BENG504 

Module Name Analysis and Modelling of Industrial Control Systems 
 Module Code BENG504 
  Level Five 
 Credits 15 

  

Module Description and General Aims 

The objective in presenting this module is to provide students with the essential skills for identifying and analysing the characteristics of physical processes that are to be managed or constrained by control systems and to provide the theoretical basis for the design of feedback control systems. 

The subject matter covered in this module will include an introduction to the principles of mathematical modelling of simple dynamic systems that are widely used to represent physical and chemical process operations; block diagram modelling with transfer functions using Laplace transforms; frequency and time domain analysis methods for the identification of dynamic lags in typical processes; and, classical feedback control models with a review of methods for determining stability of controllers and suitable loop gains and compensation parameters. 

  

Learning Outcomes 

On successful completion of this Module, students are expected to be able to: 

  1. Interpret and recognize the mathematical basis of 1st and 2nd order dynamic systems, and demonstrate by example the characteristic responses to disturbances. 
    Bloom’s Level 4 
  1. Explain and apply the principles of block diagram modelling using Laplace transforms in transfer functions. 
    Bloom’s Level 3 
  1. Design block diagram versions of feedback control applications and evaluate them for the stability of control using Nyquist and Root locus plots. 
    Bloom’s Level 6 
  1. Apply industry-standard software tools to expedite the design of a single loop control system. 
    Bloom’s Level 6 
  1. Evaluate and discuss the advanced process and digital control in typical industrial control systems. 
    Bloom’s Level 5 

  

Student Assessment 

Assessment Type When assessed Weighting (% of total module marks) Learning Outcomes Assessed 
Assessment 1 Type: Multi-choice test Example Topic: Process dynamics, mathematical models, time response to inputs, block diagrams, transfer functions, Laplace transforms Students may complete a quiz with MCQ type answers and solve some simple equations to demonstrate a good understanding of the fundamental concepts Due after Topic 4 15% 1, 2 
Assessment 2 Type: Short answer questions / Problems / Exam Example Topic: All topics to date An examination with a mix of theory and simple numerical problems to be completed in 1.5 hours Due after Topic 8 20% 1, 2, 3 
Assessment 4 Type: Project / Report / Practical / Simulation Example Topic: Physical system: Matlab model of a process with the development of a suitable controller showing responses (Bode plots, Nyquist, Root locus, PID). Include frequency diagrams, bode plots, frequency response, root locus, 1st order or 2nd order modelling of physical processes. Bonus: discuss and include advanced and / or digital control. Due after Topic 11 25% 1, 2, 3, 4, 5 
Assessment 4 Type: Examination An examination with a mix of multiple choice questions, detailed report type questions and/or simple numerical problems to be completed in 3 hours Example Topic: 1st order and 2nd order electrical and/or mechanical system modelling and simulation, applying block diagram reduction methods, Solving bode plot, Stability analysis based on Routh Hurwitz or root locus analysis, Digital control.  Final week 35% 1, 2, 3, 4, 5 
Attendance / Tutorial Participation Example: Presentation, discussion, group work, exercises, self-assessment / reflection, case study analysis, application.  Continuous 5% 1 to 5 

  

Overall Requirements: Students must achieve a result of 40% or above in the exam itself to pass the exam and must pass the exam to be able to pass the module. An overall final module score of 50% or above must be achieved to pass the module once all assessment, including the exam, has been completed. 

Prescribed and Recommended Readings 

Textbook 

  • N. S. Nise, Control Systems Engineering, 8th ed. Wiley, 2019 – ISBN: 978-1119474227 

Reference 

  • B. Barraclough, K. Dutton, S. Thompson, The Art of Control Engineering. Prentice Hall, 1997 – ISBN-13: 978-0201175455 
  • L. Ferrarini, C. Veber, Modeling, Control, Simulation, and Diagnosis of Complex Industrial and Energy Systems. ISA, 2009 – ISBN 978-1-62870-506-5. 
    Online version available at: http://app.knovel.com/hotlink/toc/id:kpMCSDCIE3/modeling-control-simulation/modeling-control-simulation 

Notes and Reference Texts 

  • IDC notes and reference texts as advised. 
  • Other material advised during the lectures 

  

Module Content 

  

Topics 1 and 2: Introduction to Process Dynamics and Mathematical Models 

  1. Review of 1st and 2nd order linear differential equations 
  1. Representation of physical processes by linear differential equations 
  1. Examples of linearity and non-linearity in physical processes 
  1. Representation of dynamic processes using transfer functions 
  1. Derivation of Laplace transforms for impulse, step, and ramp functions 
  1. The transfer function in block diagram models 

Topic 3: Time Response Modelling 

  1. Block diagram notations and examples 
  1. Representation of process dynamics by 1st and 2nd order transfer functions 
  1. Transfer functions for time delays in the process response 
  1. Determination of time responses to pulse, step, and ramp inputs 
  1. Modelling of feedback control systems 
  1. Higher order dynamic models and their simplification to approximate 2nd order plus dead time 

Topics 4 and 5: Modelling of process characteristics in MATLAB 

  1. Steady state process model representations to identify inputs, outputs, and disturbance influences 
  1. Development of a 1st order model from typical physical process such as a stirred hot water tank 
  1. Development of a 2nd order model from a spring and weight model, and from a cascaded water tank process 
  1. Development of a feed heater model with disturbances 
  1. Detailed application model of a feedback control loop applied to a 1st order process 

Topic 6: PID control and Frequency domain analysis 

  1. PID Control 
  1. Frequency response plots and their interpretation 
  1. Bode diagrams 
  1. Root locus diagrams 

Topics 7 and 8: Stability analysis of single loop feedback controllers (SISO) 

  1. Stability criteria for feedback control 
  1. Nyquist Diagrams 
  1. Compensation by lead-lag elements to achieve stability 
  1. Configuration and tuning of feedback controllers using S plane models 
  1. Feed forward control techniques and benefits for disturbance rejection 

Topic 9: Modelling, control, design and analysis of SISO systems using Matlab™ 

  1. Case studies and exercises with Matlab to: 
    a. model, tune, and analyse 1st and 2nd order systems 
    b. verify stability and response of controllers 

Topic 10: Advanced Process Control 

  1. Advanced vs classical control 
  1. Internal Model Control – IMC 
  1. Model Predictive Control – MPC 
  1. Reference models and Control model formulation 

Topic 11: Digital (Discrete) Control System Fundamentals 

  1. Digital vs Analogue 
  1. Modelling a digital sampler and Zero-order Hold 
  1. The z-transform and transfer functions 
  1. Digital compensator and digital PID control 

Topic 12: Project and Module Review 

In the final week, students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort. 

Software/Hardware Used 

Software 

  • Software: MATLAB; SCILAB 
  • Version: N/A 
  • Instructions: N/A 
  • Additional resources or files: N/A 

Hardware 

  • N/A