aa 37 EXPERIMENT Measurement of the process time constant OBJECTIVES 1. Measurement of the dynamic response of a control loop element. to a step function input. 2, Evaluation of the time constant from the dynamic diagram. 3. Comparison of experimental results with theoretical analysis. REQUIRED EQUIPMENT See page 25 PREREQUISITES Knowledge of dynamic data analysis from diagrams. Knowledge of Laplace transforms. THEORETICAL BACKGROUND From the analysis of the liquid level control system, we find that the process time constant is the product of the tank cross-section A, and the outflow constriction resistance, R. If a graph of the dynamic response to level changes to a step change in the inflow is available, the time constant may be determined from it by finding the point at which the level reaches 63.2% of its final value.36 PROCEDURE OF THE EXPERIMENT lL 2. ity a Adjust the outflow valve of tank A at the opening established in Experiment 4. On the control unit, make the following connections (see Fig. 26): - Connect the output of level reference output to the non-inverting input of the error detector No. 1 (when only the non-inverting input is connected, the output voltage of the error detector is half the input voltage). = Connect the error detector output to the input of the pump interface. - Connect the pump interface output to the input of the power buffer. - Connect the level sensor buffer output to an external DMM. On the control unit, set the POWER switch to ON, $1 to OFF, S2 to A and 83 to OFF. LeveL EXTERNAL OMM SENSOR Jl PUMP Power INTERFACE BUFFER nuue oN Ie ERROR berecron Z_ “y Leven Li REFERENCE fe Rw prarTaL, CONTROL I. = an] orairaL CONTROL FIGURE 26: Measurement of the Process Time Constant Adjust level reference output for a reading of 6V on M2 (this corresponds to 3V at the pump interface intput). Wait for level stabilization (the external voltmeter reading may be observed for this purpose). Set S1 to ON (this adds 2.4v), and start the stop watch simultaneously. Note that the voltage change at the input of the pump interface is 1.2V.24 Measure levels at the time intervals listed in Table 5 and record 6 the results. + 2 1 t 1 L L Time (sec) 0/15 | 30] 45 | 60 | 75 | 90 | 105] 120] 135/165/180/195)210 Level (cm) aptly aha Time (sec) 225 | 240 | 270 | 300 | 330 Level (cm) TABLE 5: Level as a Function of Time 7, On the control unit set the POWER switch to OFF. 8. Disconnect all connections made to the control unit. ANALYSIS OF RESULTS 1. Draw the process dynamic diagram in Fig. 27. LeveL tem) ee ~ TIME (min ) FIGURE 27: Process Dynamic Diagram 2. Byaluate the time constant from the diagram.ho + Galculate the time constant from the data of experiment 4 above, and compare it with the experimental time constant. QUESTIONS 1. Prove that the time constant is the time required for the level to reach 63.2% of its final value. 2, A tank having @ cross-section of 2m2 has been tested statically and. the results are shown by the diagram in Fig. 28, ‘ Calculate: a. The process time constant. b. The time required for the level to reach 2.5m, after the flow rate is step-changed from 5 to 7 m3/min. LEVEL m) h 3 FIGURE 28 Static Process Characteristic Derived from Test FLOW RATE 5 7 qlintaee)EBERT MEN iG) Closed—loop level control arid loop gain effect on level error OBJECTIVES 1. Drawing of the control system block diagram and measurement of the transfer functions of the system elements. Block diagram analysis. 3. " Measurement of the static response of the closed-loop system. 4. Comparison of experimental results with theoretical analysis. REQUIRED EQUIPMENT See page 25 PREREQUISITES - Knowledge of block diagram algebra. - Knowledge of Laplace transforms. THEORETICAL BACKGROUND Knowledge of the transfer function of each element in the control loop permits analysis and prediction of the closed-loop system response. If the control loop does not contain an integrator and the control element has pure gain, the change in the actual level will never equal the change in the reference level. The difference — the residual error, is a function of loop gain and of the change in the reference level value inserted into the system. The loop gain is the product of the individual element gains.42 The control element is the only control system element whose gain may be arbitrarily adjusted and used to improve the static response of the control system. PROCEDURE OF THE EXPERIMENT 1, Adjust tank A outflow.valve for the opentng established in Experiment 4. 