IT-5201 Pressure Control
IT-5201 Pressure Control
IT-5201
1
TABLE OF CONTENTS
Worksheet 1. Characteristics of the Motor Pump................................................................ .03
Worksheet 2. Pressure Sensor............................................................................................. .09
Worksheet 3. On-Off Control of the Level Through the Pressure Sensor ............................ .14
Worksheet 4. On-Off Control of the Pressure Through the Solenoid Valve Driver ............. .21
Worksheet 5. Closed Loop Proportional Control of the Pressure......................................... .28
Worksheet 6. Closed Loop Proportional – Integral Control of the Pressure......................... .33
Worksheet 7. Closed Loop Proportional – Derivative Control of the Pressure .................... .38
Worksheet 8. Closed Loop Proportional – Integral – Derivative Control of the Pressure..... .43
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WORKSHEET 1
CHARACTERISTICS
OF THE MOTOR PUMP
-Set of leads
3
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 1.1which
shows the connections for the calibration of the WATER PUMP DRIVER (Fig. 1.1 and Fig.
1.2) and sets the process simulation panel as follows:
SET POINT 1 0V
4
WHAT THE STUDENTS DO
They must:
2) Connect the tip of the probe of channel CH1 of the oscilloscope to bush X2 of the
WATER PUMP DRIVER and the earth to the earth bush (Sheet 1.1 Fig. 1.1).
3) Regulate, on the oscilloscope screen, the width of the image, by selecting 5 V/DIV
through the relevant knob.
6) Regulate the trimmer Adj.1, turning it clockwise, to obtain a triangular wave equal to
10Vpp (Sheet 1.1 Fig. 1.2).
7) Regulate the trimmer Adj.2, turning it counter-clockwise, until the maximum of the
triangular wave is at 0V (Sheet 1.1 Fig. 1.2).
8) Move the probe of the oscilloscope to bush X3 (Sheet 1.1 Fig. 1.3).
9) Connect, through a lead, bush No. 8 of the WATER PUMP DRIVER to bush 0/10V
of SET POINT 1 (Sheet 1.1 Fig. 1.3).
10) Insert a terminal of the digital voltmeter, set to dc, in bush No. 9 and the other one in
bush No 10 (Sheet 1.1 Fig. 1.3).
11) Set the voltage between 0 and 10V and observe, on the oscilloscope screen, that the
duty cycle of the square wave signal is variable although its period is constant. The
luminosity variation of the LED and the voltage read on the multimeter, which
between 0 and 12V, show that the average value of the voltage is regulated.
12) Once the test phase of the pump interface is completed, remove the terminals of the
voltmeter and of the oscilloscope probe.
13) Connect bush No 9 of the output interface of the WATER PUMP DRIVER to bush
No. 9 of the pump and bush No. 10 to bush No. 10.
5
14) Insert a terminal of the digital voltmeter, set to dc, in the bush of SET POINT 1 and
the other one in the earth bush (Sheet 1.1 Fig. 1.4).
15) Slowly increase the voltage on SET POINT 1 and write down the voltage value which
allows the start of the motor.
16) Slowly decrease the voltage on SET POINT 1 and write down the value which allows
the stop of the motor.
17) Repeat the procedure from step No. 15 and verify that the results are the same: it has
now been determined the dead zone of the pump.
6
Sheet 1.1
Fig 1.1
Fig 1.2
7
Fig 1.3
Fig 1.4
8
WORKSHEET 2
PRESSURE SENSOR
9
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 2.1
which shows the connections of the pressure sensor with the relevant interface (Fig. 2.1 and
Fig. 1.2) and sets the process simulation panel as follows:
SET POINT 1 0V
10
WHAT THE STUDENTS DO
They must:
1) Connect, through leads, bush No. 8 of the WATER PUMP DRIVER to the bush of
SET POINT 1, bush No. 9 to bush No. 9, bush No. 10 to bush No. 10 (Sheet 2.1 Fig.
2.1).
2) Connect bushes No. 1 and 2 of the PRESSURE sensor to bushes 1 and 2 of the
relevant interface (Sheet 2.1 Fig 1.2).
3) Insert one terminal of the digital voltmeter, set in dc, in bush No. 3 and the other one
in the earth bush.
5) Regulate the trimmer OFFSET to read on the multimeter the value 0V.
7) Read the value shown on the pressure gauge and stop the pump when this value is 1
bar.
8) Regulate the trimmer GAIN to read on the multimeter the value of 5V: in this case
you have calibrated the pressure sensor establishing, for 0.2 bar, 1 V.
9) Regulate the valve NEEDLE VALVE for each pressure value listed in Table 2.1 and
write down the results read on the multimeter.
