS in the
pictures. No
CHEATING

MARSHAL 22
ELECTRIC MOTORS
An electric motor (or electrical motor) is an electric machine that converts electrical energy
into mechanical energy. Most electric motors operate through the interaction between the
motor’s magnetic field and electric current in a wire winding. This interaction generates a
force (as per Faraday’s Law) in the form of torque which is applied to the motor’s shaft.

Electric motors can be powered by direct current (DC) sources, such as batteries or
rectifiers. Or by alternating current (AC) sources, such as inverters, electric generators, or
a power grid.

MARSHAL 23
ELECTRIC MOTORS
The basic principle underlying the functioning of an electrical motor is
Faraday’s Law of induction.

That is, that a force is created when an alternating current interacts with a
changing magnetic field.

MARSHAL 24
 FARADAY’S
LAW
Faraday’s law of electromagnetic
induction (referred to as Faraday’s law)
is a basic law of electromagnetism
predicting how a magnetic field will
interact with an electric circuit to produce
an electromotive force (EMF). This
phenomenon is known as
electromagnetic induction.

MARSHAL 25
TYPES OF MOTOR

MARSHAL 26
DC MOTORS

From the above definition, we can

conclude that any electric motor
that is operated using direct current
A DC motor is defined as a class
or DC is called a DC motor. We will
of electrical motors that convert
understand the DC motor
direct current electrical energy
construction and how a DC motor
into mechanical energy.
converts the supplied DC electrical
energy into mechanical energy in
the next few sections.

MARSHAL 27
DC MOTOR DIAGRAM

MARSHAL 28
 PARTS OF A DC MOTOR
Armature or Rotor

The armature of a DC motor is a cylinder of magnetic laminations that are insulated from

one another. The armature is perpendicular to the axis of the cylinder. The armature is a

rotating part that rotates on its axis and is separated from the field coil by an air gap.

Field Coil or Stator

A DC motor field coil is a non-moving part on which winding is wound to produce a 

magnetic field. This electro-magnet has a cylindrical cavity between its poles.
MARSHAL 29
 PARTS OF A DC
MOTOR
Commutator and Brushes

Commutator

The commutator of a DC motor is a cylindrical structure that is made of copper segments

stacked together but insulated from each other using mica. The primary function of a
commutator is to supply electrical current to the armature winding.

Brushes

The brushes of a DC motor are made with graphite and carbon structure. These brushes
conduct electric current from the external circuit to the rotating commutator. Hence, we come
to understand that the commutator and the brush unit are concerned with transmitting
the power from the static electrical circuit to the mechanically rotating region or the
rotor.

MARSHAL 30
WORKING PRINCIPLE OF DC
MOTOR
A magnetic field arises in the air gap when the field coil of the
DC motor is energised. The created magnetic field is in the
direction of the radii of the armature. The magnetic field enters
the armature from the North pole side of the field coil and
“exits” the armature from the field coil’s South pole side. The
conductors located on the other pole are subjected to a force
of the same intensity but in the opposite direction. These two
opposing forces create a torque that causes the motor
armature to rotate.
MARSHAL 31
WORKING PRINCIPLE OF DC MOTOR

In short words,

When kept in a magnetic field, a current-carrying conductor gains torque and

develops a tendency to move. In short, when electric fields and magnetic
fields interact, a mechanical force arises. This is the principle on which the
DC motors work.

MARSHAL 32
TYPES OF DC MOTOR
DC motors have a wide range of applications ranging from electric shavers
to automobiles. To cater to this wide range of applications, they are classified
into different types based on the field winding connections to the armature
as:

•Self Excited DC Motor

•Separately Excited DC Motor

MARSHAL 33
SELF EXCITED DC MOTOR
In self-excited DC motors, the field winding is connected either in series or
parallel to the armature winding. Based on this, the self-excited DC motor
can further be classified as:

•Shunt wound DC motor

•Series wound DC motor

•Compound wound DC motor

MARSHAL 34
SHUNT WOUND DC MOTOR

In a shunt wound motor, the field winding is connected

parallel to the armature as shown in the figure.

MARSHAL 35
SERIES WOUND DC MOTOR
In a series wound DC motor, the field winding is
connected in series with the armature winding as
shown in the figure.

MARSHAL 36
COMPOUND WOUND DC
MOTOR
DC motors having both shunt and series field winding is known as
Compound DC motor, as shown in the figure. The compound motor is
further divided into:

•Cumulative Compound Motor

•Differential Compound Motor

In a cumulative compound motor, the magnetic flux produced by both

the windings is in the same direction. In a differential compound motor,
the flux produced by the series field windings is opposite to the flux
produced by the shunt field winding.

MARSHAL 37
SEPARATELY EXCITED DC
MOTOR
In a separately excited DC motor, the field coils are
energised from an external source of DC supply as
shown in the figure.

