Liquid Control Training System

Experiment 01

Objective
To determine the characteristics of the differential as a position transducer.
Apparatus Required
 Digital Multimeter
 Set of Leads
Theory
A differential refers to a device or mechanism that can measure changes or
differences in position. It typically consists of two or more components or
sensors that are used to detect changes in position or displacement. A position
transducer is a device that converts a physical position or displacement into an
electrical signal that can be measured and analyzed. It is commonly used in
engineering and science applications to monitor the movement or position of
objects. To use a differential as a position transducer, it needs to be calibrated.
Calibration involves determining the relationship between the physical position
or displacement of the object being measured and
the electrical output of the transducer. This is
usually done by applying known displacements to
the object and recording the corresponding
electrical signals from the transducer.
Sensitivity refers to how responsive the transducer
is to changes in position. It's a measure of the
change in output signal for a given change in
position. Linearity assesses how accurately the
transducer's output corresponds to changes in
position over a range. Ideally, a transducer should
provide a linear relationship between position and
output. Deviations from linearity can be analyzed
and quantified. Resolution: Resolution is the
smallest change in position that the transducer can Figure 1.1 Liquid Level Process
reliably detect and measure. It's an important Module
characteristic, especially in applications where
fine position control is needed. The experiment may involve determining the
resolution of the differential transducer. Hysteresis is the phenomenon where
the output of a transducer depends not only on the current position but also on
the path taken to reach that position. Noise refers to random variations in the
transducer's output signal, while drift refers to slow, systematic changes over
time. Both noise and drift can affect the accuracy and reliability of position
measurements. In some cases, it's important to understand how the transducer
responds to changes in position at different frequencies. This is especially
relevant in dynamic applications.
Procedure
 Connect, through leads, bush No.1 of the Level Sensor to bush No.1 of
the correspondent interface and bush No.2 to bush No.2.
 Insert a terminal of the digital voltmeter, set in DC, in bush No.5 of the
Level Interface and the other one in the earth bush.
 Connect bush No. 10 of the WATER PUMP DRIVER to the bush of SET
POINT I, bush No.11 to bush No.11, and bush No. 12 to bush No. 12.
 Press the main switch (ON).
 Start the pump regulating the voltage on SET POINT 1 and bring the
level of the water in the PROCESS TANK to 6 cm.
 Once reach the level, stop the pump setting to 0V the voltage value of
SET POINT T.
 Gradually decrease the level of the water in the tank by turning
counterclockwise the knob NEEDLE VALVE or the knob DRAIN
VALVE, back to 4.5 cm.
 Verify that the voltage value, read on the voltmeter, corresponds to 0 V:
otherwise, regulate the OFFSET trimmer until you obtain the desired
value in this way you have fixed the minimum working point of the Level
Sensor.
 Starting the pump, increase the level of the water to 11.5 cm.
 Stop the pump and verify that the voltage value corresponds to 10 V,
otherwise, regulate the GAIN trimmer until you obtain the desired value.
 Verify that the voltage and level values are correct by repeating the steps
from step No. 7.
 Slowly drain the tank until you reach all the level values and write down,
for each level value, the corresponding voltage value
 Put OFF the main switch.
 Remove all the connections.
 Represent the characteristics of the level sensor.
 Figure 1.2 Control Loop
Calculations
Level(cm Voltage(mV)
}
11.5 8.55
10.5 7.31
9.5 5.78
8.5 4.32
7.5 3.15
6.5 1.43
5.5 0.19
4.5 -1.06

Table 1.1 Calculations

Graph
14
12
f(x)
10 = 0.716603596390421 x + 5.34229641188703
Level(cm)

8
6
4
2
0
-2 0 2 4 6 8 10
Voltage(mV)

