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Secondary 3 · Technology
Computational thinking and robotics · Control systems

Sensors, Controllers, and Actuators

Before you start, make sure you know: Control systems (Secondary Year 2)

Why does the water pump in your house shut off by itself when the rooftop tank is full? Nobody is watching it: a float measures, something decides, and the pump obeys. Almost everything automatic works with this same chain of three elements. On this page you will learn to recognize it, and at the end you will come back to this example.

Sensors: the ones that measure

A sensor is like the eyes and ears of the system: it only perceives. There are two types of signal.

Graph of the signal as a function of time: the digital signal jumps between two levels, 0 and 1, and the analog signal varies continuously within the range from 0 to 1. t signal 1 0 digital: 0 or 1 analog: continuous range
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Classify these components into sensors, actuators, and controller: a light sensor (LDR), a motor, a buzzer, a microcontroller board, a push button, and a servomotor.…

Classify these components into sensors, actuators, and controller: a light sensor (LDR), a motor, a buzzer, a microcontroller board, a push button, and a servomotor. Justify each classification based on what the component does.

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Classify these elements as sensors or actuators and justify each decision: microphone, speaker, camera, light bulb, motion sensor, and relay that switches on a motor.

Classify these elements as sensors or actuators and justify each decision: microphone, speaker, camera, light bulb, motion sensor, and relay that switches on a motor.

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A classmate states: "To know with complete certainty whether a garage door has reached the end of its travel when closing, it is much better to use a photoresistor (LDR)…

A classmate states: "To know with complete certainty whether a garage door has reached the end of its travel when closing, it is much better to use a photoresistor (LDR) than a mechanical limit switch, because being analog it gives us infinite values and much more information than a simple on-off digital sensor".

  1. a) Technically refute this statement: explain two real operating or reliability issues that the LDR would cause in this task compared to the limit switch.
  2. b) Justify why the digital sensor is superior in this specific case despite providing less data.
  3. c) Design a function in the same automatic door where using the LDR is indeed the appropriate option and the limit switch is useless.
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The controller: the one that decides

Think of the controller as the "brain": information arrives (signals from the sensors), it processes it with rules of the type "if… then…", and it orders what the actuator must do.

Control chain: the sensor sends its signal to the controller, which decides and sends a command to the actuator, which acts on the process. Sensor Controller Actuator measures decides acts

Many decisions combine conditions with logical operators (logic gates). Try the AND gate:

The comparison point

When the system measures its result again, the controller does not just receive "the temperature is 22": it compares it with what is wanted. In the diagram of a feedback system, that place is a circle (summing junction or comparator) where two values arrive:

  • the reference $r$: what we want (for example, $24\ ^\circ\text{C}$);

  • the measured output $y$: what the sensor measures now (for example, $21\ ^\circ\text{C}$).

The result is the error:

$$e = r - y$$

The controller uses the error to decide: if $e$ is positive (not warm enough), it turns on the heater; if it is zero, it does nothing; if it is negative (too warm), it turns it off or cools.

Feedback loop: the reference and the measured output arrive at the comparison point, which delivers the error to the controller; the controller commands the actuator, which acts on the process, and the sensor returns the measured output. reference r + − error e Controller Actuator Process Sensor output y
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Name the three basic components of a control system and explain what each one does using the example of a heating thermostat.

Name the three basic components of a control system and explain what each one does using the example of a heating thermostat.

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Explain what a microcontroller board does within a control system using the analogy of a "brain": what comes into it, what it does with it, and what commands it outputs.

Explain what a microcontroller board does within a control system using the analogy of a "brain": what comes into it, what it does with it, and what commands it outputs.

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A parking lot counts vehicles using a sensor at the entrance and another at the exit. Design the controller logic to determine how many spaces remain free and what the…

A parking lot counts vehicles using a sensor at the entrance and another at the exit. Design the controller logic to determine how many spaces remain free and what the entrance display panel should show when it becomes full.

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The figure shows a control system with feedback, with the comparator point marked with ?. Explain which two values are compared at this point, what result is obtained,…

The figure shows a control system with feedback, with the comparator point marked with ?. Explain which two values are compared at this point, what result is obtained, and how the controller uses it.

Reference + ? Controller Actuator and process output Sensor −
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Design a system that maintains a school greenhouse between $18\ ^\circ\text{C}$ and $25\ ^\circ\text{C}$: select the sensors and actuators and describe the controller's…

Design a system that maintains a school greenhouse between $18\ ^\circ\text{C}$ and $25\ ^\circ\text{C}$: select the sensors and actuators and describe the controller's decision logic using clear rules (if..., then...).