MARSHAL 38
AC MOTORS
An AC motor is an electric machine that converts
alternating current into mechanical rotation. AC
motor applications range from industrial bulk
power conversion from electrical to mechanical to
household small power conversion. In this article,
let us briefly discuss an AC motor’s various traits
and working.

MARSHAL 39
 CONSTRUCTION
OF AC MOTOR
Stator Core

The stator core is made of thin metal sheets known as laminations.

Laminations are used to reduce energy loss.

Stator Windings

i. Stator windings are stacked together, forming a hollow cylinder.

The slots of the stator core coils of insulated wires are insulated.

ii. When the assembled motor operates, the stator windings are
connected to a power source. Each group of coils, along with
the steel core, becomes an electromagnet when the current is
applied.

MARSHAL 40
CONSTRUCTION OF AC
MOTOR
Rotor

A rotor is a central component of a motor

that is fixed to the shaft. The most common
type of rotor used in an AC motor is the
squirrel cage rotor. A squirrel-cage rotor is
cylindrical and is made by stacking thin
steel laminations.

MARSHAL 41
TYPES OF AC MOTOR

MARSHAL 42
 i. The synchronous motor works with two electrical inputs
provided to it.
ii. The stator is equipped with a 3-phase AC supply, while the
rotor is provided with the DC supply.
iii. The stator winding supplied with 3 phase AC supply
generates 3 phase rotating magnetic flux. The rotor
carrying DC supply produces a constant flux.
iv. At a particular instant, the rotor and the stator poles might
SYNCHRONOUS be of the same polarity (N-N or S-S), causing a repulsive
MOTOR force and the very next second, it will be N-S causing an
attractive force.
v. Due to this attractive and repulsive force, the motor cannot
rotate in any direction and remains in a standstill position.
vi. To overcome this resistance to motion, the rotor is initially
fed mechanical input that rotates it in the same direction as
the magnetic field. After some time, magnetic locking
occurs, and the synchronous motor rotates in
synchronism.

MARSHAL 43
 i. In an induction motor, the stator winding is fed with an AC
supply. This causes the stator winding to develop an
alternating flux. We call this rotating flux “Rotating
Magnetic Field (RMF).”
ii. According to Faraday’s Law of Electromagnetic Induction,
the relative speed between the stator RMF and the rotor
RMF causes an induced emf in the rotor conductors. Rotor

INDUCTION conductors are short-circuited, and a rotor current is

produced due to induced emf.

MOTOR iii. This induced current produces alternating flux around it. It
should be noted that the stator flux lags behind the rotor
flux.
iv. Due to the relative velocity between the rotating stator flux
and the rotor, the rotor rotates in the same direction as that
of the stator flux to minimize the relative velocity. This is
the basic working principle of the induction motor.

MARSHAL 44
 Longevity

With only a few moving parts, AC motors have the potential to last for
years. The durability of AC motors makes them a preferred solution for
field applications such as agricultural equipment and commercial
applications such as vending machines.

Efficiency

APPLICATION
The speed-to-torque characteristics of AC motors allow them to provide
excellent performance in many applications without overheating,
degeneration or braking. This is why an AC motor is chosen for high-
OF AC demand applications such as pumps and packaging equipment.

MOTOR Quiet Operation

Producing less noise, AC motors are ideal for applications in stores,

hospitals and restaurants.

Availability

AC motors are available in a wide range of sizes and power outputs.

This wide range makes it ideal for many applications

MARSHAL 45
PRACTICAL MOTORS
i. A Schematic of a motor is shown below in
Fig.1.15, we can break categorise the motor into
two distinct parts, the stator and the rotor.
ii. The figure show the coil rotating in the magnetic
field, in practical applications it is typically the
magnets that rotate while the coils are
stationary.
iii. The magnets are mounted onto the rotor, and
the coils are mounted in gaps on the stator.
iv. The magnetic field flows through the stator to
help draw the magnetic field in towards the coils
and create a strong magnetic circuit in the
motor.
MARSHAL 46
 Upon completion of this chapter, students should be
able to
1. Identify fundamental concepts of control system
SUMMARY 2. Compare open and closed loop system
3. Differentiate between DC and AC Motor working
principle

MARSHAL 47
 PRESENTATION AND DUE DATE: 2 MAY 2023

CLASS
ACTIVITY
In a group of 3, with your own creativity, produce a
simple electric motor.
Materials
• D-cell Battery
• Insulated Wire
• 2 large-eyed, long, metal sewing needles (the
eyes must be large enough to fit the wire
through)
• Clay
• Electrical tape
• Small circular magnet

MARSHAL 48
Q&A

1. WHAT HAPPENS IF WE USE A BIGGER MAGNET?

2. WHAT HAPPENS IF WHEN YOU SPIN THE COIL AT THE

OPPOSITE DIRECTION?

3. IF YOU USE BIGGER BATTERY, ANY CHANGES OR NOT?

4. WHAT HAPPENS IF YOU USE THICKER WIRE?

MARSHAL 49
THANK YOU
ANY QUESTIONS?

MARSHAL 50