What are the most common control system troubleshooting mistakes?

2 Not following a systematic approach

Making a mistake by jumping to conclusions or trying random fixes without following a systematic approach is common. A systematic approach applies a logical and consistent method to identify, isolate, and solve the problem. This includes observing the system and collecting data, analyzing the data and formulating hypotheses, testing the hypotheses and verifying the results, and implementing the solution and monitoring the system. By taking a systematic approach, you can avoid biases, errors, and oversights that can mislead you or complicate the problem. Additionally, it helps you to track your progress and objectively evaluate your results.

3 Not understanding the system dynamics

Control systems are dynamic, meaning that they change over time and respond to inputs and disturbances. Consequently, it is essential to comprehend how the system dynamics affect the problem and the solution. To do this, you need to consider factors such as the system model and parameters, the feedback loop and stability, the control objectives and performance, the system constraints and limitations, and the system disturbances and uncertainties. If you do not understand the system dynamics, it is possible to overlook some influential factors or apply inappropriate or ineffective control strategies that are not compatible with the system characteristics or requirements.

4 Not testing the components individually

Sometimes, the problem may be caused by a faulty or damaged component in the system, such as a sensor, an actuator, a controller, or a communication device. However, if you do not test the components individually, you may not be able to identify which one is causing the problem or how it affects the system behavior. Therefore, it is important to isolate and test the components individually before you test the whole system. This way, you can verify the functionality and reliability of each component and eliminate any potential sources of error or malfunction.

5 Not verifying the code and configuration

Another possible source of error or malfunction in control systems is the code and configuration of the software or hardware that runs the system. For example, there may be bugs, typos, syntax errors, or logical errors in the code that affect the system operation. There may also be incorrect or incompatible settings, parameters, or modes in the configuration that cause conflicts or failures in the system. Therefore, it is essential to verify the code and configuration of the system before you troubleshoot it. You can use tools such as debuggers, simulators, validators, or loggers to check the code and configuration for errors and inconsistencies.

6 Not documenting and communicating the results

The last step in troubleshooting any system is to document and communicate the results. This involves recording and reporting the issue, the solution, and the outcome of the troubleshooting process. Doing this helps you to retain a record of system history and performance, share knowledge with others, enhance system quality and reliability, and reduce the likelihood of future issues. If you don't document and communicate the results, you could miss out on essential information or feedback that could help you or others to troubleshoot the system more effectively. Additionally, it could lead to confusion or misunderstanding among stakeholders or users.

7 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?