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Open loop and closed loop

There are two ways to organize the chain, depending on whether the system measures the result of what it did again.

Examples from Mexico:

  • A traffic light with fixed timing is open loop: it changes by a timer, whether or not cars come.

  • A water pump with a timer is open loop: it runs for 10 minutes even if the rooftop tank is already full.

  • The pump with a float is closed loop: the float measures the level and cuts off the pump when the tank fills.

  • A water heater with a thermostat is closed loop: it measures the water temperature and opens or closes the gas to maintain it.

The same goes for an ordinary fan (open loop, it runs until you turn it off) and an air conditioner (closed loop, it stops and starts by itself to maintain the temperature).

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A standard fan runs until you switch it off, but an air conditioner stops and starts by itself to maintain the temperature. Explain the difference between both systems…

A standard fan runs until you switch it off, but an air conditioner stops and starts by itself to maintain the temperature. Explain the difference between both systems using the concept of feedback: which one re-measures the result of its action?

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Actuators: the ones that act

Comparison of the output of an on-off actuator, which changes abruptly between two levels, with that of a proportional actuator, which varies gradually. On-off max. 0 relay · bulb · solenoid valve Proportional max. 0 servo motor · regulated motor
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The figure shows the chain of a control system, but the central block is missing. State what block this is, what it does, and write the complete chain (with concrete…

The figure shows the chain of a control system, but the central block is missing. State what block this is, what it does, and write the complete chain (with concrete examples for each block) for an automatic garage door.

Input (sensor) measures ? Output (actuator) acts
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Explain the difference between an "on-off" actuator (e.g. a relay) and a proportional actuator (e.g. a servomotor), and give a suitable application for each type.

Explain the difference between an "on-off" actuator (e.g. a relay) and a proportional actuator (e.g. a servomotor), and give a suitable application for each type.

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Threshold control and hysteresis

The simplest way to control with an on-off actuator is threshold control: if the measurement goes above a certain value, the actuator turns on; if it drops below it, it turns off.

Imagine a fan that turns on at $100\ \%$ when the temperature exceeds $25.0\ ^\circ\text{C}$ and turns off when it drops below $24.9\ ^\circ\text{C}$. On starting, the temperature drops a little, crosses the threshold, and the fan turns off; right away it rises again and the fan turns on once more. The result:

  • the fan turns on and off many times per minute (constant switching);

  • the motor and the relay wear out, and their service life is shortened;

  • the temperature oscillates nonstop around $25\ ^\circ\text{C}$ and energy consumption is higher.

For example: turn on at $26\ ^\circ\text{C}$ and turn off at $23\ ^\circ\text{C}$. Between $23$ and $26\ ^\circ\text{C}$ nothing changes, so it starts and stops only a few times. This is how the thermostat of a water heater or a refrigerator works.

Another solution is a proportional actuator: the fan speed grows little by little as the temperature rises. Suppose it is at $0\ \%$ at $20\ ^\circ\text{C}$ and at $100\ \%$ at $30\ ^\circ\text{C}$, and that between those two values it increases evenly. There is a $10\ ^\circ\text{C}$ difference to go up $100\ \%$, so each degree above $20\ ^\circ\text{C}$ adds $10\ \%$ of speed. At $27\ ^\circ\text{C}$ there are $7$ degrees above $20\ ^\circ\text{C}$: the fan runs at $70\ \%$.

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To cool a server cabinet, threshold control (on-off) is tested: when the temperature exceeds $25.0\ ^\circ\text{C}$, the fan turns on at $100\ \%$; if it drops below…

To cool a server cabinet, threshold control (on-off) is tested: when the temperature exceeds $25.0\ ^\circ\text{C}$, the fan turns on at $100\ \%$; if it drops below $24.9\ ^\circ\text{C}$, it suddenly turns off.

  1. a) Predict the negative consequences of this system on the room temperature and on the lifespan of the fan (continuous switching effect and mechanical wear).
  2. b) Design a linear proportional control alternative between $20.0\ ^\circ\text{C}$ (fan at $0\ \%$) and $30.0\ ^\circ\text{C}$ (fan at $100\ \%$). Calculate what power percentage the fan will operate at if the temperature is at $26.5\ ^\circ\text{C}$.
  3. c) Justify why this proportional control improves thermal stability and efficiency compared to threshold control.
Solve

When the sensor fails: trust and redundancy

The controller knows the world only through its sensors. If a sensor is out of calibration, the controller "believes" what it is told. A thermostat that reads $2\ ^\circ\text{C}$ too high calculates the error wrong: it thinks the room has already reached the reference when it is actually colder. It follows its rule perfectly with a wrong piece of data. That is why sensors are checked and calibrated periodically.

