Instructor workbook

Coupled Tanks Experiment for LabVIEW ™ Users

Standardized for ABET * Evaluation Criteria
Developed by:
Jacob Apkarian, Ph.D., Quanser
Hervé Lacheray, M.A.SC., Quanser
Amin Abdossalami, M.A.SC., Quanser

Quanser educational solutions

are powered by:

Captivate. Motivate. Graduate.

© 2013 Quanser Inc., All rights reserved.

Quanser Inc.
119 Spy Court
Markham, Ontario
L3R 5H6
Canada
info@quanser.com
Phone: 1-905-940-3575
Fax: 1-905-940-3576

Printed in Markham, Ontario.

For more information on the solutions Quanser Inc. offers, please visit the web site at:
http://www.quanser.com

This document and the software described in it are provided subject to a license agreement. Neither the software nor this document may be
used or copied except as specified under the terms of that license agreement. All rights are reserved and no part may be reproduced, stored in
a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior
written permission of Quanser Inc.

ACKNOWLEDGEMENTS
Quanser, Inc. would like to thank the following contributors:

Dr. Hakan Gurocak, Washington State University Vancouver, USA, for his help to include embedded outcomes assessment, and

Dr. K. J. Åström, Lund University, Lund, Sweden for his immense contributions to the curriculum content.

COUPLED TANKS Workbook - Instructor Version 2

CONTENTS
1 Introduction 4

2 Modeling 5
2.1 Background 5
2.2 Pre-Lab Questions 10

3 Tank 1 Level Control 15

3.1 Background 15
3.2 Pre-Lab Questions 18
3.3 Lab Experiments 20
3.4 Results 25

4 Tank 2 Level Control 26

4.1 Background 26
4.2 Pre-Lab Questions 28
4.3 Lab Experiments 30
4.4 Results 36

5 System Requirements 37
5.1 Overview of Files 38
5.2 Calibrating the pressure sensor measurements 38
5.3 Setup for Tank 1 Level Control Simulation 39
5.4 Setup for Tank 1 Level Control 39
5.5 Setup for Tank 2 Level Control Simulation 39
5.6 Setup for Tank 2 Level Control 40

6 Lab Report 41
6.1 Template for Tank 1 Level Control Report 41
6.2 Template for Tank 2 Level Control Report 42
6.3 Tips for Report Format 43

7 Scoring Sheets 44
7.1 Modeling Pre-Lab Questions 44
7.2 Tank 1 Level Control Pre-Lab Questions 45
7.3 Tank 1 Level Control Lab Exercises 46
7.4 Tank 2 Level Control Pre-Lab Questions 47
7.5 Tank 2 Level Control Lab Exercises 48

A Nomenclature 49

B Instructor's Guide 51
B.1 Pre-lab Questions and Lab Experiments 51
B.2 Assessment for ABET Accreditation 52
B.3 Rubrics 58

COUPLED TANKS Workbook - Instructor Version v 1.2

1 INTRODUCTION
The Coupled Tanks plant is a "Two-Tank" module consisting of a pump with a water basin and two tanks. The two
tanks are mounted on the front plate such that flow from the first (i.e. upper) tank can flow, through an outlet orifice
located at the bottom of the tank, into the second (i.e. lower) tank. Flow from the second tank flows into the main
water reservoir. The pump thrusts water vertically to two quick-connect orifices "Out1" and "Out2". The two system
variables are directly measured on the Coupled-Tank rig by pressure sensors and available for feedback. They are
namely the water levels in tanks 1 and 2. A more detailed description is provided in [2]. To name a few, industrial
applications of such Coupled-Tank configurations can be found in the processing system of petro-chemical, paper
making, and/or water treatment plants.

During the course of this experiment, you will become familiar with the design and pole placement tuning of Proportional-
plus-Integral-plus-Feedforward-based water level controllers. In the present laboratory, the Coupled-Tank system
is used in two different configurations, namely configuration #1 and configuration #2, as described in [2]. In config-
uration #1, the objective is to control the water level in the top tank, i.e., tank #1, using the outflow from the pump.
In configuration #2, the challenge is to control the water level in the bottom tank, i.e. tanks #2, from the water flow
coming out of the top tank. Configuration #2 is an example of state coupled system.

Topics Covered

• How to mathematically model the Coupled-Tank plant from first principles in order to obtain the two open-loop
transfer functions characterizing the system, in the Laplace domain.
• How to linearize the obtained non-linear equation of motion about the quiescent point of operation.

• How to design, through pole placement, a Proportional-plus-Integral-plus-Feedforward-based controller for the

Coupled-Tank system in order for it to meet the required design specifications for each configuration.
• How to implement each configuration controller(s) and evaluate its/their actual performance.

Prerequisites

In order to successfully carry out this laboratory, the user should be familiar with the following:

1. See the system requirements in Section 5 for the required hardware and software.

2. Transfer function fundamentals, e.g., obtaining a transfer function from a differential equation.
3. Familiar with designing PID controllers.

4. Basics of LabVIEW™ .

COUPLED TANKS Workbook - Instructor Version 4

2 MODELING
2.1 Background

2.1.1 Configuration #1 System Schematics

A schematic of the Coupled-Tank plant is represented in Figure 2.1, below. The Coupled-Tank system's nomen-
clature is provided in Appendix A. As illustrated in Figure 2.1, the positive direction of vertical level displacement is
upwards, with the origin at the bottom of each tank (i.e. corresponding to an empty tank), as represented in Figure
3.2.

Figure 2.1: Schematic of Coupled Tank in Configuration #1.

2.1.2 Configuration #1 Nonlinear Equation of Motion (EOM)

In order to derive the mathematical model of your Coupled-Tank system in configuration #1, it is reminded that the
pump feeds into Tank 1 and that tank 2 is not considered at all. Therefore, the input to the process is the voltage to
the pump VP and its output is the water level in tank 1, L1 , (i.e. top tank).

The purpose of the present modelling session is to provide you with the system's open-loop transfer function, G1(s),
which in turn will be used to design an appropriate level controller. The obtained Equation of Motion, EOM, should
be a function of the system's input and output, as previously defined.

COUPLED TANKS Workbook - Instructor Version v 1.2

Therefore, you should express the resulting EOM under the following format:
∂L1
= f (L1 , Vp )
∂t

where f denotes a function.

In deriving the Tank 1 EOM the mass balance principle can be applied to the water level in tank 1, i.e.,

∂L1
At1 = Fi1 − Fo1 (2.1)
∂t

where At1 is the area of Tank 1. Fi1 and Fo1 are the inflow rate and outflow rate, respectively. The volumetric inflow
rate to tank 1 is assumed to be directly proportional to the applied pump voltage, such that:
Fi1 = Kp Vp

Applying Bernoulli's equation for small orifices, the outflow velocity from tank 1, vo1 , can be expressed by the following
relationship:

√
vo1 = 2gL1

2.1.3 Configuration #1 EOM Linearization and Transfer Func-

tion

In order to design and implement a linear level controller for the tank 1 system, the open-loop Laplace transfer
function should be derived. However by definition, such a transfer function can only represent the system's dynamics
from a linear differential equation. Therefore, the nonlinear EOM of tank 1 should be linearized around a quiescent
point of operation. By definition, static equilibrium at a nominal operating point (Vp0 , L10 ) is characterized by the
Tank 1 level being at a constant position L10 due to a constant water flow generated by constant pump voltage Vp0 .

In the case of the water level in tank 1, the operating range corresponds to small departure heights, L11 , and small
departure voltages, Vp1 , from the desired equilibrium point (Vp0 , L10 ). Therefore, L1 and Vp can be expressed as
the sum of two quantities, as shown below:

L1 = L10 + L11 , Vp = Vp0 + Vp1 (2.2)

The obtained linearized EOM should be a function of the system's small deviations about its equilibrium point
(Vp0 , L10 ). Therefore, one should express the resulting linear EOM under the following format:

∂
L11 = f (L11 , Vp1 ) (2.3)
∂t

where f denotes a function.

Example: Linearizing a Two-Variable Function

Here is an example of how to linearize a two-variable nonlinear function called f (z). Variable z is defined
z ⊤ = [z1 z2 ]
and f (z) is to be linearized about the operating point
z0 ⊤ = [a b]

COUPLED TANKS Workbook - Instructor Version 6

The linearized function is
( ) ( )
∂f (z) ∂f (z)
fz = f (z0 ) + (z1 − a) + (z2 − b)
∂z1 z=z0 ∂z2 z=z0

For a function, f , of two variables, L1 and Vp , a first-order approximation for small variations at a point (L1 , Vp ) =
(L10 , Vp0 ) is given by the following Taylor's series approximation:

( ) ( )
∂2 ∂ ∂
f (L1 , Vp ) ∼
= f (L10 , Vp0 ) + f (L10 , Vp0 ) + (L1 − L10 ) f (L10 , Vp0 ) (Vp − Vp0 ) (2.4)
∂L1 ∂Vp ∂L1 ∂Vp

Transfer Function
From the linear equation of motion, the system's open-loop transfer function in the Laplace domain can be defined
by the following relationship:

L11 (s)
G1 (s) = (2.5)
Vp1 (s)

The desired open-loop transfer function for the Coupled-Tank's tank 1 system is the following:
Kdc1
G1 (s) = (2.6)
τ1 s + 1

where Kdc1 is the open-loop transfer function DC gain, and τ1 is the time constant.

As a remark, it is obvious that linearized models, such as the Coupled-Tank tank 1's voltage-to-level transfer function,
are only approximate models. Therefore, they should be treated as such and used with appropriate caution, that is
to say within the valid operating range and/or conditions. However for the scope of this lab, Equation 2.5 is assumed
valid over the pump voltage and tank 1 water level entire operating range, Vp_peak and L1_max , respectively.

2.1.4 Configuration #2 System Schematics

A schematic of the Coupled-Tank plant is represented in Figure 2.2, below. The Coupled-Tank system's nomen-
clature is provided in Appendix A. As illustrated in Figure 2.2, the positive direction of vertical level displacement is
upwards, with the origin at the bottom of each tank (i.e. corresponding to an empty tank), as represented in Figure
2.2.

2.1.5 Configuration #2, Nonlinear Equation of Motion (EOM)

This section explains the mathematical model of your Coupled-Tank system in configuration #2, as described in
Reference [1]. It is reminded that in configuration #2, the pump feeds into tank 1, which in turn feeds into tank 2.
As far as tank 1 is concerned, the same equations as the ones explained in Section 2.1.2 and Section 2.1.3 will
apply. However, the water level Equation Of Motion (EOM) in tank 2 still needs to be derived. The input to the tank
2 process is the water level, L1 , in tank 1 (generating the outflow feeding tank 2) and its output variable is the water
level, L2 , in tank 2 (i.e. bottom tank). The purpose of the present modelling session is to guide you with the system's
open-loop transfer function, G2 (s), which in turn will be used to design an appropriate level controller. The obtained
EOM should be a function of the system's input and output, as previously defined.

Therefore, you should express the resulting EOM under the following format:
∂L2
= f (L2 , L1 )
∂t

COUPLED TANKS Workbook - Instructor Version v 1.2

 Figure 2.2: Schematic of Coupled Tank in configuration #1.

where f denotes a function.

In deriving the tank #2 EOM the mass balance principle can be applied to the water level in tank 2 as follows
∂L2
At2 = Fi2 − Fo2
∂t
where At2 is the area of tank 2. Fi2 and Fo2 are the inflow rate and outflow rate, respectively.

The volumetric inflow rate to tank 2 is equal to the volumetric outflow rate from tank 1, that is to say:

Fi2 = Fo1

Applying Bernoulli's equation for small orifices, the outflow velocity from tank 2, vo2 , can be expressed by the following
relationship:

√
vo2 = 2gL2

2.1.6 Configuration #2 EOM Linearization and Transfer Func-

tion

In order to design and implement a linear level controller for the tank 2 system, the Laplace open-loop transfer
function should be derived. However by definition, such a transfer function can only represent the system's dynamics
from a linear differential equation. Therefore, the nonlinear EOM of tank 2 should be linearized around a quiescent
point of operation.

