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Why PID Controllers Remain Dominant in Industrial Control

Despite being considered “low-tech” or overly simple by some engineers, the dominance of PID (Proportional-Integral-Derivative) controllers in the industrial control domain remains unchallenged. There are several reasons for this enduring supremacy, which are outlined below: 1. Simple yet Effective PID controllers are based on a simple mathematical model, making them easy to understand and implement. […]

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Why -90kPa Negative Pressure Can’t Be Measured? The Issue May Not Be with the Instrument

When selecting pressure transmitters, terms like “absolute pressure” and “gauge pressure” often cause confusion. A user once requested a pressure transmitter with a measurement range of 0~-90kPa absolute pressure, but was told that only a gauge pressure transmitter could be used. Why is that? 1. Absolute vs. Gauge Pressure: Understanding the Difference A user wanted

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Can DI and DO Signals Share a Common Cable in SIS Systems?

In the design and installation of Safety Instrumented Systems (SIS), one seemingly “convenient” practice—routing Digital Input (DI) and Digital Output (DO) signals through the same multi-core cable—may present serious risks. Did you know that this wiring method is not only discouraged, but also prohibited in many high-reliability environments? In this article, we will explore the

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Why Setting a 90° Angle for a Butterfly Valve’s Rotary Stroke Can Lead to Errors

In industrial automation, the coordination between the valve stroke and positioner is critical for accurate control. Although butterfly valves inherently have a 90° rotational stroke, setting this value to 90° in some positioners can lead to mismatches and errors. This article explores why this happens and how to address the issue. Understanding the Feedback Mechanism

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Overview of DCS System Layout and Components

1. General Concept of DCS System A Distributed Control System (DCS) is a computer-based control system used for industrial process automation. It combines distributed control units (at the field level) with a centralized operation and monitoring system (at the upper level) to achieve real-time measurement, control, alarm handling, trend analysis, and management of production processes.

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Top 10 Essential PLC Knowledge Every Engineer Should Know

With the rise of Industry 4.0, smart manufacturing, and digital twin technologies, PLCs (Programmable Logic Controllers) have evolved from traditional logic controllers to core control units capable of data processing and intelligent decision-making. They not only determine the “operation logic” of production lines but also support the safety, stability, and scalability of entire automation systems.

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Why Pressure Transmitter Diaphragms Require Gold Coating for Hydrogen Measurement

When measuring hydrogen gas with a pressure transmitter, it is common to coat the stainless-steel diaphragm with a thin layer of gold. This may seem unnecessary at first glance, but the reason lies in the unique properties of hydrogen and its interaction with stainless steel. Below, we explore the scientific and practical reasons for this

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Difference Between Surge Protectors and Lightning Arresters

Surge protectors and lightning arresters are critical components in protecting electrical systems from overvoltages and transient currents. While they may seem similar in their roles, their applications, operational principles, and targeted protections are distinct. This article delves into their differences in greater detail. 1. Definition and Primary Function Surge Protector A surge protector is a

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Don’t Confuse “Accuracy” and “Accuracy Class” in Instruments!

In the selection and calibration of instruments, we often hear discussions like: “This pressure transmitter is 0.5 class, the accuracy should be fine” or “The measurement result is off by 0.2 kPa, the accuracy of this instrument is poor.” However, these statements confuse two crucial concepts: Accuracy and Accuracy Class. While they are related, they

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