SENSORS AND CONTROL

Chapter 1

INTRODUCTION
Semester 3

Devdatt R Pandya
Assistant Professor
Mechatronics Engineering BSPP
DRP
 Lecture topics:
❖Control device meaning, need and application.
❖Open loop control
❖Closed loop control
❖Sinking and sourcing concept
 Disclaimer
The contents used in this presentation are taken from the text books mentioned
in references and other. I do not hold any copyrights for the contents. It has
been prepared to use in the class lectures, not for commercial purpose.
Concept Introduction

The word manufacturing has Latin origin and it has been derived by using two
word that is manus in and factus in Latin.
Manus (Latin) - By hands (English) + Factus (Latin) - Whatever you do by
hands and make certain things (English)
The automation word has the origin from Greek. The basic word is automatos
and the meaning of the word automatos in English is nothing, but acting by
itself. So, it is very simple acting by itself. The system which is acting by itself
is called an automated system.
When the machines carry out the manufacturing operations, it is called an
automated manufacturing system.
Concept Introduction
What is automation?
• Definition:
Automation is the use of machines to carry out manufacturing processes with the little or least
human involvement.
• There are various manufacturing operations, chemical or other processes which have to be controlled
through control system in order to get final production using automatic machines.
• The control system has a hardware as well as a software;
The software is nothing, but a set of instructions that is called the program. These set of instructions
are controlling the operations of a process. Of course, to carry out the operations we need the power to
drive the variety of actuators of that equipment.

• Two way of automation

• Hard Automation
• Soft Automation
The main difference between hard and soft automation is that hard automation requires physical
changes to improve functionality while soft automation machines are programmed through a computer
interface.
Examples of Automatic control systems

Automatic Engine Speed Controller Automatic water level Controller

Control Devices:

Meaning:
Control devices refer to hardware components or systems that allow users to manage, regulate, or manipulate the
operation of machines, electronic systems, or processes. These devices enable users to interact with and influence the
behavior of the controlled system.

Control devices play a pivotal role

in various industries by facilitating
automation, enhancing precision,
ensuring safety, and contributing
to the overall efficiency of
processes and systems. They are
indispensable components in
modern technological
advancements and continue to
evolve with emerging technologies.
Concept Introduction
Industrial Automation Control Products & Systems
• Automation control products are mechanical, electromechanical, and solid-
state devices that monitor, control, or actuate power utilization apparatus,
including motor regulation.
• Automation and control products and solutions cover the breadth of the
manufacturing, transportation, and building sectors—from logic devices to
complex process systems, including:

−Communication devices, networks, and

software for industrial automation control
products and systems
Concept Introduction
Industrial Automation Control Products & Systems

− Machine logic control,

systems, hardware, and
associated software used
in monitoring, and control
of industrial processes,
PLC SCADA
including programmable
logic controllers, process
controllers, and distributed
control systems.

DCS
Concept Introduction
Industrial Automation Control Products & Systems

− Motor controls and accessories

that start, stop, protect, accelerate,
decelerate, reverse, and control
the speed of motors, including AC
and DC brakes and clutches,
adjustable speed and variable
frequency drives, and motor DC BRAKE
controllers

ELECTROMAGNETIC
CLUTCH Variable-Frequency Drive
Concept Introduction
Industrial Automation Control Products & Systems

− Man/machine interface devices

that require human intervention to
control and communicate the
status of machines or
manufacturing processes
Concept Introduction
Industrial Automation Control Products & Systems

− Systems integration services to plan, develop, implement, and manage integrated

manufacturing and process control systems

− System elements that include analog-digital convertors and transducers, autotransformers

and reactors, digital display devices, electromechanical and solid-state contactors, indicating
lights, medium voltage controllers, motion control, overload devices, photoelectric relays,
register and synchronizing controls, rheostats and resistors, solenoids, starters, terminal
blocks, and timers.
Concept Introduction | Need of Automatic control system

[Link] and Accuracy: Control devices are essential when precision and accuracy in managing
processes or systems are crucial. They enable users to fine-tune and optimize performance.

[Link]: In automated systems, control devices play a vital role in ensuring that processes
run smoothly and efficiently without constant manual intervention.

[Link]: Control devices are often used to implement safety measures by regulating and limiting
certain conditions or actions in a system.

[Link] Efficiency: They help in optimizing energy usage by regulating the operation of devices
or systems based on real-time conditions.

[Link] Interface: Control devices provide a means for users to interact with and influence the
behavior of machines, devices, or processes.
Applications of Control Devices:
[Link] Automation: Control devices are extensively used in manufacturing and industrial processes to
automate tasks, control machinery, and ensure efficient production.

