. 20 EYER IMENT Pump motor characteristics OBJECTIVES 1, Understanding the dead-range effect in a DC motor. 2. Studying effects of the dead range on control operation. 3. To study a method for solving the problem of dead range. REQUIRED EQUIPMENT See page 25 PREREQUISITES - Knowledge of constant-f1eld DC motor operation. THEORETICAL BACKGROUND The armature of the constant-field DC motor used in the experimental setup receives its current through carbon brushes. ‘The torque available at the motor shaft is proportional to the armature current. To overcome internal mechanical friction, and start rotation, a certain initial current must be supplied. Therefore, if the voltage applied to the DC motor is slowly increased from zero, the motor will not rotate until a certain minimum voltage value is reached. The range below this level is called the “dead range”. The “dead-range” effect is non-linear in nature and causes instability in the closed-loop behaviour. For example when a deviation between the measured and the reference level is detected, an instruction may be given by the control to 312 actuate the pump, but to no effect; the motor will start’ only at a certain higher deviation and will stop before the entire deviation has disappeared. | The experiment studies this case and the curative measures required. : Before starting, fill the lower tank (reservoir) with water up to about Sem from its top edge, and then f{11 tank A with water up to the manual valve level. PROCEDURE OF THE EXPERIMENT 1. Open the manual valve in tank A, to the maximum (0°). “On the control unit, set the POWER switch to ON, Set switch S1 and $3 to OFF, and switch S2-to A. Adjust level reference output for a reading of 1V on voltmeter M2. Connect level reference output to the power buffer input (see Fig. 15). 5. Increase level reference output voltage slowly and record the voltage at which the motor starts rotating. This voltage is 6V. ‘ pottTtaO 7 4 SONS, nour | pioirat CONTROL, FIGURE 15: Measurement of Motor Operating Voltage 6. Restore level reference output voltage to OV and repeat step 5. 7. Restore level reference output voltage to OV. Disconnect the level reference output from the power buffer input. 329% 10. le 12. 13. la, 15. 16. 22 Connect level reference output to the pump interface input (see Fig. 16). Lever REFERENCE tr VREF biairat conTrow, FIGURE 16: Measurement of Pump Interface Characteristic Using the external DMM, measure the pump interface output voltage. Increase the level reference output voltage as per Table 1 and record, the pump interface output voltage. 9 Restore level reference output to OV. Connect pump interface output to pump power buffer. Slowly increase level reference output and record the initial voltage at which the motor starts rotating. This voltage is 0.5V. a Disconnect all connections made on the control unit. Set the POWER switch to OFF. Level reference Output (Vy) {0 ]1]2|/3]/4]5]6]7)8]9] 10 Pump Interface Output (V) TABLE 1: Pump Interface Output as Function of Level Reference Voltage 3323 ANALYSIS OF RESULTS Draw a diagram of pump interface output as a function of the input. Pump INTERFACE OUTPUT 4 ww) i oy _ piouteur ° wv) FIGURE 17: Pump Interface Output Voltage vs Input Voltage J QUESTIONS 1. What is the dead range of the pump motor? 2. How can this range be reduced? 3 34 Does the pump interface cancel the dead range?| axPaRlualy 2 Pump characteristics OBJECTIVES Precise measurement of liquid flow rate. 2, Establishment of the pump calibration diagram. Evaluation of pump gain from the static characteristic. REQUIRED EQUIPMENT See page 25 PREREQUISITES - Knowledge of the meaning of static gain and its evaluation from the static characteristics of an element. THEORETICAL BACKGROUND Liquid flow rate is the volume of liquid passing a pipe cross-section for one time unit. The flow rate is measured in volume unit per time units, eg m/sec. There are several methods of measuring flow rate, some direct and some indirect. One of the most accurate methods is to measure the time required to fill a tank of known volume with the flowing liquid. The ratio of volume to time will give the average flow rate during this time. If the tank has a constant cross-section A, the rate of height change may be 3525 measured instead. Using this value and the known cross-section area, the flow rate may be calculated. PROCEDURE OF THE EXPERIMENT 1, Turn off the output valve of tank A. 2. On the control unit, connect the level reference output to the pump interface. 3, Set the POWER switch to ON. Set switches S1 and $3 to OFF, and S2 to "A". 