12) Draw the diagram of the voltage as a function of the pressure in Fig. 2.3.
11
Table 2.1
Fig 2.3
12
Sheet 2.1
Fig 2.1
Fig 2.2
13
WORKSHEET 3
14
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 3.1
which shows the connections of the ON-OFF control (Fig. 3.1) and sets the process
simulation panel as follows:
SET POINT 1 0V
15
WHAT THE STUDENTS DO
They must:
1) Connect bushes No. 1 and 2 of the PRESSURE sensor to bushes 1 and 2 of the
relevant interface.
2) Connect bush No. 9 of the WATER PUMP DRIVER to bush No. 9 and bush No. 10
to bush No. 10 (Sheet 3.1 Fig. 3.1).
3) Connect the bush of SET POINT 1 to bush No. 4 of the ON-OFF controller and bush
No.3 of the pressure interface to bush No. 3 of the ON-OFF controller (Sheet 3.1 Fig.
3.1).
4) Insert one terminal of the digital voltmeter, set in dc, in the bush of SET POINT 1 and
the other one in the earth bush (Sheet 3.1 Fig. 3.1).
7) Move the terminal of the digital voltmeter to bush X4 of the ON-OFF controller; the
voltage value must be equal to the difference between the voltages applied to bush
No.4 and that applied to bush No.3, which is 2V.
8) Connect bush No.8 of the ON-OFF controller to bush No.8 of the WATER PUMP
DRIVER: the pump will immediately start; the pressure level will increase while the
voltage value, read on the voltmeter, will decrease.
9) The voltage, at bush X4, once reached the zero value, will bring the ON-OFF
controller output to a voltage of -10V approximately, which will stop the pump.
10) Gradually turn counter-clockwise the knob NEEDLE VALVE and/or the knob
DRAIN VALVE: as soon as the level slightly decreases there will be a small voltage
difference between bushes No.4 and 3 that will bring the ON-OFF controller output
(bush No. 8) to a voltage of approximately 10V and the pump will start again.
11) The pump will continue operating until the previous level is reached.
13) Measure the up and down times of the level between start and stop of the pump with
an hysteresis of 0% and write down the results in Table 3.1.
14) Repeat the procedure of step 15 for all the values of hysteresis listed in Table 3.1 and
write down the results.
15) For each value of hysteresis repeat several times the measurement of the up and down
times.
16
16) Close the valves NEEDLE VALVE and DRAIN VALVE.
19) Draw the diagram of the characteristic of the hysteresis in Fig. 3.2, Fig. 3.3 and Fig.
3.4.
17
Table 3.1
Fig 3.2
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Fig 3.3
Fig 3.4
19
Sheet 3.1
Fig 3.1
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WORKSHEET 4
21
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 4.1
which shows the connections of the ON-OFF control (Fig. 4.1) and sets the process
simulation panel as follows:
SET POINT 1 0V
22
WHAT THE STUDENTS DO
1) Connect bushes No. 1 and 2 of the PRESSURE sensor to bushes 1 and 2 of the
relevant interface.
2) Connect SET POINT 2 to bush No. 8 and bush No. 9 of the WATER PUMP DRIVER
to bush No. 9 and bush No. 10 to bush No. 10 (Sheet 4.1 Fig. 4.2).
3) Connect bush No. 11 of the SOLENOID VALVE DRIVER to 11 and bush No. 12 to
12.
4) Connect the bush of SET POINT 1 to bush No. 3 of the ON-OFF controller and bush
No.3 of the pressure interface to bush No. 4 of the ON-OFF controller (Sheet 4.1 Fig.
4.1).
5) Insert one terminal of the digital voltmeter, set in dc, in the bush of SET POINT 1 and
the other one in the earth bush (Sheet 4.1 Fig. 4.1).
8) Move the terminal of the digital voltmeter to bush X4 of the ON-OFF controller; the
voltage value must be equal to the difference between the voltages applied to bush
No.4 and that applied to bush No.3, which is -2V.
9) Connect bush No.8 of the ON-OFF controller to bush No.8 of the SOLENOID
VALVE DRIVER. The valve will not be activated.
11) The voltage, at bush X4, once reached the zero value, will bring the ON-OFF
controller output to a voltage of 10V approximately, which will activate the
SOLENOID VALVE DRIVER.
12) Gradually turn counter-clockwise the knob NEEDLE VALVE and/or the knob
DRAIN VALVE: as soon as the pressure slightly decreases there will be a small
voltage difference between bushes No.4 and 3 that will bring the ON-OFF controller
output (bush No. 8) to a voltage of approximately -10V and the solenoid valve will be
deactivated..
