Glossary

Deutsch: Rückkopplung / Español: retroalimentación / Português: retroalimentação / Français: rétroaction / Italiano: retroazione

In industrial systems, feedback (also referred to as response or control loop) denotes the return of information about the state, behaviour, or performance of a process or system. This information is used for monitoring, controlling, or optimising operations. Feedback is a central element in automation, control loops, and quality management, allowing for dynamic adjustment.

General Description

In industrial applications, feedback plays a key role in controlling and optimising technical processes. It involves returning information about the actual state of a system to detect deviations from the target state and respond either automatically or manually. In automation technology, this is often done through sensors, actuators, and control systems such as PLCs (Programmable Logic Controllers).

A distinction is made between negative feedback (dampening, stabilising) and positive feedback (amplifying, often destabilising). Negative feedback is essential for stable control loops—for instance, in temperature regulation in manufacturing plants. Positive feedback is used intentionally, such as in alarm systems where signal chains amplify one another.

In quality control, feedback is used to gather information about product defects, customer complaints, or process deviations in order to drive continuous improvement (CIP – Continuous Improvement Process). In maintenance, feedback from condition monitoring provides vital input for predictive maintenance strategies.

Legally and normatively, feedback appears in standards such as ISO 9001, which requires organisations to systematically record process and customer feedback and use it for ongoing improvements.

With the rise of Industry 4.0 and the Industrial Internet of Things (IIoT), feedback is increasingly captured digitally, processed in real time, and integrated into intelligent systems. This enables self-optimising production environments and adaptive processes.

Special Applications

In robotics, real-time feedback systems enable adaptive motion control and collision detection. Modern collaborative robots (cobots) use force and position feedback to safely interact with humans.

Areas of Application

• Automation Technology: Control loops for temperature, pressure, speed, etc.

• Robotics: Real-time feedback for motion control, positioning, and safety

• Quality Management: Production and customer feedback for process improvement

• Maintenance: Sensor-based condition monitoring for predictive maintenance

• Product Development: Field and user feedback for technical enhancements

• Energy Supply: Smart metering feedback for load distribution and grid stability

• Logistics and Material Flow: Feedback systems for conveyor technology and warehouse control

Well-Known Examples

• In Volkswagen’s automotive production, feedback data from assembly robots is used to optimise motion paths and reduce scrap.

• Siemens applies feedback-driven systems for real-time energy optimisation via digital twins.

• In wind turbines by Enercon, sensor feedback on vibrations and wind conditions controls automatic blade pitch adjustments.

• BASF uses process feedback in the chemical industry to precisely regulate reaction conditions in real time.

Risks and Challenges

• Misinterpretation of feedback data can lead to incorrect control decisions.

• Delays (latency) in feedback signals may cause unstable control behaviour.

• Technical failure of sensors or actuators may interrupt feedback loops.

• Data overload in digital systems demands effective filtering and analytics.

• Data security and privacy are critical in cloud-based feedback systems.

• Complex feedback loops may be difficult to interpret and control.

Example Sentences

• The feedback from the temperature sensors is used to control the heating process precisely.

• A faulty signal in the feedback loop led to overheating of the system.

• The system responds to every deviation with automatic feedback for process correction.

• In modern production lines, feedback occurs almost in real time.

• Without reliable feedback, adaptive robots cannot adjust their position correctly.

Related Terms

• Control Engineering: Field concerned with controlling dynamic systems via feedback.

• Sensor Technology: Capturing physical variables to generate feedback data.

• Predictive Maintenance: Maintenance strategy based on sensor feedback.

• Quality Management System (QMS): Framework for structured feedback evaluation.

• Human-Machine Interface (HMI): Interface where feedback is displayed and entered.

Summary

Feedback is a foundational principle in industrial control and optimisation. It enables dynamic adaptation of technical processes, improves quality and efficiency, and is a core element of modern, digitised production environments.

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