Boston Engineering: Overcoming the Challenges of Control System Design

While control systems are critical for enabling advanced products and processes, designing them is no easy feat. Control system engineers face a wide range of complex challenges throughout the development lifecycle. Being aware of these hurdles is crucial for managing projects successfully.

Let's explore some of the biggest obstacles:

Modeling Complexities Creating an accurate mathematical model that captures the full system dynamics is extremely difficult, especially for complex plants with nonlinearities, distributed properties, varying parameters, and coupled interactions. If the model is too simplistic, the control design will be inadequate..

Managing Uncertainties Real-world systems always have some level of uncertainty in their dynamics, inputs, disturbances, sensor readings, etc. Evaluating the extent of uncertainties and ensuring appropriate stability and performance robustness is a major challenge.

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What are Control Systems? A control system is an interconnected set of components that regulate the behavior of other systems or processes. It consists of a controller that monitors output, determines deviations from desired performance, and provides inputs to actuators that make adjustments. The goal is to maintain output within a specified range by minimizing errors through this continuous feedback loop. Learn More

Find more details about control systems on our website: 

• Where are control systems found?
• Why use a control system?
• Elements of a control system?
• What is control system feedback?
• What are the challenges of control system design?

Empower your Control System Design!

Boston Engineering proudly presents our transformative white paper, unveiling the most Effective Strategies for Overcoming Challenges in today's dynamic landscape.

Download the Boston Engineering "Effective Strategies for Overcoming Common Control System Design Challenges" white paper. For a copy of the the complete publication, visit the Effective Strategies for Overcoming Common Control System Design Challenges download page.  

Exploring some of control systems design's the biggest obstacles

Balancing Performance Tradeoffs For any given system, there are inherent conflicts between response characteristics like rise time, settling time, overshoot, bandwidth, and disturbance rejection. Achieving an optimal balance while enforcing input, state, and output constraints becomes a multi-objective optimization problem.

Computational Limitations The mathematical analysis and optimization involved in control design can be extremely computationally intensive, especially for systems with many states, nonlinearities, constraints, and uncertainties. Engineers must work within the limits of available computing resources.

Integration Complexities Products utilize a myriad of sensors, actuators, signal conditioners, embedded processors and other heterogeneous components. Achieving cohesive interoperability between vendor-specific hardware/software while maintaining timing, throughput, reliability, fault tolerance and security requirements is immensely challenging.

Data Integrity and Security As control systems become increasingly networked and automated, protecting the integrity and confidentiality of process data from cyber threats is paramount. Secure coding, encryption, access control, intrusion detection and other measures add design effort.

Multidisciplinary Nature Control systems inherently involve multiple domains spanning electrical engineering, mechanical engineering, software engineering, and others. Bridging this divide requires close interdisciplinary collaboration at all stages to resolve interface issues and integrate diverse models.

Process Variations For batch manufacturing processes and other applications with time-varying dynamics and disturbance characteristics, the control solutions need to be adaptive or robust enough to maintain performance across the operating envelope.

Safety-Critical Requirements When failures can potentially impact safety, personnel or the environment, rigorous processes like hazard analysis, redundancy design, automated code verification and adherence to functional safety standards are mandatory.

Test Coverage For complex, nonlinear and multivariable systems, exploring the full range of potential scenario combinations through testing is extremely difficult if not impossible. Achieving comprehensive test coverage and validation is a constant challenge.

Resource Constraints Delivering robust, high-performance control solutions requires experience, skill and powerful development tools/platforms. Staffing, budgets, training, infrastructure and supply chain issues can severely hamper progress.

Whether technical, logistical or operational in nature, these challenges make control system development inherently difficult yet crucially important work. The most successful teams are those that proactively anticipate and plan for mitigating these risks.

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Boston Engineering is driving control systems innovation to enable our customers to develop differentiated, high-performance products and systems across an array of markets. Reach out to discuss how our COE can support your next control systems initiative.

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For almost three decades, Boston Engineering has designed, developed, and optimized devices and technologies the medical, Commercial, and Defense communities rely on to improve the way people work and live. We provide solutions to the challenges society faces.

Our expertise includes industrial design and product redesign, sensors and control systems, robotics technical innovation, and digital software solutions. 

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