Full Fervice Control Engineering

Simulation, Control Loop Design, Commissioning

Control technology not only in mechanical engineering - also at the America's Cup
The participants of the America's Cup sailing competition and our customers have a lot in common - their goals and the used technologies. They want to be ahead of the competitors and be winners. Or at least they don't want to lose out. Hereto they make use of high technology.
This includes early computer simulations of new ideas, concrete feasibility studies, and the implementation of automated control and regulation of hydraulic rudders and sails; and all this under consideration of hardly predictable, highly dynamic environmental influences.
In one small detail, the scope conditions differ considerably: Our customers have to implement their innovations with realistic budgets and without sponsors. A claim that we at COSATEQ are happy to meet with over 26 years of experience. We have the deep and at the same time broad know-how in all relevant areas of theory and practice of measurement and control technology.
The COSATEQ team is specialized in meeting standardized as well as highly complex tasks with simple and robust solutions.
Challenge us with your task!

COSATEQ solves control engineering tasks in complex technical Systems

COSATEQ's control systems have proven their worth across a wide range of industries and disciplines. These include solutions in the following areas:
  • hydraulic systems
  • pneumatics
  • thermodynamics
  • electrical drives
  • mechanically oscillating systems
  • systems with non-concentrated parameters (convection and diffusion)

AUTOMATIC PROCESSING: high-end solutions through efficient measurement and control technology

In a digitized world, the competitiveness of companies is determined by their ability to integrate innovative process automation into production. Control engineering plays a central role in digital transformation - especially the trend towards more individualized mass production demands shorter time-to-market, more flexibility, and higher efficiency.
With COSATEQ you have a partner at your side who designs and integrates high-end engineering, simulation, and automation.

CONTROL ENGINEERING EXAMPLES for optimized machine efficiency

25%+
Cost Savings in Production

High-precision position control of a hydraulic metal powder press

Read Case Study - click here

INDUSTRY 4.0: How does control technology influence higher efficiency in mechanical engineering?

Todays catchword "Industry 4.0" puts a development into a term that began many years ago with the increasing demands on automation. Sophisticated control technology has already been decisive for enhancing the productivity and effectiveness of machine processes and production. The increasing machinery interconnection of 2019, expanding computing power at falling hardware costs, further miniaturization of computers and sensors lead to higher expectations in automation.

But only the control technology, optimally adapted to the machine and influencing factors, enables the best information processing through precise and fast control of targets such as position, speed, force, pressure, or temperature. Many innovations in hardware and software only become effective when intelligent control technology achieves the optimum.

MODEL-BASED DEVELOPMENT: Why does it accelerate success?

The COSATEQ team follows a self-developed and proven approach to project development, based on structured and systematic planning using mathematical simulation models.
COSATEQ SYSCON Development
Model-based development plays out its advantages especially in projects where product life cycle and/or time-to-market are of importance.

REAL-TIME SYSTEMS: Why are real-time solutions significantly more efficient?

If a system is able to respond to an event in "real-time", this means that it will respond within a specified time period. Warning: The term does not describe the speed or performance of a system, even though it is commonly confused with that.

Measurement and control solutions based on real-time systems are particularly efficient. Why? Imagine a ship that has to keep its course with the help of an autopilot (a typical application of a control system). For working reliably the course must be kept stable even in the event of external disturbances affecting the driving process. If, for example, there are cross currents that threaten to cause the ship to deviate from its course, an autopilot that reacts within a certain time frame - in real-time - is an advantage. The controlled variable - the course - must be adapted to the reference variable - the correct course - within a clearly defined period of time. This is a great advantage, especially for robots and automation in general.

COSATEQ has extensive experience in dealing with the effects and disturbance variables of real systems and the practical implementation of control theory, in particular its implementation on real-time hardware.
These terms are distinguished:
  • hard real-time - it is guaranteed that the given time frame is never exceeded
  • soft real-time - the time frame is at least statistically satisfied
  • fixed real-time - in contrast to the hard real-time, variations in time downwards are also not permissible

MODEL-BASED PREDICTIVE CONTROL of systems: not only for industrial applications

Model predictive control (MPC) maps the previous course of a complex process on the basis of its past values in order to derive the future behavior of certain values. MPC, as a variant of measurement and control technology, uses methods of online optimization and is therefore particularly suitable for limited, multivariable systems and for control problems.

Due to its high flexibility, this type of control is characterized by a large number of practical application possibilities. To achieve the best possible performance, COSATEQ uses the latest methods and techniques. While the desired behavior of linear systems can often be sufficiently achieved by simple control concepts, more complex dynamic systems often require model-based controllers.