[Link] Systems: Heating, ventilation, and air conditioning systems use control devices to maintain specific
temperature, humidity, and air quality levels.

[Link]: In robotic systems, control devices are crucial for precise movement, manipulation, and
coordination of robotic components.

[Link] Control: Control devices are employed in various processes such as chemical processing, water
treatment, and food production to regulate parameters and ensure product quality.

[Link] Devices: In consumer electronics, control devices like remote controls, touchscreens, and buttons
allow users to operate and interact with devices such as TVs, audio systems, and smartphones.

[Link] Systems: Control devices in vehicles manage engine performance, stability control, and other
functions for safe and efficient operation.

[Link] Automation: Smart home systems use control devices to allow users to manage lighting, security,
and other aspects of their homes remotely.
Application of Automatic control system
Control systems are found in abundance in all sectors of industry such as:

▪ Quality control of manufactured products. ▪ Ship stabilization systems.

▪ Automatic assembly line. ▪ Intelligent Systems.
▪ Machine tool control. ▪ Temperature control systems.
▪ Space technology and weapon systems. ▪ Steering control of automobiles.
▪ Computer control. ▪ Missile launching systems.
▪ Power Systems. ▪ Voltage stabilizer systems.
▪ Robotics. ▪ Idle speed control of automobiles.
▪ Micro-Electro-Mechanical-Systems(MEMS). ▪ Industrial sewing machine.
▪ Nano technology. ▪ Sun tracking control of solar collectors.
▪ Smart transportation systems.
Concept Introduction
What is control?

• Control is the monitoring of certain

things, value or variable, that need to be
within required set limits.
 System
A system may be defined as follows :
• "A system is an arrangement, set or collection of things connected or related in such a manner
as to form an entirely or whole".
Or
"A system is an arrangement of physical components connected or related in such a manner as
to form and / or act as entire unit.“
Or
“A system is a combination or an arrangement of different physical components which act
together as a entire unit to achieve certain objective”
• A system consists of a sequence of components in which each component has some cause
as input and its effect will be its output. Broadly it is a sequential set of cause and effects.
• Each system may have a large number of subsystems; "Examples" :
I. This universe is itself a system consisting of large number of subsystems.
II. Human body as a system has digestive system, respiratory system etc.
 Control System
• A control system is an arrangement of physical components connected or related in such a
manner as to command, direct or regulate itself or another system.
Elements of Control System:

Element Definition
The quantity or condition of the controlled system which can be directly
1. Controlled variable
measured and controlled is called Controlled variable.
The quantity or condition related to controlled variable, but cannot be
2. Indirectly controlled variable
directly measured is called Indirectly controlled variable.
3. Command The input which can be independently varied is called Command.
4. Reference input A standard signal used for comparison in the close-loop system.
The difference between the feedback signal and reference signal is called
5. Actuating signal
Actuating signal.
Any signal other than the reference which affects the system
6. Disturbance
performance is called Disturbance.
The difference between the actual value and ideal value is called System
7. System error
error.
REFERENCE
INPUT OUTPUT
CONTROLLER PROCESS

F.B
Classification of Control Systems
Classification of Control Systems
1) Natural Control System
− Universe
− Human Body
2) Man-made Control System
− Vehicles
− Aeroplanes
3) Manual Control Systems
− Room Temperature regulation Via Electric Fan
− Water Level Control
4) Automatic Control System
− Room Temperature regulation Via A.C
− Human Body Temperature Control
Classification of Control Systems

5) Open-Loop Control System

− Washing Machine
− Toaster
− Electric Fan
6) Closed-loop Control System
− Refrigerator
− Auto-pilot system
− Driverless cars
7) Linear Vs Nonlinear Control System
− A Control System in which output varies linearly
with the input is called a linear control system.
Classification of Control Systems
8) Time invariant Vs Time variant
− When the characteristics of the system do not depend upon time itself then the system is
said to time invariant control system.
− Time varying control system is a system in which one or more parameters vary with time.
9) Continuous Data Vs Discrete Data System
− In continuous data control system all system variables are function of a continuous time t.
− A discrete time control system involves one or more variables that are known only at
discrete time intervals.
10) Deterministic vs Stochastic Control System
− A control System is deterministic if the response to input is predictable and repeatable.
− If not, the control system is a stochastic control system.
Open loop Control Systems
• Any physical system which does not automatically correct for variation in its output, is called
an open-loop system.
• Such a system may be represented by the block diagram as shown in Fig.