2. On the control unit, make the following connections (see Fig. 29): a+ Connect the output of level reference output to the non-inverting input of the error detector No.l. Connect the level sensor output to the inverting input of the error detector No. 1. C+ Connect the input of gate Gl to ground. This closes the solenoid driven outflow tap of tank A. d. Connect the output of amplifier Al to the pump interface input. v BurFER tevet S7em SENSOR a + ERROR lev DETECTOR Lever wi REFERENCE Pr : I 6 Veer q sav pvaivaL CONTROL TO ELECTRICAL conrrot, VALVE FIGURE 29: Level as a Function of Loop Gain10. lle 12. 13% Lae 15. 16. a 18. 19. 42 On the control unit, set the POWER switch to ON, and check that there 1s no flow through the outflow tap. : S509 Set the reference level to 15 cm. For this purpose, adjust the output voltage of level reference output (indicated by voltmeter M2). Connect the output of potentiometer P5 (temp reference) to the input of amplifier Al. Also connect to this point an external DMM. Adjust the gain of amplifier Al to 0.5 by means of potentiometer P2. Change the applied voltage by means of potentiometer P5, whose output voltage is measured by the external DMM. Disconnect the output of potentiometer P5 from amplifier Al. Connect the output of error detector No. 1 to the input of amplifier Al. Connect the output of the pump interface to the input of the power buffer, and disconnect input of gate Gl from ground. Wait for level stabilization, as indicated by the DMM connected to the output of Al. The expected stabilization time is approximately 10 minutes. Record the final level in Table 6. Set switch S1 to ON. This applies a 2.4V step-function to the control system. Allow 10 minutes for level stabilization. Record in Table 6 the new level, and the output voltage of amplifier Al. Disconnect the pump interface output from the power buffer input, and connect the input of gate Gl to ground. Set switch Sl to OFF. Repeat steps 5 through 16 for each amplifier Al gain listed in Table 6. Set the POWER switch to OFF. Disconnect all connections made to the control unit. ANALYSIS OF RESULTS Draw the system block diagram and write down the transfer function of each element, according to the results obtained in Experiments 2-5. 2by SS ~4 Gain of Amplifier AL 0.5 1.0 1.5 2.0 2.5 4.0 Level before application of { step function e Level after application of 1 rs C ‘ step function i | ouput voltage of Al after application of step function Measured level change * (cm) Calculated level change * (cm) * Fill in after analysis of results. TABLE 6: Results of Measurements Write down the closed-loop transfer function de Re Calculate the reference level change, hg, introduced by setting switch Sl to ON. Use the transfer function found in para 2. above and the calculated reference level change, hg, to calculate the level changes for each gain value given in Table 6. Record the calculated results in the Table. Referring to the output voltage values of amplifier Al recorded in Table 6 and the results of Experiment 2, explain the great discrepancy between the calculated and measured level changes for the gain value of 4. et atl4g QUESTIONS 1. Explain, using a non-mathematical reasoning, why there must always remain a residual error between the measured and reference levels. when the control element has pure gain. 2, Explain the effect of the small neglected delays on the system response as the loop gain is increased?SUPA Sa Closed-loop level control and loop gain effect on dynamic response OBJECTIVES 1. Measuring the closed-loop dynamic response of the system. 2. Observing the effect of loop gain effects on the dynamic response of the system. REQUIRED EQUIPMENT See page 25 PREREQUISITES Analysis of a dynamic diagram to obtain dynamic parameters. - Knowledge of block diagram algebra. - Knowledge of Laplace transforms. THEORETICAL BACKGROUND The closed loop has a considerable effect on the dynamic response of a control system. A stable open-loop control system may become most unstable when the control loop is closed, yet sometimes the opposite happens. Closing the loop and increasing its gain increases the system speed of response, even if stability is impaired. PROCEDURE OF THE EXPERIMENT 1, Adjust the outflow valve to the opening established in Experiment 4.on Levet DETECTOR REFERENCE wer Pt iy the ae control unit, connect the following (see Fig. 30) Connect the output of level reference output to the non-inverting input of the error detector No.1. Connect the level sensor output to the inverting input of the error detector No. Connect the output of error detector No. 1 to the input of amplifier AL. sev ERROR a boos ner +h4¥ bieiTaL, CONTROL DIGITAL TO ELECTRICAL CONTROL, VALVE FIGURE 30: Input Connections to Errof Detector No. 1 Set the control unit, set the POWER switch to ON, $1 to OFF, $2 to a, S3 to OFF. Adjust P2 to obtain a gain of 0.5 from amplifier Al. Connect the Al output to the pump interface input. Adjust level reference for a reference level of 15cm, as indicated by M2. Disconnect the ground from the Gl input, 1f connected from previous experiment. Connect the pump interface output to the power buffer input (see Fig. 31)-10. lle 12. 