Computer Aided Water Level Control System Dias H.E.P.C Department of Chemical and Process Engineering University of Moratuwa May 5, 2011 Abstract Three lab stations is to be developed to demonstrate computer aided process control principles. LabVIEW is the preferred programming language to implement the control functions inside PC and National Instruments NI-USB6008 and NI-device drivers is to be used to inteface the lab stations with the PC. Experiments with the components of these proposed lab stations was successful. Index 1 2 3 4 5 6 7 Introduction Description of the Water Level Control System Block Diagram of the Water Level Control System LabVIEW VI of the Water Level Control System Operational Details Task List Component List and Cost Estimation
1 Introduction
1.1 Background
"Introduce a number of short laboratory experiences" was among the suggested actions to reinnovate the undergraduate process control courses in recent study [1]. These suggestions are the results of a study that has been conducted in the USA, but it is assumed these suggestions are also valid in other countries. In response to above studies Telemark University Collage in Norway has been implemented a number of small air heater lab stations to demonstrate and/or learn about basic PID control topics [2]. The focus of this report is to describe proposed lab station design and implementation details those are to be contructed to demonstrate basic control aided control principles. Initially a computer aided water level control system will be constructed. Then it will be transformed into a more sophisticated 1 system with enhanced capabilities with advanced valve actuators . Thereafter a computer aided speed control system and another computer aided temperature control 2 system will be implemented .
Phase 1: Demonstrates simple computer aided water level control system with on/off actuators Phase 2: Demonstrates computer aided water level control system with PID control functions advanced actuators. Water Level Controller System maintains the water level of a tank at a set point or within the set point range by adjusting outflow of the tank when inflow varies.
Normal water valve will be coupled with mechanical device operated with a servo motor. This is to be designed and implemented from the scratch.
2
Air heater can also be used to demonstrate computer aided temperature control. This proposed system contains a boiler and water tank.
Figure 2.1- Water tank with solenoids and water level sensor
2.2.1 NI-USB-6008
NI-USB-6008 device from National Instruments is used as the data acquisition device. Device drivers for this device is available for Windows operating systems (e.g. Windows XP, Vista, 7, etc). Interfacing with LabVIEW is hassle free as both products are compatible with each other and manufactured by the National Instruments.
Fig 3.1-Simplified block diagram of the components of the water level control system PC is connected to the rest of the system via the NI-USB-6008 data acquisition device. Inputs to the water tank are actuating signals of solenoids of inflow and outflow. Output of the water tank is the water level which is sensed by the water level sensor.
Fig 3.2-Typical block diagram of the water level control system Fig 3.2 shows the typical function blocks of a control system. Controller is usually a PID controller. These systems can be implemented without using a PC (i.e. only in electronics using PLC or microcontroller system). The purpose of this kind of control system is to maintain controlled variable at the set point among the disturbances.
Fig 3.3-Simplified functional block diagram of the water level control system Fig 3.3 shows the adoption of above typical block diagram to this particular instance of water level control system. Purpose of water level control system is to maintain the desired water level as specified by the set point while the disturbances are present in the tank. Inflow is considered as a disturbance to the system. Outflow is determined by the control function according to the information about water level sensed by the water level sensor and set point of the virtual instrument.
Fig 3.1-Block diagram of the water level control system with computer interface Block diagram of the fig 3.1 shows the blocks used to interface the system to the computer. Sensors and actuators are the blocks that connect physical systems to a PC.
5.4 Report
1 What are the shortcomings of this system? 2 How this system can be improved? 3 Explain the importance of sensors and actuator in a computer aided control systems.
6 Task List
Design the Water Level Controller Buy Components Write Software Assemble Physical Setup Implement the Voltage Conversion Circuit Interface to the PC
Measurement Filter) Table 7.2- List of major components and estimation of cost Amount Price per unit Cost per components (LKR) (LKR) 2 2 1 2
Component
100Ohm 2 Other (See Note 1) Estimated cost of electronic items NOTE 1: For the component of measurement filter
100
Since the above list of components most probably add up around 100 LKR. The following list contains more costly items. Total cost of the project can be evaluated at the end of the below table. Table 7.2- List of major components and estimation of cost Amount Price per unit Cost per components (LKR) (LKR) 2 3500 7000
Component
1/4" Solenoid valve Transparent tank 1/4" pipes (See Note 1) 1/4" fittings Adhesives (See Note 2) Relay units (5-230V)
2m 2 1 2
Estimated cost of electronic items Estimated cost of the water level controller project NOTE 1: brass pipes are available as 12 foot bars NOTE 2: To connect water tank and brass pipes
Bibiliography [1] strm, K. J. and T. Hgglund, Automatic Tuning of PID Controllers, Instrument Society of America, 1988
[2] Haugen F.,Fjelddalen E., Dunia R., Edgar T.F., Demonstrating PID Control Principles using an Air Heater and LabVIEW, December 6, 2007 [3] Dias H.E.P.C, Computer Aided Control, <https://sites.google.com/site/mrtcontrol>, 2010