• In these systems, output is dependent on input but controlling action or input is totally
independent of the output or changes in output of the system.
• In these systems the output remains constant for a constant input signal provided the
external conditions remain unaltered.
Open loop Control Systems

• In any open-loop control system the output is not compared with the reference input. As a
result, the accuracy of the system depends on calibration.
• In the presence of disturbances, an open-loop control system will not perform the desired
task. Open-loop control can be used, in practice, only if the relationship between the input
and output is known and if there are neither internal nor external disturbances.
• Clearly, such systems are not feedback control systems. Note that any control system that
operates on a time basis is open loop.
• For instance, traffic control by means of signals operated on a time basis is an example of
open-loop control.
Open loop Control Systems
Advantages: The advantages of open loop control system are,
1) Such systems are simple in construction
2) Very much convenient when output is difficult to measure
3) Such systems are easy from maintenance point of view.
4) Generally these are not troubled with the problems of stability.
5) Such systems are simple to design and hence economical.

Disadvantages: The disadvantages of open loop control system are,

1. These systems are inaccurate and unreliable because accuracy of such systems are totally
dependent on the accurate pre-calibration of the controller.
2. These systems give inaccurate results if there are variations in the external environment.
3. These systems cant sense internal disturbances in the system, after the controller stage.
4. Recalibration of the controller is necessary, time to time to maintain the quality and accuracy
of the desired output.
Example of Open loop Control System

1) Automatic Toaster System

• In this system, the quality of toast depends upon the time for which the toast is heated.
• Depending on the time setting, bread is simply heated in this system.
• The toast quality is to be judged by the user and has no effect on the inputs.
Example of Open loop Control System

2) Traffic Light Controller

• A traffic flow control system used on roads is time dependent.

• The traffic on the road becomes mobile or stationary depending on the duration and sequence
of lamp glow.
• The sequence and duration are controlled by relays which are predetermined and not
dependent on the rush on the road.
Closed loop Control Systems
Feedback Control Systems.

• A system that maintains a prescribed relationship between the output and the reference input
by comparing them and using the difference as a means of control is called a feedback
control system.

Closed-Loop Control Systems.

• Feedback control systems are often referred to as closed-loop control systems.
• In practice, the terms feedback control and closed-loop control are used interchangeably.
• In a closed-loop control system the actuating error signal (which is the difference between the
input signal and the feedback signal) is fed to the controller so as to reduce the error and
bring the output of the system to a desired value.
• The term closed-loop control always implies the use of feedback control action in order to
reduce system error.
Closed loop Control Systems

The various signals are,

r(t)= Reference input
e(t) = Error signal
c(t) = Controlled output
m(t) = Manipulated signal
b(t) = Feedback signal
Closed loop Control Systems
• The part of output, which is to be decided by feedback element is fed back to the reference
input. The signal which is output of feedback element is called feedback signal, b(t).

• It is then compared with the reference input giving error signal e(t)=r(t) + b(t)

• When feedback sign is positive, systems are called positive feedback systems and if it is
negative systems are called negative feedback systems.

• This error signal is then modified by controller and decides the proportional manipulated
signal for the process to be controlled.

• This manipulation is such that error will approach zero. This signal then actuates the actual
system and produces an output. As output is controlled one, hence called controlled output
c(t).
Closed loop Control Systems
Advantages:
1. Accuracy of these systems is always very high because controller modifies and manipulates
the actuating signal such that error in the system will be zero.
2. Closed loop system senses environmental changes, as well as internal disturbances and
accordingly modifies the error.
3. There is reduced effect of nonlinearities and distortions.
4. Bandwidth (operating frequency zone) for such system is very high.
Disadvantages:
1. systems are complicated and time consuming from design point of view and hence costlier.
2. Due to feedback, system tries to correct the error from time to time. Tendency to
overcorrect the error may cause oscillations without bound in the system.
3. System has to be designed taking into consideration problems of instability due to
feedback.
4. The stability problems are severe and must be taken care of while designing the system.
Examples of a Closed loop Control Systems

1. Human Being

• The best example is human being. If a person wants to reach for a book on the table,
Position of the book is given as the reference.
• Feedback signal from eyes, compares the actual position of hands with reference position.
Error signal is given to brain.
• Brain manipulates this error and gives signal to the hands. This process continues till the
position of the hands get achieved appropriately.
Examples of a Closed loop Control Systems
2.
Difference:
Open Loop Closed Loop
Any change in output has no effect on the input Changes in output, affects the input which is
i.e. feedback does not exists. possible by use of feedback.
Output measurement is not required for Output measurement is necessary.
operation of system.
Convenient when the output is difficult to Cannot be installed if the output is not
measure. amenable to measurement.
Feedback element is absent Feedback element is present.
Error detector is absent. Error detector is necessary.
It is inaccurate and unreliable Highly accurate and reliable.
Affected by disturbances Almost independent of disturbances
Simple to construct and cheap. Complicated to design and hence costly.
Generally are stable in nature. Stability is the major consideration while
designing.
Difference:
 Concept of Sinking and Sourcing
• There are many sensors available in the market. Sensors selected for a specific
application must be electrically compatible with the machine I/O of the motion controller.
Sinking or sourcing designations are used to describe the direction of current flow
between the sensor and the I/O on the controller. The definitions are based on the
assumption of the conventional DC current flow from positive to negative.
• Consider a simple circuit made of a power supply, a switch, and a bulb, as shown in
Figure. There are two ways of wiring this circuit with the switch before the bulb or after
the bulb. Let us separate this circuit into its components to understand the concept of
sourcing and sinking.
DC Circuits:

