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How do you balance control logic design principles with customer requirements and specifications?

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Control logic is the core of any automation system, as it defines how the inputs, outputs, and internal variables interact to achieve a desired function. However, designing control logic is not a straightforward task, as it involves balancing various principles, customer requirements, and specifications. In this article, you will learn some tips and best practices to help you create effective and efficient control logic that meets the needs and expectations of your clients.

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Jason Slade

Electrical and Control Technologist (semi-retired)

1 Understand the problem

The first step in any control logic design project is to understand the problem that you are trying to solve. This means gathering and analyzing the customer requirements and specifications, as well as the existing or desired system architecture, components, and interfaces. You should also identify the key performance indicators, constraints, risks, and assumptions that will guide your design decisions. A clear and comprehensive problem statement will help you define the scope, objectives, and deliverables of your project.

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Nestor Arria

Senior Automation Engineer- PLC & SCADA Specialist- Industry 4.0 - IIOT speaker
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Entender las necesidades de tus clientes y equilibrarlo con técnicas de dise?o de sistemas de control es un arte, lo importante es que la aplicación de estas técnicas lleven a una estandarización que sea auditable y que sea replicable para futuros proyectos y ampliaciones con el mismo cliente, de esta manera se facilita el trabajo de dise?o utilizando bloques funcionales estándares que aceleren cualquier implementación y que reduzca el tiempo de comisionamiento y arranque, para ello se requiere que el integrador y cliente mantengan un flujo de información constante y efectivo, es un ciclo de dise?o y de feedback en papel que involucre al no solo al personal de ingeniería, sino también al personal que hará el mantenimiento a futuro.

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2 Follow the standards

The next step is to follow the standards and conventions that apply to your industry, domain, and platform. Standards are sets of rules and guidelines that ensure consistency, compatibility, safety, and quality in control logic design. They may cover aspects such as naming, formatting, documentation, testing, communication, and security. By following the standards, you can avoid common errors, reduce complexity, improve readability, and facilitate maintenance and troubleshooting. You can also use standard libraries and templates to speed up your development process and reuse proven solutions.

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Jason Slade

Electrical and Control Technologist (semi-retired)
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Standards also include a list of preferred equipment so as to: - prevent bloating replacement parts inventory - utilize existing configuration software licenses

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Jason Slade

Electrical and Control Technologist (semi-retired)
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Standards and conventions can also exist at the company and/or plant level. It is critical that the current requirements be followed for ease of integration and acceptance.

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3 Apply the principles

The third step is to apply the principles of control logic design to create optimal and robust solutions. Modularity divides the control logic into smaller and simpler units that can be reused and tested independently, while hierarchy organizes the logic into different levels of abstraction and detail. Structured programming techniques, such as sequence, selection, and iteration, are used to control the flow and logic of the program. State machines or state transition diagrams can be used to model the behavior and transitions of the system or device based on inputs and outputs. Additionally, events or triggers can be used to initiate or change the actions or states of the system or device.

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4 Validate and verify

The final step is to validate and verify your control logic design before deploying it to the target system or device. Validation is the process of confirming that your design meets customer requirements and specifications, while verification is the process of ensuring that your design works as expected and is free of errors. Various methods and tools can be used for validation and verification, such as simulation software to simulate the behavior and performance of your control logic in a virtual environment, hardware tools to test your control logic in a real or simulated environment, software tools for debugging and identifying any errors or bugs in your control logic, and peer review, code review, or formal methods to inspect and evaluate your control logic for quality, compliance, and correctness.

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Jason Slade

Electrical and Control Technologist (semi-retired)
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While the validation and verification processes confirm that the new system meets the previously defined design criteria and is error free, there are times when the commissioning exercise reveals shortcomings in the original design specification. The commissioning team (made up of the system designer, as well as representatives from engineering, operations, technical and maintenance) must then review and revise the control strategy so that the system performs as required.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you balance control logic design principles with customer requirements and specifications?

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1 Understand the problem

2 Follow the standards

3 Apply the principles

4 Validate and verify

5 Here’s what else to consider

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