13. 1h. ty tev 42 Wait for level stabilization, by observing the indications of the voltmeter connected at the error detector No. 1 output. i Change the reference level value by setting switch Sl at ON and simultaneously start the stop watch. Measure the levels at the time intervals listed in Table 7 and record the results in the table. Disconnect the pump interface output from the power buffer. Reconnect the input of Gl to ground. Set switch S1 to OFF. purren veven WVse7 em SENSOR Loor aain rue rower inte nrace aurren PUMP ERROR DETECTOR 8 Ne ‘es LeveL REFERENCE “10 pum piatraL, CONTROL FIGURE 31: Measurement of the Effect of Loop Gain on Closed Loop Response 15. 16. Ww. 18. Adjust P2 to obtain unity gain from amplifier A2. Repeat steps 6-11 and record the results in Table 7. Set the POWER switch to OFF. Disconnect all connections made to the control unit.49 Time (sec) 0 | 15] 30] 45} 60] 75} 90] 105 | 120 } 225 | 420 Level (cm) Kay = Time (sec) 0} 15 | 30 | 45 | 60 | 75 | 90 | 105]120]135]150 |165 ]270]330| 420} Level (em) TABLE 7: Level as a Function of Time ANALYSIS OF RESULTS 1. Draw the dynamic response curve of the closed-loop system for each of the y Al amplifier gains in Fig. 32 and 33. 2, Determine the closed-loop time constant for each amplifier gain from the dynamic response curve. LEVEL} (em) tJtitiilil, TIME (see) Closed Loop Dynamic Response Curve for Kay = 065ds ‘te — x TIME (306) FIGURE 33: Closed Loop Dynamic Response Curve for Kay = 1 Calculate the time constant of the closed-loop system for each amplifier gain, using the block diagram drawn in Experiment 6 and the transfer function of the closed citcuit. Record the results in Table 8. Calculated | Measured Time constant for Kay = 0.5 Time constant for Kay = 1 TABLE 8: Closed Loop System Time Constants QUESTIONS Amplifier Al saturates when its output reaches 12V. According to the results of Experiment 2, the pump saturates when the input voltage of the pump interface reaches 6V. Using the results of Experiment 6 and the system block diagram, calculate the pump flow rate when the gain of amplifier Al, Kaj, is set to 4 and a 2.4V step is imposed on the reference level voltage. How will the result of 1. above affect the closed-circuit time constant?5] Pau | On-off control of inflow rate OBJECTIVES 1. To study the operation of an ON-OFF level control system. 2. To understand the dynamics of an ON-OFF level control system and the design of the system according to these dynamics. REQUIRED EQUIPMENT See page 25 PREREQUISITES - Knowledge of Laplace transforms. - Ability to analyze system's response, from its transfer function. THEORETICAL BACKGROUND An on-off controller is essentially used in a closed-loop control which has a control element whose gain is very high. Under these conditions, a small deviation of the controlling variable will cause the controlling variable to change from its full dynamic range. For example, in level control system, every slight decrease from the desired value causes full-power pump operation, while a slight increase stops pump operation completely+ This kind of control may cause serious damage to mechanical equipment, such as valves and pumps which is not built for frequent switchings. To prevent damage, the two-position control has a dead-range, where the control does notB2 change the system state, until the range limits have been reached (see fig.34). These Limits are generally determined in accordance with the degree of precision required in the system. The period of a complete ON-OFF cycle is a function of system dynamics, as the experiment demonstrates. PROCEDURE OF THE EXPERIMENT 1. Adjust the tank A outflow valve for the opening established in Experiment a 2. On the control unit, connect the following (see fig. 35)- a. Connect the output of level reference output to the non-inverting input of the error detector No. 1. my at mn , — Sh (o) REFERENCE RANGE mr FIGURE 34, ON-OFF Level Control System (a) and Waveforms (b)3 Ww tev Pt 53 Connect the level sensor output to the tnverting input of the errot detector No. 1. : Cofimect the output of the error detector No. 1 to the input of the loop hysteresis element. Connect the output of the loop hysteresis element to the input of the pump interface. Connect