ME-339 Control Engineering Lab

Lab Report – 04

Plotting Characteristic Curve for Flow Sensor

Submitted to
LE. Usman Ghani

Submitted by

Name Muhammad Talha Nouman

CMS ID 366197
Semester 5th
Section ME-13-C
Group 4

School of Mechanical & Manufacturing Engineering

National University of Science and Technology – Islamabad
Control Engineering Lab
Lab Report - 04
Objectives
 To understand the working of the flow control training system
 To investigate the construction and working of the flow sensor
 To plot the characteristics curve between rotameter (LPM) and output reading of
flow sensor (volts)

Equipment
1. Flow Control Training System
2. Digital Multimeter
3. Water supply
4. Connecting Leads
5. Digital Multimeter Lead Probes

Circuit Diagrams and Apparatus Setting

Fig.1.1. Flow Control Trainer

Fig.1.2. Circuit Diagram for Flow Sensor and Water Pump Driver

2
Control Engineering Lab
Lab Report - 04

Fig.1.3. Real-time connection on the Control Panel

Theoretical Background
Rotameter
By balancing the weight of an in-stream "float" against
an upward flow, variable area flowmeters or rotameters
measure flow. Calculating the flow rate requires
knowledge of the tube and float weight and shape as
well as the characteristics of the fluid.
Working Principle
Fig.1.4. Rotameter
The variable area principle underlies the operation of the
rotameter. In other words, as a liquid flows through a tapered tube, the float rises, allowing
more liquid to travel through. The float will be increased higher as the magnitude of the flow
grows. The flowrate of the liquid determines the level of the float, which rises or falls in direct
proportion to the flowrate of the liquid and the annular space surrounding the float. The annular
space between the ball and the tube may be proportional to the flow under balanced
circumstances.
Hall Effect Flow Sensor
The Hall Effect, which is explained below, governs how Hall Effect type flow sensors operate:
“When current flows perpendicular to a magnetic field, the electrons (holes) in an n-type (p-
type) semiconductor are deflected, which results in the Hall Effect. The deflection of these

3
Control Engineering Lab
Lab Report - 04
charged carriers generates the Hall voltage, whose polarity is governed by the active charge
carriers.”
Working Principle
Positive displacement flow metres from flow Technology use the Hall Effect Sensor as a
simple yet versatile sensor. With a pinwheel sensor to gauge how much liquid has passed
through it, the sensors are installed in line with your water line. Each rotation produces an
electrical pulse. The water line is completely sealed off from the Hall Effect sensor, keeping it
secure and dry. Water flow may be simply calculated by counting the pulses that the sensor
outputs. Depending on the flow rate, fluid pressure, and sensor orientation, the pulse rate
changes

Procedure
1. First of all, establish the electrical connection on the control panel as recommended
in the circuit diagram Fig.1.2, and Fig.1.3.
2. Connect the flow sensor with connecting leads as per circuit diagram shown in
Fig.1.3.
3. Now connect the water pump driver with the set point of the ON-OFF controller in
order to set up and operate the speed of water motor as shown in Fig.1.2, and Fig
1.3.
4. After establishing the tight fitted electrical connection, press the main switch ON
and wait for at least 5 minutes for the motorized valve to become stabilized.
5. Since our main objective of the experiment is to operate the flow control by
connecting the lead with input of the flow sensor and the output voltage is to be
checked by using digital Multimeter as shown in Fig.1.3.
6. Before turning on system, make sure to properly adjusted the water supply
connection on the side associated with the process tank i.e. properly aligned
motorized valve and gate valves as shown in Fig.1.1.
7. Operate the water motor on nominal speed in order to avoid the water spillage
because it can cause the electrical damage and may lead to life threatening in any
case. Therefore, adjust the speed of motor by observing the flow from float switch
into the process tank.
8. Now, vary the flow in LPM and check the deflection in the operating voltage of the
flow sensor as shown on the connected Digital Multimeter, and note the readings
rigorously for both flow rates from rotameter and output voltage by digital
multimeter.
9. Take eight observations for the rise in flow rate versus output voltage and
investigate the behavior of output voltage with respect rise in flow rate.
10. Now take eight readings for the flow rate drop to same set points as taken for flow
rate rise and investigate the trend of the output voltage as shown on the digital
multimeter with respect to the flow rate.
11. Draw a graph between the flow rate (Lpm) and the operating voltage (V) to obtain
the characteristics of our control system.

4
Control Engineering Lab
Lab Report - 04
12. Graph both the voltage rise and voltage drop characteristic curves versus the same
flow rates in order evaluate the hysteresis (area spacing between two curves as
recorded as deviation) as shown in the Graph 1.1.
13. In order to complete the experiment accurately and properly, we need to follow the
recommended safety precautions in order to avoid any loss during the lab session.

