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Worksheets C Automated Measurement and Control
Worksheets C Automated Measurement and Control
closed-loop control
Information
This is an introduction to automated control technology and is based on the knowledge of manual control
that has already been acquired. You’ll learn the basics of computer aided control with the help of practical
examples.
Every control circuit consists of a controlled system and a controller.
1 Setpoint specification
2 System deviation = setpoint - actual value
System deviation is calculated by means of a control function and is transmitted to the controlled system as a manipulated variable
(3). The control function is generally processed with the help of software.
3 Manipulated variable
4 The manipulated variable must be boosted so that the actuator’s final control element receives a signal with which it can work.
5 The controlled system (e.g. fill level) is changed by means of the manipulated variable.
6 The controlled system’s actual value is measured and fed back to point 2.
In most cases, the actual value must be electronically converted.
Software solutions for a controller in a PC or a PLC work in a cyclical fashion, i.e. points 2 through 6 are run continuously.
Types of controllers:
Discontinuous controller
These controllers are characterised by the fact that their manipulated variables are only capable of
changing between the on and off states, i.e. two-step controller.
Continuous controller
With continuous controllers, the manipulated variable is infinitely adjustable, e.g. PID controller.
In conventional control technology, a difference is made between the following controllers according to how
the manipulated variable is determined (simplified excerpt).
Controller Graphic symbol Determination of the manipulated variable via the control function
2-step controller The manipulated variable is compared with an upper and a lower limit
value.
PI controller The characteristics of the P-controller and the I-controller are combined.
Information
The system is, as in the section on “manual measurement, open-loop and closed-loop control”, equipped
with a control panel used for manual measurement, open-loop and closed-loop control. The system must
now be modified so that signals can be transmitted via the EasyPort PC interface. The depicted control panel
is not used for automated measurement and control.
The basic setup for automated measurement, open-loop and closed-loop control will be demonstrated using
pump control as an example:
Item 1 2 3
Digital pump control , on/off PC transmits Bit3 to EasyPort generates a voltage Motor runs at nominal power
EasyPort. signal (relay) of 0 V or 24 V. with 24 V.
Analogue control PC transmits a decimal value EasyPort generates a control The motor controller boosts the
(e.g. double word) which signal of 0 to 10 V. signal to within a range of 0 to 24
corresponds to a voltage V. The motor runs at an infinitely
within a range of 0 to 10 V. adjustable speed.
Task
The system will be equipped with a preassembled I/O board. Carry out conversion as described in the
following steps:
1. Switch off supply power.
2. Unplug the laboratory cable via with safety valve socket.
3. Unplug the pump motor.
4. Mechanical removal of the control panel from the rectangular profile
Important modules are required for operation via a PLC or via a PC and EasyPort, in order to process
measured values and control the actuator.
F-U converter for flow sensor Depending on the flow rate, the flow sensor generates a
pulse frequency within a range of 40 to 1200 Hz. This
pulse frequency is converted to a voltage value within a
range of 1 to 10 V by the F-U converter.
Note
After starting the software, a message indicates whether or not a connection has been successfully
established. If this is not the case, check all connections within the system. Otherwise, exit the software
and disconnect the USB plug. Reinsert the USB plug after 5 seconds. Start the software again.
1 2 3 4 5 6 7 8
Task
The pump will be connected and tested during the following experiment. Simply pumping water into lower
tank B101 is sufficient for this function test.
– Set up the fill-level system with one tank as specified in section 1.1.1, part A.
– Base yourself on the PI flow diagram.
– Before commissioning, make sure all the project kit’s modules and piping function correctly and do not
leak.
– Replace any damaged parts.
V101
B102
V103 V102
FI
101
PI B101
103
P101
V105
– Plug the pump into the I/O board. The allocations are included in the circuit diagram on the CD-ROM.
Note
The pipe connection to tank B102 must be interrupted or equipped with a closed stopcock. Close V101
and V105, open V102 and V103.
– Select each of the values listed below and document your observations.
1 A3 = on A2 = off 0V
2 A3 = on A2 = on 0V
3 A3 = off A2 = on 4V
4 A3 = off A2 = on 8V
5 A3 = off A2 = on 10 V
The purpose of the pressure sensor is to measure liquid pressure directly downstream of the pump. According to
the data sheet, the sensor reads out a voltage of 0 to 10 V within a pressure range of 0 to 400 mbar.
