Controls Lab

Lab Report Number: 08

“ON-OFF Control of Water level and effect of

Section: ME-14 (C)

Name CMS ID
Muhammad Ahmad Nadeem 416175
Table of Contents
Objectives................................................................................................................................... 2
Equipment .................................................................................................................................. 2
Theoretical Background ............................................................................................................. 2
Procedure ................................................................................................................................... 4
Circuit Representation ............................................................................................................... 4
Data Tabulation .......................................................................................................................... 5
Graphical Representation .......................................................................................................... 5
Discussion.................................................................................... Error! Bookmark not defined.
Conclusion ................................................................................... Error! Bookmark not defined.
Safety precautions ..................................................................................................................... 6

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Objectives
• Study the operation and functionality of ON-OFF control in maintaining water levels.
• Investigate how hysteresis affects system stability and prevents rapid switching.
• Observe and measure the behavior of the water level system with and without
hysteresis.
• Discuss how ON-OFF control and hysteresis are used in industrial-level control systems.

Equipment

Figure 1: Apparatus

Theoretical Background
1. ON-OFF Control System

ON-OFF control is one of the most straightforward and biological control techniques which
is used in automation and any of the process industries. It works on a two-position mode that
is TOTW (Totally on and off) which action is performed by an actuator like a valve, pump, etc,
to keep the controlled variable e.g. – water levels close to a particular value. The controller
turns ON when the water goes beyond the set limit and turns OFF when the desired level of
water is achieved. This is however simple and cheap; it is known that very large fluctuations
occur around the setpoint in the ON-OFF method, especially in ineffective systems where the
lag is dominant.

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2. Hysteresis in Control Systems

Hysteresis is an additional boundary that is created into the control system and ensures that
the tolerance around the set point does not get worn easily. In control systems where a level
control is the dominant mode, hysteresis is effective in preventing fluctuation of on-off, and
on-off of the pump or valve whenever the water crosses the set point by some amount. This
minimizes the wear out of the mechanical parts, increases the stability of the system, and
performs the task more efficiently. Hysteresis may be used, for example, if a setpoint is defined
as 8 cm, it could be set to trigger at 7 cm and switch off at 9 cm.

3. Water Level Control Dynamics

The control system such as water level controls with the flow rate and voltage have controls
that are interdependent on those parameters.

The voltage applied affects the flow of water coming into the tank, and hence the level. The
control system includes level sensing, which is compared with the setpoint and generation of
output voltage to control the actuator either on or off.

4. The influence of Hysteresis on the System Performance

Hysteresis also decreases the oscillations about the setpoint, enabling the water level to be
stable for a given period. A disadvantage of hysteresis is the time lag in the response. The
system anticipates a level shift beyond the hysteresis band before it stimulates action. This
stability responsiveness trade-off is a key factor in the design of control systems.

5. Practical Cases of ON-OFF Control with Hysteresis

Most ON-OFF control with hysteresis applications is in industrial water level control systems
for tanks, HVAC systems, and in pressure control systems. It achieves a good compromise
between cost and performance and is therefore appropriate for systems where accuracy is
not a major concern.

This theoretical insight serves as a guide for achieving the aim of the experiment, the aim of
the observations, and the aim of the results.

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Procedure:
• The components were connected as per the circuit diagram, and a multimeter was
used to measure the voltage at key points.
• The trainer was powered on to begin the experiment.
• Upon applying voltage, the tank started to fill with water, with the flow rate varying
based on the supplied voltage.
• The output voltage was observed to vary depending on the setpoint. It displayed zero
at the setpoint (8 cm), negative values when below it, and positive values when above
it.
• Readings were taken at different hysteresis levels, and the times for raising and
lowering water levels were compared to analyze system performance.

Circuit Representation:

Figure 2: Circuit

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Data Tabulation:
Table 1: Data Table

Hysteresis No Hysteresis (0%) With Hysteresis (25%)

Setpoint 8cm 8cm

Rising Time 2.4sec 10.4sec

Upper limit 8.5cm 10.3cm

Lowering time 6.5sec 35.8sec

Lower limit 9.8cm 8.3cm

Graphical Representation:

Figure 3: Graph with 0% Hysteresis

Figure 4: Graph with 25% hysteresis

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Discussion:
In this lab, we studied the effect of hysteresis on the behavior of the Level Control Training
System. The ON-OFF control system, with and without hysteresis, demonstrated distinct
behaviors when maintaining flow levels. We performed the experiment initially with 0%
hysteresis and then repeated it with 25% hysteresis for comparison. The results, illustrated
by the graphs, reveal the impact of hysteresis on system performance.

Without hysteresis, frequent ON-OFF switching led to greater instability and oscillations
around the setpoint. When 25% hysteresis was introduced, the switching frequency
decreased, resulting in smoother, steadier flow control. However, this came at the cost of
slight deviations in flow levels, particularly near the setpoint. These deviations underscore the
trade-off between system stability and precision. The application of hysteresis reduced rapid
switching and improved efficiency but introduced small, manageable errors in flow accuracy.

This trade-off highlights that while hysteresis improves system stability by minimizing
frequent transitions, it compromises precise level control. This balance is crucial in optimizing
the system's performance for different operational needs.

Conclusion:
ON-OFF control with hysteresis provides an effective method for regulating flow levels by
reducing switching frequency and enhancing system stability. The trade-off is a slight
reduction in flow accuracy, which may be acceptable in applications where perfect precision
is not critical. By carefully tuning the hysteresis level, it is possible to achieve an optimal
balance between stability, efficiency, and accuracy, making the system adaptable to various
real-world scenarios.

Safety precautions:
• Personal Protective Equipment (PPE): Ensure that all lab personnel wear appropriate
PPE, including safety goggles, lab coats, gloves, and closed-toe shoes to protect against
chemical splashes, electrical hazards, or mechanical injuries.
• Equipment Inspection: Regularly inspect all lab equipment and apparatus for any signs
of damage or wear. Report any defects immediately and ensure that faulty equipment
is taken out of service until repaired or replaced.

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• Emergency Procedures: Familiarize all lab members with emergency procedures,
including the location of fire extinguishers, eyewash stations, safety showers, and
emergency exits. Conduct regular safety drills.
• Hazardous Materials Handling: Follow proper procedures for handling, storing, and
disposing of hazardous materials, such as chemicals and solvents. Use fume hoods and
ventilation systems as needed.
• Electrical Safety: When working with electrical circuits and equipment, ensure that
power sources are disconnected before making connections or adjustments. Avoid
contact with exposed wires and use insulated tools.
• First Aid Kit: Maintain a well-equipped kit in the lab and ensure lab personnel are
trained in basic first aid procedures. Display emergency contact numbers and locations
prominently.
• Equipment Safety: Follow the manufacturer's guidelines and instructions for operating
lab equipment and machinery. Ensure that the equipment is properly grounded and
that safety interlocks are functional.