Design for Engineering

Unit 4 Instrumentation and Control Systems

Annette Beattie
June 9, 2006

Instrumentation and Control Systems

ETP 2006 Annette Beattie
This material is based upon work supported by the National
Science Foundation under Grant No. 0402616. Any opinions,
findings and conclusions or recommendations expressed in
this material are those of the author(s) and do not necessarily
reflect the view of the National Science Foundation (NSF).

Engineering
The

engineering profession is based

upon mathematics and data.
Design decisions and changes are
ALWAYS based upon data that has
been gathered.
Data is gathered through
instrumentation and control
systems.

Instrumentation and Control Systems

Instrumentation

- the act of using

instruments for a particular purpose
Ex. - instrumentation on a car
dashboard - speedometer, odometer,
oil gauge, temperature, etc.

(ITEA/CATTS, 2003)

Instrumentation and Control Systems

Control

- to keep within limits or to

have power over
System - a means of achieving a
desired result. It has:
Input
Process
Output
Feedback

(ITEA/CATTS, 2003)

Instrumentation and Control Systems

System

example - Car

Input

- driver puts it in drive, pressure on the

pedal
Process - transmission is activated, gas is
sent to engine
Output - car is ready to move forward, car
moves according to pressure on pedal
Feedback - PRND12 - the D is highlighted,
the speedometer gives speed read out. We
also receive feedback from warning lights on
the dash to tell us if something is wrong with
the car or if we need fuel.

Instrumentation and Control Systems

Control

system - a system for

controlling the operation of another
system (dictionary.net, n.d.)
Example - the dashboard in your car
Example - the stereo in your car
What

is the control system?

What is the system its controlling?
What is the instrumentation?

Closed-Loop Control
One

that involves feedback to ensure set

conditions are met (school-resources.co, n.d.)
Example - you turn on the radio,

pick a station (input),

listen to the song (process),
you dont care for it (feedback),
and decide to change stations (output)
the loop continues picking another station until
the feedback says to stay on that station. Or
everyone else in the car is yelling at you, which
is another kind of feedback.

Open-Loop Control
The

system of commands are carried

out regardless of the consequences.
(school-resources.co, n.d.)

Example

- Sprinklers for a golf course

programmed to come on at 6:00 am
even if its raining.

Binary
The

binary number system (aka base 2)

represents values using two symbols,
typically 0 and 1.Computers call these bits.
A bit is either off (0) or on (1).
When arranged in sets of 8 bits (or 2 bytes)
256 values can be represented (0-255).
Using an ASCII chart, these values can be
mapped to characters and text can be
stored.It's not magic, it's just math! (Ciske, n.d.)

Binary
Example

- the word Tech Ed is

written in binary code as:
0101010001100101011000110110100
0001000000100010101100100 (Ciske,
n.d.)

Digital
Conversion

of information into binary

bits of data for transmission through
wire, fiber optic cable, satellite, or over
air techniques. Method allows
simultaneous transmission of voice,
data or video. (Remote Satellite Communications, 2006)
Examples - a computer, a digital clock

Analog
Also

spelled analogue, describes a device

or system that represents changing values
as continuously variable physical quantities.
A typical analog device is a clock in which
the hands move continuously around the
face. Such a clock is capable of indicating
every possible time of day. In contrast, a
digital clock is capable of representing only
a finite number of times (every tenth of a
second, for example). (webopedia.com, n.d.)

Analog vs. Digital

In

general, humans experience the

world analogically. Vision, for example,
is an analog experience because we
perceive infinitely smooth gradations
of shapes and colors.
Computers are digital machines
because at their most basic level they
can distinguish between just two
values, 0 and 1, or off and on.
(webopedia.com, n.d.)

Analog vs. Digital

A converter

is used to change analog

information into digital information that
a computer can understand.
In turn, a different converter is used to
convert digital information put out by a
computer into analog data.

Microprocessor

A microprocessor -also known as a CPU

or central processing
unit -- is a complete
computation engine
that is fabricated on a
single chip.
This is the first
microprocessor ever
invented - the Intel
4004. (Howstuffworks.com,
n.d.)

Microprocessors
The

first PC
microprocessor
was the Intel 8080.
It had 6000
transistors.

Todays

processor
for PCs is the
Pentium 4. It has
42 million
transistors.
(Howstuffworks.com, 2000)

Fuzzy Logic
A problem-solving

control system method

It provides a simple way to arrive at a
definite conclusion based upon vague,
ambiguous, imprecise, noisy, or missing
input information.
It mimics how a person would make
decisions, only much faster. (Seattle Robotics
Society, n.d.)