– Electrically connect the pressure sensor in accordance with the circuit diagram (CD-ROM).
– Valve settings: V101 and V105 closed, V102 and V103 open, remove piping to tank 102, insert a
blanking plug into the end of the pipe or install a stopcock in the bottom inlet and close it.
– Fill with water.
– Set up the software.
– Set the pressure value at the PC after opening the “Setup” menu:
– Determine factor and offset: calculate the physical display value:
0.4bar
Factor 0.04
10V 0V
Default setting for the pressure duct: factor = 0.04 and offset = 0.0 (see figure)
In order to ensure correct representation of the scales in the diagrams, it’s important to always enter the
maximum physical value and the appropriate unit of measure (see the two right-hand columns in the
screenshot).
Task
At a pressure of 0 to 10 bar, the pressure sensor reads out a voltage within a range of 2 to 10 V.
Final value
Factor
Final voltage Initial voltage
– Operate the pump with the three following voltage values and make a note of what you observe at the
software pressure display.
1 A3 = on A2 = off 0V
2 A3 = off A2 = on 5V
3 A3 = off A2 = on 10 V
– Change the pump speed again by setting supply voltage to three different settings and make a note of
what you observe at the flow rate display in the software.
1 A3 = on A2 = off 0V
2 A3 = off A2 = on 5V
3 A3 = off A2 = on 10 V
2.4 Project task: determine the fill level of the upper tank
LIC
102
V101
B102
V103 V102
FI
101
PI B101
103
P101
V105
– Mount upper tank B102 and lay piping for the system in accordance with the PI flow diagram.
– Mount the ultrasonic sensor onto the upper tank.
– Electrically connect the ultrasonic sensor in accordance with the circuit diagram (CD-ROM).
– Set the valves so that liquid can be pumped into the upper tank: V101 open, V103 open , V102 approx.
5% open.
– Start the software and open the “Setup” menu.
– Set factor and offset
Depending on which physical quantity is to be displayed, factor and offset are entered as follows:
The following applies in the case of a sensor signal within a range of 0 to 3 litres and a voltage of 0 to 10 V:
Note
The sensor signal lies within a range of 0 and 2.7 l, which corresponds to 0 to 10 V. Due to the fact that
the bottom of the tank is conical, measurement begins as of the cylindrical portion of the tank and
roughly the first 0.5 l are disregarded in this example.
– Fill upper tank B102 according to the entries in the table and document your observations.
– Complete the table.
2 A3 = on A2 = off
Approx. 50% full =
100% full =
3 A3 = off A2 = off
LA+
111
V101
B102
LS–
114
FIS+
101
PIS+ B101
103 LS–
113
P101
V105
– Carry out the experiment as indicated in the table and document your observations.
2 A3 = off A0 = off –
– First, modify the system according to the PI flow diagram or the figure. A setup including one tank, the
pressure sensor and the flow sensor is required.
– Double check the piping layout and the electrical connections before commissioning.
– Test the pump, the pressure sensor and the flow sensor for correct functioning.
– Fill tank B101 with 2 to 2½ litres of water.
V103 V102
FI
101
PI B101
103
P101
V105
B101
FI101
PI103
P101
Task
– Connect the EasyPort, start the software and select the settings menu.
– Enter and double-check factor and offset settings for the sensors.
– Enter the corresponding values in the table.
V102
V103
– Measure pressure and volumetric flow rate with changing line resistance.
– Carry out the steps specified in the table and document your observations.
Task
– What is the relationship between the pipe’s cross section, volumetric flow rate and pressure?
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– Carry out the experiments described below, document your observations in the table and create a
characteristic curve.
10
Task
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– What is the effect of varying the speed at which control voltage is changed?
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LA+ LA+
111 111
V101 V101
B102 B102
LS– LS–
114 114
FIS+
101
PIS+ B101
103 LS–
113
P101
V105
– Set the system up with two tanks as shown in the flow diagram. Connect and test the pump and the
ultrasonic sensor.
– Base yourself on section 2.4 during setup.
– Double-check the piping layout and the electrical connections.
3.3.3 Experiment: filling the tank from below using the pump
– Carry out the experiment as indicated in the table and document your observations.
1 V101 closed
V107 closed
V103 open
V102 closed (A0 = off)
V112 closed
3.3.4 Experiment: filling the tank from above using the pump
– Carry out the experiment as indicated in the table and document your observations.
