1.0 Introduction - Optimizing Industrial Control System Performance
The “Industrial Control System” is also called an ICSs which monitors and controls any Industrial process. SCADA is the part of the ICS which uses GUI (“Graphical User Interface”), and different types of communication channels which helps to control the aunty equipment remotely. Industrial system control is information on any system which helps to control the industrial process like manufacturing, production, distribution, and handling the products. It always includes the control of supervisory and the system of the acquisition data which helps to control the assets of dispersed. With the help of this one can control the distribution system and all the small controlling systems with the help of using the controllers which depend on the programmable logic to the process of the localized control. With the help of this industrial system control can realize the function of the controller and also helps to ensure the safety of the working environment. So, it can be said it is necessary to make a controller system in the industrial area. The basic components of this industrial system controller are a “Programmable logic controller”, “Remote terminal Unit”, Electronic Devices, etc. The best example of this industrial control system is PLC which is used to develop the controller system in any industry. The main aim of this research paper is to find the uses of the controlling system, and also how to develop the controlling system. The importance of the electrical, mechanical, and electronic system will be found with the help of this research paper and also find the relation between these three systems.
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A Control system is always present in each and every piece of equipment which can consume energy. A control system is always needed which helps to control all the devices and gives protection from any type of light threats, or any high voltage supply. The electronics control system mainly used the HVDC equipment for primary use. All these principles and technologies are also used in the case of other electrical equipment like production, lightning, “Compressed air system”, etc. The equipment of the control system mainly responds to the input signals and also can generate the signal of the output which causes all the equipment under control to operate in a particular manner.
2.1 Elements
“Industrial Control Systems” are very popular in the present world and use several types of equipment. It is necessary that every industry should have a controller which helps to control all the equipment which is working in this industry. For controlling all this equipment a controller is needed and for making the controller some equipment is needed which makes the circuit of the controller (Alexander et al. 2020). There are so many types of equipment used in the “Industrial Control System” which are sensors, controllers, output devices like relays, valves, indicating devices, accessory and interfacing devices, etc. All these things help to control the devices and electricity in any industry field. With the help of the sensors helps to provide information on changing the condition of the concern with the help of sense. And all these things are visible with the help of the monitor. There are so many types of sensors used in the industry like temperature sensors, RTD sensors, humidity sensors, pressure sensors, etc. With the help of these sensors, it helps to detect any small changes in the machines or any electrical equipment.
The controller is another device that is used in the industry which mainly collects the signal of the sensors. The signal of the output typically shows an actuator position. The controller sequences and functions are very easy to handle with the help of several circuits which have multiple inputs (Alladi, et al. 2020). There are several types of controllers present which are temperature controllers, humidity controllers, controllers for enthalpy, universal controllers, output controllers, etc.
The output devices in the ISC help to show the output of the sensors and controllers. All these outputs are shown with the help of a monitor and some indicating devices are also used to help show the output.
The circuit of the power supply is another important part of the controller device, which helps to give the power in the controller security. It mainly requires the voltage to the DC voltage which is regulated (Bhamare, et al. 2020). The Actuator is the component that helps to control and move the mechanism. There are several types of actuators used like valves, motors, breakers, and switches. Maintenance of all the devices with the help of a remote makes the control system advanced. So, it is necessary to make a controlling system.
2.2 Analysis
This part mainly analyses the controlling system of the Industry. Every industry has so much equipment which needs to be controlled. If all the electrical devices are not controlled then they can be damaged, so it is necessary to maintain all the devices and use a controller (Bueno, et al. 2020). With the help of this analysis, it helps to understand how many types of controllers are used here, understand the difference between those controllers, and also helps to know all the advantages and disadvantages of that controller.
Elevating the platform of the industrial control system is necessary which helps to increase the control system. Also, it helps to control the industrial system and make it more advanced. Advanced techniques are used everywhere which makes it more advanced that is why advanced technologies are used in the industry which makes the industry modern (Cardin, and O., 2019). There are mainly two types of control systems used to control industrial equipment. The two types of control systems are “Open loop controlling systems” and “Closed loop control systems”.
There are several types of comparisons that can be found between “Open loop controlling systems” and “Closed loop control systems”. In the case of open loop control, the main advantage is the element of feedback is absent as compared to the closed loop (Cimini, et al. 2020). The controller system of the open circuit is very easy to construct where the closed loop is very critical and it is not easy to handle. The construction of the “Open loop controlling systems” is very easy and simple and making the design of the circuit is very easy. On the other hand “Closed loop control systems” circuit design is very complex and is not easy to handle, it is complex.
Figure 1: Closed-loop controller
With the help of the “Closed loop controller,” all the external factors in the industry can be controlled but it cannot be possible with the help of the open circuit, it is the main disadvantage of the open circuit controller. The “Closed loop controller,” can change and helps to distribute the resilient which is a very important part of the controlling system but with the help of the open circuit it is not possible (Derhab, et al. 2019). That is why sometimes the closed loop is required but for the handling and sentence issues sometimes the open circuit is used for the controlling system in any type of Industry. With the help of this controller, it helps to elevate the industrial controller platform.