Deals

with reason that is approximate

instead of precise. (wikipedia.org, n.d.)

Fuzzy Logic
For

example, rather than dealing with

temperature control in terms such as
"SP
=500F and "T <1000F", terms like "IF
(process is too cool) AND (process is getting
colder) THEN (add heat to the process)" or
"IF (process is too hot) AND (process is
heating rapidly) THEN (cool the process
quickly)" are used.
These terms are imprecise and yet very
descriptive of what must actually happen.
Similar to how you would think and react in
the shower if the temperature changed.
(Seattle Robotics Society, n.d.)

Fuzzy Logic
Fuzzy

truth represents membership in

vaguely defined sets, not likelihood of
some event or condition. To illustrate
the difference, consider this scenario:
Bob is in a house with two adjacent
rooms: the kitchen and the dining
room. In many cases, Bob's status is
"in the kitchen" which is completely
plain: he's either "in the kitchen" or
"not in the kitchen". (wikipedia.org, n.d.)

Fuzzy Logic
What

about when Bob stands in the

doorway? He may be considered "partially in
the kitchen". Quantifying this partial state
yields a fuzzy set membership. With only his
little toe in the dining room, we might say
Bob is 99% "in the kitchen" and 1% "in the
dining room", for instance. No event (like a
coin toss) will resolve Bob to being
completely "in the kitchen" or "not in the
kitchen", as long as he's standing in that
doorway. Reasoning that is approximate
rather than precisely deduced. (wikipedia.org, n.d.)

Fuzzy Logic
Fuzzy

logic allows for values between and

including 0 and 1, shades of gray as well as
black and white.
Fuzzy logic is used in air conditioners,
dishwashers, elevators, video games, etc.
It was also used to create MASSIVE
(Multiple Agent Simulation System in Virtual
Environment). It is computer animation and
artificial intelligence software that was
developed for the Lord of the Rings trilogy.
(wikipedia.org, n.d.)

Fuzzy Logic
Fuzzy

logic
software was used
to create award
winning visual
affects, particularly
the battle scenes of
Lord of the Rings.
The software was
also used in The
Lion, the Witch, and
the Wardrobe.
(wikipedia.org, n.d.)

Neural Systems
A type

of artificial intelligence that attempts

to imitate how a human brain works.
Rather than using a digital model, in which
all computations manipulate 0s and 1s, a
neural network works by creating
connections between processing elements,
as if computer neurons.
The organization and weights of the
connections determine the output.
(Pcwebopidia.com, n.d.)

Neural Systems
Neural

network systems are

particularly effective for predicting
events when the networks have a
large database of prior examples to
draw on.
Strictly speaking, a neural network
system implies a non-digital computer,
but neural network systems can be
simulated on digital computers.
(Pcwebopidia.com, n.d.)

Neural Systems
Neural

networks
are currently used
prominently in voice
recognition
systems, image
recognition
systems, industrial
robotics, medical
imaging, and
aerospace
applications.
(Pcwebopidia.com, n.d.)

Sensors
A device

that responds to a stimulus,

such as heat, light, or pressure, and
generates a signal that can be
measured or interpreted. (St. Jude, 2006)
A significant change involves an
exchange of energy, so sensors can
be classified according to the type of
energy transfer they detect. (Wikipedia.org,
n.d.)

Sensor Examples
Thermal

sensors

Thermometers,

thermocouples

thermostats,

Electromagnetic
Ohmmeter,

Mechanical
Altimeter,

Motion

sensors

voltmeter, metal detectors

sensors

pressure gauge

sensors

Radar

gun, speedometer, odometer

(Wikipedia.org, n.d.)