COUPLED TANKS Workbook - Instructor Version 8

In the case of the water level in tank 2, the operating range corresponds to small departure heights, L11 and L21 ,
from the desired equilibrium point (L10 , L20 ). Therefore, L2 and L1 can be expressed as the sum of two quantities,
as shown below:

L2 = L20 + L21 , L1 = L10 + L11 (2.7)

The obtained linearized EOM should be a function of the system's small deviations about its equilibrium point
(L20 , L10 ). Therefore, you should express the resulting linear EOM under the following format:

∂
L21 = f (L11 , L21 ) (2.8)
∂t

where f denotes a function.

For a function, f , of two variables, L1 and L2 , a first-order approximation for small variations at a point (L1 , L2 ) =
(L10 , L20 ) is given by the following Taylor's series approximation:

( ) ( )
∂2 ∂ ∂
f (L1 , L2 ) ∼
= f (L10 , L20 ) + f (L10 , L20 ) + (L1 − L10 ) f (L10 , L20 ) (L2 − L20 ) (2.9)
∂L1 ∂L2 ∂L1 ∂L2

Transfer Function
From the linear equation of motion, the system's open-loop transfer function in the Laplace domain can be defined
by the following relationship:

L21 (s)
G2 (s) = (2.10)
L11 (s)

the desired open-loop transfer function for the Coupled-Tank's tank 2 system, such that:
Kdc2
G2 (s) = (2.11)
τ2 s + 1
where Kdc2 is the open-loop transfer function DC gain, and τ2 is the time constant.

As a remark, it is obvious that linearized models, such as the Coupled-Tank's tank 2 level-to-level transfer function,
are only approximate models. Therefore, they should be treated as such and used with appropriate caution, that is to
say within the valid operating range and/or conditions. However for the scope of this lab, Equation 2.10 is assumed
valid over tank 1 and tank 2 water level entire range of motion, L1_max and L2_max , respectively.

COUPLED TANKS Workbook - Instructor Version v 1.2

2.2 Pre-Lab Questions
Answer the following questions:

1. A-1, A-2, A-3 Using the notations and conventions described in Figure 2 derive the Equation Of Motion (EOM)
characterizing the dynamics of tank 1. Is the tank 1 system's EOM linear?
Hint: The outflow rate from tank 1, Fo1 , can be expressed by:

Fo1 = Ao1 vo1 (2.12)

Answer 2.1

Outcome Solution
A-1 As a remark, the cross-section area of tank 1 outlet hole can be calcu-
lated by:
1 2
Ao1 = πDo1 (Ans.2.1)
4
Using Equation Ans.2.1, the outflow rate from tank 1 given in Equation
2.12 becomes: √
Fo1 = Ao1 2gL1 (Ans.2.2)

A-2 Moreover, using the mass balance principle for tank 1, we obtained
a first-order differential equation for L1 in Equation 2.1. Substituting
in Equation 2.1 Fi1 and Fo1 with their expressions given in Equation
Ans.2.1 and Equation Ans.2.2, respectively, and rearranging results in
the following equation of motion for the tank 1 system:
√ √
∂L1 Kp Vp − Ao1 2 gL1
= (Ans.2.3)
∂t At1

A-3 The EOM of tank 1 given in Equation Ans.2.3 is nonlinear.

2. A-1, A-2 The nominal pump voltage Vp0 for the pump-tank 1 pair can be determined at the system's static
equilibrium. By definition, static equilibrium at a nominal operating point (Vp0 , L10 ) is characterized by the water
in tank 1 being at a constant position level L10 due to the constant inflow rate generated by Vp0 . Express the
static equilibrium voltage Vp0 as a function of the system's desired equilibrium level L10 and the pump flow
constant Kp . Using the system's specifications given in the Coupled Tanks User Manual ([2]) and the desired
design requirements in Section 3.1.1, evaluate Vp0 parametrically.

COUPLED TANKS Workbook - Instructor Version 10

 Answer 2.2

Outcome Solution
A-1 At equilibrium, all time derivative terms equate zero and Equation
Ans.2.3 becomes:
√ √
Kp Vp0 − Ao1 2 gL10 = 0 (Ans.2.4)

A-2 Solving Equation Ans.2.4 for Vp0 gives the pump voltage at equilibrium.
Vp0 results to be a function of L10 and Kp , as expressed below:
√ √
Ao1 2 gL10
Vp0 = (Ans.2.5)
Kp V

Using the system's specifications given in the Coupled Tanks User Man-
ual ([2]) and the desired design requirements in Section 3.1.1, the eval-
uation of Equation Ans.2.5 results to be:

Vp0 = 9.26V

3. A-1 Linearize tank 1 water level's EOM found in Question #1 about the quiescent operating point (Vp0 , L10 ).

Answer 2.3

Outcome Solution
A-1 Applying the Taylor's series approximation about (Vp0 , L10 ), Equation
Ans.2.3 can be linearized as represented below:
√ √ √
∂L1 Kp Vp0 − Ao1 2 gL10 1 Ao1 2gL11 Kp Vp1
= − √ + (Ans.2.6)
∂t At1 2 gL10 At1 At1

Substituting Vp0 in Equation Ans.2.6 with its expression given in Equa-

tion Ans.2.5 results in the following linearized EOM for the tank 1 water
level system: √
∂L11 1 Ao1 2gL11 Kp Vp1
=− √ + (Ans.2.7)
∂t 2 gL10 At1 At1

4. A-1, A-2 Determine from the previously obtained linear equation of motion, the system's open-loop transfer
function in the Laplace domain as defined in Equation 2.5 and Equation 2.6. Express the open-loop transfer
function DC gain, Kdc1 , and time constant, τ1 , as functions of L10 and the system parameters. What is the
order and type of the system? Is it stable? Evaluate Kdc1 and τ1 according to system's specifications given in
the Coupled Tanks User Manual ([2]) and the desired design requirements in Section 3.1.1.

COUPLED TANKS Workbook - Instructor Version v 1.2

 Answer 2.4

Outcome Solution
A-1 Applying the Laplace transform to Equation Ans.2.7 and rearranging
yields:
√ √ √ √
Kp 2 gL10 At1 2 gL10
Kdc_1 = , τ1 = (Ans.2.8)
Ao1 g Ao1 g

A-2 Such a system is stable since its unique pole (system of order one) is
located on the left-hand-side of the s-plane. By not having any pole
at the origin of the s-plane, G1 (s) is of type zero. Evaluating Equation
Ans.2.8, accordingly to the system's parameters and the desired design
requirements, gives:
V
Kdc_1 = 3.2 , τ1 = 15.2s (Ans.2.9)
cm

5. A-1, A-2, A-3 Using the notations and conventions described in Figure 2.2, derive the Equation Of Motion
(EOM) characterizing the dynamics of tank 2. Is the tank 2 system's EOM linear?
Hint: The outflow rate from tank 2, Fo2 , can be expressed by:
Fo2 = Ao2 vo2 (2.13)

Answer 2.5

Outcome Solution
A-1 As a remark, the cross-section area of tank 2 outlet hole can be calcu-
lated by:
1 2
Ao2 = πDo2 (Ans.2.10)
4
Using Equation Ans.2.10, the outflow rate from tank 2 given in Equation
2.13 becomes: √ √
Fo2 = Ao2 2 gL2 (Ans.2.11)

A-2 Moreover, using the mass balance principle for tank 2, we obtain the
following first-order differential equation in L2 :

∂L2
At2 = Fi2 − Fo2 (Ans.2.12)
∂t
Substituting in Equation Ans.2.12 Fi2 and Fo2 with their expressions
given in Equation Ans.2.10 and Equation Ans.2.11, respectively, and
rearranging results in the following equation of motion for the tank 2
system: √ √
∂L2 Kp Vp − Ao2 2 gL2
= (Ans.2.13)
∂t At2

A-3 The EOM of tank 2 given in Equation Ans.2.13 is nonlinear.

6. A-1, A-2 The nominal water level L10 for the tank1-tank2 pair can be determined at the system's static
equilibrium. By definition, static equilibrium at a nominal operating point (L10 , L20 ) is characterized by the
water in tank 2 being at a constant position level L20 due to the constant inflow rate generated from the top
tank by L10 . Express the static equilibrium level L10 as a function of the system's desired equilibrium level L20
and the system's parameters. Using the system's specifications given in the Coupled Tanks User Manual ([2])
and the desired design requirements in Section 4.1.1, evaluate L10 .

COUPLED TANKS Workbook - Instructor Version 12

 Answer 2.6

Outcome Solution
A-1 At equilibrium, all time derivative terms equate zero and Equation
Ans.2.3 becomes:
√ √ √ √
Ao1 2 gL10 − Ao2 2 gL20 = 0 (Ans.2.14)

A-2 Solving Equation Ans.2.14 for L10 gives the tank 1 water level at equi-
librium. L10 results to be a function of L20 , as expressed below:

A2o2 L20
L10 = (Ans.2.15)
A2o1

Using the system's specifications given in the Coupled Tanks User Man-
ual ([2]) and the desired design requirements in Section 4.1.1, the eval-
uation of Equation Ans.2.15 results to be:

L10 = 15 cm

7. A-1 Linearize tank 2 water level's EOM found in Question #5 about the quiescent operating point (L10 , L20 ).

Answer 2.7

Outcome Solution
A-1 Applying the Taylor's series approximation about (L20 , L10 ) Equation
Ans.2.13 can be linearized as represented below:
√ √ √ √ √ √
∂L2 Ao1 2 gL10 − Ao2 2 gL20 1 Ao2 2gL21 1 Ao1 2gL11
= − √ + √
∂t At2 2 gL20 At2 2 gL10 At1
(Ans.2.16)
Simplifying Equation Ans.2.16 with its expression given in Equation
Ans.2.15 results to the following linearized EOM for the tank 2 water
level system:
√ √
∂L21 1 Ao2 2gL21 1 Ao1 2gL11
=− √ + √ (Ans.2.17)
∂t 2 gL20 At2 2 gL10 At1

8. A-1, A-2 Determine from the previously obtained linear equation of motion, the system's open-loop transfer
function in the Laplace domain, as defined in Equation 2.10 and Equation 2.11. Express the open-loop transfer
function DC gain, Kdc2 , and time constant, τ2 , as functions of L10 , L20 , and the system parameters. What is
the order and type of the system? Is it stable? Evaluate Kdc2 and τ2 according to system's specifications given
in the Coupled Tanks User Manual ([2]) and the desired design requirements in Section 4.1.1.

COUPLED TANKS Workbook - Instructor Version v 1.2

Answer 2.8

Outcome Solution
A-1 Applying the Laplace transform to Equation Ans.2.17 and rearranging
yields:
√ √ √
Ao1 L20 At2 2 gL20
Kdc_2 = √ , τ2 = (Ans.2.18)
Ao2 L10 Ao2 g

A-2 Such a system is stable since its unique pole (system of order one) is
located on the left-hand-side of the s-plane. By not having any pole
at the origin of the s-plane, G2 (s) is of type zero. Evaluating Equation
Ans.2.18, according to the system's parameters and the desired design
requirements, gives:
cm
Kdc_2 = 1.0 , τ2 = 15.2 s (Ans.2.19)
cm

COUPLED TANKS Workbook - Instructor Version 14

3 TANK 1 LEVEL CONTROL
3.1 Background

3.1.1 Specifications

In configuration #1, a control is designed to regulate the water level (or height) of tank #1 using the pump voltage. The
control is based on a Proportional-Integral-Feedforward scheme (PI-FF). Given a ±1 cm square wave level setpoint
(about the operating point), the level in tank 1 should satisfy the following design performance requirements:

1. Operating level in tank 1 at 15 cm: L10 = 15 cm.

2. Percent overshoot less than 10%: P O1 ≤ 11 %.

3. 2% settling time less than 5 seconds: ts_1 ≤ 5.0 s.

