Lab Report=10

“Introduction to PWM and to Control the

Flowrate Using ON-OFF Controller and Effect of
Hysteresis”

Name: Muhammad Abdullah Zafar Ghauri

Class: ME-14

Section: C

CMS ID: 405642

Subject Code ME-339

Subject: Control Engineering

Submitted To: Sir Usman Ghani

Due Date: 11th December 2024

Group B
 Introduction to PWM and to Control the Flowrate Using
ON-OFF Controller and Effect of Hysteresis
Muhammad Abdullah Zafar Ghauria
a
School of Mechanical and Manufacturing Engineering (SMME), National University
of Science and Technology (NUST), Islamabad, 44000, Pakistan
mghauri.ug22smme@student.nust.edu.pk

4th December 2024

Abstract
This lab is aimed at effectively using the flow rate Control Sensor by making necessary important
connections for for understanding the ON-OFF control system in sensor action and deliberating into
the effect of implementation of hysteresis on the flow rate control system and deliberating much to
understand the effectiveness of configurations and analyze the role of hysteresis in affecting the curve
. This lab also focuses on introducing the concept of Pulse Width Modulation (PWM) and how it
influences the observations and calculations
Keywords: fluid flow control sensor; forward configuration; reverse configuration; hysteresis

1 Laboratory Analysis
Objectives The main objectives of the experimentation are as follows:
• Develop acquaintance with the Flow rate Control Trainer Module
• Understand the necessary connections to ensure proper working of the apparatus
• Deliberate upon the ON-OFF control system in flow rate control system
• Understand the relation between the flow rate and generated signals of voltage
• Understand the effect of hysteresis on final readings of voltage.

Introduction

Pressure Process Control Module and Trainer (SMT-9202) Pressure Process Control Module and
Trainer, traded as SMT-9202, is the first major and important component in the laboratory. The main purpose
of this apparatus is to observe the pressure control electronically. The apparatus is depicted below highlighting
its major aspects

Figure 1: Pressure Process Control Module and Trainer (SMT-9202)

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 Generally, there are five driver modules on the control panel which can be devised from aforementioned figure

Figure 2: Control Panel Interface for Flow Rate Control System

The main components of process control system are explained as follows: Solenoid Valve Driver:
A solenoid valve driver regulates the operation of solenoid valves by providing the necessary electrical signals to
control the flow of liquids within the system.
PID Controller:
A PID (Proportional-Integral-Derivative) controller continuously adjusts control elements such as pumps or valves
to uphold a precise and stable liquid level. It computes control output by evaluating the discrepancy between
desired and actual levels, considering proportional, integral, and derivative terms to optimize control. This ensures
precise and responsive level regulation.
Water Pump Interface
A water pump driver oversees the operation of a water pump, starting or stopping it in response to inputs from
level sensors. Its primary function is to maintain desired liquid levels, thereby preventing overflow or depletion
and optimizing the efficient utilization of resources.
Pressure Sensor Interface:
A pressure sensor looks after the maintenance of desired pressure level within the process tank, keeping in check
whether the desired pressure level has been attained or not. Excessive pressure buildup might lead to explosion
in the tank.
Float Switch:
Float switch which is attached at that point tends to terminate the flow of more fluid as the desired level is
achieved.
Rotameter:
Rotameter is an important instrument extensively used in laboratories for determines the volume flow rate much
accurately.
It comprises of a tube in which a float is suspended in the influence of fluid. As fluid flows in, there establishes
imbalance in stability of float. At such circumstance, there are three forces simultaneously acting on the float,
the buoyancy force, weight of float and the upthrust of force. The force of buoyancy is balanced by the weight
on float.
Pump
Water pump is a device which uses the electrical energy to supply water from lower to higher height.

Pulse Width Modulation (PWM) : Pulse-width modulation is a digital technique to control a signal by
repeatedly toggling a signal between a HIGH and a LOW state in a consistent pattern. One may portray new
information by changing how long the signal is HIGH versus LOW. The PWM signal has two key parameters,
respectively as frequency and duty cycle.

Figure 3: Pulse Width Modulation (PWM) of Digital Signal Operating between 0 and 1

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 Figure 4: Schematic of Circuitry buildup from Control Panel Interface

The period of the PWM signal (measured in seconds) indicates the amount of time it takes for the signal to
complete one cycle. Refer to the image above, it maybe observed that a period is a complete cycle of the signal,
changing from LOW signal to a HIGH signal and back to a LOW signal. The signal pattern of each period is
repeated over and over again. The frequency of the PWM signal, measured in Hertz (Hz), indicates the number
of complete periods that occur in 1 second. The period and frequency of a signal are closely related, in that the
faster the frequency, the smaller the period. The slower the frequency, the larger the period.

