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The following article was published in our article directory on October 13, 2011.
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The Basics of Control Systems Design

Article Category: Computers and Technology

Author Name: Michael Garza

Control systems design is the process of applying control theory to systems design. Any automated device or system will need a sufficiently well designed control system in order for it to run properly and perform the way it is intended to. All automated systems need a control system of some sort, designed by a controls engineer, operated by human operators or by programmable logic controllers or PLCs.

A control system is any set of tools designed to control, manage, or regulate other devices, groups of devices or an entire distributed system of devices. There are two main classes of control systems, logic and feedback controls. These two classes are further divided by many variations and combinations. A systems engineer is mainly interested in designing a control system that fits the specifications set by the client - in this case, either full automation, partial automation, or monitored automation.

A control system has four main purpose: gauge, evaluate, calculate, and correct. These functions are performed by five elements of the system: detector, transmitter, transducer, controller and final control element. The first three elements; detector, transmitter, and transducer are all contained in one unit, and functions as one, performing the functions of measuring and comparing variables within the system. The latter two are part of the unit that changes the input or output of variables within the system by means of the controller (the switch or physical control, which can be mechanical or electronic) and the final control element which can be a PID controller or a PLC. These two perform the functions of computing and rectifying variables. All these elements and functions are essential for a properly working control system. A flaw in the design in any of these elements is fatal, and will leave any designed system vulnerable or unworkable.

Control systems design is a highly specialized field, and one would need to have multiple skills and degrees from other encompassing fields in order to be a systems designer. For example, designing a fully automated product line of a modern factory would need one to have a background in the following: systems engineering, software design, mechanical engineering, logic controls, etc. A control system designer can afford to have one or two specialties only if he is part of a team. One can be a software specialist while another can be the hardware specialist while still another focuses on user psychology and systems design. But definitely the team leader will need to know a bit of each field in order to lead the team successfully.

Control systems design is an exciting new field that is just beginning to be fully explored. Like most industries there are more innovations yet to be discovered and more lessons to be learned. It's an exciting time to be a systems designer, and the field is wide open for more changes. It is an exciting time for clients too, as business models are changing, and the need for better control systems push companies to set up better and more efficient control systems and find more ways to eliminate waste and inefficiencies in the production line, while increasing ROI.

Keywords: automation controls, factory floor automation, plant automation, industrial automation, control systems integration, control systems design, distributed controls systems, SCADA, supervisory control and data acquisition, PLC programming, programmable logic controller, Allen Bradley, A-B, Siemens, S7, S5, WinCC, Wonderware, iFix, Factory Talk, Rockwell Automation, RS View, RS Logix, ControlLogix, Compact Logix, Kinetics, Ladder Logic, Factory Talk Transaction Manager, Human Machine Interface, Panel Views, vision systems, motion control and design

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