Flow Control Training System

Experiment 01

Objective
To determine the characteristics of a flow transducer as a position.
Apparatus Required
 Digital Multimeter
 Set of Leads
Theory
The fundamental concept underlying the use of a flow transducer for position
determination revolves around the alteration of fluid flow characteristics as a
consequence of an object's displacement within a fluid medium.
Fluid dynamics describes the behavior of fluids (liquids and gases) and how
they respond to forces and motion. Within this framework, we consider the
Navier-Stokes equations, which describe the conservation of momentum and
energy in a fluid. These equations govern how fluid properties change with
respect to spatial and temporal variations. When an object moves within a fluid,
it creates disturbances in the surrounding flow field. These disturbances
manifest as changes in fluid velocity, pressure, and density in the vicinity of the
moving object. The extent and nature of these disturbances depend on factors
such as the object's shape, size, speed, and the fluid's properties.
The effectiveness of using a flow transducer for position determination hinges
on the sensor's sensitivity to detect and quantify the alterations in fluid flow
caused by the moving object. A highly sensitive transducer is essential to
capture subtle changes accurately. To establish a quantitative connection
between flow data and object position, calibration experiments or simulations
are conducted. During calibration, the object's position is systematically varied
within the fluid, and corresponding variations in flow parameters are
meticulously recorded. This empirical data is subsequently utilized to create
mathematical models or lookup tables that establish the correlation between
flow measurements and object positions. It is crucial to acknowledge that the
relationship between fluid flow and object position may be nonlinear and
intricate. Factors such as turbulence in the fluid, boundary layer effects, and the
object's geometry can introduce complexity into the analysis. Therefore, careful
consideration and potential mathematical modeling are required to account for
these factors.
Recognize the inherent limitations of this approach. The feasibility and
accuracy of using a flow transducer for position determination may be
influenced by factors such as the required precision, the object's speed, and the
prevailing environmental conditions. Careful consideration of these factors is
necessary to determine the suitability of this method for a specific application.
Explore potential applications where this method might offer advantages over
traditional position sensors. Examples include situations where traditional
sensors are unsuitable due to harsh environmental conditions, such as
underwater positioning, measurement within corrosive or radioactive
environments, or scenarios involving objects with irregular shapes.
In summary, the theory of using a flow transducer for position determination is
grounded in the interplay between an object's motion and the consequential
changes in fluid flow properties. This principle serves as the basis for
developing a technique to indirectly deduce an object's position from flow data.
The practicality and adaptability of this approach are contingent on the specific
characteristics of fluid dynamics and the transducer used within the system
under consideration.
Procedure
 Connect, through leads, pin No. 8 of the PUMP DRIVER to the bush of
SET POINT 1, pin No. 9 to the adjacent bush, and pin No. 10 to its
adjacent bush.
 Start the pump regulating the voltage on SET POINT at 10V.
 Regulate the valve MANUAL VALVE to read on the FLOW METER 6
It/min: if the flow is slightly lower, regulate MANUAL VALVE to reach
the value closely higher.
 Regulate the voltage on SET POINT 1 at OV
 Connect pins No. 1 and 2 of the flow sensor FLOW to its adjacent pins of
the relevant interface.
 Insert one terminal of the digital voltmeter, set in dc, in pin No. 3 and the
other one in the earth bush.
 Regulate the trimmer OFFSET to read the value 0V on the multimeter.
 Start the pump regulating the voltage on SET POINT 1 at 10V.
 Regulate the trimmer GAIN to read on the multimeter the value 9V, in
case the flow read and calculated is 6 lt/min.
 Regulate the valve MANUAL VALVE for all the value of flow and write
down the voltage values read on the voltmeter.
  Put OFF the main switch.
 Remove all the connections.
 Draw the diagram of the voltage as a function of the flow.