Graph 1 level vs voltage

Analysis of Results
The results show a clear relationship between the level (position in centimeters)
and the voltage output (in millivolts). As the level increases, the voltage
generally decreases, indicating an inverse relationship between level and
voltage. Here is some curvature in the data points, especially at the extremes
(11.5 cm and 4.5 cm). This shows that the transducer's response may not be
entirely linear across the entire range due to some errors. The sensitivity of the
transducer is 0.7166 get this value from the slope of graph. It appears that the
transducer is more sensitive at higher levels (larger position values) compared to
lower levels. There is some variation in the data, especially around 5.5 cm and
4.5 cm levels due to noise, and measurement error.
Conclusion
In conclusion, the experiment shows that the differential position transducer
exhibits a mostly linear response within its defined operating range from 11.5
cm to 4.5 cm. Sensitivity increases with level.
 Experiment 02
Objective
 To understand the operation of a closed loop ON-OFF control system.
 To understand the effects of hysteresis on the control.
Apparatus Required
 Digital Multimeter
 Set of leads
Theory
Control systems are crucial in various applications, from maintaining the
temperature of a thermostat in a home to regulating the speed of a motor in an
industrial plant. One type of control system is the closed-loop ON-OFF control
system, which is simple yet effective. A closed-loop ON-OFF control system
consists of several key components:
Process: The system or process being controlled, such as a heater, air
conditioner, or motor.
Sensor: Measures a relevant parameter (e.g., temperature, pressure) of the
process and provides feedback to the controller.
Controller: Analyzes the sensor feedback and decides when to actuate the
control element.
Actuator/Control Element: Responsible for making changes to the process,
such as turning on or off a heater or adjusting a valve.
Reference/Setpoint: The desired value or target for the controlled parameter.
The controller continuously compares the actual process variable (measured by
the sensor) to the reference/setpoint value. If the actual value deviates from the
setpoint, the controller takes action to bring the process back to the desired
state. In ON-OFF control, the controller makes binary decisions, either turning
the actuator fully ON or fully OFF. When the process variable is below the
setpoint, the controller activates the actuator to the ON state. When the process
variable exceeds the setpoint, the controller deactivates the actuator to the OFF
state. This cycling of ON and OFF states continues until the process variable
stabilizes around the setpoint. Hysteresis is a phenomenon where the system's
response to a change in input depends not only on the current input but also on
its past values. In the context of control systems, hysteresis can introduce delays
and oscillations in the system's behavior.
Hysteresis in control systems can lead to "lag time," where the system remains
in its current state even after the error signal changes.
This can result in oscillatory behavior and can be detrimental to system stability
and performance. One way to reduce the effects of hysteresis is by introducing a
dead band or a tolerance range around the setpoint. When the error signal falls
within this dead band, no action is taken, preventing rapid ON-OFF cycling.
This dead band allows for smoother control and reduces wear and tear on
actuators.
Procedure
 Connect, through leads, bush No. 1 of the Level Sensor to bush No. 1 of
the relevant interface and bush No. 2 to bush No. 2.
 Connect bush No. 11 of the WATER PUMP DRIVER to bush No. 11 and
bush No. 12 to bush No. 12.
 Connect the bush of SET POINT 1 to bush No. 6 of the ON-OFF
controller and bush No. 5 of the level interface to bush No. 5 of the ON-
OFF controller.
 Insert one terminal of the digital voltmeter, set in dc, in the bush of SET
POINT 1 and the other one in the earth bush.
 Press the main switch (ON).
 Regulate the voltage on SET POINT 1 at 5 V.
 Move the terminal of the digital voltmeter from the bush of SET POINT 1
to bush No. 5 of the ON-OFF controller: the voltage value must be equal
to 3V; if the voltage is different, control that the level of the water in the
tank be 6.5 cm otherwise calibrate the sensor.
 Move the terminal of the digital voltmeter to bush X4 of the ON-OFF
controller: the voltage value must be equal to the difference between the
voltage applied to bush No. 5 and the voltage applied to bush No. 6,
which is 2V.
 Connect bush No. 10 of the ON-OFF controller to bush No. 10 of the
WATER PUMP DRIVER: the pump will start immediately; the level will
start to increase while the voltage value read on the voltmeter will
decrease.
 As soon as the voltage difference between bush No. 6 and bush No. 5 will
be null, the output of the ON-OFF controller (bush No. 10), going to a
voltage of approx. -10V, will stop the pump: the level must then be equal
 to 8cm, corresponding to the starting level (6.5cm) plus the starting
voltage difference between bush No. 6 and bush No. 5.
 Slowly turn counter-clockwise the knob NEEDLE VALVE and/or the
knob DRAIN VALVE in order to decrease a little the level: the voltage
difference between bush No. 6 and bush No. 5, caused by the level
variation, brings the output of the ON-OFF controller (bush No. 10) to a
voltage of approx. 10V and the pump will start again.
 The pump will operate for a short time until the previous level is reached
(8cm). Regulate the knob NEEDLE VALVE and/or the knob DRAIN
VALVE until you determine, approximately, an equal time, for level
increase and decrease, between the start and stop of the pump: the up and
down cycle of the level will repeat itself.
 Repeat step No. 12.
 Measure the up and down times of the level between the start and stop of
the pump with a hysteresis of 0%.
 Repeat the procedure from step No. 15 for all the hysteresis values and
write down the results.
 For each value of hysteresis repeat the measurement of the up and down
time several times.
 Close the NEEDLE VALVE and the DRAIN VALVE.
 Put OFF the main switch.
 Remove all the connections.
 Represent the characteristic diagram of the hysteresis.

