DE LERNZO (DL2314 )

Process controller system

containing of :
An educational board with set of
sensor ,actuator ,holding tank
,pipes and source tank
 A control module
,containing the interface
circuit for sensor,
actuator and controller
Input
process Output
Controller Pump system

Sensor
We can control :
1- level
2-Temperature
3- flow
4- Pressure
EXPERIMENT 1
LEVEL
SENOR
LVDT
LVDT : linear variable
differential transformer which
is used for measuring
displacement and convert it
into voltage
LVDT

Gain = ??
Voltage LEVEL
(gain of

LVDT)
LVDT USED AS POSITION
FEEDBACK
CALIBRATION OF LVDT
HOW WE CALIBRATE LVDT
 14 13 ………………………… 4
Level ……….

Voltage 10 ………………………………… 0
……….
CALIBRATION DIAGRAM
12

10

8
Voltage

6
voltage

0
0 5 10 15
Experiment 2
We used centrifugal pump
in lab
 Centrifugal
Flow rate
Voltage
pump GPUMP =

???
 Objective :
1-To measure flow velocity

2-To determine the calibration

diagram of the pump
Note : d tank = 17.5 cm
d pipe = 0.78cm

12 cm

5
c

7cm
 Calibration of LVDT
VOLTAGE 3 4 5 6 7 8 9 10

VOLUME = area of tank х high= 1202

(cm3)
Time (sec)

Flow Volume
(cm3/sec)
Time

Flow (L/h)

FLOW flow (cm3/sec)

VELOCITY
Area of the pipe
Calibration diagram
Flow rate (L/h)

Voltage
 Experiment 3 :
characteristic of static
process
Objective :

1- To measure static gain of

the process ( Restriction)

2- To determine diagram of
the process
Restriction : is a resistance of the
drain valve to drain the water
through it .
Note :

Before we calculate
(Restriction) we must know if
the flow laminar or turbulent
 In laminar flow :
(Restriction) = slope graph
between flow rate at steady
state (X axes ( and steady state
level
Steady state
level
Flow rate
 In turbulent flow :
(Restriction) =steady state level
at operating point /steady
state flow rate at operating
point
R= H
Q
Voltage 10 9 8 7
Flow rate
(L/h)
Level steady state
Re Flow velocity × D pipe
1× 10-6 m2/s

R
Experiment 4
TIME CONSTANT OF THE
PROCESS
 Objective :
1-To measure the dynamic
response of the process

2-To determine the dynamic

diagram
Experiment procedure :
1. connect ,through leads , circuit
as shown here
2. Regulate the voltage on set point 9
volt to start the pump
3. Read value of the flow rate at 9
VOLT and record it
4. Regulate the voltage on set point at
10 volt
5. Measure the level at 60 seconds
intervals and write down the
values in the table

Time 0 60 120 180 240 300 360 420 480 540 600 660 720 780
(sec)
Level
(cm )
6. Read value of the flow rate at 10
VOLT and record it
7. Put off the main switch ,remove
all connection and represent
the dynamic diagram of the
process
 Dynamic diagram
Dynamic Diagram
Level (cm)

Time (s)
 Calculation :
Find from Dynamic diagram
1. hss (steady state level )
2. τ (time constant )
3. R (Restriction )
 hss= hmax – hi
time constant : time @ 0.68 hss
+hi R= time constant (τ )/ c( area of
the tank )
 Experiment 5
on /off control of the
level
Input process system

Pump R=?? Output

Controller
GP=?? Hss=??
Т=??

LVDT
GLVDT=??
 The on-off control is the simplest form of a
controller, which switches ON when the error
is positive and switches OFF when the error is
zero or negative. An on-off controller doesn’t
have intermediate states but only fully
ON or fully OFF states. Due to the switching
logic, an on-off controller is often called a bang-
bang controller or a two-step controller.
On – off controller
 A common example of on-off
control is the temperature control
in a domestic heating system.
When the temperature is below the
thermostat set point the heating
system is switched on and when
the temperature is above the set
point the heating switches off.
• an industrial plant, a closed-loop control
system has the role of keeping a
measured physical signal to a predefined
value (set point). The physical signal, also
called controlled variable, can be of any kind,
electrical (voltage, current, power),
mechanical (position, speed, force, torque),
hydraulic (pressure, flow) or thermal
(temperature)
• The difference between the controlled
variable (measured) and the predefined
value is called error.
NOTE:
From this experiment we will start using
software for de Lorenzo the output of software
will be drawing that we will analyze it
If set point (desired level )=5cm

