UNIVERSITI TUN HUSSEIN ONN MALAYSIA

Faculty of Engineering Technology

DEPARTMENT OF MECHANICAL
ENGINEERING TECHNOLOGY
CONTROL LABORATORY
LAPORAN MAKMAL/LABORATORY REPORT
Kod M/Pelajaran/ ENGINEERING LABORATORY IV
Subject Code BNJ 37301
Kod & Tajuk Ujikaji/
Code & Title of Experiment
Kod Kursus/
Course Code
Kumpulan/Group
Nama Pelajar/Name of
Student
Lecturer/Instructor/Tutor’s 1.
Name 2.
Nama Ahli Kumpulan/ No.
Penilaian / Assesment
Group Members Matrik
1. Teori / Theory 10 %
Keputusan /
2. 15 %
Results
Pemerhatian
3. 20 %
/Observation
Pengiraan /
4. 10 %
Calculation
Perbincangan /
5. 25 %
Discussions
Tarikh Ujikaji / Kesimpulan /
15 %
Date of Experiment Conclusion
Tarikh Hantar / Rujukan /
5%
Date of Submission References
JUMLAH / TOTAL 100%
ULASAN PEMERIKSA/COMMENTS
COP DITERIMA/APPROVED
STAMP
 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

COURSE INFORMATION

COURSE TITLE: ENGINEERING LABORATORY IV (BNJ 37301)

TOPIC 3: PROPORTIONAL CONTROL (LIQUID LEVEL AND

FLOW SYSTEM)

1. OBJECTIVES

In this activity you will accomplish the following:

i. Describe the action of the proportional control algorithm
ii. Define offset
iii. Describe the system using Laplace transformations
iv. Run the system with the proportional controller

2. SKILLS

In this activity you will develop the following skills:

i. Technology: apply technology.
ii. System: understand systems.
iii. Resources: manage time, manage materials/facilities.
iv. Interpersonal: work as a member of a team.
v. Information: use computers to process information.
vi. Personal: responsibility, self-esteem, self-management.

3. MATERIALS

In this activity you will need the following materials:

i. Process Line panel for Level Control
ii. PC computer with Process Motion software.

4. THEORY

4.1 PROPORTIONAL CONTROL ALGORITHM

The proportional control algorithm output m is defined as:

m = Kc*e + mo Eq. 1-1

Where:
m proportional control algorithm output, which is expressed in terms
of percent input to the pump.
Kc proportional control algorithm constant (gain)
e error
mo controller bias. This is a fixed value that will provide a constant
value to the control algorithm.

2 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

When the error is 0, m will be equal to mo. When the error is positive, m will be
greater than mo, and when the error is negative m will be less than mo.

Using the automobile cruise control example, when the cruise control is set to 55
miles per hour and the car is travelling at 55 miles per hour, the error is zero.
However, the controller needs to send a constant amount of gas to the engine to
keep the car going 55 mph. This constant amount of gas is the m for the cruise
controller.

Suppose that the car starts climbing a hill. Its speed will decrease and an error will
develop. The cruise controller will add an amount of gas equal to Kc*e to the
constant amount mo. As the car speeds up and approaches 55 mph, the error will
decrease, and the controller will decrease the amount of gas sent to the engine
back to the mo value.

This example illustrates an important principle of the proportional controller.

When a load is presented to a system, or when the reference value changes, an
error is created. The proportional control algorithm output m changes
proportionally to the error e. The ratio between the changes in the control
algorithm output Δm and the error Δe is determined by the controller gain Kc, as
expressed in Kc = Δm
Δe

The block diagram that describes the level control system with a proportional
control algorithm is as shown in Fig1-1:

Controller Final Control

Algorithm Element (pump) Tank

Reference level error m q in Actual Level

-+

Level Sensor

Figure 1-1: Level control system – block diagram.

With the proportional control algorithm is used the output m is proportional to the
error (e) thus for a small error the signal will be relatively small and for a larger
error it will be bigger.