Figure 2: Open-loop controller
2.3 Recommendation
The part of this recommendation, here mainly describes all the critiques. The main key of the controlling element is the measurement, the strategy of the controller, and the final elements which help to implement the action of the controller. The industrial controller has so many responsibilities which have to do with the help of the controller (Derigent, et al. 2021). All the ascites of the dispersed geographical control. It mainly recommended that the industrial controller should use advanced technologies like software which helps to make the controller system advanced and easy to Handle. Also with the help of using advanced technologies the security of the controller system will be increased. It is recommended that the industrial controller should use PLC, DCS, and PAC which help the controller system more advanced. For making the controller system it is also necessary to make a proper plan before implementation and make a plan how can implement the instrument and make the circuit which required less price. The circuit should be required less cost which helps to save money for the industry.
In the present world, automation services are very popular. That is why processes of automation are also required in the system of an industrial controller. With the help of automation, the engineer should not be present in the controller circuit and the system can automatically handle the situation (Gao, et al. 2020). With the help of the automation service, the system can automatically analyze if any faults occur in the controlling system. After finding the faults the circuit can automatically analyze the faults and try to remove the faults. So, it can be recommended to make the controlling system automatic where it never needs any manual effort. With the help of using any programming language like PLC or any software, it helps to make the controlling system self-improvisation.
Figure 3: Industrial Control System
With the help of the firewall, the controlling system can be more advanced and it also helps to make the industrial system more secure. So, it can be recommended that for making the industrial controller more secure it is necessary to use a firewall, which helps to make the controlling circuit more secure.
2.4 Conclusion
“Industrial System Controller'' is very useful in the present world. It is necessary to make the controller system advanced, which is why there is so much software and equipment used to make the controller system advanced. At the end of this report, it can be said that there is so much equipment used in the controller systems like sensors, controllers, etc. Also, there are two types of circuits used which are open circuits and closed circuits. Also, there are some recommendations that help to make the controlling system advanced. With the help of using a programming language like PLC or any other language one can develop the controlling system. Also, it is necessary to make the controlling system secure which is why firewalls or any other advanced technologies are used. Also, with the help of this report, it can be said that the controlling system can be automated which will be easy to handle.
3.0 Task 2
Figure 4: climate control system Simulink
With the help of the above figure, the structure of the control system is described here. The above structure is the main structure of the control system in any industry. Here several equipment’s are used for making the controller circuit which is the BLDC motor, bus bar, speed controller, etc (Ivanov, et al. 2020). With the help of this equipment, the system of the climate controller can be created.
Figure 5: First Output
The above picture mainly describes the first output of the climate controller which is created with the help of MATLAB. The above picture helps to understand the speed, eabc, and the hall sensor of the climate. The base of the sample T= 6.000.
Figure 6: Second Output
The above picture shows the second output with the help of MATLAB. With the help of the above picture, it mainly shows the speed, Te vs TL graph, and also shows the stator current of the climate controller. The speed based on the climate controller is T=6.000.
Figure 7: Third Output
The above picture shows the third output with the help of MATLAB. With the help of the above picture, it mainly shows the speed. In this case, the base of the sample is T=6.000.
3.1 Climate controller in Server room
The climate controller mainly helps to control the temperature in the room. There are several types of a generator running which create so much heat. With the help of the generator, the room temperature becomes increasing. But sometimes there are several types of equipment present like sensitive circuits, transistors, and some integrated circuits. That extra heat can damage all these equipment which are present in that room. That is why it is necessary to remove the temperature and make the climate under control.
Figure 8: Effect of temperature in the server room
A controller of the climate is mainly the function of temperature and humidity control function. It mainly deals with temperature. In the server room, the generator always makes the room hot which is why for cooling the room a fan will be needed (Khan, et al. 2020). To control the room temperature there is some equipment present like a motor, motor equipment, and thermocouples. All this equipment helps to control the room temperature. For running the fan a motor is needed which helps to run the fan. With the help of the motor controller, the speed of the fan can be controlled.
Thermocouples are another important device that can be used in the climate-controlled system. The thermocouples mainly help to measure the room temperature of the server room. After running the generator the room temperature of the server room will be increased (Laaki, et al. 20019). For measuring the temperature of the server room the thermocouple will be used which helps to indicate the temperature. It is mainly a sensor, which senses the temperature of the room and helps to decrease the temperature.
3.2 Facilitate effective communication
Facilitated effective communication mainly eliminates the soil between every department and helps to make a strong communication. With the help of facilitated effective communication, it helps to understand the relation between the electrical, electronic, and mechanical systems. Creating the controlling system here always needs to implement some electronic devices (Lins, et al. 2020). All these devices need to connect with each other and also some mechanical efforts are also required. So it can be said that implementing the controlling system can be completed with the help of electrical, electronic, and mechanical systems. Effective communication is created in this electrical, electronic, and mechanical system.
Creating facilitated effective communication is necessary to use electrical, electronic, and mechanical systems (Liu, et al. 2020). With the help of creating facilitated communication between the electrical electronics and mechanical system, it helps to create a perfect controlling system. So for creating a perfect controlling system it is necessary to take help from all these three systems.