5 cm level of ‫ سم‬5 ‫بدنا مستوى المياه يضل ثابت عند‬

tank

Run experiment 5 on software then insert 5cm

on box of set point , and put hysteresis =
16% then the output similar as :
Set point =5cm ,hysteresis =16%
From drawing (the result of using on off controller
with set point 5cm,hyseresis =16 % find :
1- upper point from experiment =
2-Lower point from experiment =
3-time on ( time when level increase ) =
4-time off ( time when level decrease )=
5- upper point theoretically =set point +1/2 hysteresis
6-Lower point theoretically = set point -1/2 hysteresis
• Then we will repeat what
we do with hysteresis = 0% ,
24%
,44%
 Results
set point =5 cm, hysteresis = 0%
Set point = 5cm , hysteresis = 24%
Set point = 5cm , hysteresis = 44%
In report
• Mention advantage & disadvantage of
using on- off controller without hysteresis
• Mention advantage & disadvantage of
using on- off controller with hysteresis
Experiment 6
 Closed loop
Proportional
control of the level
• In this experiment we will
use proportional controller
P-controller
• Now we are discuss proportional controllers, as the
name suggests in a proportional controller the output is
directly proportional to the error signal.

• OUTPUT (T) α e(t )

• OUTPUT (T) = KP × e(t )
• Kp is proportional constant also known
as controller gain.
INPUT OUTPUT

Kp GP R/(RCS+1)

1
 Objective :
1-To verify the effects of the
gain of the loop (Kp) on the
dynamic response of the system
 EXPERIMENT PROCEDURE
• using software of De lorenzo
• Run experiment 6 then we put
• Set point = 4 cm , KP For example =10 then the
controller name is P10
• Then program will draw drawing as :
 Calculation :
From drawing find :
1- set point =step input
= 2- hss =
3-ess from experiment (steady state error) =
4- time constant (τ) =time @0.63×hss +hi
4-delay time = time @0.50 ×hss +hi
5- rise time = time @0.90 ×hss +hi - time @0.10 ×hss +hi
6- system order ???
7-ess theoretically (steady state error) = step input /1+kpGPR
Then we will repeat what we
do with P20( KP =20 )
P30 (KP= 30)
Experiment 7
 Closed loop
Proportional derivative
control
of the level
• In this experiment we will
use proportional
derivative controller
PD-controller
• Kp is proportional gain
• Kd is derivative gain

• Then gain of PD

controller Gc= Kp + Kd s
INPUT
Kp + Kd s OUTPUT

GP R/(RCS+1)

1
 Objective :
1-To verify the effects of the
gain of the loop (Kd) on the
dynamic response of the system
𝑂𝑈𝑇𝑃𝑈𝑇 𝐻(𝑠)
T.F = 𝐼𝑁𝑃𝑈𝑇 = 𝑅(𝑠) .

𝑅
(𝐾𝑝+𝐾𝑑𝑆)∗𝐺𝑝∗( )
T. 𝑅𝐶𝑆+1
𝑅
F 𝑅𝐶𝑆+1
 1+(𝐾𝑝+𝑘𝑑𝑆)∗𝐺𝑝∗ ∗𝐺𝑠

The G s =1 … gain feedback sensor.

(𝐾𝑝+𝐾𝑑𝑠)∗𝐺𝑝∗𝑅
T.F = 𝑅𝐶𝑆+(𝐾𝑝+𝐾𝑑𝑆)∗𝐺𝑝∗𝑅+1.

K p is not effect on order of system.

Error = input – output.
E(s) =R(s) – H(s) …… Divided The Equation
on R(s).

𝑬(𝒔)
= 1- T.F.
𝑹(𝒔)

𝑬(𝒔) (𝐾𝑝+𝐾𝑑𝑠)∗𝐺𝑝∗𝑅
= 1- .
𝑹(𝒔) 𝑅𝐶𝑆+(𝐾𝑝+𝐾𝑑𝑆)∗𝐺𝑝∗𝑅+1
• 𝑬(𝒔) 𝑹𝑪𝑺+𝟏
𝑹(𝒔) =
𝑹𝑪𝑺+(𝑲𝒑+𝑲𝒅𝒔)∗𝑮𝒑∗𝑹+𝟏
• STEADY STATE ERROR …e ss.

