
A control system manages, commands, directs, or regulates the behavior of other devices or systems using
control loop
A control loop is the fundamental building block of industrial control systems. It consists of all the physical components and control functions necessary to automatically adjust the value of a measured process variable (PV) to equal the value of ...
s. It can range from a single home heating controller using a
thermostat
A thermostat is a regulating device component which senses the temperature of a physical system and performs actions so that the system's temperature is maintained near a desired setpoint.
Thermostats are used in any device or system tha ...
controlling a domestic boiler to large
industrial control system
An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and in ...
s which are used for controlling
processes
A process is a series or set of activities that interact to produce a result; it may occur once-only or be recurrent or periodic.
Things called a process include:
Business and management
*Business process, activities that produce a specific se ...
or machines. The control systems are designed via
control engineering
Control engineering or control systems engineering is an engineering discipline that deals with control systems, applying control theory to design equipment and systems with desired behaviors in control environments. The discipline of controls o ...
process.
For continuously modulated control, a
feedback controller
Control theory is a field of 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 ...
is used to automatically control a process or operation. The control system compares the value or status of the
process variable
In control theory, a process variable (PV; also process value or process parameter) is the current measured value of a particular part of a process which is being monitored or controlled. An example of this would be the temperature of a furnace ...
(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
Plants are predominantly Photosynthesis, photosynthetic eukaryotes of the Kingdom (biology), kingdom Plantae. Historically, the plant kingdom encompassed all living things that were not animals, and included algae and fungi; however, all curr ...
to the same value as the setpoint.
For
sequential
In mathematics, a sequence is an enumerated collection of objects in which repetitions are allowed and order matters. Like a set, it contains members (also called ''elements'', or ''terms''). The number of elements (possibly infinite) is calle ...
and
combinational logic
In automata theory, combinational logic (also referred to as time-independent logic or combinatorial logic) is a type of digital logic which is implemented by Boolean circuits, where the output is a pure function of the present input only. This ...
,
software logic, such as in a
programmable logic controller, is used.
Open-loop and closed-loop control
Feedback control systems
Logic control
Logic control systems for industrial and commercial machinery were historically implemented by interconnected electrical
relay
A relay
Electromechanical relay schematic showing a control coil, four pairs of normally open and one pair of normally closed contacts
An automotive-style miniature relay with the dust cover taken off
A relay is an electrically operated swit ...
s and
cam timer
A cam timer or drum sequencer is an electromechanical system for controlling a sequence of events automatically. It resembles a music box with movable pins, controlling electrical switches instead of musical notes.
Description
An electric mot ...
s using
ladder logic
Ladder logic was originally a written method to document the design and construction of relay racks as used in manufacturing and process control. Each device in the relay rack would be represented by a symbol on the ladder diagram with connecti ...
. Today, most such systems are constructed with
microcontroller
A microcontroller (MCU for ''microcontroller unit'', often also MC, UC, or μC) is a small computer on a single VLSI integrated circuit (IC) chip. A microcontroller contains one or more CPUs ( processor cores) along with memory and programma ...
s 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
actuator
An actuator is a component of a machine that is responsible for moving and controlling a mechanism or system, for example by opening a valve. In simple terms, it is a "mover".
An actuator requires a control device (controlled by control signal) a ...
s. 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 chart Sequential function chart (SFC) is a visual programming language used for programmable logic controllers (PLCs). It is one of the five languages defined by IEC 61131-3 standard. The SFC standard is defined as ''Preparation of function charts for co ...
s) or
statement lists.
On–off control
On–off control uses a feedback controller that switches abruptly between two states. A simple bi-metallic domestic
thermostat
A thermostat is a regulating device component which senses the temperature of a physical system and performs actions so that the system's temperature is maintained near a desired setpoint.
Thermostats are used in any device or system tha ...
can be described as an on-off controller. When the temperature in the room (PV) goes below the user setting (SP), the heater is switched on. Another example is a pressure switch on an air compressor. When the pressure (PV) drops below the setpoint (SP) the compressor is powered. Refrigerators and vacuum pumps contain similar mechanisms. Simple on–off control systems like these can be cheap and effective.
Linear control
Fuzzy logic
Fuzzy logic is an attempt to apply the easy design of logic controllers to the control of complex continuously varying systems. Basically, a measurement in a fuzzy logic system can be partly true.
The rules of the system are written in natural language and translated into fuzzy logic. For example, the design for a furnace would start with: "If the temperature is too high, reduce the fuel to the furnace. If the temperature is too low, increase the fuel to the furnace."
Measurements from the real world (such as the temperature of a furnace) are ''fuzzified'' and logic is calculated arithmetic, as opposed to
Boolean logic
In mathematics and mathematical logic, Boolean algebra is a branch of algebra. It differs from elementary algebra in two ways. First, the values of the variables are the truth values ''true'' and ''false'', usually denoted 1 and 0, whereas in ...
, and the outputs are ''de-fuzzified'' to control equipment.
When a robust fuzzy design is reduced to a single, quick calculation, it begins to resemble a conventional feedback loop solution and it might appear that the fuzzy design was unnecessary. However, the fuzzy logic paradigm may provide scalability for large control systems where conventional methods become unwieldy or costly to derive.
Fuzzy electronics Fuzzy electronics is an electronics, electronic technology that uses fuzzy logic, instead of the two-state Boolean logic more commonly used in digital electronics. Fuzzy electronics is fuzzy logic implemented on dedicated hardware. This is to be co ...
is an electronic technology that uses fuzzy logic instead of the two-value logic more commonly used in
digital electronics
Digital electronics is a field of electronics involving the study of digital signals and the engineering of devices that use or produce them. This is in contrast to analog electronics and analog signals.