4. No steady-state error: ess = 0 cm.

3.1.2 Tank 1 Level Controller Design: Pole Placement

For zero steady-state error, tank 1 water level is controlled by means of a Proportional-plus-Integral (PI) closed-loop
scheme with the addition of a feedforward action, as illustrated in Figure 3.1, below, the voltage feedforward action
is characterized by:
√
Vp_f f = Kf f _1 Lr_1 (3.1)

and

Vp = Vp1 + Vp_f f (3.2)

As it can be seen in Figure 3.1, the feedforward action is necessary since the PI control system is designed to
compensate for small variations (a.k.a. disturbances) from the linearized operating point (Vp0 , L10 ). In other words,
while the feedforward action compensates for the water withdrawal (due to gravity) through tank 1 bottom outlet
orifice, the PI controller compensates for dynamic disturbances.

Figure 3.1: Tank 1 Water Level PI-plus-Feedforward Control Loop.

COUPLED TANKS Workbook - Instructor Version v 1.2

The open-loop transfer function G1 (s) takes into account the dynamics of the tank 1 water level loop, as characterized
by Equation 2.5. However, due to the presence of the feedforward loop, G1 (s) can also be written as follows:

L1 (s)
G1 (s) = (3.3)
Vp1 (s)

3.1.3 Second-Order Response

The block diagram shown in Figure 3.2 is a general unity feedback system with compensator, i.e., controller C(s)
and a transfer function representing the plant, P (s). The measured output, Y (s), is supposed to track the reference
signal R(s) and the tracking has to match to certain desired specifications.

Figure 3.2: Unity feedback system.

The output of this system can be written as:

Y (s) = C(s) P (s) (R(s) − Y (s))

By solving for Y (s), we can find the closed-loop transfer function:

Y (s) C(s) P (s)
=
R(s) 1 + C(s) P (s)

The input-output relation in the time-domain for a proportional-integral (PI) controller is

Ki (r − y)
u = Kp (r − y) + (3.4)
s

where Kp is the proportional gain and Ki is the integral gain.

In fact, when a first order system is placed in series with PI compensator in the feedback loop as in Figure 3.2, the
resulting closed-loop transfer function can be expressed as:
Y (s) ωn2
= 2 (3.5)
R(s) s + 2ζ ωn s + ωn2
where ωn is the natural frequency and ζ is the damping ratio. This is called the standard second-order transfer
function. Its response properties depend on the values of ωn and ζ.

Peak Time and Overshoot

Consider a second-order system as shown in Equation 3.5 subjected to a step input given by
R0
R(s) = (3.6)
s
with a step amplitude of R0 = 1.5. The system response to this input is shown in Figure 3.3, where the red trace is
the response (output), y(t), and the blue trace is the step input r(t).

COUPLED TANKS Workbook - Instructor Version 16

 Figure 3.3: Standard second-order step response.

The maximum value of the response is denoted by the variable ymax and it occurs at a time tmax . For a response
similar to Figure 3.3, the percent overshoot is found using

100 (ymax − R0 )
PO = (3.7)
R0

From the initial step time, t0 , the time it takes for the response to reach its maximum value is

tp = tmax − t0 (3.8)

This is called the peak time of the system.

In a second-order system, the amount of overshoot depends solely on the damping ratio parameter and it can be
calculated using the equation ( )
− √π ζ
1−ζ 2
P O = 100 e (3.9)

The peak time depends on both the damping ratio and natural frequency of the system and it can be derived as
π
tp = √ (3.10)
ωn 1 − ζ 2

Tank 1 level response 2% Settling Time can be expressed as follows:

4
ts = (3.11)
ζω

Generally speaking, the damping ratio affects the shape of the response while the natural frequency affects the
speed of the response.

COUPLED TANKS Workbook - Instructor Version v 1.2

3.2 Pre-Lab Questions

1. A-1, A-2 Analyze tank 1 water level closed-loop system at the static equilibrium point (Vp0 , L10 ) and determine
and evaluate the voltage feedforward gain, Kf f _1 , as defined by Equation 3.1.

Answer 3.1

Outcome Solution
A-1 By definition, at the static equilibrium point (Vp0 , L10 ):

L1 = Lr_1 = L10 , Vp = Vp_f f = Vp0 (Ans.3.1)

Using Equation Ans.2.5, the voltage feedforward gain results to be:

√
Ao1 2g
Kf f _1 = (Ans.3.2)
Kp

A-2 Evaluating Equation Ans.3.2 with the system's parameters given in the
Coupled Tanks User Manual ([2]) leads to:
V
Kf f _1 = 2.39 √ (Ans.3.3)
cm

2. A-1, A-2 Using tank 1 voltage-to-level transfer function G1 (s) determined in Section 2.2 and the control
scheme block diagram illustrated in Figure 3.1, derive the normalized characteristic equation of the water level
closed-loop system.
Hint#1: The feedforward gain Kf f _1 does not influence the system characteristic equation. Therefore, the
feedforward action can be neglected for the purpose of determining the denominator of the closed-loop transfer
function. Block diagram reduction can be carried out.
Hint#2: The system's normalized characteristic equation should be a function of the PI level controller gains,
Kp_1 , and Ki_1 , and system's parameters, Kdc_1 and τ1 .

Answer 3.2

Outcome Solution
A-1 Neglecting the feedforward action and carrying out block diagram re-
duction using Equation 2.6 and Equation 3.4 one has
Kdc_1 Ki_1
Y (s) = (Kp1 (R(S) − Y (s)) + (R(S) − Y (s))) (Ans.3.4)
τ1 s + 1 s
which results in the following closed-loop transfer function

Y (s) Kdc_1 (Kp_1 s + Ki_1 )

= (Ans.3.5)
R(s) τ1 s2 + (1 + Kdc_1 Kp_1 )s + Kdc_1 Ki_1

A-2 Re-arranging Equation Ans.3.5 results in tank 1 normalized character-

istic polynomial:

(1 + Kdc_1 Kp_1 )s Kdc_1 Ki_1

s2 + + =0 (Ans.3.6)
τ1 τ1

3. A-2 By identifying the controller gains Kp_1 and Ki_1 , fit the obtained characteristic equation to the second-
order standard form expressed below:

COUPLED TANKS Workbook - Instructor Version 18

 s2 + 2ζ1 ωn1 s + ωn1
2
=0 (3.12)

Determine Kp_1 and Ki1 as functions of the parameters ωn1 , ζ1 , Kdc_1 , and τ1 using Equation 3.5.

Answer 3.3

Outcome Solution
A-2 The system's desired characteristic equation is expressed by Equation
Ans.3.6. Solving for the two unknowns Kp_1 and Ki_1 the set of two
equations resulting from identifying the coefficients of Equation Ans.3.6
with those of Equation 3.12, the PI controller gains can be expressed as
follows:
2ζ1 ωn1 τ1 − 1 2
ωn1 τ1
Kp_1 = , Ki_1 = (Ans.3.7)
Kdc_1 Kdc_1

4. A-1, A-2 Determine the numerical values for Kp_1 and Ki_1 in order for the tank 1 system to meet the closed-
loop desired specifications, as previously stated.

Answer 3.4

Outcome Solution
A-1 The minimum damping ratio to meet the maximum overshoot require-
ment, P O1 , can be obtained by solving Equation 3.9. The following
relationship results:
1 2
ln( 100 P O1 ) ωn1 τ1
ζ1 = √ , Ki_1 = (Ans.3.8)
1
ln( 100 P O1 )2 + π 2 Kdc_1

The system natural frequency, ωn1 , can be calculated from Equation

3.11, as follows:
4
ωn1 = (Ans.3.9)
ζ1 ts_1

A-2 Evaluating Equation Ans.3.8 and Equation Ans.3.9 according to the de-
sired design requirements, then carrying out the numerical application
of Equation Ans.3.7 leads to the following PI controller gains:
V V
Kp_1 = 7.2 , Ki_1 = 9.1 (Ans.3.10)
cm cm − s

COUPLED TANKS Workbook - Instructor Version v 1.2

3.3 Lab Experiments

3.3.1 Objectives

• Tune through pole placement the PI-plus-feedforward controller for the actual water level in tank 1 of the
Coupled-Tank system.
• Implement the PI-plus-feedforward control loop for the actual Coupled-Tank's tank 1 level.
• Run the obtained PI-plus-feedforward level controller and compare the actual response against the controller
design specifications.
• Run the system's simulation simultaneously, at every sampling period, in order to compare the actual and
simulated level responses.

3.3.2 Tank 1 Level Control Simulation

Experimental Setup

The Coupled Tanks -Tank1 Level Control simulation VI shown in Figure 3.4 is used to perform tank 1 level control
simulation exercises in this laboratory.

Figure 3.4: VI used to run PI-FF control Simulation on Coupled Tanks system in configuration #1.

IMPORTANT: Before you can conduct these simulations, you need to make sure that the lab files are configured
according to your setup. If they have not been configured already, then you need to go to Section 5 to configure the
lab files first.

Follow this procedure:

1. In Coupled Tanks.lvproj, open Coupled Tanks- Tank1 Level Control Simulation.vi. The model implements the
system's simulation Proportional-plus-Integral (PI) closed-loop with feedforward action, as studied in Section
3.1.2. To familiarize yourself with the diagram, it is suggested that you open the model subsystems to get a
better idea of their composing blocks as well as take note of the I/O connections.
2. To generate a square wave that goes between 14 and 16 cm for the tank 1 level reference, go to the Amplitude
Command (cm) section and set the controls to the following:
• Amplitude = 1 cm

COUPLED TANKS Workbook - Instructor Version 20

 • Frequency = 0.02 Hz
• Offset = 15 cm
The total level setpoint for tank 1 should result to be a square wave of ±1cm around the desired equilibrium
level L10
3. Enter the proportional, integral, and feedforward control gains found in Section 3.2 in the kp_1, ki_1, and kff_1
controls in the Control Parameters section on the front panel. Have your lab assistant check your values.
4. Run the VI.
5. The VI should start the Coupled Tanks simulation filling tank 1 up to its operating level L10 . Then after a 15-
second settling delay (in order to stabilize the system at its operating point), the water level in tank 1 should start
tracking the desired ±1cm square wave setpoint around the desired operating level L10 . The corresponding
commanded pump voltage, which is proportional to the control effort spent, can also be monitored and plotted
on-line.
6. B-5, K-2 Attach plots showing the Implemented Tank 1 Level Control response and the input voltage.

Answer 3.5

Outcome Solution
B-5 If the procedure was followed properly, Tank 1 level control simulation
file should have been run. The response similar to Figure 3.5 should
have been obtained.
K-2 The closed-loop Tank 1 level response is shown in Figure 3.5.

Figure 3.5: Tank 1 level closed-loop control response.

7. K-1, B-9 Assess the actual performance of the level response and compare it to the design requirements.
Measure your response actual percent overshoot and settling time. Are the design specifications satisfied? Ex-
plain. If your level response does not meet the desired design specifications, review your PI-plus-Feedforward
gain calculations and/or alter the closed-loop pole locations until they do. If you are still unable to achieve the

COUPLED TANKS Workbook - Instructor Version v 1.2

 required performance level, ask your T.A. for advice. Does the response satisfy the specifications given in
Section 3.1.1?
Hint: Use the graph cursors in the Measure tab to take measurements.

Answer 3.6

Outcome Solution
K-1 The settling time in the response shown in Figure 3.7 is

ts1 = 0cm.

The peak time and percentage overshoot of the response are:

tp1 = 2.56 − 2.5 = 0.06 sec

and
1.58 − 1.5
P O1 = 100 × = 12.0%.
1.5

B-9 Both the peak time and percent overshoot measured satisfy the specifi-
cations given in Section 3.1.1.

3.3.3 Tank 1 Level Control Implementation

Experimental Setup

The Coupled Tanks Tank1 Level Control VI shown in Figure 3.6 is used to perform tank 1 level control exercises in
this laboratory. This VI interfaces with the pump and pressure sensors of the Coupled Tanks system.

Note that a first-order low-pass filter with a cut-off frequency of 2.5 Hz is added to the output signal of the tank 1 level
pressure sensor. This filter is necessary to attenuate the high-frequency noise content of the level measurement.
Such a measurement noise is mostly created by the sensor's environment consisting of turbulent flow and circulating
air bubbles. Although introducing a short delay in the signals, low-pass filtering allows for higher controller gains in
the closed-loop system, and therefore for higher performance. Moreover, as a safety watchdog, the controller will
stop if the water level in either tank 1 or tank 2 goes beyond 27 cm.

