The Controller

The controller is the place where the control algorithm is executed. Although most control algorithms in the chemical industry are now executed in digital systems (computers) the hardware isn't particularly important - what is important is how the controller processes changes in its inputs to produce changes in its output signal.

An old-style control roon. Note the paper charts and analogue instrumentsA modern control room - with a lot of people with not much to do!

 

A bi-metallic strip being used in a automotive fuel guageA very common type of controller that doesn't require any electronics is a bi-metallic strip. This is a strip made up of of two metals with different rates of thermal expansion, bonded together longitudinally. The different rates of thermal expansion cause the strip to bend when it is heated or cooled. The strip can then be used to make or break electrical contacts to switch things on and off depending on the temperature. Bimetallic strips are used to control toasters and home central heating systems (amongst many other uses). Another easily obtained controller is the human brain - many plants are still controlled manually for higher level control (e.g. production rate, quality, etc). Humans learn how to control a process by experience and no maths is involved!