Actuator
A

mechanism that puts something into

automatic action.
Examples A

mail delivery system that delivers email

into the users mailbox
A human - moving arms, legs, fingers
A robot - that grasps parts and moves
them
Motors - used when circular motions are
needed or a rack and pinion is used in
conjunction to make a linear motion
(Howstuffworks.com, 2000)

Actuator example
A model

actuator

of an

(IX SCARA
Applications, n.d.)

http://www.intellig

entactuator.com/med
ia/m-ap-ix-0001_01.
swf

Actuator example
Actuator

used to open power door locks

The hook at the end of the actuator rod
moves up or down which mimics a person
moving the knob up or down. (Howstuffworks.com,
2000)

Actuator example
Inside

of the actuator
The small electric motor turns the gears
which move the rack and pinion which
moves the actuator rod up or down.
(Howstuffworks.com, 2000)

Stepper Motor

These are small electric

motors that can spin
quite quickly and can be
started and stopped on
a dime. Instead of
moving continuously,
they move is small,
precise increments.
Stepper motors are
used to spin floppy
disks.
They are also used to
move an ink jet printer
head assembly back
and forth. (Howstuffworks.com,
2000)

Synchro Motor
A system

consisting of a generator
and a motor so connected that the
motor will assume the same relative
position as the generator; the
generator and the motor are
synchronized (Thefreedictionary.com, n.d.)
A synchro motor resembles a small
electric motor in size and appearance
and operates like a variable
transformer.

Synchro Motor
Synchros

are used
primarily for the
rapid and accurate
transmission of
data.
They are used to
move small dials to
give read-outs.
(Concord University, n.d.)

Putting it all together

Most

manufactured cars today have

around 50 microprocessors.
The following is a picture of the most
important computer in a car which
uses many microprocessors - the
engine control unit (ECU).
(Howstuffworks.com, 2000)

Putting it all together

Putting it all together

It

gathers data from many different sensors

It uses closed-loop control to monitor the
outputs of a system to control the new
inputs of that system.
It knows everything about:

Coolant temperature
Amount of oxygen in the exhaust, etc.

With

this information it performs millions of

calculations each second.
This determines the best spark timing and
how long the fuel injector is open, for
instance. (Howstuffworks.com, 2000)

Putting it all together

The

pins on this ECUs connector interface

with sensors and control systems all over
the car. (Howstuffworks.com, 2000)

Other components in the ECU are:

An

analog-to-digital converter is
used to read the outputs of some of
the sensors in the car, such as the
oxygen sensor. The output of an
oxygen sensor is an analog voltage,
usually between 0 and 1.1 volts (V).
The processor only understands
digital numbers, so the analog-todigital converter changes this voltage
into a 10-bit digital number.
(Howstuffworks.com, 2000)

Other components in the ECU are:

Digital-to-analog

converters Sometimes the ECU has to provide an

analog voltage output to drive some
engine components. Since the
processor on the ECU is a digital
device( a computer), it needs a
component that can convert the digital
number into an analog voltage.
(Howstuffworks.com, 2000)

Sources

Ciske. (n.d.). Retrieved June 9, 2006 from the website: Nickciske.com

Concord University (n.d.). Retrieved June 9, 2006 from the website:
students.concord. edu
Dictionary.net. (n.d.). Retrieved June 9, 2006 from the website:
http://www.dictionary.net/control+system
Howstuffworks.com. (2000). Retrieved June 9, 2006 from the website:
Howstuffworks.com
ITEA/CATTS. (2003). Introduction to engineering: units of instruction. Retrieved
June 9, 2006 from the website: http://www.vcsu.edu
IX SCARA Applications. (n.d.). Retrieved June 9, 2006 from the website:
intelligentactuator.com
Pcwebopidia.com. (n.d.). Retrieved June 9, 2006 from the website:
Pcwebopidia.com
Remote Satellite Communications. (2006). Retrieved June 9, 2006 from the
website: Spidersat.net
School-resources. (n.d.). Retrieved June 9, 2006 from the website: schoolresources.co
Seattle Robotics Society. (n.d.). Retrieved June 9, 2006 from the website:
seattlerobotics.org
St. Jude. (2006). Retrieved June 9, 2006 from the website: stjude.org
Webopedia.com. (n.d.). Retrieved June 9, 2006 from the website: webopedia.com
Wikipedia.org, (n.d.). Retrieved June 9, 2006 from the website: Wikipedia.org

Standards
Standard

#2: Students will develop an

understanding of the core concepts of
technology
[2.Y]

The stability of a technological

system is influenced by all of the
components in the system, especially
those in the feedback loop.
[2.FF] Complex systems have many
layers of controls and feedback loops to
provide information.

Standards
Standard

#17: Students will develop an

understanding of and be able to select and
use information and communication
technologies.

[17.M] Information and communication systems

allow information to be transferred from human
to human, human to machine, machine to
human, and machine to machine.
[17.Q] Technological knowledge and processes
are communicated using symbols,
measurement, conventions, icons, graphic
images, and languages that incorporate a variety
of visual, auditory, and tactile stimuli.