Figure 3.6: VI used to run PI-FF control on Coupled Tanks system in configuration #1.

COUPLED TANKS Workbook - Instructor Version 22

IMPORTANT: Before you can conduct these experiments, you need to make sure that the lab files are configured
according to your setup. If they have not been configured already, then you need to go to Section 5 to configure the
lab files first.

Follow this procedure:

1. In Coupled Tanks.lvproj, open Coupled Tanks Tank1 Level Control.vi. The model implements the system's
actual Proportional-plus-Integral (PI) closed-loop with feedforward action. To familiarize yourself with the dia-
gram, it is suggested that you open the model subsystems to get a better idea of their composing blocks as
well as take note of the I/O connections.

2. To generate a square wave that goes between 14 and 16 cm for the tank 1 level reference, go to the Amplitude
Command (cm) section and set the controls to the following:

• Amplitude = 1 cm
• Frequency = 0.02 Hz
• Offset = 15 cm

The total level setpoint for tank 1 should result to be a square wave of ±1 cm around the desired equilibrium
level L10

3. Enter the proportional, integral, and feedforward control gains found in Section 3.2 in the Kp, Ki, and Kff controls
in the Control Parameters section on the front panel. Have your lab assistant check your values.

4. Run the VI. The pump should start running and filling up tank 1 to its operating level, L10 . After a settling delay,
the water level in tank 1 should begin tracking the ±1 cm square wave setpoint (about operating level L10 ).

5. B-5, K-2 Attach plots showing the Implemented Tank 1 Level Control response and the input voltage.

Answer 3.7
Attention Instructors: For safety reasons, the values of the PI-plus-feedforward level controller
gains, as determined and calculated by the students, should be checked by the instructor before
they actually start the controller. In configuration #1, the controller gain values for Kp_1 , Ki_1 , and
Kf f _1 are given in Equation Ans.3.3 and Equation Ans.3.10. However, it should be reminded that
the students are expected to have determined Equation Ans.3.3 and Equation Ans.3.10 as a results
of their pre-lab assignments.

Outcome Solution
B-5 If the procedure was followed properly, Tank 1 level control file should
have been run on the Coupled Tanks system and the response similar
to Figure 3.7 should have been obtained.
K-2 The closed-loop Tank 1 level response is shown in Figure 3.7. You can
generate this using Export | Export Simplified Image command, as ex-
plained earlier in Section 3.3.2.

6. K-1, B-9 Assess the actual performance of the level response and compare it to the design requirements.
Measure your response actual percent overshoot and settling time. Are the design specifications satisfied? Ex-
plain. If your level response does not meet the desired design specifications, review your PI-plus-Feedforward
gain calculations and/or alter the closed-loop pole locations until they do. If you are still unable to achieve the
required performance level, ask your lab instructors for advice. Does the response satisfy the specifications
given in Section 3.1.1?
Hint: Use the graph cursors in the Measure tab to take measurements.

COUPLED TANKS Workbook - Instructor Version v 1.2

 Figure 3.7: Closed-loop Tank 1 Control Response.

Answer 3.8

Outcome Solution
K-1 The settling time and percent overshoot found in the response shown in
Figure 3.7 are
ts1 = 94 − 90 = 4 s
and
14.3 − 14
P O1 = 100 × = 15%.
2

B-9 The percent overshoot measured does not satisfy the specifications
given in Section 3.1.1, but the settling time does.

7. Specifically discuss in your lab report the following points:

• How does your actual tank 1 level compare to the simulated response?
• From the plot of the actual level response, measure your system settling time and percentage overshoot.
Are the values in agreement with the design specifications? If not exactly, find some of the possible
reasons.
• Include in your lab report your final values for Kp_1 , Ki_1 , and Kf f _1 as well as the resulting response plot
of the actual and theoretical L1 versus Lr_1 . Also include from the same run the corresponding plot of Vp .
Ensure to properly document all your results and observations before moving on the the next section.
• You can now proceed to the next section, which deals with the actual implementation of your PI-plus-
Feedforward level controller for tank 2 of the Coupled-Tank system in configuration #2.

COUPLED TANKS Workbook - Instructor Version 24

3.4 Results

B-6 Fill out Table 3.1 with your answers from your control lab results - both simulation and implementation.

Description Symbol Value Units

Pre Lab Questions
Tank 1 Control Gains
√
Feed Forward Control Gain Kf f1 2.39 V/ cm
Proportional Control Gain kp1 -7.2 V/cm
Integral Control Gain ki1 -9.1 V/(cm-s)
Tank 2 Control Simulation
Steady-state error ess 0 cm
Settling time ts1 15 s
Percent overshoot P O1 3 %
Tank 2 Control Implementation
Steady-state error ess 0 cm
Settling time ts1 15 s
Percent overshoot P O1 3 %

Table 3.1: Results

COUPLED TANKS Workbook - Instructor Version v 1.2

4 TANK 2 LEVEL CONTROL
4.1 Background

4.1.1 Specifications

In configuration #2, the pump feeds tank 1 and tank 1 feeds tank 2. The designed closed-loop system is to control
the water level in tank 2 (i.e. the bottom tank) from the water flow coming out of tank 1, located above it. Similarly
to configuration #1, the control scheme is based on a Proportional-plus-Integral-plus-Feedforward law.

In response to a desired ± 1 cm square wave level setpoint from tank 2 equilibrium level position, the water height
behaviour should satisfy the following design performance requirements:

1. Tank 2 operating level at 15 cm: L20 = 15 cm.

2. Percent overshoot should be less than or equal to 10%: P O2 ≤ 10.0 %.
3. 2% settling time less than 20 seconds: ts,2 ≤ 20.0 s.
4. No steady-state error: ess,2 = 0 cm.

4.1.2 Tank 2 Level Controller Design: Pole Placement

For zero steady-state error, tank 1 water level is controlled by means of a Proportional-plus-Integral (PI) closed-loop
scheme with the addition of a feedforward action, as illustrated in Figure 4.1, below.

In the block diagram depicted in Figure 4.1, the water level in tank 1 is controlled by means of the closed-loop system
previously designed in Section 3.1. This is represented by the tank 1 closed-loop transfer function defined below:

L1 (s)
T1 (s) = (4.1)
Lr_1 (s)

Such a subsystem represents an inner (or nested) level loop. In order to achieve a good overall stability with such
a configuration, the inner level loop (i.e. tank 1 closed-loop system) must be much faster than the outer level loop.
This constraint is met by the previously stated controller design specifications, where ts_1 ≤ ts_2 .

However for the sake of simplicity in the present analysis, the water level dynamics in tank 1 are neglected. There-
fore, it is assumed hereafter that:

L1 (t) = Lr_1 (t) i.e. T1 (s) = 1 (4.2)

Furthermore as depicted in Figure 4.1, the level feedforward action is characterized by:

Lf f _1 = Kf f _2 Lr_2 (4.3)

and

L1 = L11 + Lf f _1 (4.4)

COUPLED TANKS Workbook - Instructor Version 26

The level feedforward action, as seen in Figure 4.1, is necessary since the PI control system is only designed to
compensate for small variations (a.k.a. disturbances) from the linearized operating point L10 , L20 . In other words,
while the feedforward action compensates for the water withdrawal (due to gravity) through tank 2's bottom outlet
orifice, the PI controller compensates for dynamic disturbances.

Figure 4.1: Tank 2 Water Level PI-plus-Feedforward Control Loop.

The open-loop transfer function G2 (s) takes into account the dynamics of the tank 2 water level loop, as characterized
by Equation 2.10. However, due to the presence of the feedforward loop and the simplifying assumption expressed
by Equation 4.2, G2 (s) can also be written as follows:

L2 (s)
G2 (s) = (4.5)
L1 (s)

COUPLED TANKS Workbook - Instructor Version v 1.2

4.2 Pre-Lab Questions

1. A-1, A-2 Analyze tank 2 water level closed-loop system at the static equilibrium point (L10 , L20 ) and determine
and evaluate the voltage feedforward gain, Kf f _2 , as defined by Equation 4.3.

Answer 4.1

Outcome Solution
A-1 By definition, at the static equilibrium point (Vp0 , L10 ):

L2 = L2_1 = L20 , L1 = Lr_1 = Lf f _1 = L10 (Ans.4.1)

Using Equation Ans.2.15, the voltage feedforward gain results to be:

A2o2
Kf f _2 = (Ans.4.2)
A2o1

A-2 Evaluating Equation Ans.4.2 with the system's parameters given in Ref-
erence [2] leads to:
Kf f _2 = 1.0 (Ans.4.3)

2. A-1 Using tank 2 voltage-to-level transfer function G2 (s) determined in Section 2 and the control scheme
block diagram illustrated in Figure 4.1, derive the normalized characteristic equation of the water level closed-
loop system.
Hint#1: Block diagram reduction can be carried out.
Hint#2: The system's normalized characteristic equation should be a function of the PI level controller gains,
Kp_2 , and Ki_2 , and system's parameters, Kdc_2 and τ2 .

Answer 4.2

Outcome Solution
A-1 Neglecting the feedforward action and carrying out block diagram re-
duction using Equation 2.11 and Equation 3.4 one has
Kdc_2 Ki_2
Y (s) = (Kp_2 (R(S) − Y (s)) + (R(S) − Y (s))) (Ans.4.4)
τ2 s + 1 s
which results in the following closed-loop transfer function

Y (s) Kdc_2 (Kp_2 s + Ki_2 )

= 2
(Ans.4.5)
R(s) τ1 s + (1 + Kdc_2 Kp_2 )s + Kdc_2 Ki_2

A-2 Re-arranging Equation Ans.4.5 results in tank 2 normalized character-

istic polynomial:

(1 + Kdc_2 Kp_2 )s Kdc_2 Ki_2

s2 + + =0 (Ans.4.6)
τ2 τ2

3. A-2 By identifying the controller gains Kp_2 and Ki_2 , fit the obtained characteristic equation to the standard
second-order equation: s2 + 2ζ2 ωn2 s + ωn2
2
= 0. Determine Kp_2 and Ki2 as functions of the parameters ωn2 ,
ζ2 , Kdc_2 , and τ2 .

COUPLED TANKS Workbook - Instructor Version 28

 Answer 4.3

Outcome Solution
A-2 The system's desired characteristic equation is expressed by Equation
2.11. Solving for the two unknowns Kp_2 and Ki_2 the set of two equa-
tions resulting from identifying the coefficients of Equation 2.11 with
those of Equation Ans.4.6, the PI controller gains can be expressed as
follows:
2ζ2 ωn2 τ2 − 1 2
ωn2 τ2
Kp_2 = , Ki_2 = (Ans.4.7)
Kdc_2 Kdc_2

4. A-1, A-2 Determine the numerical values for Kp_2 and Ki_2 in order for the tank 2 system to meet the closed-
loop desired specifications, as previously stated.

Answer 4.4

Outcome Solution
A-1 The minimum damping ratio to meet the maximum overshoot require-
ment, P O2 , can be obtained by solving Equation 3.9. The following
relationship results:
1
ln( 100 P O2 )
ζ2 = √ (Ans.4.8)
1
ln( 100 P O2 )2 + π 2

The system natural frequency, ωn2 , can be calculated from Equation

3.11 (i.e. Hint #2), as follows:
4
ωn2 = (Ans.4.9)
ζ2 ts_2

A-2 Evaluating Equation Ans.4.8 and Equation Ans.4.9 accordingly to the

desired design requirements, then carrying out the numerical application
of Equation Ans.4.7 leads to the following PI controller gains:

Kp_2 = 5.1 cm/cm

Ki_2 = 1.7 s−1 (Ans.4.10)

COUPLED TANKS Workbook - Instructor Version v 1.2

4.3 Lab Experiments

4.3.1 Objectives

• Tune through pole placement the PI-plus-Feedforward controller for the actual water level of the Coupled-Tank
system's tank 2.
• Implement the PI-plus-Feedforward control loop for the actual tank 2 water level.
• Run the obtained Feedforward-plus-PI level controller and compare the actual response against the controller
design specifications.
• Run the system's simulation simultaneously, at every sampling period, in order to compare the actual and
simulated level responses.
• Investigate the effect of the nested PI-plus-Feedforward level control loop implemented for tank 2.