1 V101 open
V107 open
V103 closed
V102 closed (A0 = off)
V112 closed (while filling)
3.3.5 Experiment: filling the tank from above while simultaneously withdrawing water
– Carry out the experiment as indicated in the table and document your observations.
1 V101 open !
V107 open
V103 closed
V102 open (A0 = on)
V112 20% open
Characteristic curve for filling from above while simultaneously withdrawing water
Task
– Why is the surface of the water less turbulent when the tank is filled from below?
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– Why does the fill level rise more slowly when water is withdrawn simultaneously?
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Task
– Set the system up with one tank in accordance with the PI flow diagram.
– Connect and test the pump, the pressure sensor and the flow sensor.
– Double-check the piping layout and the electrical connections before commissioning.
V103 V102
FI
101
B101
P101
V105
– Carry out the work steps described below and record your observations in the table.
V102
V103
3 Set to analogue A2 = on
mode
Task
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– How long does the pump have to run (Q = 2 l/min.) in order to deliver 0.5 litres of water?
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Information
A control circuit always consists of a control device (closed-loop controller) and a device to be regulated
(controlled system), for example a fill-level system.
Y
Final control element
Control function
Process
(system)
e=w-x
– X Measuring
transducer
+
Setpoint generator
Description
The task of the closed-loop controller (control function) is to control the controlled system so that it remains
at setpoint w. Actual value x is continuously measured and compared with setpoint w to this end. The
regulator calculates manipulated variable y. The manipulated variable influences the process via a final
control element.
Knowledge of the characteristics of the controlled system is essential for selecting and adjusting the
regulator. Characteristics of controlled systems are usually determined during a test run.
The characteristics of the controlled system, “tank B102”, will be observed as described below. The tank will
be filled from above via a piping system.
Graphic symbol
Fill-level
Input quantity
(pump power)
Time
Graphic symbol
Input quantity
(pump power)
Fill-level
63 %
Zeit
Note
Due to the minimal fill level (hydrostatic pressure), the exponential function is not very distinctive.
Systems which demonstrate these characteristics are called 1st order systems. The characteristic variable is
time constant T [seconds]. It’s the time required to achieve approximately 63% of the final level. As system
performance varies, the control circuit also responds variously. In the experiments described below, we will
only examine the performance of a control circuit with a PT1 system.
Task
– How does the integral system perform when the pump is switched off during filling from above?
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– How does the PT1 system perform when the pump is switched off during filling from above?
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4.1 Project task: controlling the fill level using a two-step controller
Disturbance variables include, for example, opening and closing hand valves V101 and V103, as well as 2-
way ball valve V102 with pneumatic actuation.
– Set the system up with two tanks according to the PI flow diagram.
– Connect the pump, the flow sensor and the 2-way ball valve with pneumatic actuation and test them.
– Double-check the piping layout and the electrical connections.
LA+
111
V101
B102
LS–
114
FIS+
101
PIS+ B101
103 LS–
113
P101
V105
4.1.4 Commissioning
– Please check all the points listed in the following report and confirm completion of all tasks before
commissioning.
Information
The values in the control circuit are specified in a standardised fashion, i.e. 0 and 1 or 0 and 100%. These
values are frequently converted to physical values for the user, for example so that the fill level can be
specified in litres or the water level in mm.
Term Symbol
Setpoint w
Actual value x
Switching difference sd
Manipulated variable (pump on/off) y
Fundamental performance of a control circuit as an example of a fill-level system with open outlet (PT1) and
a 2-step controller
Actual value
Switching difference
Setpoint
Manipulated variable
Various settings must be entered in order to test performance. In order to be able to draw any conclusions
about the control circuit, it’s always advisable to change only one parameter at a time and then conduct the
experiment. The respective settings included in the following table are suggestions.
3 0.6 0.05
Task
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– How does the interference variable affect the outcome of the experiment?
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Examples: irons, refrigerators, heaters, solar systems, fill levels for cooling lubricant, fill levels in galvanising
systems and swimming pools etc.
These systems have a large time-constant, so that only minimal switching frequencies occur despite a small
switching difference.
4.2 Project task: controlling the fill level using a continuous controller
Controller Process
w (0...1) Manipulated
Control function Signal amplifier Controlled system Sensor Actual value
Setpoint variable
Y = ... y (0...1) x (0...1)
P controller y = kp e
kp = adjustable amplification factor
e = system deviation w - x
Note
The pump must be operated in the analogue mode for continuous control. Control voltage from the
EasyPort to the motor control is between 0 and 10 V. Changeover relay K1 must be set with A2 = 1 to this
end.