Figure 1.1 Flow Control Training

System
Calculations
Flow(L/min) voltage(mV)
1 3
1.5 5.9
2 8.42
2.5 9.26
3 10.23
3.5 11.09
4 12.07
4.5 12.61

Table 1.1 Calculations

Graph
FLOW VS VOLTAGE
20
15
Voltage(mv)

10
5
0
0 1 2 3 4 5 6
Flow(L/min)
 Graph 1 Flow vs voltage
Analysis of Results
From the plot, it shows that there is a direct relationship between the flow rate
(in L/min) and the voltage output (in mV) of the flow transducer. As the flow
rate increases, the voltage output also increases. The relationship between flow
rate and voltage appears to be roughly linear, especially within the range of 1
L/min to 4.5 L/min. This suggests that there might be a linear correlation
between the two variables. Notice that there is a non-zero voltage output
(approximately 3 mV) even when there is no flow (0 L/min). This is likely due
to the transducer's offset or baseline reading. The sensitivity of the transducer
can be calculated as the change in voltage (mV) per unit change in flow rate
(L/min). In conclusion, the experiment shows that the differential position
transducer exhibits a mostly linear response within its defined operating range
from 11.5 cm to 4.5 cm. Sensitivity increases with level.
Conclusion
A linear relationship between flow rate and voltage output in the range of 1
L/min to 4.5 L/min, with a noticeable voltage offset. Calibration is essential to
accurately convert voltage readings to flow rates. Further validation against a
reference flow meter and noise reduction techniques should be considered for
precise measurements in practical applications.
 Experiment 02
Objective
 To understand the operation of a closed loop ON-OFF control system.
 To understand the effects of hysteresis on the control.
Apparatus Required
 Digital Multimeter
 Set of leads
Theory
Control systems are crucial in various applications, from maintaining the
temperature of a thermostat in a home to regulating the speed of a motor in an
industrial plant. One type of control system is the closed-loop ON-OFF control
system, which is simple yet effective. A closed-loop ON-OFF control system
consists of several key components:
Process: The system or process being controlled, such as a heater, air
conditioner, or motor.
Sensor: Measures a relevant parameter (e.g., temperature, pressure) of the
process and provides feedback to the controller.
Controller: Analyzes the sensor feedback and decides when to actuate the
control element.
Actuator/Control Element: Responsible for making changes to the process,
such as turning on or off a heater or adjusting a valve.
Reference/Setpoint: The desired value or target for the controlled parameter.
The controller continuously compares the actual process variable (measured by
the sensor) to the reference/setpoint value. If the actual value deviates from the
setpoint, the controller takes action to bring the process back to the desired
state. In ON-OFF control, the controller makes binary decisions, either turning
the actuator fully ON or fully OFF. When the process variable is below the
setpoint, the controller activates the actuator to the ON state. When the process
variable exceeds the setpoint, the controller deactivates the actuator to the OFF
state. This cycling of ON and OFF states continues until the process variable
stabilizes around the setpoint. Hysteresis is a phenomenon where the system's
response to a change in input depends not only on the current input but also on
its past values. In the context of control systems, hysteresis can introduce delays
and oscillations in the system's behavior.
Hysteresis in control systems can lead to "lag time," where the system remains
in its current state even after the error signal changes.
This can result in oscillatory behavior and can be detrimental to system stability
and performance. One way to reduce the effects of hysteresis is by introducing a
dead band or a tolerance range around the setpoint. When the error signal falls
within this dead band, no action is taken, preventing rapid ON-OFF cycling.
This dead band allows for smoother control and reduces wear and tear on
actuators.
Procedure
 Connect, through leads, bush No. 1 of the Flow Sensor to bush No. 1 of
the relevant interface and bush No. 2 to bush No. 2.
 Connect bush No. 11 of the WATER PUMP DRIVER to bush No. 11 and
bush No. 12 to bush No. 12.
 Connect the bush of SET POINT 1 to bush No. 6 of the ON-OFF
controller and bush No. 5 of the Flow interface to bush No. 5 of the ON-
OFF controller.
 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.
 Press the main switch (ON).
 Regulate the voltage on SET POINT 1 at 5 V.
 Move the terminal of the digital voltmeter from the bush of SET POINT 1
to bush No. 5 of the ON-OFF controller: the voltage value must be equal
to 3V; if the voltage is different, control that the flow of the water in the
tank be 4L/min otherwise calibrate the sensor.
 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
voltage applied to bush No. 5 and the voltage applied to bush No. 6,
which is 2V.
 Connect bush No. 10 of the ON-OFF controller to bush No. 10 of the
WATER PUMP DRIVER: the pump will start immediately; the flow will
start to increase while the voltage value read on the voltmeter will
decrease.
 As soon as the voltage difference between bush No. 6 and bush No. 5 is
null, the output of the ON-OFF controller (bush No. 10), going to a
voltage of approx. -10V, will stop the pump: the level must then be equal
 to 4L/min, corresponding to the starting flow plus the starting voltage
difference between bush No. 6 and bush No. 5.
 Slowly turn counter-clockwise the knob NEEDLE VALVE and/or the
knob DRAIN VALVE in order to decrease a little the flow: the voltage
difference between bush No. 6 and bush No. 5, caused by the flow
variation, brings the output of the ON-OFF controller (bush No. 10) to a
voltage of approx. 10V and the pump will start again.
 The pump will operate for a short time until the previous flow is reached
(4L/min). Regulate the knob NEEDLE VALVE and/or the knob DRAIN
VALVE until you determine, approximately, an equal time, for flow
increase and decrease, between the start and stop of the pump: the up and
down cycle of the flow will repeat itself.
 Repeat step No. 12.
 Measure the up and down times of the flow between the start and stop of
the pump with a hysteresis of 0%.
 Repeat the procedure from step No. 15 for all the hysteresis values and
write down the results.
 For each value of hysteresis repeat the measurement of the up and down
time several times.
 Close the NEEDLE VALVE and the DRAIN VALVE.
 Put OFF the main switch.
 Remove all the connections.
 Represent the characteristic diagram of the hysteresis.

