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A control system manages, commands, directs, or regulates the behavior of other devices or systems using control loops. It can range from a single home heating controller using a thermostat controlling a domestic boiler to large industrial control systems which are used for controlling processes or machines. The control systems are designed via control engineering process. For continuously modulated control, a feedback controller is used to automatically control a process or operation. The control system compares the value or status of the process variable (PV) being controlled with the desired value or setpoint (SP), and applies the difference as a control signal to bring the process variable output of the plant to the same value as the setpoint. For sequential and combinational logic, software logic, such as in a programmable logic controller, is used. Logic control systems for industrial and commercial machinery were historically implemented by interconnected electrical relays and cam timers using ladder logic. Today, most such systems are constructed with microcontrollers or more specialized programmable logic controllers (PLCs). The notation of ladder logic is still in use as a programming method for PLCs. Logic controllers may respond to switches and sensors and can cause the machinery to start and stop various operations through the use of actuators. Logic controllers are used to sequence mechanical operations in many applications. Examples include elevators, washing machines and other systems with interrelated operations. An automatic sequential control system may trigger a series of mechanical actuators in the correct sequence to perform a task. For example, various electric and pneumatic transducers may fold and glue a cardboard box, fill it with the product and then seal it in an automatic packaging machine. PLC software can be written in many different ways – ladder diagrams, SFC (sequential function charts) or statement lists. Bang–bang control On–off control uses a feedback controller that switches abruptly between two states.

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Feedback

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.

Current loop

In electrical signalling an analog current loop is used where a device must be monitored or controlled remotely over a pair of conductors. Only one current level can be present at any time. A major application of current loops is the industry de facto standard 4–20 mA current loop for process control applications, where they are extensively used to carry signals from process instrumentation to proportional–integral–derivative (PID) controllers, supervisory control and data acquisition (SCADA) systems, and programmable logic controllers (PLCs).

Fieldbus

A fieldbus is a member of a family of industrial digital communication networks used for real-time distributed control. Fieldbus profiles are standardized by the International Electrotechnical Commission (IEC) as IEC 61784/61158. A complex automated industrial system is typically structured in hierarchical levels as a distributed control system (DCS). In this hierarchy the upper levels for production managements are linked to the direct control level of programmable logic controllers (PLC) via a non-time-critical communications system (e.

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Electrical networks

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Control theory

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. To do this, a controller with the requisite corrective behavior is required.

Embedded systems

An embedded system is a computer system—a combination of a computer processor, computer memory, and input/output peripheral devices—that has a dedicated function within a larger mechanical or electronic system. It is embedded as part of a complete device often including electrical or electronic hardware and mechanical parts. Because an embedded system typically controls physical operations of the machine that it is embedded within, it often has real-time computing constraints. Embedded systems control many devices in common use.