4, Adjust level reference for 1V on M2. 5. Connect the pump interface output to the power buffer input (see Fig. 18). The pump now starts filling the tank. 6. Watch the water level closely. When the level has reached 4,5 cm, start the stop watch and measure the time required to raise the level up to 17 cm. Record the result in Table 2. Pune Hv POWER IWTERF ACE: fOrren rue Leven, REFERENCE et By) =~ 1 74 f° is . Te oisirat, conTROL, Yaer +2av pioiraL CONTROL FIGURE 18: Pump Characteristics 7. Disconnect the interface output from the pump buffer and turn the output valve on, letting the water level drop down to 4-5 cm. Turn the output valve off. 9. Repeat steps 5-8 for all voltages listed in Table 2, and record the results. 10. Set the POWER switch to OFF. 11, Disconnect all connections made to the control unit. 364 | i 26 Pump Voltage Filling Volume Filling Time Pump Flow Rate Ww) (m3) (sec) (em3/sec) 0.5 i rs TABLE 2: Flow Rate as a Function of Pump Voltage ANALYSIS OF RESULTS 1. Fill all columns of Table 2. 2. Draw the pump calibration diagram in Fig. 19. 3. Evaluate the pump static gain from the calibration diagram. QUESTIONS how can it be improved? What are the factors affecting the flow rate measurement precision and What are the units in which the pump's static gain is measured? 3738 caw mae lomirs0c) 24 80} rH a 7 PUMP VOLTAGE mw FIGURE 19: Pump Calibration Diagram eran neenmenenanmeneastne en emeorneen28 SUP UWE : Characteristics of the level measuring unit OBJECTIVES 1+ Measurement of the level sensor calibration diagram. 2. Evaluation of the level sensor gain from the static characteristics. REQUIRED EQUIPMENT See page 25 PREREQUISITES > Knowledge of principles of floating bodies. ~ Understanding of rotary potentiometer operation. THEORETICAL BACKGROUND The float is a widely used element in level measurements. Its principle of operation, Archimedes Law, is based on the fact that a body floating in a jpautd loses part of its weight equal to the weight of the liquid volume it displaces. This principle also determines how deep the body submerges - just enough to displace its own weight of liquid. The float will always follow the liquid surface, whether rising or falling since its submersion is invariable and is independent of the liquid level. To make usé of the float for level measurement, a wire {s wound around a pulley, and one end is connected to the float. A counterweight 1s connected tes other end of the wire. The weight must be lighter than the float, and tts function is to keep the wire under tension. The pulley rotates potentiometer which has a constant DC voltage actoss its outer terminals. The potentiometer then produces a variable voltage at its middle terminal according to the float position (see Fig. 20). 3927 input ourpuT = VOLTAGE VOLTAGE FIGURE 20: Rotary Potentiometer The level sensor is an element of the control loop. Since its response ts essentially instantaneous, only its static gain must be known. The static gain can be determined from the characteristic diagram obtained in this experiment. PROCEDURE OF THE EXPERIMENT 1. Set the POWER switch to ON. 2. Open the output tap of tank A and drain off the water. Close the tap. 4. Set switches $1 and $3 to OFF and switch $2 to (analog) Adjust level reference for a reading of 12V on M2. 6. Connect the elements of the control unit according to Fig. 21: - Connect the output of the level sensor buffer to the external Di. = Connect the output of level reference jack to the input of the pump interface. - Connect the pump interface output to the input of the power buffer. + When the water level in tank A reaches 10 cm, disconnect the pump interface output from the input of the power buffer. . If the water level exceeds 10 cm, open the output tap of the tank and drain off the excess water. 9. Read the output voltage of the level sensor potentiometer by means of the external DMM. The output voltage should be 6V. If it differs from this value, lif 4010. i. 12: 13. 30 v teve SENSO" 1 extenwat - oun = i pune Power rump INTERFACE. BurFeR ae tiey ever REFERENCE ¥ aa) FIGURE 21: Measurement of Level Sensor Characteristic counter-veight and rotate the pulley to obtain the required voltage. Connect the pump interface output to the power buffer. Wait until the water level reaches 21 cm, then disconnect the previously-made connection. C WRN) Open the output tap of the tank and slowly drain off the water, until the level is exactly 20 cm. Make sure that the water level does not fall below this value. Read the output voltage of the level sensor potentiometer and record its value in Table 3. Level (cm) 20} 18] 16] 14] 12] 1] 8 | ofa fe Level sensor voltage TABLE 3: Level Sensor Characteristic Drain off water until the level decreases by 2 cm and record in Table 3 the level sensor voltage. 