13) The pump will continue operating until the previous pressure is reached.
15) Measure the up and down times of the level between start and stop of the pump with
an hysteresis of 10% and write down the results in Table 4.1.
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16) Repeat the procedure of step 15 for all the values of hysteresis listed in Table 4.1 and
write down the results.
17) For each value of hysteresis repeat several times the measurement of the up and down
times.
21) Draw the diagram of the characteristic of the hysteresis in Fig. 4.3, Fig. 4.4 and Fig.
4.5.
Table 4.1
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Fig 4.3
Fig 4.4
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Fig 4.4
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Sheet 4.1
Fig 4.1
Fig 4.2
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WORKSHEET 5
28
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 5.1
which shows the connections of the control (Fig. 5.1) and sets the process simulation panel as
follows:
SET POINT 1 0V
29
WHAT THE STUDENTS DO
They must:
1) Connect, through leads, bush No. 9 of the WATER PUMP DRIVER to bush No. 9
and bush No. 10 to bush No. 10 (Sheet 5.1 Fig. 5.1).
2) Connect bush No. 1 of the Pressure Sensor to bush No. 1 of the relevant interface
and bush No. 2 to bush No. 2 (Sheet 5.1 Fig. 5.1).
3) Connect the bush of SET POINT 1 to bush No. 4 of the PID controller and bush
No. 3 of the pressure interface to bush No. 3 of the PID controller (Sheet 5.1 Fig.
5.1).
4) Insert one terminal of the digital voltmeter, set in dc, in the bush of SET POINT 1
and the other one in the earth bush.
6) Move the terminal of the digital voltmeter from the bush of SET POINT 1 to bush
No. 3 of the PID controller: the voltage value must be equal to 0V.
7) Move the terminal of the digital voltmeter to bush X1 of the PID controller: the
voltage value must be equal to the difference between the voltage applied to bush
No. 4 and that applied to bush No. 3, which is 2V.
9) Connect bush No. 5 of the PID controller to bush No. 5 and bush No. 8 to bush
No. 8 of the WATER PUMP DRIVER.
10) Move the terminal of the digital voltmeter to bush No.3 of the PID controller:
write down in Table 5.1 the voltage value.
11) Write down in Table 5.1 the voltage value read every 15 seconds until the
transitory is completed.
12) Move the terminal of the digital voltmeter to bush X1 of the PID controller: the
voltage value, to be written down, represents the steady state error.
13) Regulate the PROPORTIONAL knob to 50% and repeat the procedure from step
No. 9.
14) Repeat the procedure with the PROPORTIONAL knob at 75% and 100%.
16) Draw the curves of the closed loop dynamic response for all the values of the
PROPORTIONAL knob.
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17) Analyze the results.
Table 5.1
Fig 5.2
31
Sheet 5.1
Fig 5.1
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WORKSHEET 6
33
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 6.1
which shows the connections of the control (Fig. 6.1) and sets the process simulation panel as
follows:
SET POINT 1 0V
34
WHAT THE STUDENTS DO
They must:
1) Connect, through leads, bush No. 9 of the WATER PUMP DRIVER to bush No. 9
and bush No. 10 to bush No. 10 (Sheet 6.1 Fig. 6.1).
2) Connect bush No. 1 of the Pressure Sensor to bush No. 1 of the relevant interface
and bush No. 2 to bush No. 2 (Sheet 6.1 Fig. 6.1).
3) Connect the bush of SET POINT 1 to bush No. 4 of the PID controller and bush
No. 3 of the pressure interface to bush No. 3 of the PID controller (Sheet 6.1 Fig.
6.1).
4) Insert one terminal of the digital voltmeter, set in dc, in the bush of SET POINT 1
and the other one in the earth bush.
6) Move the terminal of the digital voltmeter from the bush of SET POINT 1 to bush
No. 3 of the PID controller: the voltage value must be equal to 0V.
7) Move the terminal of the digital voltmeter to bush X1 of the PID controller: the
voltage value must be equal to the difference between the voltage applied to bush
No. 4 and that applied to bush No. 3, which is 2V.
9) Connect bush No. 5 of the PID controller to bush No. 5 and bush No. 8 to bush
No. 8 of the WATER PUMP DRIVER.
11) Press the RESET button to reset the integrator that is to discharge the circuit
integrating condensers.
12) Connect bush No. 6 of the PID controller to bush No. 6 (Sheet 6.1 Fig. 6.1).
13) Move the terminal of the digital voltmeter to bush No.3 of the PID controller:
write down in Table 6.1 the voltage value.
14) Write down in Table 6.1 the voltage value read every 15 seconds until the
transitory is completed.
