Instrumentation & Control Lab, ELEC 433

Exp.3: Air Pressure Control

Eng. Sameer Mohammad

9
Fig (1): Air Pressure Control System

Introduction

Fig.(1): Temperature Control Unit

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Exp.3: Air Pressure Control

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The objective of this experiment is to study how to control the air pressure in a pipe in the
system shown in figure 2 using a PID controller in PC, a pneumatic valve (VN1), and I/P
converter. The system contains two circuits: a main air circuit (steel pipes) where the air flow and
pressure can be controlled and a control air circuit (plastic hoses) which is used to control the
pneumatic valve (VN1).

VRP1
VRP2

V2

VR

V3

V4

V1

Fig (2): Edibon system

Equipment

Compressor to provide the compressed air to the system.

Edibon Process Control Unit

Main Air Circuit

Pneumatic valve (Air Controlled) VN1.
Pressure Gauge EN 837-1 up to 2.5 bars. (The front one)
Pressure Sensor SP-1 to change the pressure to an electrical signal.
Differential pressure sensor to measure the air flow SPD-1.
Flow meter has a scale 0-100% or 0-9.4 m3/h is used to calibrate the flow sensor.
Hand/Manual valves.
Compressed air tank CRVZS-2.

Control Air Circuit.

1) Air pressure regulator.
2) Pressure Gauge EN 837-1 up to 2.5 bars (The Back one)
3) I/P converter to convert the current signal from the PC to pressure to open and close
the pneumatic valve VN1.
Procedure:

Fig.(1): Temperature Control Unit

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Exp.3: Air Pressure Control

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Part I: Define the system components and understand how the system operates
1.1 Define the entire pressure/flow control system (EDIBON) on figure 1 and draw a table with
the names and description of all parts corresponding to the numbers in the figure.
1.2 Understand the system. Check how the air is flowing from the air compressor through the
pipes.
1.3 Draw the block diagram of the open and closed loop system. Identify, the system, the
processed variable, the main input, the actuator, the control signal, and the sensor used in
the feedback control system. What are the units of the various variables (Pressure, control
input) considered in this control system?
Part II: Start up the unit
2.1 Turn on the compressor and open its main valve.
2.2 Adjust the Air pressure regulator VRP-1 manually to 1.5 bar (already adjusted). You can
read the value in the manometer (pressure gauge) just below air pressure regulator VRP-1
2.3 Close the manual valves V1, V2, V3, and V4
2.4 Adjust the Air pressure regulator VRP-2 manually to 1.5 bar (already adjusted). You can
read the value in the pressure gauge EN 837-1
2.5 Turn on the Edibon UCP-P (Edibon Process Control Unit),
2.6 In the attached PC, run the software SACED UCP-P, where the following window will
appear.

Fig (3): SACED UCP-P software interface

2.7 Click on the START to run the software.

2.8 Select the name and location of the file to save the captured data.
2.9 In Sensors to plot area set the toggle switch and the option button to show only one graph
for SP-1 sensor reading.
2.10 Select control type Manual then open the pneumatic valve to 100%.

Instrumentation & Control Lab, ELEC 433

Exp.3: Air Pressure Control

2.11 Open the manual valve V1 and adjust the flow rate to 50%
using the manual valve (red) just under the flow meter.
Flowmeter has a scale divided from 0 to 100%. The internal
floating metal piece gives the flow rate depending on its
position. The flowmeter has a maximum flow rate of 9.4 m 3/h
and a minimum flow of 0.8 m 3/h. To measure the flow, we
have to read in the line, under the plate of the flowmeter as
shown in the following figure.

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Reading edge

Part III: Static Characteristic

At this part, you have to check the linearity of the system, to do so, the static characteristic
should be plotted. The static characteristic corresponds to the output of the system versus its
input (for values taken in steady-state).
3.1 Check that the calibration constants; Gain and Offset for the SP-1 sensor are set to -0.21
and -0.096 respectively.
3.2 Vary the ACI-P valve (pneumatic valve) form 0-100% and fill the table below with the
readings of the pressure sensor (SP-1) in Bar.
3.3 Plot the relation between the valve opening (%) and pressure sensor reading to determine
the linear region of the system.
Valve
opining (%)