An ultrasonic sensor, for example, fails with fabrics (they absorb sound) and with angled surfaces (they deflect the echo). A robot that relies only on it may crash.

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A thermostat reads $2\ ^\circ\text{C}$ higher than actual due to being out of calibration. Explain why the controller "believes" it is performing its job perfectly while…

A thermostat reads $2\ ^\circ\text{C}$ higher than actual due to being out of calibration. Explain why the controller "believes" it is performing its job perfectly while the room remains colder than desired, and state the implications for sensor maintenance.

Solve
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Analyse the full control chain of a push-button pedestrian crossing: what it detects, decides, and actuates at each stage, and explain what happens if the button sensor…

Analyse the full control chain of a push-button pedestrian crossing: what it detects, decides, and actuates at each stage, and explain what happens if the button sensor fails and what failsafe behavior the system should have.

Solve
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An ultrasonic distance sensor fails with fabrics and angled surfaces. Explain what this implies for a robot that blindly "trusts" it, and propose a redundancy solution…

An ultrasonic distance sensor fails with fabrics and angled surfaces. Explain what this implies for a robot that blindly "trusts" it, and propose a redundancy solution (combining sensors or cross-checks).

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Identifying the chain in daily life

To analyze any system, ask yourself three questions: What does it measure? Who decides? What does it do? Then add a fourth: does it measure the result again? (if so, it is closed loop).

System Sensor Controller Actuator
Rooftop tank pump Float Control circuit Water pump
Water heater with thermostat Thermostat (temperature) Thermostat / board Gas valve
Automatic irrigation Humidity sensor Microcontroller board Solenoid valve
Smart traffic light Camera or car sensor Intersection controller Traffic light bulbs
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Choose a control system in your home (heating, automatic staircase light, smoke detector with alarm...) and complete its chain: sensor → controller → actuator.

Choose a control system in your home (heating, automatic staircase light, smoke detector with alarm...) and complete its chain: sensor → controller → actuator.

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What is the difference between a temperature sensor and a full thermostat? Explain which components the sensor lacks to be a control system.

What is the difference between a temperature sensor and a full thermostat? Explain which components the sensor lacks to be a control system.

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An irrigation system has a soil moisture sensor and a solenoid valve. Which component is missing for it to operate automatically, and what simple rule would it execute?

An irrigation system has a soil moisture sensor and a solenoid valve. Which component is missing for it to operate automatically, and what simple rule would it execute?

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A smart plant pot waters the plant when the soil is dry. Identify the sensor, controller, and actuator of this system and explain what information passes from one…

A smart plant pot waters the plant when the soil is dry. Identify the sensor, controller, and actuator of this system and explain what information passes from one component to another.

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A traffic light operates on fixed timings, whether cars pass or not. Does this control system have sensors? What sensor would you add to make it "smart", and how would…

A traffic light operates on fixed timings, whether cars pass or not. Does this control system have sensors? What sensor would you add to make it "smart", and how would that change improve it?

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A line-following robot uses two infrared sensors positioned on either side of the line. Explain what information each sensor provides and how the controller decides…

A line-following robot uses two infrared sensors positioned on either side of the line. Explain what information each sensor provides and how the controller decides whether to turn left or right.

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Design a smart pedestrian crossing that extends the green signal duration if it detects people still crossing slowly. Specify the sensors, decision rules, and actuators,…

Design a smart pedestrian crossing that extends the green signal duration if it detects people still crossing slowly. Specify the sensors, decision rules, and actuators, and discuss a potential risk or system misuse.

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A greenhouse is equipped with a heater, a fan, and a motorised window. Prioritise the three actuators based on power consumption and safety, and write the controller's…

A greenhouse is equipped with a heater, a fan, and a motorised window. Prioritise the three actuators based on power consumption and safety, and write the controller's decision rules for readings of $15\ ^\circ\text{C}$, $22\ ^\circ\text{C}$, and $30\ ^\circ\text{C}$.

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Analyse the control system of a traffic light with cameras that gives priority to city buses: what it detects, decides, and actuates in each case, and what should happen…

Analyse the control system of a traffic light with cameras that gives priority to city buses: what it detects, decides, and actuates in each case, and what should happen if an emergency ambulance approaches.

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Summary

See all the exercises in this section