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Example Control Expert Program for Dynamic Pump Control with PID

The document outlines a control program for dynamically adjusting the speeds of up to five pumps using PID control. It includes functions for rounding adjustments, applying speed changes, setting the number of active pumps, and initializing frequencies. The main control loop periodically adjusts pump speeds based on a computed PID output while ensuring they remain within safe limits.

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autshop168
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3 views

Example Control Expert Program for Dynamic Pump Control with PID

The document outlines a control program for dynamically adjusting the speeds of up to five pumps using PID control. It includes functions for rounding adjustments, applying speed changes, setting the number of active pumps, and initializing frequencies. The main control loop periodically adjusts pump speeds based on a computed PID output while ensuring they remain within safe limits.

Uploaded by

autshop168
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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-- Example Control Expert Program for Dynamic Pump Control with PID

-- Assumptions:

-- 1. PID output (PID_Output) is already computed.

-- 2. Minimum Hz Step: 0.25 Hz

-- 3. Initial pump speeds are stored in an array `Pump_Speeds`.

-- 4. Total number of pumps can vary dynamically (1 to 5).

-- Configuration

local MAX_PUMPS = 5 -- Maximum number of pumps

local MIN_HZ_STEP = 0.25 -- Minimum step for frequency adjustment

-- Variables

local Active_Pumps = 4 -- Number of active pumps (1 to MAX_PUMPS)

local Pump_Speeds = {35.0, 35.0, 35.0, 35.0, 0.0} -- Current pump speeds

local Initial_Frequencies = {35.0, 35.0, 35.0, 35.0, 0.0} -- Variable initial frequencies

local Current_Pump_Index = 1 -- Tracks which pump to adjust next

-- Input: PID Output

local PID_Output = 0.25 -- Example PID output

-- Function to round to the nearest step

local function round_to_step(value, step)

return math.floor(value / step + 0.5) * step

end

-- Function to apply PID adjustment

local function adjust_pumps()

-- Check if PID output exceeds minimum step threshold

if math.abs(PID_Output) >= MIN_HZ_STEP then


-- Determine the direction of adjustment

local adjustment = round_to_step(PID_Output, MIN_HZ_STEP)

-- Apply adjustment continuously to the current pump in the active range

Pump_Speeds[Current_Pump_Index] = Pump_Speeds[Current_Pump_Index] + adjustment

-- Ensure pump speed stays within safe limits (e.g., 0 Hz to 50 Hz)

if Pump_Speeds[Current_Pump_Index] < 0 then

Pump_Speeds[Current_Pump_Index] = 0

elseif Pump_Speeds[Current_Pump_Index] > 50 then

Pump_Speeds[Current_Pump_Index] = 50

end

-- Move to the next pump in a round-robin sequence within the active pumps

Current_Pump_Index = Current_Pump_Index + 1

if Current_Pump_Index > Active_Pumps then

Current_Pump_Index = 1

end

end

end

-- Function to set the number of active pumps

local function set_active_pumps(num_pumps)

if num_pumps >= 1 and num_pumps <= MAX_PUMPS then

Active_Pumps = num_pumps

print("Number of active pumps set to: " .. Active_Pumps)

-- Reset pump speeds to initial frequencies for any newly added pumps

for i = 1, MAX_PUMPS do
if i > Active_Pumps then

Pump_Speeds[i] = 0 -- Inactive pumps are set to 0 Hz

else

Pump_Speeds[i] = Initial_Frequencies[i]

end

end

else

print("Invalid number of pumps. Must be between 1 and " .. MAX_PUMPS)

end

end

-- Function to set initial frequencies for all pumps

local function set_initial_frequencies(frequencies)

for i = 1, math.min(#frequencies, MAX_PUMPS) do

Pump_Speeds[i] = frequencies[i]

Initial_Frequencies[i] = frequencies[i]

end

print("Initial frequencies set.")

end

-- Main Control Loop (called periodically in PLC)

local function main()

adjust_pumps()

-- Print pump speeds for debugging

for i = 1, Active_Pumps do

print("Pump " .. i .. ": " .. Pump_Speeds[i] .. " Hz")

end

end
-- Example Usage

set_initial_frequencies({35.0, 35.0, 35.0, 35.0, 35.0}) -- Set initial frequencies for pumps

set_active_pumps(4) -- Set number of active pumps to 4

-- Progressive Increase Example

print("--- Progressive Speed Increase ---")

PID_Output = 0.25

for t = 1, 10 do

main()

end

-- Progressive Decrease Example

print("--- Progressive Speed Decrease ---")

PID_Output = -0.25

for t = 11, 20 do

main()

end

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