10

20

27

30

35

38

40

45

50

60

70

80

90

100

Pressure
(Bar)
Part IV: Step Response
Now, we are going to study the step response of the system.
4.1 Keep the control type to manual control mode (Open loop) and set the % open to zero.
4.2 Change the time between data captured (sampling time) to 0.2 seconds.
4.3 Start saving the data of the experiment.(Click on the start saving button)
4.4 Create a reasonable step response (choice your values in the linear region for example keep
the ACI-PI valve value at 30% for a certain time then increase it to 80%). Wait till it
reaches the steady state.
4.5 Open the saved file (saved in the folder you chose in the open loop part) with EXCEL,
keep the time, Pressure, and valve opining columns only and delete the other data and the
headers.
4.6 Load the saved file in the MATLAB to plot the input (%opening of the valve) and output
(Pressure) versus time. Select only the final step response.

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Exp.3: Air Pressure Control

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4.7 From these data, you can calculate L and R for Ziegler Nichols method or K, T, and for
Broda method as described below. Those parameters will help in the next stage to
calculate the controllers parameters.
Part V: Closed-loop
5.1 P-Controller
5.1.1

Use Ziegler Nichols method or Broda method to estimate PG (Proportional Gain)

in case of proportional control* and enter this value in the proper field in the PID
controller while Ti and Td set to zero** (if you set Ti to zero it means the
integration factor is zero).

5.1.2

Select the control type PID on Pressure

5.1.3

Select a certain set-point value (within the pressure range) and wait until the system
reaches the steady-state. Increase or decrease the set-point to check the system
performance***. Take screen shots for your results.

5.1.4

Repeat this part again with Kp greater and then less than the calculated. Save the
data and compare all results.
*

Since the actuator input in the software is in percent, the control signal must
be changed to percent (out of 100) so multiply Kc by 100/(max. pressure(2
Bar))

**

As you may note, the system performance may behave better with Kp less than
the calculated value (try Kp/2), if so, use the new one for the next parts.

*** This analysis should be done by comparing the output for the three cases on
the same plot with the same set-points.
5.2 PI-Controller
5.2.1

Use the same method to estimate the proportional gain and the integral time in case
of PI control (Td =0)

5.2.2

Repeat step 5.1.3

5.2.3

Compare this controller with the previous one

5.2.4

Consider other values for the Ti (greater and less than the calculated) and compare.

5.3 PID-Controller
5.3.1

Use the same method to estimate the proportional gain, the integral time, and the
derivative time in case of PID control

5.3.2

Repeat step 5.1.3

5.3.3

Compare this controller with the previous one

5.3.4

Consider other values for the Td (greater and less than the calculated) and compare.

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Exp.3: Air Pressure Control

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Part VI: Closed-loop with delay tank

Repeat part 5.3 (closed loop with PID controller) using the best parameters attained in
part5 but with the delay tank (open V2 and V3 and close V1). Draw you conclusion.

Broda Method

The values of the controller parameters can be calculated using the following table.

The choice of the controller may be based on the rate T/:

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Exp.3: Air Pressure Control

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If T/ 20 : On-Off
If 10 / 20: P
If 5 / 10 : PI
If 2 / 5 : PID
If / 2 : limits of the PID Controller

Ziegler-Nichols Method
u

u
Fig (2)

t0

The values of the controller parameters can be calculated using the following table.
P controller
PI controller
PID controller

PG (Kp)
u/(RL)
0.9*u/(RL)
1.2*u/(RL)

IAT (Ti)

DAT (Td)

3.3L
2L

0.5L

Remarks:
o u and y should be considered in % of the total range.
o To calculate L and R a great attention should be paid to the line that you have
to draw. This line corresponds to the tangent to the curve at the inflection
point.

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Exp.3: Air Pressure Control

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Warnings and Precautions

Review the following safety precautions to avoid injury and prevent damage to this product or
any products connected to it. To avoid potential hazards, use this product only as specified.
Only qualified personnel should perform service procedure.
To avoid possible electric shock or personal injury, follow these guidelines:
Use the equipment only as specified in this manual or the protection provided by the
equipment might be impaired.
Install the equipment on a clean, dry and flat place.
Connect and disconnect properly.
Use the regular voltage and multi consent (electric outlet) which have earth ground
contact so that protect an electric shock.
Remove the magnetic substances around the controller to prevent malfunction.
Do not operate with suspected failures. If you suspect there is damage to this product,
have it inspected by qualified service personnel.
Do not operate in an explosive atmosphere.
Do not open the case of controller or modular part.
Use proper air pressure and do not change pneumatic circuit.