Various settings must be entered in order to test the performance of the control circuit. In order to be able to
draw any conclusions, it’s always advisable to change only one parameter at a time and then conduct the
experiment. The settings included in the following table are suggestions.
Depending on the software revision level, the setpoints may also have to be entered in a sub-window.
Note
Empty B102 before each start-up!
– Select each of the values listed below and carry out the experiment.
– Document your observations.
Settings Observations
Task
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Note
Empty B102 before each start-up.
Software setup
The manipulated value of the I controller is calculated as follows:
Y = total of all system deviation (e:sum) x sampling time (TA)/integral action time (Ti)
This formula makes it clear that Y is quickly changed by the controller when Ti is small, and Y is changed
slowly, i.e. the controller is sluggish, when Ti is large. Make sure that Ti does not drop to 0, otherwise Y
would be undefined in this case. Switch the software to “I controller”.
The physical setpoint depends on the size of the tank and whether the unit of measure of the fill level will be
in litres or in mm.
– Select each of the values listed below and carry out the experiment.
– Document your observations.
Settings Observations
Note
It is possible that no stabilisation occurs in an actual system and that continuous oscillation takes place.
Task
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4.2.5 Experiment: controlling the fill level using a proportional-integral controller (parallel P and I
components)
In order to take advantage of the positive characteristics of both the P and the I controller, the two will be
combined. This can be done in two different ways:
kp = 1
kp
The controllers are connected in parallel in the combination shown on the left and in series in the combination
on the right. In actual industrial practice, the combination shown on the right is used in accordance with
IEC 60050-351.
Note
Empty B102 before each start-up.
– Select each of the values listed below for the PI controller and carry out the experiment.
– Document your observations.
Settings Observations
Task
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Liquid in piping
PI controller Motor and pump system
– Set the system up with one tank according to the PI flow diagram, or disconnect the piping to upper
tank B102 and seal the bottom outlet of tank B102 with a blanking plug.
– Connect and test the pump and the flow sensor.
V103 V102
FI
101
PI B101
103
P101
V105
– Install and start the software, and select “Continuous controller” from the menu. Entries are
standardised from 0 to 1.
– Please check all the points listed in the following report and confirm completion of all tasks before
commissioning.
Note
Various settings must be entered in order to test performance. In order to be able to draw any
conclusions, it’s always advisable to change only one parameter at a time and then conduct the
experiment. The settings included in the following table are suggestions.
– Select each of the values listed below and document your observations.
Settings Observations
5 20% open
6 100% open
Task
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– How does the interference variable affect the outcome of the experiment?
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2. List various controlled systems with one practical example for each.
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4. Data (e.g. actual value x) is acquired using sensors. The following, for example, appears in a data sheet
for a sensor: pressure range: 0 to 400 mbar, signal: 0 to 10 V. How is the signal processed by the PC so
that the physical value is displayed on the PC monitor?
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5. An ultrasonic sensor provides data in accordance with the following screenshot. Determine factor and
offset for a physical representation of the value on the screen.
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10
6
U
0 3
-1 0 20 40 60 mbar 100
2 1
P
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– Which values do factor and offset have to be set to in order to display pressure correctly as a physical
quantity?
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7. How are actuators (e.g. pump motor) controlled with the PC?
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9. As is the case with all microprocessor controllers, the PC works cyclically according to the IPO model
(input, processing, output). The time required for a single sequence is called cycle time or sampling time
(TA).
– For example, a programme has a sampling time of 25 ms. How many measurements can be carried out
in one second?
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– In order to determine the flow rate of a medium as accurately as possible, at least 50 measurements
must be performed per second. Determine the required sampling time.
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10. A pump fills a tank from above with water. After a given period of time, the pump is switched off. Draw
conceivable characteristic fill level curves for two different cases: in case 1 the drain at the bottom of
the tank is open. In case 2 the drain is closed.
11. An impeller pump causes volumetric flow rate within a circuit. What is the relationship between
volumetric flow rate and pressure? Give reasons for your answer.
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12. The following figure depicts a characteristic pump curve. Control voltage is increased from 0 to 10 V in
case 1. In case 2, it’s decreased back to 0 V.
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13. A two-step controller can be used for simple control of the fill-level.
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14. After the process, the process, measurement and control data can be stored as ASCII data.
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