Observations & Calculations

Relationship between Voltage Rise/Drop with Flow rate
Sr. No. Flow Rate Voltage Rise
(Lpm) (V)
1 1 0.08
2 2 1.66
3 3 2.85
4 4 3.91
5 5 5.79
6 6 6.68
7 7 7.88
8 8 8.73
Table.1.1: Relationship of Voltage rise with flow rate

Sr. No. Flow Rate Voltage Drop

(Lpm) (V)
1 1 9.98
2 2 8.15
3 3 7.01
4 4 5.56
5 5 4.02
6 6 2.50
7 7 1.36
8 8 0.07
Table.1.2: Relationship of Voltage drop with Flow rate

5
Control Engineering Lab
Lab Report - 04

Graph

Output Voltage vs Flow Rate

12
y = 1.4094x - 1.5111
Output Voltage (V)
10 R² = 0.9978
8
6 y = 1.2502x - 0.9286
4 R² = 0.9933
2
0
-2 1 2 3 4 5 6 7 8
Flow Rate (Lpm)

Support Hysteresis
Voltage Rise Voltage Drop
Linear (Voltage Rise) Linear (Voltage Drop)

Graph.1.1. Relationship between Voltage Rise & Drop versus Flow Rate

Discussion
Since an experiment is performed in order to determine the effect of the water flow rate in
the process tank as recorded by rotameter on the output voltage of flow sensor as recorded by
using digital multimeter instantly with respect to particular flow rates.
As with reference to the Table.1.1, we have observed with the increase in the water flow
rate, output voltage of flow sensor also increases. On further investigating from the respective
characteristic curve (Voltage Rise) on the Graph.1.1, it has been observed that it has strictly
followed the linear relationship which means that output voltage of flow sensor is (strictly
saying) directly proportional to the water flow rate as recorded by rotameter.
As with reference to Table.1.2, since when motor driver is turned off or operated on the
low speed in reverse direction, so that water flow rates drop which can significantly affect the
output voltage of the flow sensor. After evaluation, we have observed that with the decrease in
the water flow, the output voltage of flow sensor has also decreased which is shown from the
characteristic curve (Voltage Drop) on Graph.1 that it has strictly followed the linear
relationship which means that output voltage of flow sensor is (strictly saying) directly
proportional to the water flow rate as recorded by rotameter.
However, a certain amount of deviation in the voltage rise and voltage drop are recorded
with the same water flow rates. This certain extent of deviation has inferred that the hysteresis
(area spacing between voltage rise and drop curves) as shown in the Graph.1.1, has introduced
due to certain reasons which may include;
a) Fluctuation in the pressure of water flow which may impact the reading of output
voltage of flow sensor.

6
Control Engineering Lab
Lab Report - 04
b) This deviation may introduce due to certain level of faultiness in the apparatus either
on the water supply side (piping system and connection) or electrical connection.
c) It can be caused by electrical interference of strayed waves with the output voltage as
sensed by the flow sensor at that instant.
d) Turning off the motor driver instantly can cause the certain level of deviation into the
output voltage when the water flow rates is dropped.
e) It can be caused due to poor confinement of the readings as recorded by faulty or non-
synchronized digital multimeter.

Conclusion
After performing this experiment, we have observed that the output voltage of flow sensor
as measured by digital multimeter is directly related with the water flow rates as recorded by
the rotameter. On further investigating from the characteristic curves of voltage rise and
voltage drop with the same water flow rates, it has been observed that output voltage of flow
is linearly dependent on the water flow rate. However, a certain amount of deviation
(hysteresis) is significantly observed from the graph which may be caused due to the reasons
as aforementioned. Conclusively, this experiments provides us the insights to the engineers or
manufactures how to work with much precision and calibration while working with the sensor
technology.

Safety Precautions
i. Avoid instantly turning on or off the water motor driver because it can create the eventual
water splash and cause the water spillage which may lead to electrical connection damage
and thus become life threatening in any case.
ii. Observe the reading from the rotameter on straight line angle in order to avoid from
parallax error which may lead to any electrical damage due to eventual water splash.
iii. Switch OFF the setup when not in use.
iv. Disconnect the power supply before making any connections or adjustments to the circuit.
v. Use insulated tools and equipment to handle electrical components.
vi. Operate the motor on nominal input voltage range (0-10V) in order to avoid the motor
overload condition.
vii. To avoid fire or shock hazards, observe all ratings and marks on the instrument
viii. Do not operate the system in wet / damp conditions.
ix. Make sure that all the connections are tightly fitted on the control panel and water supply
connections
x. Do not overload electrical outlets or use damaged extension cords to prevent short circuits
and potential fires.
xi. Maintain a clean and organized workspace to prevent tripping hazards and facilitate easy
access to emergency equipment.
xii. Use one hand whenever possible to minimize the risk of a complete electrical path through
the body.
xiii. Do not touch exposed wires or components when the circuit is live.