Digital electronic circuits are usual ...
.
Physical implementation

The range of control system implementation is from
compact controller
A compact controller is a generic name given to a small autonomous controller which can control one or several control loops. They are also known as panel mounted, discrete, dedicated, or universal process controllers. The controllers can be easily ...
s often with dedicated software for a particular machine or device, to
distributed control system
A distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory cont ...
s for industrial process control for a large
physical plant
Physical plant, mechanical plant or industrial plant (and where context is given, often just plant) refers to the necessary infrastructure used in operation and maintenance of a given facility. The operation of these facilities, or the department ...
.
Logic systems and feedback controllers are usually implemented with
programmable logic controllers.
See also
*
Building automation
Building automation (BAS), also known as building management system (BMS) or building energy management system (BEMS), is the automatic centralized control of a building's HVAC (heating, ventilation and air conditioning), electrical, lighting, ...
*
Coefficient diagram method In control theory, the coefficient diagram method (CDM) is an algebraic approach applied to a polynomial loop in the parameter space, where a special diagram called a "''coefficient diagram''" is used as the vehicle to carry the necessary informatio ...
*
Control theory
Control theory is a field of 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 ...
*
Cybernetics
*
Distributed control system
A distributed control system (DCS) is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory cont ...
*
Droop speed control
Droop speed control is a control mode used for AC electrical power generators, whereby the power output of a generator reduces as the line frequency increases. It is commonly used as the speed control mode of the governor of a prime mover driving ...
*
Education and training of electrical and electronics engineers
Both electrical and electronics engineers typically possess an academic degree with a major in electrical/ electronics engineering. The length of study for such a degree is usually three or four years and the completed degree may be designated a ...
*
EPICS
The Experimental Physics and Industrial Control System (EPICS) is a set of software tools and applications used to develop and implement distributed control systems to operate devices such as particle accelerators, telescopes and other large sci ...
*
Good regulator
The good regulator is a theorem conceived by Roger C. Conant and W. Ross Ashby that is central to cybernetics. Originally stated that "every good regulator of a system must be a model of that system", but more accurately, every good regulator mus ...
*
Guidance, navigation, and control
Guidance, navigation and control (abbreviated GNC, GN&C, or G&C and within the context of NASA operations, often pronounced 'Gintsee' or (IPA) ʤɪnsiː) is a branch of engineering dealing with the design of systems to control the movement o ...
*
Hierarchical control system A hierarchical control system (HCS) is a form of control system in which a set of devices and governing software is arranged in a hierarchical tree. When the links in the tree are implemented by a computer network, then that hierarchical control sy ...
*
HVAC control system
HVAC (Heating, Ventilation and Air Conditioning) equipment needs a control system to regulate the operation of a heating and/or air conditioning system. Usually a sensing device is used to compare the actual state (e.g. temperature) with a target s ...
*
Industrial control system
An industrial control system (ICS) is an electronic control system and associated instrumentation used for industrial process control. Control systems can range in size from a few modular panel-mounted controllers to large interconnected and in ...
*
Motion control
Motion control is a sub-field of automation, encompassing the systems or sub-systems involved in moving parts of machines in a controlled manner. Motion control systems are extensively used in a variety of fields for automation purposes, includi ...
*
Networked control system A networked control system (NCS) is a control system wherein the control loops are closed through a communication network. The defining feature of an NCS is that control and feedback signals are exchanged among the system's components in the form of ...
*
Numerical control
Numerical control (also computer numerical control, and commonly called CNC) is the automated control of machining tools (such as drills, lathes, mills, grinders, routers and 3D printers) by means of a computer. A CNC machine processes ...
*
Perceptual control theory Perceptual control theory (PCT) is a model of behavior based on the properties of negative feedback control loops. A control loop maintains a sensed variable at or near a reference value by means of the effects of its outputs upon that variable, as ...
*
PID controller
A proportional–integral–derivative controller (PID controller or three-term controller) is a control loop mechanism employing feedback that is widely used in industrial control systems and a variety of other applications requiring continuou ...
*
Process control
An industrial process control in continuous production processes is a discipline that uses industrial control systems to achieve a production level of consistency, economy and safety which could not be achieved purely by human manual control. ...
*
Process optimization
Process optimization is the discipline of adjusting a process so as to optimize (make the best or most effective use of) some specified set of parameters without violating some constraint. The most common goals are minimizing cost and maximizing ...
*
Programmable logic controller
*
Real-time computing
Real-time computing (RTC) is the computer science term for hardware and software systems subject to a "real-time constraint", for example from event to system response. Real-time programs must guarantee response within specified time constra ...
*
Sampled data system In systems science, a sampled-data system is a control system in which a continuous-time plant is controlled with a digital device. Under periodic sampling, the sampled-data system is time-varying but also periodic; thus, it may be modeled by a s ...
*
SCADA
Supervisory control and data acquisition (SCADA) is a control system architecture comprising computers, networked data communications and graphical user interfaces for high-level supervision of machines and processes. It also covers sensors an ...
*
VisSim
VisSim is a visual block diagram program for simulation of dynamical systems and model-based design of embedded systems, with its own visual language. It is developed by Visual Solutions of Westford, Massachusetts. Visual Solutions was acq ...
References
External links
SystemControlCreate, simulate or HWIL control loops with Python. Includes Kalman filter, LQG control among others.
Semiautonomous Flight Direction - Reference unmannedaircraft.orgControl System Toolboxfor design and analysis of control systems.
Control Systems ManufacturerDesign and Manufacture of control systems.
*
ttps://github.com/mck-sbs/PyConSys Python Control System(PyConSys) Create and simulate control loops with Python. AI for setting PID parameters.
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Control theory
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