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How do you balance control logic functionality and simplicity?

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Control logic is the set of rules and instructions that govern the behavior and operation of an automation system. It can range from simple on-off switches to complex algorithms and sequences. As a control engineer, you need to balance the functionality and simplicity of your control logic to ensure optimal performance, reliability, and usability of your system. Learn some tips and best practices to help you achieve this balance.

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1 Define your goals and requirements

Before you start designing your control logic, have a clear understanding of what you want your system to do and how you want it to do it. Define your goals and requirements in terms of inputs, outputs, functions, modes, conditions, constraints, and criteria. This will help avoid unnecessary features, errors, and complications in your control logic.

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Pramit Baul

Connected Vehicles | Transportation Electrification
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*Try* to Make sure your requirements proceed your logic development and not the other way around. Emphasis on try, this is easier said than done , and extremely challenging on first gen programs with tight deadlines.

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Jeffrey Smith

Chief Technology Officer at DYNICS, Inc.
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That's great on paper, but often the equipment is in the process of being built when the logic development starts. The reality of the process is that you put the foundation in place first, enter the i/o from the drawings, create the faults, alarms, messages, etc. for all of the standard functionality not specifically related to a unique machine process, and then adapt and complete later as the equipment gets closer to "done".

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2 Use modular and hierarchical design

One way to simplify your control logic is to use a modular and hierarchical design approach. This means breaking down your system into smaller and manageable components that can perform specific tasks and functions. Organize these components into different levels of hierarchy, such as subsystems, modules, blocks, and elements. This will reduce the complexity and redundancy of your control logic, as well as improve its readability, maintainability, and scalability.

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Jeffrey Smith

Chief Technology Officer at DYNICS, Inc.
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This *may* reduce complexity, it depends on how it's done. It can also greatly increase the complexity. There is a balancing act between modular and complex.

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3 Choose the right tools and methods

Another way to balance your control logic functionality and simplicity is to choose the right tools and methods for your design and implementation. Depending on your system and application, use different types of control logic, such as ladder logic, function block diagram, structured text, or sequential function chart. Use different software and hardware platforms, such as PLCs, PCs, or embedded systems. Select the tools and methods that best suit your needs and preferences, as well as the standards and regulations of your industry and domain.

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Engr. Edache Kelvin (MIAENG)

Automation Engineer | Foxboro DCS Expert | PLC | SCADA | Commissioning | Maintenance
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Also know that in a Large process plant, a separate organisation is always contracted to carry out the development of logic diagram based on the plant P&ID which is platform independent, such logic diagram can be implemented using either Ladder logic, function block, structured text or sequential function chart, using any OEM controller ( PLCs, DCS etc). When we talk about simplicity it has to be factored in During detailed engineering design such as Control narrative and Control philosophy, From my experience you have to follow logic diagram when implementing any logic program on any platform.

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Jeffrey Smith

Chief Technology Officer at DYNICS, Inc.
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Using the right tool is always a good approach, but you also need to use the tool that your maintenance team will understand. Just because you can do something in structured text or function block instead of ladder logic, doesn't mean you should. Logic needs to: 1- Work 2- Be maintainable by others less skilled 3- Be Efficient

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4 Test and debug your control logic

Once you have designed and implemented your control logic, test and debug it to ensure its functionality and simplicity. Verify that your control logic meets your goals and requirements, as well as the expectations and needs of your users and stakeholders. Identify and correct any errors, bugs, or inconsistencies in your control logic, as well as any potential risks or hazards that may affect your system's safety and security. Use appropriate testing and debugging tools and techniques, such as simulation, emulation, monitoring, or logging.

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Jeffrey Smith

Chief Technology Officer at DYNICS, Inc.
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All great in theory, the most likely way to get this done is to create a set of test scripts ahead of time that test simple functionality, manual moves, automatic functionality, trigger all the faults and make sure they are properly logged and annunciated.

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5 Document and communicate your control logic

Finally, document and communicate your control logic to ensure its functionality and simplicity. Create and maintain clear and concise documentation of your control logic, such as diagrams, charts, tables, or comments. This will help others understand, modify, or reuse your control logic in the future. Communicate your control logic to your users and stakeholders, such as operators, managers, or customers. This will allow them to learn, operate, or evaluate your system effectively and efficiently.

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Jeffrey Smith

Chief Technology Officer at DYNICS, Inc.
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Documentation is great, until it's not. Once equipment hits a plant floor, it will be modified within days, months, years. If the documentation isn't kept up, which can be a job in itself, which most plant floor personnel simply don't have the time, or don't have the discipline to do. Once the documentation is out of date, it becomes more of a problem than a help in some cases. Again, the degree to which you document is critical. Only manage those things you can successfully manage.

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6 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 functionality and simplicity?

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2

3

4

5

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1 Define your goals and requirements

2 Use modular and hierarchical design

3 Choose the right tools and methods

4 Test and debug your control logic

5 Document and communicate your control logic

6 Here’s what else to consider

Control Logic

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