4.2 LAPLACE TRANSFORMATIONS

To examine the effect of changes in Kc over the system, you will use Laplace
transforms. The Laplace transform is a technique for translating certain
complicated differential equations into simple algebraic equations. By substituting

3 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

a complex number S for t, we translate the equation from the real time plane into
an imaginary plane called the Laplace space. After the Laplace transform, time t is

removed from the system and is replaced with S. The system is now said to be in
the Laplace space, also known as the Laplace plane or Laplace domain.

4.3 LEVEL CONTROL AND ITS LAPLACE TRANSFORM

The following is a block diagram in Fig 1-2 describes the level control system and
specifically for this case it is a first order system in the Laplace domain.

ControllerFinal Control
Algorit hmElement (pump) Tank
+
Ref s error m q in
ms=F(e)s Kp

- Level Sensor

Km

Figure 1-2 : Control system in Laplace space - block diagram

4.4 DERIVING THE SYSTEM GAIN

The four blocks of the system shown in fig 1-2 and their functions are:

1. Controller block.The function in the controller block in time domain is m

= Kc *e mo. The controller multiplies the error e by the controller gain Kc
and then adds the constant mo to determine the proportional algorithm
output m. In the Laplace domain the controller function is m = Kc.
e
2. The Final Control Element (controlled pump gain).The controlled pump
gain is Kp. The dynamic properties of the pump will be ignored. In the
Laplace domain the controller function is qin = K p .
m
3. The tank is a first order system whose gain is K and whose time constant
is τ. The gain K and time constant τ need to be determined first. The
h tan k K
Laplace transform of the tank is =
qin τS + 1
4. The level sensor gain is Km. The level sensor gain in this system can be
regarded as 1 and it will not affect the overall gain in the tank. However,
the sensor’s inability to measure itself leads to a very significant difference
between the actual system output and the reference output. This difference

4 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

is called the offset error. The relation between the level in the tank and the
reference value is ;-

You should note here, that the reference value is always going to be slightly larger
than the tank pressure. This will cause a condition called an offset error. In
actuality, this means that a proportional controller can never really direct the
system all the way up to the true reference value, and the system output will
always be slightly lower than the reference. You will observe the offset when you
run the system.

Simplifying equation 1-2 using algebra yields equation 1-3:

Where;-

4.5 CONCLUSIONS

From the analysis of the proportional control system, it can be concluded as

follows;-

1. When a proportional control algorithm is used to control a first order

system the entire system acts also like a first order system (as
demonstrated in equation 1-3).

2. The entire system gain is

3. The system gain is always smaller than 1. Thus, for a step input, the
system will always display an offset error where the actual output is
slightly less than the reference value.

4. Increasing Kc (the controller gain) increases the system gain and decrease
the offset error.

5 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

5. The system time constant is . The value of the

system’s time constant  system is smaller then the tank time constant.

6. Increasing the controller gain, Kc decreases the system’s time constant and
the system response time.

4.6 ADDITIONAL THEORY

6 BNJ 37301-Engineering Laboratory IV

UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

7 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

5. TASK

In this activity you will:

1. Run the system using the proportional control algorithm.

2. Introducing a step input in the reference value and monitor the resulting
system response (time constant and error).
3. Vary the controller gain to test the resultant system response (in both
dynamic and static systems).

5.1 TASK 1; INVENTORY AND SAFETY CHECKS1

1. Check whether all materials required for this activity are available at your
lab station.
2. Check whether your lab station conforms to the Safety Guidelines.
3. Complete the Inventory and Safety Check List on the Worksheet for this
activity.

5.2 TASK 2; SETTING UP

1. Turn on the computer.

2. Run the ProcessMotion Software.
3. Activate the PressureLine panel, making sure that the panel is connected to
a COM port on your computer and that the Communications key is turned
to PC.
4. Drain the tank so that it is at its minimum level. Then close valve A and
keep valve B open. Valve C should remain closed throughout.
5. Click On-Line (at modes).
6. Click the Level Control / Proses button.
7. Select the PID Controller from the dialog box and enter the following
parameters:
Setpoint : 110
Kc :5
Ti : 100000
Td :0
Mo :0
In setting these parameters, you have created a system where the Ti, Td,
and Mo parameters will not contribute to the final m. m will be equal to Kc
* e. This is a strict proportional control algorithm with no bias.
8. Click Run.
9. Run the system until it reaches steady state.
Question: Is there an offset?
10. Record the system output H in column 1 of the chart on your worksheet.
This column is marked Initial reference value. Record this value in every
row of this column.
11. Record the controller output m in column 5 of the chart on your
worksheet.

