Industrial process control
This ensures that the industrial machines run smoothly and safely in factories and efficiently use energy to transform raw materials into high-quality finished products with reliable consistency while reducing energy waste and economic costs, something which could not be achieved purely by human manual control.
A programmable logic controller (PLC, for smaller, less complex processes) or a distributed control system (DCS, for large-scale or geographically dispersed processes) analyzes this sensor data transmitted to it, compares it to predefined setpoints using a set of instructions or a mathematical model called the control algorithm and then, in case of any deviation from these setpoints (e.g., temperature exceeding setpoint), makes quick corrective adjustments through actuators such as valves (e.g. cooling valve for temperature control), motors or heaters to guide the process back to the desired operational range.
This creates a continuous closed-loop cycle of measurement, comparison, control action, and re-evaluation which guarantees that the process remains within established parameters.
The HMI (Human-Machine Interface) acts as the "control panel" for the IPC system where small number of human operators can monitor the process and make informed decisions regarding adjustments.
It ensures consistent and improved product quality with little variability, which satisfies the customers and strengthens the company's reputation.
It improves safety by detecting and alerting human operators about potential issues early, thus preventing accidents, equipment failures, process disruptions and costly downtime.
Analyzing trends and behaviors in the vast amounts of data collected real-time helps engineers identify areas of improvement, refine control strategies and continuously enhance production efficiency using a data-driven approach.
In automotive manufacturing, IPC ensures consistent quality by meticulously controlling processes like welding and painting.
Mining operations are optimized with IPC monitoring ore crushing and adjusting conveyor belt speeds for maximum output.
In power plants, it helps maintain stable operating conditions necessary for a continuous electricity supply.
During the Industrial Revolution in the 18th century, there was a growing need for precise control over boiler pressure in steam engines.
Henry Ford applied the same theory in 1910 when the assembly line was created to decrease human intervention in the automobile production process.
[5] Minorsky was researching and designing automatic ship steering for the US Navy and based his analysis on observations of a helmsman.
Effectively this was the centralization of all the localized panels, with the advantages of lower manning levels and easier overview of the process.
It enabled sophisticated alarm handling, introduced automatic event logging, removed the need for physical records such as chart recorders, allowed the control racks to be networked and thereby located locally to plant to reduce cabling runs, and provided high level overviews of plant status and production levels.
The accompanying diagram is a general model which shows functional manufacturing levels in a large process using processor and computer-based control.
The control model is a set of equations used to predict the behavior of a system and can help determine what the response to change will be.
Continuous processes in manufacturing are used to produce very large quantities of product per year (millions to billions of pounds).
The economic nature of many products manufactured in batch and continuous processes require highly efficient operation due to thin margins.
Once margins are narrowed, an economic analysis can be done on the process to determine how the set point target is to be shifted.
