Inexpensive re-configurable process simulator for the feedback control lab

A variety of control concepts and techniques must be covered in a comprehensive course on feedback controls. This need for variety imposes severe demands on laboratory facilities if they are to demonstrate an appropriate range of practical control exercises using all or most of the techniques. This problem has been minimized through the development of a re-configurable process simulator for a senior-level feedback control class in electro-mechanical engineering technology. This paper describes a process simulator that is built from linear circuit components. It simulates the transfer functions of typical processes that would be encountered in an industrial environment. The parameters of the transfer function can be easily changed allowing the simulator to simulate a variety of possible process situations. It can be used to illustrate the procedures involved in calculating PID parameters in the classroom as well as determining "in the field". The simulator then can be used to test the results and thereby give the student experience in tuning PID controllers. It can be used to verify the root locus and frequency domain calculations for various compensators such as lead, lag, and lead/lag. It can be also used to investigate steady-state error and process stability.