ADAPTIVE CONTROL: Ensure long machine running times with minimum maintenance requirements

The external conditions affecting a system or process can change abruptly. The special feature of adaptive controllers is that they automatically adapt to changing environmental conditions. This means that changes in the conditions over time are compensated by independent readjustment. In this way, COSATEQ's adaptive controllers ensure long machine running times with low maintenance requirements.

CONTROL ENGINEERING Know-how

Controller types for full control in any situation

Linear Controllers
COSATEQ's linear controllers require minimal computing power and are ideal for less complex tasks. The use of linear controllers pays off especially in manufacturing mass products.

Non-linear Controllers
Non-linear controllers from COSATEQ control the dynamic behavior of technical devices. They perform more complex tasks than linear controllers and significantly increase the performance and stability of the system to be controlled - reliably achieving a high control quality.

Variable-Structure Controllers
Variable-structure controllers combine the advantages of linear and non-linear controllers. Thus, despite simple hardware with low computing power, they achieve a high control quality - even with discontinuous system behavior. This is made possible by active modification of the controller elements during operation. They can also be used at different operating points by means of control mode switching.

Adaptive Controllers
The adaptive controllers from COSATEQ guarantee long autonomous running times with very low maintenance requirements. They compensate for changes in conditions over time - such as wearout, ageing, or changing environmental conditions such as temperature - with automatic readjustment.

Optimality-Based Controllers
The COSATEQ controller library significantly increase the efficiency of plants and machines. They are characterized by very high steady-state accuracy and precise tracking of highly dynamic reference curves. COSATEQ's know-how, the use of an abstract framework, and the high degree of automation in development mean considerable cost savings for you. Contact us and find out how we can optimally combine the advantages of the different controllers for your requirements.

What is the difference between automation and feedback control?

The difference between automation and feedback control lies in the scope of their respective tasks. In automation a process is influenced without receiving feedback about the result. This is done using so-called actuators, i.e. the components of a system that can make physical changes. The actuators receive a command, for example from a software program. They execute this command, but it is not possible to determine whether the desired state has actually been reached. When controlling the volume of water flowing through a pipe, for example, the valve is the actuator that lets more or less water through based on preset signals. The controller can thus be regarded as the opposite pole to the sensor system.

The control system and the sensors work together to regulate the water flow. This means that changes to a process are no longer carried out "blindly", but can also be measured. In the dynamic process of measurement and control technology, attempts are constantly made to bring a controlled variable to a certain value and to keep it independent of external influences. Control and sensor technology are in constant interaction and the control instance, which calculates the difference between setpoint and actual value, mediates between them. The stabilization of unstable systems is only possible through the use of measurement and control technology - it must be possible both to measure and to correct.

What is a closed loop control system?

In a closed control loop the system constantly receives feedback on the status of certain variables and can thus adjust them to a setpoint. The control instance influences the process on the basis of a so-called manipulated variable and then receives an update from the sensor instance about the changed actual state - which is compared with the specified target state. If necessary, a new manipulated variable is then calculated which brings the process even closer to the target variable. Interference factors affecting the process from outside can also be intercepted in this way. The closed control loop is characterized by the fact that the controlled variable constantly influences itself.

What measurement technology requires a closed control loop in technical cybernetics?

Technical cybernetics (another term for control engineering) is applied in numerous areas of industry - accordingly there is a huge variety of measurement technologies as without exactly measured values nothing works in control engineering. There are different measurement methods for different measured variables. What matters is that any difference between the target and actual values can be quantitatively determined. This is the only way to formulate a reference variable that influences the controlled variable.

Which measurement and control technology is particularly suitable for automation technology?

Control technology plays a particularly important role in automation. Depending on the situation different measurement and control technologies are required. For example if the temperature of a system has to be controlled, a temperture sensor, a heating/cooling device, and a control device are required. When it comes to measuring the speed of vehicles, a tachometer and control of the fuel supply are required etc.
COSATEQ's control systems have proven their worth across a wide range of industries and disciplines. These include solutions in the following areas:
  • hydraulic systems
  • pneumatics
  • thermodynamics
  • electrical drives
  • mechanically oscillating systems
  • systems with non-concentrated parameters (convection and diffusion)

What does DIN 19226 mean for applied control engineering?

DIN 19226 used to be the valid standard for definition issues in the field of control engineering. Since 2002, however, it no longer applies.

Basic terms, including from the field of control, are now defined in the standard "IEC 60050-351 International Electrotechnical Vocabulary (IEV) - Part 351: Control technology". In Germany it replaces the standards DIN IEC 60050-351 and DIN V 19222:2001-09.

"Control technology" is therefore defined as follows:
Control technology is a process in which one variable, the controlled variable, is continuously recorded, compared with another variable, the reference variable, and influenced in the sense of adaptation to the reference variable.
The characteristic feature of control is the closed action sequence in which the controlled variable continuously influences itself in the action path of the control loop.
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