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C1) 4 eee ” Po Cote ae $36 ” ec ” ee '37 aw P£o ” — aida pr500 | CHAPTER 10 10.4 PNEUMATIC CONTROLLERS Historically, the reason for using pneumatics in process control was probably that methods were not yet competitive in cost or reliability, Safety was and still isa factor: danger of explosion from electrical malfunctions exists. It is also true that the final ‘ement is often pneumatically or hydraulically operated, which suggests that an all process-control loop might be advantageous. It appears that analog or digital electronie ‘ods will eventually replace most pneumatic installations. But we will still have equipment for many years until these are depreciated in industry. A good underst process-control principles can be applied to either electronic or pneumatic techniques, necessary to consider some special features of pneumatic technology. This section brief description of operations by which controller modes are pneumatically implemet 10.4.1 General Features ‘The outward appearance of a pneumatic controller is typically the same as that for the} tronic controller shown in Figure 10.1. The same readout of setpoint, error, and c output appears, and adjustments of gain, rate, and reset are available. The working si ‘most typically the 3- to 15-psi standard pneumatic process-control signal, usually from a regulated air supply of 20 to 30 psi. As usual, we use the English system unit of sure because its use is so widespread in the process-control industry. Eventual conv to the SI unit of N/m? or Pa will require some alteration in scale (of measurement) range of 20 to 100 kPa. q ‘The pneumatic controller is based on the nozzle /flapper described in Section 7.3, the basic mechanism of operation, much as the op amp is used in electronics. The sche drawings of controller mode implementation are intended to convey the operating ples. Specific designs may vary considerably from the systems shown, however. 10.4.2 Mode Implementa' ‘The following discussions present the essential features of controller-mode implement using pneumatic techniques. The equations are stated in general form with units in SI, the reader should be prepared to work with English units when necessary. Proportional A proportional mode of operation can be achieved with the sy shown in Figure 10.13. Operation is understood by noting that if the input pressure creases, then the input bellows forces the flapper to rotate to close off the nozzle. When happens, the output pressure increases so that the feedback bellows exerts a force to ance that of the input bellows. A balance condition then occurs when torques exerted each about the pivot are equal, or (Peat ~ Po) Aas = (Pin ~ Pop) Ar% This equation is solved to find the output pressure my, Pow Pa ~ Pop) + Po (10.ANALOG CONTROLLERS | 507 40.13 input pelows Setoom velows natic proportional-mode controller. », 1 Do ie, ‘i Feedback betows Pow % estncion Pressure supply pressure with no error input pressure {Pa) input and setpoint bellows effective area (m’) level arm of input (m) pit Ba wutput pressure (Pa) i= 2% = feedback bellows effective area (m°) jeedback lever arm (m) setpoint pressure > N “This elation is based on the notion of torque equaling force times lever arm, and the fact that a pressure in a bellows produces a foree that is effectively the pressure times bellows trea, much like a diaphragm. Equation (10.13) displays the standard respons of a pro- portional mode in that output is directly proportional to input. The gain in this case is given by (3 Y( a: ) As (10.14) Because the bellows are usually of fixed geometry, the gain is varied by change the peat length, In this simple representation, the gain is established by the distance totween the bellows. If this separation is changed, the forees are no longet balanced, and for the same pressure a new controller output will be formed, corresponding to the new gain, PLE Suppose a proportional pneumatic controller has A, = A2 = em?, x, = 8 em, and 0 xX = 5 em. The input and output pressure ranges are 3 to 15 psi. Find the input pressures ‘Fat will drve the output from 3 to 15 psi. The setpoint pressure is 8 psi, and Po = 10 psi. Find the proportional band.502 | CHAPTER 10 Solution First we find the gain from Now we have w Pout Pout ‘The low input occurs when Pq. = 3 Psi, SO 3 = 1.6(p, — 8) + 10 Ky(Pin — Pry) + Po 1.6(Pig — 8) + 10 which gives pr = 3.625 psi ‘The high is found from 15 = 1.6(py — 8) + 10 which gives Py = 11.125 psi ‘The proportional band (PB) is PB = PB = 62.5% Note that this checks with 100 100 PB = —~ = — = 62.5% Ky, 16 aan which could be used because the input and output ranges are the same. Proportional-integral This control mode is also implemented using pne by the system shown in Figure 10.14. In this ease, an extra bellows with a variable tion is added to the proportional system. Suppose the input pressure shows a si crease. This drives the flapper toward the nozzle, increasing output pressure unt proportional bellows balances the input as in the previous case. The integral bellows i at the original output pressure, because the restriction prevents pressure changes f ing transmitted immediately. As the increased pressure on the output bleéds through striction, the integral bellows slowly moves the flapper closer to the nozzle, thereby a steady increase in output pressure (as dictated by the integral mode). The variabl striction allows for variation of the leakage rate, and hence the integration time.ANALOG CONTROLLERS | 503 Pout Pivot Pwwpoly 10.15 ic proportional-derivative Pe: ————— vn Variable seriction Serng [ Pout Pooh Proportional-Derivative This controller action can be accomplished pneumati- cally by the method shown in Figure 10.15. A variable restriction is placed on the Fine lead- ing to the balance bellows. Thus, as the input pressure increases, the flapper is moved toward the nozzle with no impedance, because the restrictions prevent an immediate re- sponse ofthe balance bellows. Thus, the output pressure rises very fast and then, as the in- creased pressure leaks into the balance bellows, decreases as the balance bellows moves the flapper back away from the nozzle. Adjustment of the variable restriction allows for chang ing the derivative time constraint.504 | CHAPTER 10 Veriable Veriable restriction restriction Pour Restriction Pivot Pet FIGURE 10.16 Pneumatic three-mode (PID) controller. Three-Mode The three-mode controller is actually the most com duced, because it can be used to accomplish any of the previous modes by’ strictions. This device is shown in Figure 10.16, and, as can be seen, if combination of the three systems presented. "By opening or closing restrictions, the three-mode controller can be i rent the other composite modes. Proportional gain, reset time, and rate are ment of bellows separation and restriction size 10.5 DESIGN CONSIDERATIONS ‘To illustrate some of the facets involved in setting up valuable to follow through some hypothetical examples. The following ¢ that a process-control loop is required, and that the controller operation ml by electronic analog circuits. a process-control I EXAMPLE Design a process-control system that regulates light level by outputting @ 10.11 a lighting system that provides 30-180 lux. The sensor has a tang «120 O/lux with a 10-k0 resistance at 100 lux. The setpoint is to be 75M tional control with a 75% proportional band has been selected Solution We solve such problems by first establishing the characteristics of each 1. The illumination varies from 30 to 180 lux. We find the resi cording to R= 10 kQ—0.12 kO(/ — 100) where / is the illumination in lux.