Figure 2.1 ON-OFF controller loop

Calculations
Hysteresis (%) 0 12.5 25
Set Point 8cm 8cm 8cm
Lower Limit Set Point (cm) 7.9 7.5 7.2
Up-Raising tine of the level (sec) 2 4 5.1
Upper Limit Set Point (cm) 8.2 8.5 9
Lowering tine of the level (sec) 10 17 45

Table 2.1 Calculations

Hysteresis 25%
Time(s) Level(cm)
0 8
2.55 9
47.55 7.2
52.65 9
97.65 7.2
102.75 9
147.75 7.2
Table 2.2 Hysteresis 25%, 12.5%, 0%
Hysteresis 12.5%
Time(s
) Level(cm)
0 8
2 8.5
19 7.5
23 8.5
40 7.5
44 8.5
61 7.5
65 8.5
82 7.5
86 8.5
103 7.5
107 8.5
124 7.5
128 8.5
145 7.5
149 8.5

Hysteresis 0%
Time(s Level(cm
) )
0 8
1 8.2
11 7.9
 13 8.2
23 7.9
25 8.2
35 7.9
37 8.2
47 7.9
49 8.2
59 7.9
61 8.2
71 7.9
73 8.2
83 7.9
85 8.2
95 7.9
97 7.9
107 8.2
109 7.9
119 8.2
121 7.9
131 8.2
133 7.9
143 8.2
145 7.9

Graphs
Hystersis 25%
10
8
Level(cm)

6
4
2
0
0 20 40 60 80 100 120 140 160
Time(s)
 Hystersis 12.5%
8.6
8.4
8.2
8

Level(cm)
7.8
7.6
7.4
7.2
7
0 20 40 60 80 100 120 140 160
Time(s)

Hystersis 0%
8.25
8.2
8.15
8.1
8.05
Level(cm)

8
7.95
7.9
7.85
7.8
7.75
0 20 40 60 80 100 120 140 160
Time(s)

Graphs 2.1
Analysis of results
Increasing hysteresis levels from 0% to 25% progressively widens the dead
band around the 8 cm setpoint. As hysteresis increases, the control system
responds more slowly to deviations from the setpoint. For instance, with 25%
hysteresis, it takes 45 seconds to correct when the level exceeds 9 cm, resulting
in significant delays and larger fluctuations compared to the 0% hysteresis case,
which responds rapidly. The choice of hysteresis should be based on the desired
trade-off between stability and responsiveness in the specific control
application. As the level of hysteresis increases from 0% to 25%, the response
time of the control system becomes progressively slower and oscillations
around the setpoint become more pronounced, and the system spends more time
in stable states between control actions.
Conclusion
In this experiment, we observed the impact of varying hysteresis levels (0%,
12.5%, and 25%) on a closed-loop ON-OFF control system with an 8 cm
setpoint. Increasing hysteresis led to progressively slower responses and
increased oscillations. The choice of hysteresis level should be adjusted to the
specific control application, balancing stability with responsiveness for optimal
control system performance.