APPLIED REAL-TIME INEGRATED DISTRIBUTED CONTROL SYSTEMS: AN INDUSTRIAL OVERVIEW AND AN IMPLEMENTED LABORATORY CASE STUDY Wael Khaled Zaitouni Thesis Prepared for the Degree of MASTER OF SCIENCE UNIVERSITY OF NORTH TEXAS August 2016 APPROVED: Yan Wan, Major Professor Xinrong Li, Committee Member Shengli Fu, Committee Member and Chair of the Department of Electrical Engineering Costas Tsatsoulis, Dean of the College of Engineering Victor Prybutok, Vice Provost of the Toulouse Graduate School Zaitouni, Wael Khaled. Applied Real-Time Integrated Distributed Control Systems: An Industrial Overview and an Implemented Laboratory Case Study. Master of Science (Electrical Engineering), August 2016, 356 pp., 11 tables, 202 figures, 126 numbered references. This thesis dissertation mainly compares and investigates laboratory study of different implementation methodologies of applied control systems and how they can be adopted in industrial, as well as commercial, automation and control applications. Specifically, the research paper aims to assess or evaluate eventual feedback control loops’ performance and robustness over multiple conventional or state-of-the-art technologies in the field of applied industrial automation and instrumentation by implementing a laboratory case study setup: the ball on beam system. Hence, the paper tries to close the gap between industry and academia. The first chapter gives a historical study and background information of main evolutional and technological eras in the field of industrial process control automation and instrumentation. Then, some related basic theoretical as well as practical concepts are reviewed in Chapter 2 of the report before displaying the detailed design. Chapter 3 analyses the ball on beam control system problem as the case studied in the context of this research through reviewing previous literature, modeling and simulation. The following chapter details the proposed design and implementation of the ball on beam case study as if it is under the introduced distributed industrial automation architecture. Finally, Chapter 5 concludes this work by listing several points leaned, remarks, and observations, and stating possible development and the future vision of this research. Copyright 2016 by Wael Khaled Zaitouni ii ACKNOWLEDGEMENTS I begin with Allah’s blessed name, praise him and glorify him as he ought to be praised and glorified. Then, I pray for peace and blessings for all of his noble messengers, in particular on the last of them all, the blessed prophet Mohammed, peace be upon him. After that, I would like to express my gratitude to my advisor, Dr. Yan Wan, for everything she has done for me during my graduate studies at UNT. Words cannot describe my gratefulness to Dr. Wan for all the lessons I have learnt working under her. Her doors were always open for students anytime. She inspired me, encouraged me and taught me how to conduct scientific research and to be a good researcher. Working under her supervision has been a great pleasure, and I am proud that I was a lab member of such an outstanding individual as Dr. Yan Wan. Thank you to my family. My beloved mother has thought me the real value and the importance of education and seeking knowledge. Thank you to my father! Words cannot explain my appreciation for the continuous financial support you always provide. Thank you, my parents, for all of your prayers, wishing, and support. Special appreciation also goes to my brothers who have helped me through and before my health situation and diagnosis and who won’t hesitate in assisting and supporting me. I would like also to particularly reward my wife for all of her cooperation and sacrifices throughout our professional and educational paths to earn success, especially since we decided to pursue our graduate studies in the U.S. Finally, to all of my professors, friends, colleagues, and the nice staff of Electrical Engineering department at UNT, thank you for your trust and support, especially Dr. Shengli Fu, the department chair, and my committee member, Dr. Xinrog Li. I won’t ever forget your support. Thank you all and God bless you. Special reward is also given to Mr. Bobby Grimes, laboratory manager/academic technician at Engineering Technology for the mechanical work. iii TABLE OF CONTENTS Page ACKNOWLEDGMENTS ............................................................................................................. iii LIST OF TABLES ........................................................................................................................ vii LIST OF FIGURES ..................................................................................................................... viii NOMENCLATURE, ACRONYMS AND ABBREVIATIONS ................................................ xvii CHAPTER 1. INTRODUCTION ....................................................................................................1 1.1 Background and Historical Information ..................................................................2 1.1.1 Overview of Industrial Plants and Control and Automation .......................2 1.1.2 Developing Eras of Industrial Process Control Automation Instrumentation ............................................................................................9 1.2 Communication Protocols and Networks in Control Automation .........................30 1.2.1 Field Communications and Networks ........................................................31 1.2.2 Control Network(s) ....................................................................................47 1.2.3 Higher-Level Networks .............................................................................49 1.2.4 Subsystems Communication ......................................................................50 1.3 Wireless Technology in Control and Industrial Automation .................................60 1.3.1 WiMAX (Wi-Fi), IEEE 802.16 .................................................................60 1.3.2 WLAN, IEEE 802.11 .................................................................................61 1.3.3 WPAN ........................................................................................................62 1.3.4 Others .........................................................................................................65 1.4 Industrial WSN Protocols and Standards ...............................................................66 1.4.1 Zigbee ........................................................................................................66 1.4.2 W-HART....................................................................................................68 1.4.3 ISA .............................................................................................................71 1.5 Summary and Motivation ......................................................................................73 1.5.1 Summary ....................................................................................................73 1.5.2 Purpose and Scope .....................................................................................79 CHAPTER 2. BASIC THEORETICAL AND PRACTICAL CONCEPTS AND DEFINTIONS ................................................................................................................................81 iv 2.1 Dynamic Systems and Feedback Control Between Theory and Practice ..............81 2.2 Measurement Systems and Sensing Elements .......................................................94 2.2.1 Displacement and Distance Sensors ..........................................................98 2.2.2 Rational Position Measurement and Encoders ........................................104 2.2.3 Other Common Industrial Instrumentation ..............................................108 2.2.4 Calibration................................................................................................119 2.3 Signal Conditioning and Processing in Control Instrumentation ........................119 2.3.1 Analog Signal Conditioning ....................................................................120 2.3.2 Signal Processing and DAQ.....................................................................126 2.4 Control Units and Systems...................................................................................133 2.4.1 Analog Controllers and Systems ..............................................................133 2.4.2 Basic and Industrial Digital Systems and Controllers .............................135 2.5 Control Algorithms ..............................................................................................154 2.5.1 ON/OFF Control ......................................................................................155 2.5.2 Regulatory Control...................................................................................155 2.5.3 Sequential Control ...................................................................................173 2.6 Final Control Elements (Actuators) .....................................................................173 2.6.1 Motors ......................................................................................................174 2.6.2 Motor Driving Fundamentals ...................................................................182 2.6.3 Other Instrumentation ..............................................................................188 2.7 Summary and Discussion .....................................................................................192