4.3.2 Tank 2 Level Control Simulation

Experimental Setup

The Coupled Tanks -Tank2 Level Control simulation VI shown in Figure 4.2 is used to perform tank 2 level control
simulation exercises in this laboratory.

Figure 4.2: VI used to run PI-FF control Simulation on Coupled Tanks system in configuration #2.

IMPORTANT: Before you can conduct these simulations, you need to make sure that the lab files are configured
according to your setup. If they have not been configured already, then you need to go to Section 5 to configure the
lab files first.

Follow this procedure:

1. In Coupled Tanks.lvproj, open Coupled Tanks- Tank2 Level Control Simulation.vi. The model implements the
system's simulation Proportional-plus-Integral (PI) closed-loop with feedforward action, as studied in Section
4.1.2. As mentioned in the pre-lab assignments, the tank 2 water level control loop is based on tank 1 level
controller, as developed and tuned in the previous sections. The level controller diagram for the Coupled-Tank
in configuration #2 also interfaces directly with your Coupled-Tank hardware. To familiarize yourself with the
diagram, it is suggested that you open the model subsystems to get a better idea of their composing blocks as
well as take note of the I/O connections.

COUPLED TANKS Workbook - Instructor Version 30

2. To generate a square wave that goes between 14 and 16 cm for the tank 2 level reference, go to the Amplitude
Command (cm) section and set the controls to the following:
• Amplitude = 1 cm
• Frequency = 0.02 Hz
• Offset = 15 cm
The total level setpoint for tank 2 should result to be a square wave of ±1cm around the desired equilibrium
level L20
3. Enter the proportional, integral, and feedforward control gains found in Section 4.2 in the kp_2, ki_2, and kff_2
controls in the Control Parameters section on the front panel. Keep in the the PI-plus-feedforward controller
gains for tank 1 of the Coupled-Tank system in configuration #1, as previously implemented. Those are kp_1,
ki_1, and kff_1 controls in the Control Parameters section on the front panel. Have your lab assistant check
your values.
4. Run the VI.
5. The VI should start the Coupled Tanks simulation filling tank1 and tank 2 up to their operating levels L10 and
L20 , respectively. Then after a 35-second settling delay (in order to stabilize the system at its operating point),
the water level in tank 2 should start tracking the desired ±1cm square wave setpoint around the desired
operating level L20 . The corresponding commanded pump voltage, which is proportional to the control effort
spent, can also be monitored and plotted on-line.

6. B-5, K-2 Attach plots showing the Implemented Tank 2 Level Control response and the input voltage.

Answer 4.5

Outcome Solution
B-5 If the procedure was followed properly, Tank 2 level control simulation
file should have been run. The response similar to Figure 4.3 should
have been obtained.
K-2 The closed-loop Tank 2 level response is shown in Figure 4.3.

7. K-1, B-9 Assess the actual performance of the level response and compare it to the design requirements.
Measure your response actual percent overshoot and settling time. Are the design specifications satisfied? Ex-
plain. If your level response does not meet the desired design specifications, review your PI-plus-Feedforward
gain calculations and/or alter the closed-loop pole locations until they do. If you are still unable to achieve the
required performance level, ask your lab instructor for advice. Does the response satisfy the specifications
given in Section 2.1.4?
Hint: Use the graph cursors in the Measure tab to take measurements.
Answer 4.6

Outcome Solution
K-1 The settling time in the response shown in Figure 4.5 is

ts2 = 0 cm.

The peak time and percentage overshoot of the response are:

tp2 = 40 − 25 = 15 sec

and
16.3 − 16
P O2 = 100 × = 1.8%.
16

B-9 Both the peak time and percent overshoot measured satisfy the specifi-
cations given in Section 2.1.4.

COUPLED TANKS Workbook - Instructor Version v 1.2

 Figure 4.3: Tank 2 level closed-loop control response.

4.3.3 Tank 2 Level Control Implementation

Experimental Setup

The Coupled Tanks Tank2 Level Control VI shown in Figure 4.4 is used to perform tank 2 level control exercises
in this laboratory. This VI interfaces with the pump and pressure sensors of the Coupled Tanks system. It should
be noted that two simple low-pass filters cut-off frequency 2.5 Hz are added to the output signal of the tank 1 and
tank 2 level pressure sensors. These filters are necessary to attenuate the high-frequency noise content of the level
measurements. Such a measurement noise is mostly created by the sensors environment made of turbulent flow
and circulating air bubbles. Although introducing a short delay in the signals, low-pass filtering allows for higher
controller gains in the closed-loop system, and therefore for higher performance. Moreover, as a safety watchdog,
the controller will stop if the water level in either tank 1 or tank 2 goes beyond 27cm.

IMPORTANT: Before you can conduct these experiments, you need to make sure that the lab files are configured
according to your setup. If they have not been configured already, then you need to go to Section 5 to configure the
lab files first.

Follow this procedure:

1. In Coupled Tanks.lvproj, open Coupled Tanks Tank2 Level Control.vi. The model implements the system's
actual Proportional-plus-Integral (PI) closed-loop with feedforward action, as studied in Assignment #3. To
familiarize yourself with the diagram, it is suggested that you open the model subsystems to get a better idea
of their composing blocks as well as take note of the I/O connections.

2. To generate a square wave that goes between 14 and 16 cm for the tank 2 level reference, go to the Amplitude
Command (cm) section and set the controls to the following:

• Amplitude = 1 cm
• Frequency = 0.02 Hz
• Offset = 15 cm

COUPLED TANKS Workbook - Instructor Version 32

 Figure 4.4: VI used to run PI-FF control on Coupled Tanks system in configuration #2.

The total level setpoint for tank 2 should result to be a square wave of ±1cm around the desired equilibrium
level L20

3. Enter the proportional, integral, and feedforward control gains found in Section 4.2 in the kp_2, ki_2, and kff_2
controls in the Control Parameters section on the front panel. Keep in the the PI-plus-feedforward controller
gains for tank 1 of the Coupled-Tank system in configuration #1, as previously implemented. Those are kp_1,
ki_1, and kff_1 controls in the Control Parameters section on the front panel. Have your lab assistant check
your values.
4. Run the VI.

5. The VI should start the gear pump thrusting water filling tank1 and tank 2 up to their operating levels L20 .
Then after a 35-second settling delay (in order to stabilize the system at its operating point), the water level in
tank 2 should start tracking the desired ±1cm square wave setpoint around the desired operating level L20 .
The corresponding commanded pump voltage, which is proportional to the control effort spent, can also be
monitored and plotted on-line.

6. B-5, K-2 Attach plots showing the Implemented Tank 2 Level Control response and the input voltage.

Answer 4.7
Attention Instructors: For safety reasons, the values of the PI-plus-feedforward level controller
gains, as determined and calculated by the students, should be checked by the instructor before
they actually start the controller. In configuration #2, the controller gain values for Kp_2 , Ki_2 , and
Kf f _2 are given in Equation Ans.4.10 and Equation Ans.4.3. However, it should be reminded that
the students are expected to have determined Equation Ans.4.10 and Equation Ans.4.3 as a results
of their pre-lab assignments.

Outcome Solution
B-5 If the procedure was followed properly, Tank 2 level control file should
have been run on the Coupled Tanks system and the response similar
to Figure 4.5 should have been obtained.
K-2 The closed-loop Tank 2 level response is shown in Figure 4.5.

7. K-1, B-9 Assess the actual performance of the level response and compare it to the design requirements.
Measure your response actual percent overshoot and settling time. Are the design specifications satisfied? Ex-
plain. If your level response does not meet the desired design specifications, review your PI-plus-Feedforward

COUPLED TANKS Workbook - Instructor Version v 1.2

 Figure 4.5: Closed-loop coil current control response.

gain calculations and/or alter the closed-loop pole locations until they do. If you are still unable to achieve the
required performance level, ask your lab instructor for advice. Does the response satisfy the specifications
given in Section 2.1.4?
Hint: Use the graph cursors in the Measure tab to take measurements.

Answer 4.8

Outcome Solution
K-1 The settling time in the response shown in Figure 4.5 is

ts2 = 0 cm

. The peak time and percentage overshoot of the response are:

tp2 = 79 − 70 = 9 sec

and
16.3 − 16 ∼
P O2 = 100 × = 2.0%.
16

B-9 Both the peak time and percent overshoot measured do not satisfy the
specifications given in Section 2.1.4.

8. Specifically discuss in your lab report the following points:

• How does your actual tank 2 level compare to the simulated response?
• From the plot of the actual level response, measure your system settling time and percentage overshoot.
Are the values in agreement with the design specifications? If not exactly, find some of the possible
reasons.

COUPLED TANKS Workbook - Instructor Version 34

• Include in your lab report your final values for Kp_2 , Ki_2 , and Kf f _2 as well as the resulting response plot
of the actual and theoretical L2 versus Lr_2 . Also include from the same run the corresponding plot of Vp .
Ensure to properly document all your results and observations before moving on the the next section.
• You can now proceed to the next section, which deals with the actual implementation of your PI-plus-
Feedforward level controller for tank 2 of the Coupled-Tank system in configuration #2.

COUPLED TANKS Workbook - Instructor Version v 1.2

4.4 Results

B-6 Fill out Table 4.1 with your answers from your control lab results - both simulation and implementation.

Description Symbol Value Units

Pre Lab Questions
Tank 2 Control Gains
Feed Forward Control Gain Kf f2 1 cm/cm
Proportional Control Gain kp2 -5.1 cm/cm
Integral Control Gain ki2 -1.7 1/(s)
Tank 2 Control Simulation
Steady-state error ess 0 cm
Settling time ts2 5 s
Percent overshoot P O2 2 %
Tank 2 Control Implementation
Steady-state error ess 0 cm
Settling time ts2 5 s
Percent overshoot P O2 2 %

Table 4.1: Results

COUPLED TANKS Workbook - Instructor Version 36

5 SYSTEM REQUIREMENTS
Required Software

Make sure LabVIEW™ is installed with the following required add-ons:

1. LabVIEW™

2. NI-DAQmx
3. NI LabVIEW™ Control Design and Simulation Module

4. Quanser Rapid Control Prototyping Toolkitr

Note: Make sure the Quanser Rapid Control Prototyping (RCP) Toolkit is installed after LabVIEW. See the RCP
Toolkit Quick Start Guide for more information.

Required Hardware

• Data acquisition (DAQ) device that is compatible with Quanser Rapid Control Prototyping Toolkitr . This in-
cludes Quanser DAQ boards such as Q2-USB, Q8-USB, QPID, and QPIDe and some National Instruments
DAQ devices.

• Quanser Coupled Tanks.

• Quanser VoltPAQ-X1 power amplifier, or equivalent.

Before Starting Lab

Before you begin this laboratory make sure:

• LabVIEW™ is installed on your PC.

• DAQ device has been successfully tested (e.g., using the test software in the Quick Start Guide).

• Coupled Tanks and amplifier are connected to your DAQ board as described Reference [2].

COUPLED TANKS Workbook - Instructor Version v 1.2

5.1 Overview of Files

File Name Description

Coupled Tanks User Manual.pdf This manual describes the hardware of the Coupled Tanks
system and explains how to setup and wire the system for
the experiments.
Coupled Tanks Workbook (Student).pdf This laboratory guide contains pre-lab questions and lab
experiments demonstrating how to design and implement
controllers for on the Coupled Tanks plant using Lab-
VIEW™ .
Coupled Tanks.lvproj LabVIEW project that contains all the LabVIEW™ Virtual
Instrument (VI) files required for running the Quanser Cou-
pled Tanks labs.
Coupled Tanks -Calibration.vi VI that is used to calibrate the pressure sensor measure-
ments on the Coupled Tanks system.
Coupled Tanks -Tank1 Level Simula- VI that simulates Tank1 level controller (configuration 1)for
tion.vi the Coupled Tanks system.
Coupled Tanks -Tank2 Level Simula- VI that simulates Tank2 level controller (configuration 2)
tion.vi for the Coupled Tanks system.
Coupled Tanks -Tank1 Level Control.vi VI that implements the PI Tank1 level controller (configu-
ration 1) on the Coupled Tanks system using LabVIEW™
.
Coupled Tanks -Tank2 Level Control.vi VI that implements the Tank2 level controller on the Cou-
pled Tanks system using LabVIEW™ .