Circuitry Buildup Following the rules and guidelines of the laboratory, the circuit was completed before
the apparatus appeared in working order. The following figure shows the circuit buildup in lieu of the schematic
as aforementioned in Figure 4:

Figure 5: Circuitry Buildup

Procedure Following procedure protocols have been brought into consideration

1. The apparatus was brought forward, and it was ensured it rested perfectly on the ground
2. Initially the circuit between the pressure sensor and the transmitter was built up by connecting the connection

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wire about the concerned ports (Connection devised between port 1 and 1 respectively).
3. On the water pump interface, the circuit had a break between PWM Drive and water pump, which was
completed by connecting the connection wires about port 8.
4. Lastly, port 8 was connected to the Setpoint-1 channel located in the setpoint interface and the set point was
set to 8 in accordance with the port numeral.
5. From Setpoint 1, a wire was connected to the ON-OFF controller, for which the second wire was devised from
flow rate sensor interface.
6. After all necessary connections accurately devised, the apparatus was connected to the voltage supply (220 V,
50 Hz).
7. The initial flow rate for analysis was kept 4 lpm (liters per minute) and ultimately leveled down.
8. Once all the readings were effectively devised, corresponding characteristic curves were plotted, and the be-
havior of curves was extensively deliberated upon.

Calculation Data Pertaining to the experiment, following table evaluated the values of flow rate and time
in circuital configuration

Table 1: Calculation Data

Hysteresis 0% 5%
Setpoint 4 lpm 4 lpm
Upper Limit 4 lpm 4.5 lpm
Lower Limit 3.5 lpm 3.1 lpm
Rising Time 6s 4s
Lowering Time 1s 3s

Figure 6: Graph between Time and Flow Rate with and without Hysteresis

Results and Discussions In view of figure 6 which demonstrate the flow rate versus time plot with and
without hysteresis. It is necessary to mention that without hysteresis, the system operates within constrained
feedback loop which initiates the rapid rise and fall of fluid level which stabilizes upon attaining set-point value. It
is necessary to mention that the system maintains constant fluid level after initial rising phase and the absence of
oscillations reflect smooth control process thereby indicating precise regulation. The lack of hysteresis minimizes
fluctuations in fluid level but may increase the operational frequency of the controller, potentially reducing the
lifespan of the system components. Referring to the other curve for which the addition of 5% hysteresis introduces
buffer about set-point fluid level to which the system does not react immediately upon attaining target level rather
allows some deviation before switching on or off. From the plot, periodic oscillations can be observed where level
cycles between lower and upper thresholds. The hysteresis prevents the rapid switching thereby reducing strain
and wear in system. Hysteresis introduces a delay that smoothens system operation, reducing wear and operational
frequency. However, it also leads to flow rate fluctuations, which may be undesirable in sensitive applications
requiring precise control.

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Conclusions From the graphs in figure 6, it has been concluded that introducing hysteresis in circuit increases
the response time which leads to prolonged chattering between two fluid level values. The introduction of hysteresis
in system increases the response time as discussed above which proves beneficial for the system to mitigate effects
of wear and tear among the moving parts.

Safety Precautions Following are some important and necessary safety precautions which must be taken
into account significantly while deliberating into this experiment. They are as follows:
• Get acquainted with emergency protocols for responding to fires, electrical accidents, chemical spills, and
personal injuries.
• Before working on circuits or equipment, disconnect power sources. Adhere to electrical safety recommendations
to avoid electrical accidents.
• Before using any equipment, conduct a thorough inspection, promptly report any defects, and treat all lab tools
and equipment with caution.
• Avoid messing around with sensitive instrumentation to avoid them being damaged.

Practical Applications Fluid flow rate level control sensor control system plays a significant role in industrial
applications where variation in level is crucial to the concurrent processes. An important application of fluid level
sensors is within a nuclear reactor where nuclear fission is concurrently taking place and regulation of flow rate of
coolant water is extremely necessary to prevent nuclear meltdown by continuously pumping water to and removing
heated water through steaming. In crucial applications, fluid flow rate level sensors detect the level of coolant
fluid within the nuclear pool and keeps the control rods cool to avoid uncontrolled fission.

2 Supplementary Information
Owing to breakdown of apparatuses in the laboratory, the lab report calculations and data had to be borrowed
from a fellow student. Following parts are excerpts of borrowed file, Figure 5 and Table 1. Rest, the entire lab
report has been devised meticulously with efforts using LaTeX file.