the output of the pump interface to the input of the power buffer. On the control unit, set the POWER switch to ON, $1 to OFF, $2 to A, and $3 to OFF. Rotate potentiometer P3 fully counterclockwise to obtain the minimum state of the loop hysteresis element. Adjust P1 for a 10-cm reference level, as indicated by M2. Adjust P3 for a 9-11 cm dead range. Record the actual limits in Table 9. Measure the rise and fall time of the level between pump turn-on and turn-off, and record the results in Table 9. Measure the input voltage of the pump interface: surreR La7em Lever SENSOR tt ERROR Pune DETECTOR INTERFACE we Lever REFERENCE Loop HYSTERESIS: Vrer +2.4v prorray coNTROL, FIGURE 35: ON-OFF Control System34 Dead-range lower limit (em) Dead range upper value (cm) Level rise time (sec) Calculated* Measured Level fall time (sec) Calculated* Measured * To be filled during analysis of results TABLE 9: Level Rise and Fall Times as a Function of the Dead Range % On the control unit, set the POWER switch to OFF. 10. Disconnect all connections made to the control unit. / ANALYSIS OF SYSTEM OPERATION The starting point for the analysis of the system operation is the static process characteristic measured in Experiment 4, FIGURE 36: Static Process Characteristic The limits of the dead-range will now be marked on the static characteriati hp and hy are the lower and upper level limits of the dead-range.65 - _F and E are the corresponding outflow limits. ‘The valués of F and E are read off the static characteristic curve measured in Experiment 4. Using these values, we can calculate the hydraulic resistance, R, of the outflow tap in the dead-range: (43) In order to analyze the dynamic response of the system, we will write the differential equation of the system and find the appropriate initial conditions. ‘The differential equation was given in Chapter 1: ah -q =A 4a Ve Te” ae a We analyze the operation of the system in the dead range, therefore: ay = a(t) = = hoe) Feq(t)=F+Q h = by + h(t) (45) The resulting differential equation is: h(t). dh (46) aft) - e+ Yea Using the fact that the pump flow rate changes between B (when the pump operates) to zero (when the pump is off), we rewrite the differential equation in the following form: rates! B-F-A any with initial condition: h(t = 0) = 0 (48) 2ump_of f+ ope a Shce), R(t) (ag) Fok Ge TR with initial condition: h(t = 0) = hy ~ hp (50) The solution of the differential equation during the period that the pump56 operates, which gives the system response during level increase, is: a aR h(t) = R(B- F)* (l-e d (51) The solution of the differential equation during the pertod that the pump does not operates, which gives the system response during level decrease, ist h(t) = (hy ~ hy + RF)e ~ RF (52) h(t) is measured from hp and upward. QUESTIONS Fill in the following data: wessem?/secs Pump flow rate Boe. Dead-range upper Limit bys sem. Dead-range lower limit hy = wee eeme Tap resistance (from Experiment 4) - sesvessec/em?. jy Tank area H seeeeeeeeevem? Flow rate corresponding to Level hy S beseseeeeescm/see som > " = seseeseeeesem?/aee Flow rate corresponding to level hy Calculate the level rise and fall times from this data; compare the theoretical results to those obtained in the experiment. 2. Prove that the solution for pump turn-off ist aR hh (t) = (hy - hy + RF)e “" ~ RF (53) 3. Prove that the solution for pump turn-on is: h(t) =RB-FI-e “) 34) 4 Calculate the oscillation perfod in the experimental setup when the dead range is 1 cm.5% EXPER TM ENT On-off control of outflow rate OBJECTIVES 1. To study the ON-OFF control system dynamics, when the outflow rate is controlled. 2. To understand the design method for ON-OFF control systems. REQUIRED EQUIPMENT See page 25 PREREQUISITES - Knowledge of system analysis by Laplace transforms. - Knowledge of system dynamic response analysis by means of transfer functions. THEORETICAL BACKGROUND In the ON-OFF control, where the outflow rate is the controlled factor, inflow rate variations cause disturbances in the system. As already seen, the control system must allow sufficient time intervals between the turn-on and turn-off of mechanical elements to prevent damage. The dead range of a two-position control system will, in fact, be determined by the highest inflow rate expected, since the level variation rate both for rise and fall of level depends on inflow rate. When the outflow valve is closed, the tank operates as an integrator for theSe inflow rate. For @ constant inflow rate, the level rises at a constant rate. When designing the dead range, these characteristics must be taken into consideration, as shown in this experiment. PROCEDURE OF THE EXPERIMENT 1. Adjust the outflow valve for the opening established in Experiment 4. 