Table 5.1: Files supplied with the Coupled Tanks

File Name Description

Coupled Tanks Workbook (Instructor).pdf Same as the student version except with solutions.
Coupled Tanks.mws Maple worksheet used to develop the model for the Cou-
pled Tanksexperiment. Waterloo Maple 15, or a later re-
lease, is required to open, modify, and execute this file.
Coupled Tanks.html HTML presentation of the Maple Worksheet. It allows
users to view the content of the Maple file without hav-
ing Maple 9 installed. No modifications to the equations
can be performed when in this format.

Table 5.2: Instructor files supplied with the Coupled Tanks

5.2 Calibrating the pressure sensor measurements

Follow these steps:

1. Load the LabVIEW™ software.

2. Open the LabVIEW Project COUPLEDTANK.lvproj.

3. Open the LabVIEW VI called Coupled Tanks- Calibration.

4. Follow the steps in the VI to calibrate both pressure sensors. The sensors should measure about 0V when
empty and about 4.1V when filled up to 25cm.

COUPLED TANKS Workbook - Instructor Version 38

5.3 Setup for Tank 1 Level Control Simulation
Follow these steps:

1. Load the LabVIEW™ software.

2. Open the LabVIEW Project COUPLEDTANK.lvproj.

3. Open the LabVIEW VI called Coupled Tanks- Tank 1 Control Simulation, shown in Figure 3.4.

4. Ensure the PI-FF control gains the kp_1, ki_1, and kff_1 on the VI front panel are set to the value found in the
Pre-Lab Questions in Section 3.2.

5.4 Setup for Tank 1 Level Control

Follow these steps to get the system ready for this lab:

1. Setup the Coupled Tanks as detailed in the Coupled Tanks User Manual ([2]).
2. If using the VoltPAQ-X1, make sure the Gain switch is set to 3.

3. Open COUPLEDTANK.lvproj project as outlined in Section 5.3.

4. Open Coupled Tanks- Tank1 Level Control.vi shown in Figure 3.6.

5. As discussed in Section 5.3, set the PI gains according to the Pre-Lab Exercise values.
6. Configure DAQ: Ensure the HIL Initialize block is configured for the DAQ device that is installed in your system.
To do this, go to the block diagram (CTRL-E) and double click on the HIL Initialize Express VI shown in Figure
5.1.

Figure 5.1: HIL Initialize Express VI

7. Under the Main tab, select the data acquisition device that is installed on your system in the Board type section.
For example, in Figure 5.2 the Q2-USB is chosen.

5.5 Setup for Tank 2 Level Control Simulation

Follow these steps:

1. Load LabVIEW™ and open COUPLEDTANK.lvproj.

2. Open the Coupled Tanks- Tank2 Level Control Simulation VI, shown in Figure 4.2.

3. Make sure the control gains are set to the values found in Section 4.2.
4. Ensure the PI-FF control gains the kp_2, ki_2, and kff_2 on the VI front panel are set to the value found in the
Pre-Lab Questions in Section 4.2.

COUPLED TANKS Workbook - Instructor Version v 1.2

 Figure 5.2: Select DAQ board that will be used to control system

5.6 Setup for Tank 2 Level Control

Follow these steps to get the system ready for this lab:

1. Go through step 1-4 in Section 5.4 to setup the Coupled Tankssystem and open COUPLEDTANK.lvproj.

2. Open Coupled Tanks-Tank 2 Level Control.vi shown in Figure 4.4.

3. Make sure the control gains are set as dictated in Section 5.5.

4. Configure DAQ: Ensure the HIL Initialize Express VI is configured as explained in Section 5.4.

COUPLED TANKS Workbook - Instructor Version 40

6 LAB REPORT
This laboratory contains two groups of experiments, namely,

1. Tank 1 Level control, and

2. Tank 2 Level control.

For each experiment, follow the outline corresponding to that experiment to build the content of your report. Also,
in Section 6.3 you can find some basic tips for the format of your report.

6.1 Template for Tank 1 Level Control Report

I. PROCEDURE

1. Simulation

• Briefly describe the main goal of the simulation.

• Briefly describe the simulation procedure in Step 6 in Section 3.3.2.
2. Implementation

• Briefly describe the main goal of this experiment.

• Briefly describe the experimental procedure in Step 5 in Section 3.3.3.

II. RESULTS
Do not interpret or analyze the data in this section. Just provide the results.

1. Response plot from step 6 in Section 3.3.2, Tank1 level control simulation.
2. Response plot from step 5 in Section 3.3.3, Tank 1 level control implementation.

3. Provide applicable data collected in this laboratory (from Table 3.1).

III. ANALYSIS
Provide details of your calculations (methods used) for analysis for each of the following:

1. Peak time, percent overshoot, steady-state error, and input voltage in Step 7 in Section 3.3.2.
2. Peak time, percent overshoot, steady-state error, and input voltage in Step 6 in Section 3.3.3.

IV. CONCLUSIONS
Interpret your results to arrive at logical conclusions for the following:

1. Whether the controller meets the specifications in Step 7 in Section 3.3.2, Tank1 level control simulation.
2. Whether the controller meets the specifications in Step 6 in Section 3.3.3, Tank1 level control implementation.

COUPLED TANKS Workbook - Instructor Version v 1.2

6.2 Template for Tank 2 Level Control Report
I. PROCEDURE

1. Simulation

• Briefly describe the main goal of the simulation.

• Briefly describe the simulation procedure in Step 6 in Section 4.3.2.
2. Implementation

• Briefly describe the main goal of this experiment.

• Briefly describe the experimental procedure in Step 6 in Section 4.3.3.

II. RESULTS
Do not interpret or analyze the data in this section. Just provide the results.

1. Response plot from step 6 in Section 4.3.2, Tank2 level control simulation.

2. Response plot from step 6 in Section 4.3.3, Tank2 level control implementation.
3. Provide applicable data collected in this laboratory (from Table 4.1).

III. ANALYSIS
Provide details of your calculations (methods used) for analysis for each of the following:

1. Peak time, percent overshoot, steady-state error, and input voltage in Step 7 in Section 4.3.2.

2. Peak time, percent overshoot, steady-state error, and input voltage in Step 7 in Section 4.3.3.

IV. CONCLUSIONS
Interpret your results to arrive at logical conclusions for the following:

1. Whether the controller meets the specifications in Step 7 in Section 4.3.3, Tank2 level control implementation.

COUPLED TANKS Workbook - Instructor Version 42

6.3 Tips for Report Format
PROFESSIONAL APPEARANCE

• Has cover page with all necessary details (title, course, student name(s), etc.)

• Each of the required sections is completed (Procedure, Results, Analysis and Conclusions).
• Typed.

• All grammar/spelling correct.

• Report layout is neat.

• Does not exceed specified maximum page limit, if any.

• Pages are numbered.

• Equations are consecutively numbered.

• Figures are numbered, axes have labels, each figure has a descriptive caption.

• Tables are numbered, they include labels, each table has a descriptive caption.

• Data are presented in a useful format (graphs, numerical, table, charts, diagrams).
• No hand drawn sketches/diagrams.

• References are cited using correct format.

COUPLED TANKS Workbook - Instructor Version v 1.2

7 SCORING SHEETS
7.1 Modeling Pre-Lab Questions

Student Name :

Question2 A-1 A-2 A-3

1
2
3
4
5
6
7
8
Total

2 This scoring sheet is for the Modeling Pre-Lab questions in Section 2.2.

COUPLED TANKS Workbook - Instructor Version 44

7.2 Tank 1 Level Control Pre-Lab Questions

Student Name :

Question2 A-1 A-2 A-3

1
2
3
4
Total

2 This scoring sheet is for the Tank1 Pre-Lab questions in Section 3.2.

COUPLED TANKS Workbook - Instructor Version v 1.2

7.3 Tank 1 Level Control Lab Exercises

Student Name:

CONTENT FORMAT
Item1 K-1 K-2 K-3 B-1 B-4 B-5 B-6 B-7 B-9 GS-1 GS-2
I.1. Simulation
1
I.2. Implementation
2
II. RESULTS
1
2
3
III. ANALYSIS
1
2
IV. CONCLUSIONS
1
2
Total

1 This scoring sheet corresponds to the report template in Section 6.1.

COUPLED TANKS Workbook - Instructor Version 46

7.4 Tank 2 Level Control Pre-Lab Questions

Student Name :

Question1 A-1 A-2 A-3

1
2
3
4
Total

1 This scoring sheet is for the Ball Position Control Pre-Lab questions in Section 4.2

COUPLED TANKS Workbook - Instructor Version v 1.2

7.5 Tank 2 Level Control Lab Exercises

Student Name:

CONTENT FORMAT
Item1 K-1 K-2 K-3 B-1 B-4 B-5 B-6 B-7 B-9 GS-1 GS-2
I.1. Simulation
1
I.2. Implementation
2
II. RESULTS
1
2
3
III. ANALYSIS
1
2
IV. CONCLUSIONS
1
2
Total

1 This scoring sheet corresponds to the report template in Section 6.2.

COUPLED TANKS Workbook - Instructor Version 48

APPENDIX A

NOMENCLATURE
Table A.1, below, provides a complete listing of the symbols and notations used in the Coupled-Tank system math-
ematical modelling, as presented in this laboratory. The numerical values of the system parameters can be found
in Reference [2].

COUPLED TANKS Workbook - Instructor Version v 1.2

Symbol Description Units Notation
Pump Volumetric Kp
Kp cm3 /s/V
Flow Constant
Actual Pump Input Vp
Vp V
Voltage
Steady-State Pump Vp0
Vp0 V
Voltage
Small Variation Vp11
Vp1 V
Around Vp0
Feedforward Pump Vp_ff
Vp_f f V
Voltage
Tank 1 Inside Dt1
Dt1 cm
Diameter
Tank 1 Outlet Do1
Do1 cm
Diameter
Tank 1 Inside At1
At1 cm2
Cross-Section Area
Tank 1 Outlet Ao1
Ao1 cm2
Cross-Section Area
Volumetric Inflow
Fi1 cm3 /s
Rate To Tank 1
Volumetric Outflow
Fo1 cm3 /s
Rate From Tank 1
L1 Tank 1 Water Level cm L1
Steady-State Water L10
L10 cm
Level in Tank 1
Small Variation L11
L11 cm
Around L10
Tank 1 Reference
Lr_1 (a.k.a. Desired) cm Lr_1
Level
Tank 1 Water Level K_L1
KL1 cm/V
Sensor Sensitivity
Tank 2 Inside Dt2
Dt2 cm
Diameter
Tank 2 Outlet Do2
Do2 cm
Diameter
Tank 2 Inside At2
At2 cm2
Cross-Section Area
Tank 2 Outlet Ao2
Ao2 cm2
Cross-Section Area
Volumetric Inflow
Fi2 cm2 /s
Rate To Tank 2
Volumetric Outflow
Fo2 cm2 /s
Rate From Tank 2
L2 Tank 2 Water Level cm L2
Steady-State Water L20
L20 cm
Level in Tank 2
Small Variation L21
L21 cm
Around L20
Tank 2 Reference
Lr_2 (a.k.a. Desired) cm Lr_2
Level
Tank 2 Water Level K_L2
K12 cm/V
Sensor Sensitivity
Gravitational g
g cm/s2
Constant on Earth
COUPLED TANKS Workbook - Instructor Version 50
Table A.1: Nomenclature
APPENDIX B

INSTRUCTOR'S GUIDE
Every laboratory in this manual is organized into four parts:

Background section provides all the necessary theoretical background for the experiments. Students should read
this section first to prepare for the Pre-Lab questions and for the actual lab experiments.