8 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

5.3 TASK 3 ; USING PROPORTIONAL CONTROL

1. Click the Level Control button and change the Kc setting to 10.
2. Now perform a step input. Increase the set point, by changing it to the
Initial reference value + 30% (e.g. if your initial reference was 100mm,
change the set point to 130mm.)Record the new set point value in column
2 of your chart. Click Run.
3. Wait till the system reaches steady state. Record the error in column 4 of
the graph on your worksheet. Record the controller output m in column 5
of your graph.
4. Record the total response time (Time at reaching steady state minus Time
of step input) in column 6.
5. Record the percentage of the offset error (Error/Reference) in column7.

Question: Describe the system output response

6. Reset the setpoint back to the initial reference value and allow the system
to return to the reference value. Repeat the experiment, for step inputs of
+40%, +50%, -20%, -30%and –40%, respectively. Record your results in
the chart.

Question: When is the offset percentage highest? Lowest?

Question: What is the cause of offset?

5.4 TASK 4 ; VARY THE Kc VALUE

Change the Kc value will change the system response. You will now present the
system with a step input, and vary the Kc setting to see how the proportional
control affects the system response. You will also add system loads to see how the
system responds.

1. Reset the Setpoint to the initial reference value in Task 1-3. Click Run
and allow the system to come to steady state. You will now raise the Kc
value and test the system with step inputs and various loads.
2. Change the Kc to a value of 100. Perform a step input by increasing the
setpoint by 30%.
3. Now present the system with a load, by opening valve A and closing valve
B. Valve A drains more quickly than valve B, thus putting an added load on
the system and Click Run.

Q: Describe the general system response, the response time, and the
percentage of offset.

4. Now open both valve A and valve B.

Q: How does the system respond?

9 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

5. Change the Kc to a value of 1. Perform a step input by increasing the

setpoint by 30%. Click Run

Q: Describe the general system response, the response time, and the
percentage of offset.

6. Change the Kc to a value of 10. Perform a step input by increasing the

setpoint by 30%. Click Run.

Q: Describe the general system response, the response time, and the
percentage offset.

Q: How does the Kc affect the system response time? The offset? (Kc
100,Kc1 and Kc 10)

6. OBSERVATIONS

10 BNJ 37301-Engineering Laboratory IV

UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

11 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

7. CALCULATIONS

12 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

8. GRAPH ANALYSIS

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

13 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

9. QUESTIONS

TASK 2 (REFERE TO TASK 2 PROCEDURES):

Question: Is there an offset?

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

TASK 3 (REFER TO TASK 3 PROCEDURES):

Question: Describe the system output response

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

14 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

Question: When is the offset percentage highest? Lowest?

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

Question: What is the cause of offset?

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

15 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

TASK 4 (REFER TO TASK 4 PROCEDURES):

Q: Describe the general system response, the response time, and the percentage
of offset.

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

Q: How does the system respond?

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

16 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

Q: Describe the general system response, the response time, and the percentage
of offset.
....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

Q: Describe the general system response, the response time, and the percentage
of offset.

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

17 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

Q: How does the Kc affect the system response time? The offset? (Kc 100,Kc1
and Kc 10)

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

10. CONCLUSION

Deduce conclusions from the experiment. Please comment on your experimental

work in terms of achievement, problems faced throughout the experiment and
suggest recommendation for improvements.

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

18 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

19 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

11. REFERENCES

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

....................................................................................................................................

20 BNJ 37301-Engineering Laboratory IV

 UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

RESULTS WORKSHEET

Column Column Column Column Column Column Column

1 2 3 4 5 6 7

Initial Reference Percentage Error Controller Total Error/

reference value of step output response reference
value (after step time value
(e=0) input)
Same 0%

30%

40%

50%

-20%

-30%

-40%

21 BNJ 37301-Engineering Laboratory IV

UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Faculty of Engineering Technology

22 BNJ 37301-Engineering Laboratory IV