• e ss= 𝐦
𝐢𝐥 𝒔 𝑬(𝒔)
𝒔→𝟎

• e =𝐦
𝐢𝐥 𝑹𝑪𝑺+𝟏 ) ∗ 𝑹(𝒔)
ss
𝒔→𝟎 𝒔∗ ( 𝑹𝑪𝑺+(𝑲𝒑+𝑲𝒅𝒔)∗𝑮𝒑∗𝑹+𝟏
𝑨
where R(s) is suit step input R(s) = .
𝑺

• e ss 𝑨
= 𝑲𝒑∗𝑮𝒑∗𝑹+𝟏
Note: added derivative controller not effected
on order of system and its error but
system become more stable.
 EXPERIMENT PROCEDURE
• using software of De lorenzo
• Run experiment 7 then we put
• Set point = 6 cm , KP For example
• Kp =10 , Kd =10,
• then the controller name is PD10 10
• Then program will draw drawing as :
 Calculation :
From drawing find :
1- set point =step input
= 2- hss =
3-ess from experiment (steady state error) =
4- time constant (τ) =time @0.68×hss +hi
4-delay time = time @0.50 ×hss +hi
5- rise time = time @0.90 ×hss +hi - time @0.10 ×hss +hi
6- system order ???
7-ess theoretically (steady state error) = step input /1+kpGPR
Then we will repeat what we
do with PD105(Kp =10 , Kd =5
)
PD105(Kp =10 , Kd =5 )
• From result we can see
• Kd first order system (1 st order system )
• increasing kd increasing stable
• Kd not effect on value of error
Experiment 8
 Closed loop
Proportional integral
control
of the level
• In this experiment we will use
proportional integral
controller
PI-controller
• Kp is proportional gain
• Ki is integral gain

• Then gain of PI

controller Gc= Kp + Ki /s
INPUT OUTPUT
Kp + Ki /s R/(RCS+1)
GP

1
 Objective :
1-To verify the effects of the
gain of the loop (Ki) on the
dynamic response of the system
𝑂𝑈𝑇𝑃𝑈𝑇 𝐻(𝑠)
T.F = .
𝐼𝑁𝑃𝑈𝑇 𝑅(𝑠)
=
𝑅
(𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗( )
𝑆(𝑅𝐶𝑆+1)
T.F 𝑅
1+(𝐾𝑝𝑆+𝑘𝑖)∗𝐺𝑝∗ 𝑆(𝑅𝐶𝑆+1)
∗𝐺𝑠
The G s =1 … gain feedback
 sensor.
(𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗𝑅
T.F = .
𝑆 𝑅𝐶𝑆+1 +(𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗𝑅
Error = input – output.
E(s) =R(s) – H(s) …… Divided The Equation on R(s).
𝑬(𝒔)
𝑹(𝒔)
= 1- T.F.

𝑬(𝒔) (𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗𝑅
= 1- .
𝑹(𝒔) 𝑆 𝑅𝐶𝑆+1 +(𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗𝑅

𝑬(𝒔)
= 𝑺(𝑹𝑪𝑺+𝟏)
𝑹(𝒔) 𝑆
𝑅𝐶𝑆+1 +(𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗𝑅
STEADY STATE ERROR …e ss.
e ss= 𝐦
𝐢𝐥 𝒔 𝑬(𝒔)
𝒔→𝟎
𝑺(𝑹𝑪𝑺+𝟏)
e ss = 𝐦
𝐢𝐥 𝒔 ∗ ( ) ∗ 𝑹(𝒔) where R(s) is suit
𝒔→𝟎 𝑆 𝑅𝐶𝑆+1 +(𝐾𝑝𝑆+𝐾𝑖)∗𝐺𝑝∗𝑅
𝑨
step input R(s) = .
𝑺
e ss = zero
 EXPERIMENT PROCEDURE
• using software of De lorenzo
• Run experiment 8 then we put
• Set point = 4 cm , KP For example
• Kp =10 , Ki =10,
• then the controller name is PI10 10
• Then program will draw drawing as :
 Calculation :
From drawing find
:
1- set point =step input =
2- hss =
3-ess from experiment (steady state error) =
4- time constant (τ) =time @0.63×hss +hi
4-delay time = time @0.50 ×hss +hi
5- rise time =
6- system order ???
7-ess theoretically (steady state error) =
8- over shoot =
9- under shoot =
10- Settling time =
11- Peak time =
12 – over shoot percentage = over shoot / set point *100%
PI1010 (Kp =10 , Ki =10 )
• From result we can see
• Ki second order system (2 nd
order system )
• increasing ki increasing over shoot
• Ki error =zero
Experiment 9
 Closed loop
Proportional derivative
integral control
of the level
• In this experiment we will use
proportional derivative
integral controller
PID-controller
• Kp is proportional gain
• Ki is integral gain
• KD is derivative gain