Pre-Lab Questions section is not meant to be a comprehensive list of questions to examine understanding of the
entire background material. Rather, it provides targetted questions for preliminary calculations that need to be done
prior to the lab experiments.

Lab Experiments section provides step-by-step instructions to conduct the lab experiments and to record the col-
lected data. The lab may also include a set of pre-lab questions that need to be done prior to the lab experiments.

System Requirements section describes all the details of how to configure the hardware and software to conduct
the experiments. It is assumed that the hardware and software configuration have been completed by the instructor
or the teaching assistant prior to the lab sessions. However, if the instructor chooses to, the students can also
configure the systems by following the instructions given in this section.

Assessment of ABET outcomes is incorporated into this manual as shown by indicators such as A-1, A-2 . These
indicators correspond to specific performance criteria for an outcome.

B.1 Pre-lab Questions and Lab Experiments

B.1.1 How to use the pre-lab questions

All or some of the questions in the Pre-Lab Questions sections can be assigned to students as homework. One
possibility is to assign them as a homework one week prior to the actual lab session and ask the students to bring
their assignment to the lab session. This would help them get ready for the lab session. You should encourage
them to study the background section of the chapter prior to attempting the pre-lab questions. Note that solutions
for some of the Pre-Lab questions are parameters needed for the experiments in the lab session.

Another possibility is to go over some of these questions either in class or in the lab session together with the
students. This could generate an interactive learning opportunity for them prior to the lab.

Finally, it is possible to use some of the pre-lab questions in your mid-term or final exams. This would reinforce the
concepts covered in the labs; connections between the abstract theory and the real hardware; and would give you
an option to integrate some of the work done in the lab sessions into your exams.

B.1.2 How to use the laboratory experiments

This manual is organized into several laboratory sections. Each section contains several experiments which are,
for the most part, independent of each other. Therefore, one possible way to use this material is to conduct the
individual experiments in your weekly lab sessions. Another possibility is to divide the class into teams and have
each team conduct an experiment given in a section.

COUPLED TANKS Workbook - Instructor Version v 1.2

B.2 Assessment for ABET Accreditation
In the United States, accreditation is a peer-review process. Educational institutions or programs volunteer to un-
dergo this review periodically to determine if certain criteria are being met. The Accreditation Board for Engineering
and Technology, ABET, is responsible for the specialized accreditation of educational programs in applied science,
computing, engineering, and technology. ABET accreditation is assurance that a college or university program
meets the quality standards established by the profession for which it prepares its students.

It is the responsibility of the program seeking accreditation to demonstrate clearly that the program meets a set of
criteria. One of these criteria is the ``Criterion 3: Program Outcomes''. Engineering programs must demonstrate
that their students attain program outcomes (a) through (k). Much more information about this can be found in the
``Criteria for Engineering Accreditation'' document ABET publishes on its website annually (http://www.abet.org).

For fulfillment of Criterion 3, a program must show that there is an assessment and evaluation process in place that
periodically documents and demonstrates the degree to which the program outcomes are attained by their students.
Most programs do this by mapping the outcomes (a) through (k) to the courses in the curriculum1 . Then, these
outcomes are assessed in the courses. Finally, the assessment results are collected from the courses and compiled
into program-level data to demonstrate the ``degree to which the program outcomes are attained by their students''.

If your course is part of a similar assessment effort in your program, you probably need to assess the following
outcomes in your course:

(A) An ability to apply knowledge of mathematics, science, and engineering,

(B) An ability to design and conduct experiments, as well as to analyze and interpret data,
(G) An ability to communicate effectively, and
(K) An ability to use the techniques, skills, and modern engineering tools necessary for engineering practice.

These outcomes can be assessed in your course using various assessment tools, such as student surveys and
assignments or questions targeting specific outcomes. To measure achievement of an outcome (such as outcome
``A'' in the list above), typically some performance criteria are defined for the outcome. The performance criteria
are a set of measurable statements to define each learning outcome. They identify the specific knowledge, skills,
attitudes, and/or behavior students must demonstrate as indicators of achieving the outcome.

For the purpose of this laboratory curriculum, we defined a set of performance criteria for each outcome. These
criteria are labeled as ``A-1, A-2, B-3, ..., K-3'' as indicated in the rubrics in Section B.3 below. We also embedded
these performance criteria in the curriculum shown by indicators such as A-1, A-2 .

B.2.1 Assessment in your course

Assessment of outcomes is different than grading. A course grade (or a grade on an assignment or exam), is a
composite indicator. For example, if a student receives "B" as a grade in your course, it is probably difficult to tell
his/her level of achievement in outcome "A" versus "G". One of the purposes of assessment is to "measure" the level
of achievement of these specific skills and knowledge so that improvements can be made in the future offerings of
the course.

So, how should you introduce outcomes assessment into your course? The outcomes assessment approach
described here can be applied to each pre-lab homework assignment and lab report of each student throughout the
semester. This may or may not be feasible depending on your class size. In general, a representative sample of
student work is assessed.

You can continue to give assignments/exams and grade them in the traditional way. To introduce assessment into
your course, you can pick a representative sample of student work and "score" their work using the scoring sheets
and rubrics given in this manual. This is a good way to start introducing assessment into your course.
1 Disclaimer: The opionions expressed or the assessment techniques described here have not been endorsed by ABET in any way.

COUPLED TANKS Workbook - Instructor Version 52

Recall that for fulfillment of Criterion 3, a program must ``document'' the assessment process. Programs collect sam-
ple student work in the academic year prior to the site visit by an ABET team. You can retain the sample homeworks,
lab reports, their scoring sheets and the assessment workbook as ``evidence'' for the ongoing assessment effort in
your course. This collection can then be given to the assessment committee in your program to be incorporated into
the program-level evidence they will compile prior to the ABET site visit.

B.2.2 How to score the pre-lab questions

If you choose to assign the pre-lab questions as homework, then the outcome targetted by these questions can be
assessed using the student work. The pre-lab questions require students to ``apply'' their math and engineering
science knowledge through calculations and problem solving strategies. Therefore, outcome ``A'' was mapped to
the pre-lab questions through its performance criteria.

If you assign the pre-lab questions as homework, you can ``score'' the returned homeworks using the rubric for
outcome ``A'' given in Section B.3 and the scoring sheet provided for that pre-lab in that chapter.

To score homework of one student:

1. Print the scoring sheet for the Pre-Lab Questions section you assigned as homework. One sheet is used per
student.
2. Use the rubric for ``Outcome A'' (Section B.3) to assign a score for each question. The rubric gives the descrip-
tion of ``levels of achievement'' (4 = exemplary, 3 = proficient, 2 = developing and 1 = beginning/incomplete)
for each criterion. As an example, below is a completed sample scoring sheet after evaluating the homework
of one student.

Question A-1 A-2 A-3

1 3 2
2 4 2
3 3
4 3
5 4
6 3
7 3
8 3
9 3 3
10 3 4
11 3 4
Total 10 32 8

3. You can then enter the ``Total'' for each performance criterion into the assessment workbook [1] as shown in
Figure B.1.

B.2.3 How to score the lab reports

As mentioned earlier in Section B.1.2, there are various ways in which you can use the material provided in this
manual. In any case, the outcomes targetted by the lab experiments can be assessed from the lab reports submitted
by the students. These reports should follow the specific template for content given at the end of each laboratory
chapter. This will provide a basis to assess the outcomes easily.

The lab activities correspond to the ``applied'' part of engineering. Therefore, outcomes ``B'' and ``K'' were mapped
to the lab activities through their performance criteria. The lab reports themselves match outcome ``G'' on effective
communication skills.

If you choose to do an individual experiment in your weekly lab sessio then you can ask the students to submit a lab
report using the report template provided for this experiment. The template contains the main ``content'' sections you

COUPLED TANKS Workbook - Instructor Version v 1.2

 Figure B.1: Pre-Lab entry into the assessment workbook for one student.

would expect in a typical lab report (procedure, results, analysis, conclusions). Each section of the report template
ties back to the activities in the lab and the corresponding assessment indicators. It also contains performance
criteria related to the ``format'' of the report.

You can score the lab reports using the rubric for outcome ``G'' given in Section B.3 and the scoring sheet provided for
the experiment in that section. Note that each lab report scoring sheet directly corresponds to the lab report content
template for that experiment. Also, note that the rubric for outcome ``G'' already contains rubrics for outcomes ``B''
and ``K'' since these outcomes appear as an integral part of the report.

To score the lab report of one student:

1. Print the scoring sheet for the Lab Report for the experiment they conducted in the lab. One sheet is used per
student.

2. Use the ``Content'' rubric (Section B.3) to assign a score for each entry in the scoring sheet. The rubric
gives the description of ``levels of achievement'' (4 = exemplary, 3 = proficient, 2 = developing and 1 = begin-
ning/incomplete) for each criterion. As an example, below is a completed scoring sheet after evaluating the
lab report of one student.
3. Use the ``Format'' rubric (Section B.3) for the ``GS-1 and GS-2'' criteria to score the formatting of the report
on the same scoring sheet.

COUPLED TANKS Workbook - Instructor Version 54

 CONTENT FORMAT
Item1 K-1 K-2 B-5 B-6 B-7 B-9 GS-1 GS-2
I. PROCEDURE
I.1. Frequency Response Experiment
1 4
I.2. Bump Test Experiment
1 4
I.3. Model Validation Experiment
1 4
II. RESULTS
1 4
2 3
3 3
4 3
III. ANALYSIS
III.1. Frequency Response Experiment
1 2
2 3
III.2. Bump Test Experiment
1 3
IV. CONCLUSIONS
1 3
Total 6 10 12 3 2 3 4 3

4. You can then enter the ``Total'' for each performance criterion into the assessment workbook [1] as show in
Figure B.2.

Figure B.2: Lab report score entries in the workbook for one student.

B.2.4 Assessment of the outcomes for the course

As explained earlier, the performance criteria, such as A-1, A-2, A-3, are used to describe a set of measurable
statements to define each learning outcome. Up to this point, we explained how to assess each performance
criterion using the pre-labs, the lab reports and the scoring sheets.

A single score for each outcome can be computed to indicate the level of attainment of that outcome by the entire
class. One approach is to simply average the scores for the performance criteria for that outcome. For example, in
case of outcome ``A'', you can use:
SCOREA−1 + SCOREA−2 + SCOREA−3
SCOREA = (B.1)
3

Another possibility is to use a weighted-average where some of the performance criteria are considered to be more
important than the others. In case of outcome ``A'', you can use:

w1 · SCOREA−1 + w2 · SCOREA−2 + w3 · SCOREA−3

SCOREA = (B.2)
w1 + w2 + w3
where w1 , w2 and w3 are weights you can assign (on the 0 to 1 scale) for the performance criteria A-1, A-2 and A-3,
respectively. The total of all weights should equal 1.

COUPLED TANKS Workbook - Instructor Version v 1.2

B.2.5 Course Score for outcome A

The assessment workbook [1] incorporates the simple average approach as shown in Figure B.3.

Figure B.3: Computation of single score for outcome ``A'' in the assessment workbook.

B.2.6 Course Scores for outcomes B, K and G

Similarly, the simple average approach is also used for outcomes B, K and G. Referring to the rubrics in Section B.3,
it should be noted that outcome ``G'' contains performance criteria for both ``B'' and ``K'' to assess the content of
the report. In addition, there are two performance criteria, GS-1 and GS-2, to assess the format of the report. The
scores for all of these performance criteria are averaged to arrive at the single score for outcome G. For example,
the single score for outcome G in Figure B.4 for the Modelling experiment was calculated using:

SCOREG = AV ERAGE(SK−1 + SK−2 + SB−5 + SB−6 + SB−7 + SB−9 + SGS−1 + SGS−2 ) (B.3)
where SK−1 · · · SGS−2 are the scaled average scores for K-1 through GS-2 in the workbook.

Figure B.4: Computation of single score for outcome ``G'' in the assessment workbook.

COUPLED TANKS Workbook - Instructor Version 56

B.2.7 Assessment workbook

The assessment workbook [1] was developed using Microsoft Excelr . It is intented to give a general idea for how
the assessment scores can be tracked and brought together. On purpose we designed the workbook to have no
automatic features. You can use it as is or customize it in any way you like.

