Digital process control uses computers and sensors to monitor and control machinery in automated factories. It includes batch, continuous, discrete, and statistical control, with data indicators displaying variables such as voltage, temperature, and pressure. This allows for efficient production and quality control.
Process control is a way for automated factories to operate their machinery from a central control room, typically requiring fewer workers to keep things running. It is used by engineers to maintain targeted output levels for variables such as voltage and production rate on running machines. Digital process control is process control that uses computers to monitor machines and environmental conditions on the production line. The different types of digital process control are batch control, continuous control, discrete control and statistical process control.
Digital batch processing control is achieved by combining raw materials in certain quantities, sometimes by heating or gluing them together. Pharmaceutical factories use batch control to synthesize chemicals and mix them to create medicines. Food manufacturing plants use batch control to ensure that the quality of a food product is the same every time it is produced.
Continuous digital processing control is concerned with monitoring and controlling a process so that it is always running. Continuous production processes may include maintaining a constant water temperature in a water boiler or monitoring the presence of combustible gases in the atmosphere. To ensure workplace safety, manufacturing plants that create petroleum products, such as plastics and fuels, use sensors to monitor flammable – and sometimes fatally explosive – hydrocarbon gases naturally emitted from petroleum.
Discrete digital process control is used to monitor and execute assembly lines that use robotic arms. Car manufacturing plants have robots that assemble car frames and spray paint the bodies. Metal factories may have machines that create stamped or formed metals. Other manufacturing plants use discrete control to monitor machines that package food products.
Statistical digital process control is used to monitor how efficiently a machine is operating. The data used to create statistics is compiled from sensors connected to a process control transmitter. The transmitter sends the data to computers which display the information in a series of graphs or control tables. The charts are used by engineers and other factory workers to determine if there have been any fluctuations during the manufacturing process that could cause defects in the finished product. This allows workers to detect potential problems and work to correct them.
Digital process control is done with computers and sensors called data indicators. Data indicators can be designed to display the amount of voltage a machine is using, levels or humidity in the air, temperature levels, gas or water pressure of a system, and current or electric voltage. Two common types of digital process control data indicators are water flow meters and thermostats. Water flow meters are sensors that test the temperature and speed of water as it moves through your plumbing system. Thermostats measure the temperature of a substance and control a heating valve to raise or lower the temperature to maintain a set temperature.
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