In a DC circuit, power flows in one

direction: from the positive side of
the power source, through the load,
to the negative side of the power
source.

To switch the load, you can place

the switch either in front of the load
(on the positive leg of the circuit) or
behind the load, on the negative leg.
Sourcing:

If the switch is connected to the positive side of the

power supply as shown in Figure, the switch becomes a
sourcing device, since it provides current to the bulb. A
sinking device must be connected to the switch so that
a path for the current to return to the negative side of
the power supply can be provided. Then the bulb is a
sinking device since it receives current from the
switch.
Sinking:

If the switch is connected to the negative side of the

power supply as shown in Figure, then it becomes a
sinking device since it receives current from the bulb.
On the other hand, the bulb now is a sourcing device
since it provides current to the switch device. Again the
sourcing device has to be connected to a sinking device
to complete the circuit.

Here, Sinking sensor allows current to flow into the

sensor to voltage common. Sourcing sensor allows
current to flow out of the sensor from a positive source.
 Sinking:

example, with ground as common

A modern example of this choice would be an LED quad-color

stack light. (Sometimes called a tower light, it is a stack of red,
yellow, green and white colored LEDs in a housing). Does it have a
common positive, or a common negative? We usually cannot
change the stack light wiring. It is built either way by the
manufacturer. We then need to pick a digital output module that
can drive the four lights to the specified rail and thus turn each of
the LEDs on as required. One of the most common quad-color
stack lights has a common anode (positive) lead.
In this case we would wire that lead to the
positive power supply rail, wire the other
four legs to our digital output module, and
then wire the digital module’s common to
the negative rail of the power supply.

This is a sink configuration. We turn on the

digital output, the power is sourced from
the positive rail, flows through the LED, is
switched through the digital module, sunk
to ground, and the LED is turned
on.
Sinking sensor (By use of NPN)

In fig 1.6a shows that the signal line id connected with base
of NPN transistor. If signal line is active current flow into
NPN transistor from collector and connected to via emitter.

In fig 1.6b, shows that the sensor is a sinking while our

output is a sourcing. In this case our sensor is normally
open. Here current flow first in load and then it flow from the
sensor.
Sourcing sensor (By using PNP)

In fig 1.7a shows that the PNP transistor used for sourcing
sensor switch. As we know in PNP transistor if signal line is
on transistor works as OFF switch means No Flow of
Current. So in this case our sensor is Normally Closed. Load
connection to sourcing sensor is shown 1.7b.

In fig 1.7b, shows that our sensor is providing source for our
sinking output. In this case load is activated only if out PNP
transistor activated. Means load is depended on our sensor.
Here current flow first from sensor and then it pass from
load
Where does sink or source matter in automation?
You often have to choose a module because the device you are wiring requires either a sink or
source. For example, if you have a prebuilt electrical cabinet, it may be wired using a common
positive or a common negative method. Thus you HAVE to choose the correct digital output
module for the way the panel is wired.

Thankfully, you don’t have to worry about choosing between sinking or sourcing when it comes to
alternating current. Since AC swings back and forth between a positive voltage and a negative
voltage, it requires a different switching method. It’s direct current (DC) where we have to choose.
A little background
on the construction of transistors: there are two types, NPN and PNP. They
are built differently at a silicon level and switch currents with different
methods.
Back in the day (1950s to 1970s), transistors could sink (NPN) more
current than they could source (PNP) for the price, so a sinking or sourcing
decision made a difference in cost. In fact, even today many electronic
components have asymmetric current drive ability and can switch more
current to ground than to the positive rail.
Distinction between Sinking and Sourcing sensor

Sinking Sourcing

A sinking input or output circuit requires an NPN A sourcing input or output circuit requires a
transistor. PNP transistor.
Current flow into sensor. Current flow out of sensor.

NPN is sinking and load is sourcing. PNP is sourcing and load is sinking.

Current flow first in load and then sensor. Current flow first in sensor and then in load.

Normally open sensor. Normally close sensor.

THANK YOU