2. Set the POWER switch to ON and check that the tank is being drained. 3. On the control unit, connect the following (see Fig. 37): a. Connect the level reference output to the non-inverting input of error detector No. 1. b. Connect the level sensor buffer output to the inverting input of the error detector No. 1. c+ Connect the error detector No. 1 output to the input of the sign inverter A2. d. Connect the A2 output to the input of the draining hysteresis No. 2 element input. e+ Connect the draining hysteresis output to the input of the lower gate cl. f£. Connect the potentiometer P5 (temp reference) output to the input of the pump interface. On the control unit, set the POWER switch to ON, $1 to OFF, $2 to a and S3 to OFF. 5. Adjust potentiometer P5 for a reading of 2V on voltmeter M4. 6. Adjust potentiometer level reference to close the solenoid-operated valve at a level of 12 cm as indicated by voltmeter M2. 7. Rotate potentiometer P4 fully clockwise. + Connect the output of the pump interface to the power buffer. 9. When liquid level reaches 13 cm, rotate gently P4 counter-clockwise until the valve closes. 10. Record in Table 10 the upper and lower limits of the dead-range as measured during system operation. 11. Measure the time required for the level to rise, from the instant the solenoid-operated valve closes to the instant it opens. Record the result in Table 10.64 PUMP. INTERFACE eurren " Seves, Wetrem Sexson ay ‘a oe = + verecror Ps: i DIGITAL CONTROL. 8 a eve, my REFERENCE a picitat, 82 hes I 34 %e] A eav | piaiiaL CONTROL. DRAINING oa HYSTERESIS: pisital To CONTROL ELECTRICAL, FIGURE 37: ON-OFF Control of Outflow Rate Dead-range lower Limit (em) Dead range upper value (cm) Level rise time (sec) Calculated* Measured Level fall time (sec) Calculated* Measured * To be filled during analysis of results TABLE 10: Level Rise and Fall Time as Function of Dead Range60 12, Measure the time required for the level to fall, from the instant of . valve opening to the instant of valve closing. 13. On the control unit, set the POWER switch to OFF. 14. Disconnect all connections made to the control unit. ANALYSIS OF SYSTEM OPERATION The response of the system, following the opening- of the solenoid-operated valve, is similar to the system response observed in Experiment 8, that is, during the draining period, the system response is governed by its static characteristic. _ The “differential equation of the system, as given in Chapter 1, is: (55) Liquid level, h, will be measured from the lower limit, therefor: h = hp + h(t) (56) We assume that when the system operates, the inflow rate is a constant, B: / QG =B G7) The outflow rate, when the liquid level is at its lower limit, is F} the actual value can be found from the results of Experiment 4. Using this value, we obtain: h(t) et - (58) qa F+ gg (t) Ft B is measured between the Linits of the dead range. Substituting the known values in the differential equation: . h(E), 2 dh(t) 59 poet My aa she 59) After some manipulation, we obtain: an {hence = (BFR (60) The initial conditions are found using the facts that the corrective operation starts only after the level reaches hy and h(t) is measured from the lowerél limit, hp: j h(t = 0) = hy - hp (61) The system response during the filling period does not depend on the static characteristic, because during this period there is no outflow. We start again from the basic differential equation: dh(t) ay at A RO (62) We use the fact that pump flow rate remains constant during system operation: a =B (63) During the filling period, the outflow valve is closed: G = 0 (64) Substituting into the differential equation we obtain: pm a Sete) (65) The initial conditions are found using the fact that the level is measured from the Lower Limit: h(t = 0) = 0 (66) The solution of the differential equation during the draining period is: t (B ~ F)RJe + (B~ F)R (67) h(t) = [hy h The solution of the differential equation during the filling period is: h(t) (68) QUESTIONS 1. Fill in the following data: Pump flow rate B som/sec. Dead range upper limit byt some Dead range lower limit hy = scm. Valve resistance (Experiment 4) R - saucfen?s Tank area A= Fe. Flow rate corresponding to level hy3. » 62 Calculate the level rise and fall times from this data. Compaze the | theoretical results to those obtained in the experiment. . Applying the law of mass conservation, prove that when the outflow is zero the tank functions as an integrator for the input flow rate. Prove that when the outflow is zero, the solution is ht =Be