15) Move the terminal of the digital voltmeter to bush X1 of the PID controller: the
voltage value, to be written down, represents the steady state error.
35
16) Regulate the INTEGRAL knob at 50% leaving the PROPORTIONAL knob at
25% and repeat the procedure from step No. 11.
17) Repeat the procedure with the INTEGRAL knob at 75% and 100%.
18) To reduce the steady state error, regulate the PROPORTIONAL knob to 50%,
75% and 100% if necessary.
20) Draw the curves of the closed loop dynamic response for all the values listed in
the table.
Table 6.1
Fig 6.2
36
Sheet 6.1
Fig 6.1
37
WORKSHEET 7
38
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he gives to the students the sheet 7.1
which shows the connections of the control (Fig. 7.1) and sets the process simulation panel as
follows:
SET POINT 1 0V
39
WHAT THE STUDENTS DO
They must:
1) Connect, through leads, bush No. 9 of the WATER PUMP DRIVER to bush No. 9
and bush No. 10 to bush No. 10 (Sheet 7.1 Fig. 7.1).
2) Connect bush No. 1 of the Pressure Sensor to bush No. 1 of the relevant interface
and bush No. 2 to bush No. 2 (Sheet 7.1 Fig. 7.1).
3) Connect the bush of SET POINT 1 to bush No. 4 of the PID controller and bush
No. 3 of the pressure interface to bush No. 3 of the PID controller (Sheet 7.1 Fig.
7.1).
4) Insert one terminal of the digital voltmeter, set in dc, in the bush of SET POINT 1
and the other one in the earth bush.
6) Move the terminal of the digital voltmeter from the bush of SET POINT 1 to bush
No. 3 of the PID controller: the voltage value must be equal to 0V.
7) Move the terminal of the digital voltmeter to bush X1 of the PID controller: the
voltage value must be equal to the difference between the voltage applied to bush
No. 4 and that applied to bush No. 3, which is 2V.
9) Connect bush No. 5 of the PID controller to bush No. 5 and bush No. 8 to bush
No. 8 of the WATER PUMP DRIVER.
11) Connect bush No. 7 of the PID controller to bush No. 7 (Sheet 7.1 Fig. 7.1).
12) Move the terminal of the digital voltmeter to bush No.3 of the PID controller:
write down in Table 7.1 the voltage value.
13) Write down in Table 7.1 the voltage value read every 15 seconds until the
transitory is completed.
14) Move the terminal of the digital voltmeter to bush X1 of the PID controller: the
voltage value, to be written down, represents the steady state error.
15) Regulate the DERIVATIVE knob at 50% leaving the PROPORTIONAL knob at
25% and repeat the procedure from step No. 11.
40
16) Repeat the procedure with the DERIVATIVE knob at 75% and 100%.
17) To reduce the steady state error, regulate the PROPORTIONAL knob to 50%,
75% and 100% if necessary.
19) Draw the curves of the closed loop dynamic response for all the values listed in
the table.
Table 7.1
Fig 7.2
41
Sheet 7.1
Fig 7.1
42
WORKSHEET 8
43
WHAT THE TEACHER DOES
After checking the knowledge of the prerequisites, he analyzes with the students the curves
drawn during the work experiences 5, 6 and 7. After determining the possible values of Kp,
Ki and Kd to be used, he gives to the students the sheet 8.1 which shows the connections of
the control (Fig. 8.1) and sets the process simulation panel as follows:
SET POINT 1 0V
44
WHAT THE STUDENTS DO
They must:
1) Determine the value of Kp for which oscillations start through the analysis of the
curves or repeating the experiment with intermediate values of Kp following the
procedure listed in Worksheet 5: The value of the position of Kp, for which
oscillations start, must be reduced by 0.6 times.
2) Once determined the value of Kp and analyzed the curves of Ki drawn during work
experience 6, establish the optimum value of Ki repeating, if necessary, the procedure
listed in the same Worksheet for all the intermediate values.
3) Exclude the integral action without modifying the value chosen for Ki.
4) Determine the optimum value of Kd through the analysis of the curves drawn during
work experience 7 or repeating, if necessary, the procedure listed in the same
Worksheet.
5) Utilize at the same time the proportional, integral and derivative actions and perform
the experiments of Worksheet 5, 6 and 7 (Sheet 8.1 Fig. 8.1).
6) Write down in Table 8.1 the voltage value read every 15 seconds until the transitory is
completed after its conversion in centimeters (1V = 0.2bar).
7) Draw the curves of the closed loop dynamic response (Fig. 8.2).
45
Table 8.1
Fig 8.2
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Sheet 8.1
Fig 8.1
47