(IV) Water Level Control System

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 .

1.2 Computer Aided Water Level Control System

Water Level Controller is to be implemented in 2 phases.

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.

1.3 Computer Aided Speed Control System

A system with a servomotor and a tachometer. Preferred speed of rotation of the shaft of the servo motor is set via the LabVIEW VI front panel and the servo motor is to be actuated thereafter through the computer interface. Measured speed of the shaft with tachometer is constantly sent back to PC to implement feedback control loop.

1.4 Computer Aided Temperature Control System

This lab station contains a boiler with an air heater within it. Air heater is actuated through the transformed PC signal. Temperature sensor is sending the temperature of the water tank. Then the control function inside PC determines the heater actuating signal based on temperature set point on the VI front panel and the received temperature measurement. _________________________________________________________________________________ __________________
1

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.

2 Description of the Water Level Control System

2.1 Water Tank with Solenoids and Level Sensor

Figure 2.1- Water tank with solenoids and water level sensor

2.1.1 Transparent Tank

This Tank is either to be purchased ready-made or to be constructed from perspex. Transparency of the tank is important so that the water level is easy to observe which is to be computer controlled. (See Appendix A for the discussion on purchasing options of the tank.)

2.1.2 Solenoid Valves

To make the system more portable and observable, minimum possible size of the lab stations was preferred. Thus 1/4" solenoid valves was decided to use. Available minimum size of the solenoid valve was a critical factor of the size of the lab station if the solenoid valves were to use as the control valves.

2.1.3 Level Sensor

Water level sensor or float switch senses the level of water in the tank and send it back to the PC via DAQ device.

2.1.4 Inflow and Outflow

Inflow is connected to a water supply pipe under available pressure of the water supply, which is then then controlled via the inflow solenoid. Outflow is connected to a drainage pipes or directed to a proper place for the removal of water as allowed by the outflow solenoid.

2.2 PC with DAQ card and Relay Circuits

Fig 2.2-DAQ card and relay circuit with PC

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.

2.2.2 Relay Circuit

Solenoid valves need 230V actuating signal to be turned on and off. PC output is only 0-5V. Thus a conversion device is needed. This function is done through the relay circuit. A simple measurement filter can also be implemented electronically to reduce the measurement noise in the water level sensor if needed.

2.2.3 Personal Computer (PC)

LabVIEW virtual instrument is running inside PC, processing the measured water level together with the setpoint to determine solenoid actuator signals. PC with Windows operating system is needed as device drivers for the data acquisition device is available only for Windows.

3 Block diagram of the Water Level Control System

3.1 Block Diagram of the components of the water level control system

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.

3.2 How control function is implemented inside PC

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.

4 LabVIEW VI of the Water Level Control System

4.1 Front Panel View of the Virtual Instrument

Fig 4.1 Front Panel View of the Virtual Instrument

4.2 Block Diagram View of the Virtual Intrument

Fig 4.2 Block Diagram View of the Virtual Intrument

5 Operational Instructions and Lab Report

5.1 Set up tank
1 Connect inflow to the pipe of the water supply and allow water to come up to solenoid 2 Connect outflow to the drainage pipes or direct water flow into a container 3 Power on the relay circuit board 4 Connect NI-USB-6008 to the PC via USB port

5.2 Set up software

1 Download the LabVIEW VI from this site 2 Open LabVIEW and load the VI 3 Start VI using the run button

5.3 Control water level via the VI

1 Set the desired water level 2 Wait until water level stabilize at the desired set poing 3 Apply a disturbance by turning inflow valve on and off. 4 Observe how the computer aided control system maintains the water level at the desired level

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

7 Component List and Cost Estimation

7.1 Circuit components for the implementation of the relay circuit board.
This list includes electronics components discussed in the Appendix F (Relay Circuit Board and

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

2N2222/2N3904 or BC547 1N4148/1N4001 741IC 10K

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