Figure 2.1 ON-OFF controller loop

Calculations
Hysteresis (%) 25 37.5 50
 Set Point 4 4 4
Lower Limit Set Point (L/min) 3.5 3 2.8
Up-Raising time of the level (sec) 4 5 6
Upper Limit Set Point (L/min) 6 6.5 6.8
Lowering time of the level (sec) 5 7 9

Table 2.1 Calculations

Hysteresis 50%
Time(s) Flow(L/min)
0 4
3 6.8
12 2.8
18 6.8
27 2.8
33 6.8
41 2.8

Hysteresis 37.5%
Time( Flow(L/
s) min)
0 4
2.5 6.5
9.5 3
14.5 6.5
21.5 3
26.5 6.5
33.5 3
38.5 6.5
45.5 3

Hysteresis 25%
Time(s
) Flow(L/min)
0 4
2 6
7 3.5
11 6
16 3.5
20 6
25 3.5
29 6
34 3.5
38 6
43 3.5
47 6
 Table 2.2 Hysteresis 50%, 37.5%, 25%
Graphs
50% HYSTERESIS
8
7
6
Flow(L/min)
5
4
3
2
1
0
0 5 10 15 20 25 30 35 40 45
Time(sec)

37.5% HYSTERESIS
7
6
5
Flow(L/min)

4
3
2
1
0
0 5 10 15 20 25 30 35 40 45 50
Time(sec)

25% HYSTERESIS
7
6
5
Flow(L/min)

4
3
2
1
0
0 5 10 15 20 25 30 35 40 45 50
Time(sec)

Graphs 2.1
Analysis of results
50% Hysteresis: At the beginning (0 sec), the flow rate is 4 L/min. As the
hysteresis time increases, the flow rate alternates between 2.8 L/min and 6.8
L/min. The flow rate decreases from 4 L/min to 2.8 L/min as the hysteresis time
increases from 0 to 12 seconds. Subsequently, as the hysteresis time continues
to increase from 12 to 41 seconds, the flow rate oscillates between 2.8 L/min
and 6.8 L/min in a repeating pattern.
37.5% Hysteresis: At the start (0 sec), the flow rate is 4 L/min. With increasing
hysteresis time, the flow rate alternates between 3 L/min and 6.5 L/min. The
flow rate decreases from 4 L/min to 3 L/min as the hysteresis time increases
from 0 to 9.5 seconds. Then, the flow rate increases to 6.5 L/min as the
hysteresis time increases from 9.5 to 14.5 seconds. This pattern repeats as the
hysteresis time continues to increase.
25% Hysteresis: Initially (0 sec), the flow rate is 4 L/min. As the hysteresis
time increases, the flow rate alternates between 3.5 L/min and 6 L/min. The
flow rate decreases from 4 L/min to 3.5 L/min as the hysteresis time increases
from 0 to 7 seconds. Subsequently, as the hysteresis time continues to increase
from 7 to 47 seconds, the flow rate alternates between 3.5 L/min and 6 L/min in
a repeating pattern.
Conclusion
In conclusion, the experiment demonstrates the presence of hysteresis effects in
the relationship between hysteresis time and flow rate for three different
hysteresis levels (50%, 37.5%, and 25%). Flow rates exhibit memory-dependent
behavior, with distinct oscillations and variations in response to changing
hysteresis time.