In the case of electrical and electronic communication, the wires play an important role which helps to connect it. The electronics design always helps to improve the electrical equipment. The electronics system mainly helps to know the output of the controller and also helps to improve the tools of the electrical devices and the electrical circuits (Lu, et al. 2020). With the help of the electronics system, it mainly helps to control and regulate all the electrical equipment and circuits. Also, it can regulate the mechanical devices which can be used in the industry.
The mechanical system always plays an important role in designing the controlling system in any industry. The mechanical system cannot design the circuit. For making the circuit the electrical system always played an important role but for developing the electrical circuit and making design, doing research, building, and make testing the circuit can be done with the help of the mechanical system (Makhataeva, et al. 2020). So, it can be said the electrical system makes a circuit and with the help of the mechanical system, one can develop the circuit.
So at the end of this part, it can be said that the electrical, electronic, and mechanical systems are connected to each other and make effective communication by which the control system can be created (Malik, et al. 2021). Also, with the help of this effective communication, all the industrial equipment can be regulated, and also can control the speed of the equipment.
4.0 Task 3
Figure 9: Circuit Diagram for developing the controlling system
The above picture mainly describes the circuit diagram which is created with the help of MATLAB. The above diagram is mainly done for developing the controller system.
Figure 10: Output one
The above picture mainly shows the speed, which is the Driving cycle speed and Achieved speed cycle. The sample-based T=13.000.
Figure 11 : Output two
The above picture mainly describes the output of the second scope. In this case, the base of the sample is 13.000.
Figure 12: Output three
The above picture shows the output of another scope with the help of using MATLAB. The output of the current, and voltage is shown here. The base of the sample is 13.000.
Figure 13: Output four
The above picture mainly shows the electromagnetic torque and the rotor angle. All these things are done with the help of MATLAB.
Figure 14: Output five
The above picture mainly shows the EMF of the stator which is created with the help of MATLAB. There are three different types of EMF shown here. The sample base is 13.000.
4.1 Transducers
Transducers are important electrical equipment that is used to measure very small changes in the circuit. In this case, a boiler is used here, which should be analyzed (Mistry et al. 2020). It is necessary to keep the boiler at a minimum temperature of 1000C. But, the boiler is able to run at a constant pressure. With the help of this huge change in the pressure can create a fault in this system. That is why a transducer is needed here. With the help of the transducer, it helps to decrease the change and also helps to monitor the conditions.
The transducer mainly helps to convert the signal from one energy to another. In the case of the industrial controller, the transducer is mainly used to measure the pressure, temperature, force, conductivity of the electricity, strain, etc. In this case, the best transducer is “The Purpose of Piezo Transducers”. With the help of this transducer, it will show the exact output, and also it will help to monitor each and every condition. It mainly follows the principle of the converse effect in piezoelectricity (Padfield, et al. 2019). In the future with the help of this transducer can reduce the waste of energy, and can measure the frequency, and also can monitor every small change. Mainly this type of transducer is small in size so easily can be installed on the industrial sides (Winkelhaus, et al. 2020). Also, these types of transducers are easy to handle just because of their size. Sometimes in this transistors are constructed rugged and less amount of phase shift can be shown here. So, it can be said that using these “The Purpose of Piezo Transducers” will be beneficial for the industrial controller system.
4.2 Steam-powered turbine
In this case a steam turbine is installed here which helps to give the energy source to the generator. With the help of the generator, all the electricity will be created. It is necessary to control the pressure, speed of the turbine, and the pressure which is exhausted from it. It is necessary to operate the turbine at the same speed (Peruzzini, et al. 2020). But the change in the speed of the turbine is always required to change the inlet pressure. All these things help to bring back the system to its original speed which is optional.
Figure 15: A steam-powered turbine schematic
In this case for controlling the system mainly the electrical and mechanical approaches are used here. With the help of these approaches, helps to monitor the speed, and pressure, and also can help to change the variables of the turbine. With the help of the electrical system, helps to produce the current, and also with the help of the electrical equipment helps to measure the frequency of the current and also helps to monitor the voltages (Sandberg, et al. 2020). The mechanical system will be used in the case of running the turbine. Mainly the thermodynamic efficiencies are applied in the steam turbine for generating the current. The efficiency of the thermodynamics is 65% in the case of small units which is over 90% for huge industries. The main work of the turbine is to make mechanical energy into electrical energy. All these things are done with the help of a generator.
The mechanical system is also used in the generator which also helps to convert mechanical energy or any time of chemical energy into electrical energy. So, it can be said that with the help of the Electrical and mechanical systems, a mixture of the three disciplines would be effective. It helps to make the system more advanced and it will be easy to control. With the help of both electrical and mechanical systems helps to make the system more advanced (Upadhyay, et al. 2020). For controlling the inlet pressure the electrical equipment plays an important role. In the case of controlling the speed of the turbine, the electrical control system also plays an important role. So, it can be said that for controlling all the mechanical and electrical equipment it is necessary to use both systems.
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