Module 7- Analysis, closed-loop control, and control

technology with the Mixing Station 2 Closed-loop control technology

2.3 Exercise: Determining the operating point of the controlled

system
Information
To
determine the working point of the controlled system, knowledge of the
and the working range of the controlled system or final measuring range of the sensor
Inpractice, the working point of a controlled svstem is
control element is required.
selected based on process specifications. The
measuring and final control element are then defined and
By default, the working point of the flow control system selected.
final control element! should be in the middle of the working range of the

Problem description
Determine a suitable working point of the flow control system for the coming
commissioning.
Procedure
1. Which measured value lies exactly in the center of the working
range? Set the pump voltage for this
working point. Measure the sensor signal or the output signal of the measuring transducer.
2. Fill the mixing tank VE4 with ~7l
water each.
3. Open hand valve VW10 and VV12. Close allother
hand valves.
4. Start FluidLab®.PA closed-loop - select the "Measure and
control" menu.
5 Select "low rate", "A_OUTO Pump", and "OUT" as display values.
6. Switch on binary output bito (MA1).
7. Select "A_OUTO Pump" as the manipulated variable and specify a pump
voltage.
8. Start the execution andswitch the "manipulated variable" ON.
9. Change the pump voltage. What is the pump voitage for the constant flow rate at the working point?
Enter the values for the working point (center of the working range) into the worksheet.

Procedure

FBow sensor Pump voltage

Flow rate [L/min] [V]

Working point 5.7

Question
Howcan the system behavior of the flow system be influenced?

Adiferent filling of tank VE1 or in the tanks VE1-VE3 changes the inlet pressure of the pump PL1. A
malfunction due to ball valve VW12 or air in the piping also influences the flow system. With a time
Variant measurement, the flow rate decreases proportionally to the current level.

O Festo Didactic 8131020 M7-17

 2 Closed-loop control technology Mixing Station
Module 7- Analysis, closed-loop control, and control technology with the

2.4 Exercise: ldentification of the behavior of the controlled system

Information
n order to select the optimum controller, the behavior of the controlled system must be known. ne
controller settings are derived from the system dynamics.

The dynamic behavior of a system is determined via the "step

response".
Problem description
Carry out the following series of measurements to determine the step response of the flow systei.

Preparation
1. Fill the mixing tank VE4 with ~7l water each.
2. Open hand valve VW10 and VW12. Close all other hand valves.
3. Start Fluidlab®-PA closed-loop - select the Measure and control" menu.
4. Select "Flow rate", "A_OUTO pump", and "0UT" as measured variables.
5. Select A_OUT0 pump" as the manipulated variable.
6. Switch on binary output bito (MA1).
7. Set the pump voltage at the working point.
8. Start the execution.
9. Switch the "Manually controlled ON" switch ON.
10. Determine the parameters of the controlled system: system gain Ke, system time constant TP, and dead
time T using the following diag1ams and formulas.

Ayj

system with time delay and dead time

Step response of a proportional

Ax
Ks = Ay

Dimensionless value
Parameter Value <
Ks

value for the following exercises.

Use the dimensionless

O Festo
M7-18
Didactic 8131020
 2 Closed-loop control technology
Module 7-Analysis, ciosed-ioop control, and control technology with the Mixing Station

Procedure for the graphical determination of the time constants Ts

Ax
63%

2 4

the maximum of the curve.

1. Draw the "maximum value" as a horizontal line (1) at
of the curve.
2. Draw the "perpendicular as a vertical line (2) at the origin value Ax.
jump height of the
3. Draw a horizontal line (3) at 63% of the maximum
4. Draw a vertical line (4) at the intersection of
the 63% line with the curve.
63 %. This is the
With the help of the time scale, determine how long it takes for the system to reach
5.
time constant Ts.
stationary (steady state) state after the input jump.
6. Determine the system gain Ks in the

Calculations

Ax =3.9 /min / 0.39

Ay -5.7 V/057
63% of Axot 2.45 1/min
and control
Cursor evaluation in measurement
to 3.95 s
t1 4.25 s
t2 = 4.55s

t2-t1 = 0.3 s
System time constant Ts =
3.9/min / 5.7V= 0.68 1/min / V
System gain Ks = Ax /Ay =
0.39/ 0.57 = 0.68
Ks dimensionless =
very short dead time
The deceleration during
start-up of the pump results in a
= 0.3 s
Dead time Tt = t1-t0

M7-19
 the Mixing Station
controltechnology/with
control, and
2 Closed-loop control technology Module 7-Analysis, closed-loop

2.5 Exercise: Operation ofa controller in a flow system

the
Information continuous signal for
controllers generate a
As opposed totwo-step controllers, continuous-action control deviation.
manipulated variable, the magnitude of which depends upon

Procedure continuouS-action controllers.

types of
Familiarize yourself with the modes of operation of the various
Use the determined operating point.
Value dimensionless
Parameter
Value [l/min]

Reference variable (w) at the working 0.4

point

parameters.
with different controllers and control
Check the behavior of the controlled system

Malfunction
Close hand valve VV12 further.

M7-20 OFesto Didactic 8131020

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M7-
2
Module 7- Analysis, closed-loop control, and control technology with the Mixing Station 2 Closed-loop control technology

2.8 Exercise: Tuning a PID controller for flow control

Problem
Aflow system should be operated with a PID controller with specified control parameters.
Procedure
1. Fillthe mixing tank VE4 with ~7 lwater each.
2. Open hand valve VV10 and VW12. Close allother hand valves.
3. Start FluidLab-PA closed-loop - select the"Continuous control" menu.
4. Select "Flow" as the
controlled system.
5. Switch on binary output bito
(MA1).
6. Select A_OUTO pump" as the manipulated variable.
7. Select the Plcontroller and set the reference variable of the controller.
8. Set the determined offset of the manipulated value (exercise 1.9).
9. Seta parameter pair for the PID controller and start the execution.

Parameter Value

Kp 1

T 2

T 0.5

Question
How does the system respond ifthe reference variable is changed in small steps aroundthe working
point or the manual valve VV12 is slightly closed?

if there is a malfunction, the Dcomponent of the closed-loop controller reacts the fastest and
increases the manipulated variable.

O Festo Didactic 8131020

M7-29