41Bi 14, Repeat step 13 for each level given in Table 3. 15. Set the POWER switch to OFF. 16. Disconnect all connections made on the control unit. ANALYSIS OF RESULTS 1. Draw the level sensor characteristic in Fig. 22. LeveL y SENSOR VOLTAGE mw / > ° LEVEL (em) FIGURE 22: Level Measuring Unit Characteristic Diagram 2, Evaluate the static gain of the level sensor from Fig. 22. QUESTIONS 1, What will be the effect of adding liquid on the float level? 2. Will the liquid temperature affect measurement precision in the float method? ' 42— i i smsvenene 32 EXERT IMENT | Measurement of the static process characteristics OBJECTIVES 1. Analysis of turbulent flow. 2. Measurement of the liquid level static control characteristic ‘in a tank Measurement of the static gain of a non-linear system by linearization around the operating point. eet sbvanes che np REQUIRED EQUIPMENT See page 25 PREREQUISITES 7 - Knowledge of basic Liquid flow principles. - Understanding hydraulic resistance and its experimental evaluation: THEORETICAL BACKGROUND In a Liquid flow system, wherein liquid flows out of a tank and the output flow, qo, passes through a constriction, R, (see Fig. 23), the liquid level in the tank, h, as a function of inflow rate depends on the head losses along the constriction. Since water flow in non-capillary pipes is turbulent, these losses are non-linear. As derived in the literature, the flow rate ist ay = k Via (40) 43—) a Where: a hb k 8 For 32 FIGURE 23: Container Liquid Level System —> flow rate within the constriction liquid level in the tank - a constant depending on constriction shape and dimensions. - gravitational acceleration on earth. control purposes, Linearization around the operating point is required. The static gain, R, is defined as R = h/q, namely, the ratio between level and constriction flow rate. ast For the purpose of linearization, R will be defined R = bh/Aq (a) which is the ratio between the level change and the resulting flow rate change in the constriction at the operating point. PROCEDURE. OF THE EXPERIMENT 44 Adjust the tank's output valve for maximum opening. On the control unit, connect level reference output to the pump interface, and the output of the pump interface - to the input of the power buffer. Also connect the level sensor buffer output to external DMM (see Fig. 24). On the control unit, Set the POWER switch to ON, $1 to OFF, S2 to A, and 83 to OFF. Adjust level reference for a reading of 12V on M2. Wait about 10 minutes for the level to stabilize. Measure and record the level in Table 4, Level changes may also be observed by observing the3% changes in the voltmeter reading. wv aurren beven Wvsl.e7em Sengon 4 exrenwar (°) 0 pee Levew iP O . it t REFERENCE sz = 2 Re ihe overrat mn consi we] od oierrat CONTROL FIGURE 24: Measurement of the Static Process Characteristics Experiment 6. The level should stabilize in the range of 17 to 20 cm. If the level exceeds 20 cm; reduce the tap angle by 5°. Conversely, if the level stabilizes below 17 cm, increase the angle by 5°. If necessary, continue changing the tap position until a position is found at which the level stabilizes within the required range. Do not change the tap position in the following experiments 7. Repeat steps 4,5 for all voltages listed tn Table 4. 8. On the control unit, set the POWER switch to OFF. 9. Disconnect all connections made on the control unit. ANALYSIS OF RESULTS 1. Fil all columns of Table 4. 2. Draw the process characteristic diagram in Fig. 25. 3. Calculate the static gain in the operating range of 10-14 cm. 453S Punp interface Input voltage (V) Flow rate as per pump calibration diagram (cm3/sec)(ftom Table 2) Final level (cm) | 12 TABLE 4: Stable Level as a Function of Pump Voltage Lever (em) 4 t 20 =I. 15} 10. + 5 LLL, 1 + FIGURE 25: 46 oo ab 80 5 | 80 Process Characteristic Diagram FLOW RATE (em3/aec)i BE QUESTIONS is as Prove that Ris the static process gain, using both the static gain definition and the liquid level behavior tn a tank. In liquid level measurements, a 0,2m level was obtained from a 0.04m?/sec flow rate. Evaluate: a. The constriction constant, k, from the turbulent flow equation. b. The hydraulic resistance, if the flow rate changes in the range of 0.10 ~ 0.12 m/sec. Klom’} = 42) 9800 cm/sec” 47