•Then gain of PID

controller Gc= Kp + KD *S +
Ki /s
INPUT OUTPUT
Kp + KD *S + Ki /s
GP R/(RCS+1)

1
 Objective :
1-To verify the effects of the gain
of the loop (Ki), (KD) (KP), , on the
dynamic response of the system
• T.F 𝑂𝑈𝑇𝑃𝑈𝑇 𝐻(𝑠)
= .
= 𝐼𝑁𝑃𝑈𝑇 𝑅(𝑠)

• T.F
 𝑅
(𝐾𝑝𝑆+𝐾𝑑𝑆² +𝑘𝑖)∗𝐺𝑝∗( )
𝑆(𝑅𝐶𝑆+1)
𝑅
1+(𝐾𝑝𝑆+𝑘𝑑𝑆²+𝐾𝑖)∗𝐺𝑝∗ 𝑆(𝑅𝐶𝑆+1) ∗𝐺𝑠
• The G s =1 … gain feedback sensor.

• T.F (𝐾𝑝+𝐾𝑑𝑠)∗𝐺𝑝∗𝑅
.
= 𝑆(𝑅𝐶𝑆+1)+(𝐾𝑝𝑆+𝐾𝑑𝑆²+𝐾𝑖)∗𝐺𝑝∗𝑅
• Error = input – output.
• E(s) =R(s) – H(s) …… Divided
The Equation on R(s).
• 𝑬(𝒔)
𝑹(𝒔) = 1- T.F.

• 𝑬(𝒔) (𝐾𝑝𝑆+𝐾𝑑𝑆2+𝑘𝑖)∗𝐺𝑝∗(
𝑅
)
𝑹(𝒔) 𝑆(𝑅𝐶𝑆+1)
= 1- 𝑅
1+(𝐾𝑝𝑆+𝑘𝑑𝑆2+𝐾𝑖)∗𝐺𝑝∗ 𝑆(𝑅𝐶𝑆+1) ∗𝐺𝑠

• 𝑬(𝒔) 𝑺(𝑹𝑪𝑺+𝟏)
𝑹(𝒔) = 1+(𝐾𝑝𝑆+𝑘𝑑𝑆²+𝐾𝑖)∗𝐺𝑝∗ 𝑅
𝑆(𝑅𝐶𝑆+1) ∗𝐺𝑠
• STEADY STATE ERROR …e ss.

• e ss= 𝐦
𝐢𝐥 𝒔 𝑬(𝒔)
𝒔→𝟎

• e ss = 𝐦
𝐢𝐥 𝒔 ∗ ( 𝑺(𝑹𝑪𝑺+𝟏) ) ∗ 𝑹(𝒔) where
𝒔→𝟎 𝑅
1+(𝐾𝑝𝑆+𝑘𝑑𝑆²+𝐾𝑖)∗𝐺𝑝∗ 𝑆(𝑅𝐶𝑆+1) ∗𝐺𝑠
𝑨
R(s) is suit step input R(s) = .
𝑺

• e ss = zero
From drawing find :
1- set point =step input
= 2- hss =
3-ess from experiment (steady state error)
= 4- time constant (τ) =time @0.63×hss +hi
4-delay time = time @0.50 ×hss
+hi 5- rise time =
6- system order ???
7-ess theoretically (steady state error)
= 8- over shoot =
9- under shoot =
10- Settling time =
11- Peak time =
12 – over shoot percentage = over shoot / set point *100%
• For this experiment because we used Ki then
the system second order system (2
nd order system )
• If we increase kd more stable