The assessment workbook has a tab for the Pre-Lab Questions and a tab for each of the laboratory chapters. Only
10 students were listed assuming you would use samples of student work and not the entire class. If you want to
add more students, you can insert rows into the spreadsheets. Note: If you insert new rows, make sure that the
formula ranges in the cells with calculations are correct.

At the bottom of each pre-lab section, there is a row entitled ``Total Possible''. To count a pre-lab assignment in
the calculation of the overall scores, you need to enter the correct totals here. For example, to count the Pre-Lab
for modeling, you need to enter 12, 44 and 8 (Figure B.1). If you want to exclude an assignment from the overall
calculation, enter ``0'' as shown in Figure B.5. Of course, if you are excluding a pre-lab, then do not enter any scores
for the students under those columns.

Figure B.5: Enter ``0'' to exclude or ``correct totals'' to include a Pre-Lab assignment in the calculation of the overall
scores.

COUPLED TANKS Workbook - Instructor Version v 1.2

B.3 Rubrics

4 3 2 1
Code Perf. Criteria Exemplary Proficient Developing Beginning or
incomplete
A-1 Has strategies Uses a Uses an Has a strategy Uses a wrong
to solve the sophisticated appropriate for solution but strategy or there
problem strategy. strategy for content is no evidence
Employs refined solution. knowledge has of a strategy.
Apply math, science and engineering

and complex Content some Content

reasoning to knowledge is conceptual knowledge has
arrive at the used correctly. errors. many errors.
solution.
A-2 Performs Arrived at Arrived at Arrived at No answer or
calculations correct answer. correct answer correct answer. arrived at wrong
Calculations are with correct Calculations are answer.
complete. calculations. mostly correct Calculations are
Precise math but there are mostly or
language, some minor completely
symbolic errors. wrong.
notation, graphs
diagrams, etc.
are used.
A-3 Explains results Explains the Explains the Some There are no
result in the result in the explanation of explanations of
context of the context of the the result is the result or an
completed completed provided but it attempt was
calculations by calculations. does not made to provide
providing Logical demonstrate an explanation
complex conclusions are logical but it is
reasoning and drawn. reasoning. incomplete or
interpretations. wrong.
Clear logical
conclusions are
drawn.

Table B.1: OUTCOME A: An ability to apply knowledge of mathematics, science, and engineering

COUPLED TANKS Workbook - Instructor Version 58

 4 3 2 1
Code Perf. Criteria Exemplary Proficient Developing Beginning or
incomplete
B-1 Identifies hy- Framed a Framed a Framed a ques- Incomplete or
pothesis to testable ques- testable ques- tion that may no testable
test tion correctly tion correctly or may not be question
and explained testable
the anticipated
cause-and-
effect expecta-
tion leading to
the question
Design

B-2 Identifies inde- All variables All variables Most variables None or only a
pendent and are identified are identified are identified few variables
dependent correctly, expla- correctly correctly are identified
variables nations about correctly
their relations
are provided
B-3 Lists assump- All assumptions All assumptions Assumptions No assumptions
tions made and their rea- are listed are listed but listed or most of
sons are clearly some are miss- them are miss-
listed ing ing
B-4 Formulates ex- Developed a Developed cor- Attempted but Could not
perimental plan sophisticated rect experimen- could not com- develop an
to investigate a experimen- tal procedure to pletely develop accurate ex-
phenomenon tal procedure test the hypoth- an experimental perimental
complete with esis procedure to procedure
details of every test the hypoth-
step to test the esis
hypothesis
(Continued on the next page)

COUPLED TANKS Workbook - Instructor Version v 1.2

 4 3 2 1
Code Perf. Criteria Exemplary Proficient Developing Beginning or
incomplete
B-5 Follows ex- Follows ex- Follows exper- Follows ex- Follows ex-
perimental perimental imental proce- perimental perimental
procedures procedures dures leading procedures procedures
carefully with to correct mea- with some mis- with many mis-
great atten- surements takes leading to takes leading to
Conduct

tion to detail. mostly correct mostly wrong

Makes precise measurements measurements
measurements
B-6 Documents data Systematically Documents all Documents No data are
collected documents all data and with data with some documented or
data in an ex- accurate units. mistakes in the there are major
emplary way units or some mistakes in the
and by using data missing. units
accurate units Data organi-
zation needs
improvement
B-7 Uses appropri- Excellent, in- Appropriate Some data anal- No analysis or
ate methods to depth analysis level of analysis ysis but incom- attempts to ana-
analyze data of the data us- of data using plete lyze with wrong
ing appropriate correct methods methods
methods
Analyze

B-8 Accounts for Is aware of Is aware of all Is aware of Is unaware of

experimental all potential potential experi- some of the any experimen-
uncertainties experimental mental errors potential experi- tal errors
errors and can mental errors
fully account
for them with
suggestions to
improve them
B-9 Interprets re- Provides clear, Provides accu- Provides expla- No explanation
sults with in-depth, accu- rate explana- nations and con- or conclusions
Interpret

respect to the rate explana- tions and logical clusions but with are provided or
original hypoth- tions, including conclusions some errors they are wrong
esis trends, and based on data
arrives at logical and results
conclusions
based on data
and results

Table B.2: OUTCOME B: An ability to design and conduct experiments, as well as to analyze and interpret data.

COUPLED TANKS Workbook - Instructor Version 60

 4 3 2 1
Code Perf. Crite- Exemplary Proficient Developing Beginning or
ria incomplete
B-1 Identifies Framed a testable Framed a testable Framed a question Incomplete or no
hypothesis question correctly question correctly that may or may not testable question
to test and explained be testable
the anticipated
cause-and-effect
expectation leading
to the question
B-2 Identifies All variables are All variables are Most variables are None or only a few
indepen- identified correctly, identified correctly identified correctly variables are identi-
dent and explanations about fied correctly
dependent their relations are
Procedure

variables provided
B-3 Lists as- All assumptions and All assumptions are Assumptions are No assumptions
sumptions their reasons are listed listed but some are listed or most of
made clearly listed missing them are missing
B-4 Formulates Developed a sophis- Developed correct Attempted but could
experimen- ticated experimental experimental pro- not completely
tal plan to procedure complete cedure to test the develop an experi-
investigate with details of every hypothesis mental procedure to
a phe- step to test the hy- test the hypothesis
nomenon pothesis Could not develop
an accurate experi-
mental procedure
B-5 Follows ex- Follows experi- Follows experimen- Follows experimen- Follows experimen-
perimental mental procedures tal procedures lead- tal procedures with tal procedures with
procedures carefully with great ing to correct mea- some mistakes lead- many mistakes lead-
attention to detail. surements ing to mostly correct ing to mostly wrong
Makes precise measurements measurements
measurements
(Continued on the next page)

COUPLED TANKS Workbook - Instructor Version v 1.2

 4 3 2 1
Code Perf. Crite- Exemplary Proficient Developing Beginning or
ria incomplete
B-6 Documents Systematically doc- Documents all data Documents data No data are docu-
data col- uments all data in and with accurate with some mistakes mented or there are
lected an exemplary way units. in the units or some major mistakes in
and by using accu- data missing. Data the units
rate units organization needs
improvement
K-2 Uses soft- Can use various Can use software Can use software Cannot use soft-
Results

ware tools software tools and tools correctly for tools for data pre- ware tools for data
to present their advanced fea- data presentation sentation with only a presentation or
data in use- tures correctly for few mistakes attempts to use
ful format data presentation them but with many
(graphs, mistakes (missing
numeri- labels, etc.)
cal, table,
charts,
diagrams)
K-3 Uses soft- Can use software Can use software Can use software Cannot use software
ware tools tools and their ad- tools correctly for tools for simulation tools for simulation
to simulate vanced features simulation with only a few or attempts to use
physical correctly for simula- mistakes them but with many
systems tion mistakes
B-7 Uses appro- Excellent, in-depth Appropriate level of Some data analysis No analysis or at-
priate meth- analysis of the data analysis of data us- but incomplete tempts to analyze
ods to ana- using appropriate ing correct methods with wrong methods
lyze data methods
B-8 Accounts Is aware of all poten- Is aware of all poten- Is aware of some of Is unaware of any
for exper- tial experimental er- tial experimental er- the potential experi- experimental errors
Analysis

imental rors and can fully ac- rors mental errors

uncertain- count for them with
ties suggestions to im-
prove them
K-1 Uses soft- Can use various Can use software Can use software Cannot use software
ware tools software tools and tools correctly for tools for analysis tools for analysis
for analysis their advanced fea- analysis with only a few or attempts to use
tures correctly for mistakes them but with many
analysis mistakes
B-9 Interprets Provides clear, Provides accurate Provides explana- No explanation or
results with in-depth, accurate explanations and tions and conclu- conclusions are pro-
Conclusions

respect to explanations, in- logical conclusions sions but with some vided or they are
the original cluding trends, and based on data and errors wrong
hypothesis arrives at logical results
conclusions based
on data and results

Table B.3: OUTCOME G: Ability to communicate effectively. (for Lab Report - CONTENT)

COUPLED TANKS Workbook - Instructor Version 62

 4 3 2 1
Code Perf. Exemplary Proficient Developing Beginning or
Criteria incomplete
GS-1 Content • Each of the required sections is Two of the Three of the Four or none
presen- completed. conditions conditions of the condi-
tation • If necessary, subsections are used for the "ex- for the "ex- tions for the
well or- • All necessary background princi- emplary" emplary" "exemplary"
ganized ples and information for the experi- category category category
ment are given were not met were not met were not met
• All grammar/spelling correct
• References are cited

GS-2 Professional • Has cover page with all neces- Two of the Four of the Five or more
appear- sary details (title, course, student conditions conditions of the condi-
ance name(s), etc.) for the "ex- for the "ex- tions for the
• Typed emplary" emplary" "exemplary"
• Report layout is neat category category category
• Does not exceed specified maxi- were not met were not met were not met
mum page limit
• Pages are numbered
• Equations are consecutively num-
bered
• Figures are numbered, axes have
labels, each figure has a descriptive
caption
• Tables are numbered, they include
labels, each table has a descriptive
caption
• No hand drawn sketches/diagrams
• References are cited using correct
format

Table B.4: OUTCOME G: Ability to communicate effectively. (for Lab Report - FORMAT)

COUPLED TANKS Workbook - Instructor Version v 1.2

 4 3 2 1
Code Perf. Criteria Exemplary Proficient Developing Beginning or
incomplete
Use techniques, skills and modern eng. tools

K-1 Uses software Can use various Can use software Can use software Cannot use
tools for analysis software tools tools correctly for tools for analysis software tools for
and their analysis with only a few analysis or
advanced mistakes attempts to use
features correctly them but with
for analysis many mistakes
K-2 Uses software Can use various Can use software Can use software Cannot use
tools to present software tools tools correctly for tools for data software tools for
data in useful and their data presentation presentation with data presentation
format (graphs, advanced only a few or attempts to
numerical, table, features correctly mistakes use them but with
charts, diagrams) for data many mistakes
presentation (missing labels,
etc.)
K-3 Uses software Can use software Can use software Can use software Cannot use
tools to simulate tools and their tools correctly for tools for software tools for
physical systems advanced simulation simulation with simulation or
features correctly only a few attempts to use
for simulation mistakes them but with
many mistakes

Table B.5: OUTCOME K: An ability to use the techniques, skills, and modern engineering tools necessary for engi-
neering practice

COUPLED TANKS Workbook - Instructor Version 64

REFERENCES
[1] Quanser Inc. Assessment workbook microsoft excel file, 2012.

[2] Quanser Inc. Coupled Tank User Manual, 2012.

COUPLED TANKS Workbook - Instructor Version v 1.2

 Process control plants for teaching and research

Coupled Tanks Magnetic Levitation

These plants are ideal for intermediate level teaching. They are also suitable for research
relating to traditional or modern control applications of process control. For more
information please contact info@quanser.com
©2013 Quanser Inc. All rights reserved.

INFO@QUANSER.COM +1-905-940-3575 QUANSER.COM

Solutions for teaching and research. Made in Canada.