PDF Planta Control

Control Technology – a classic discipline of technical training Advancing automation is increasingly conferring the monitoring and control of technical processes and production techniques to autonomous control systems. Mechanical controls are thus relieving humans from performing monotonous control and operating tasks. However technical systems often require a level of accuracy, speed and reliability that humans would not be able to fulfill. Our control technology training system employs an training panel system for basic and advanced courses. The multimedia training system, based on COM3LAB, is equally well suited to student self-help practice and experiment demonstrations with a PC beamer.

Basic Course Basic courses in control technology employ real technical controlled systems. These produce non-electrical controlled variables (fill level, temperature, flow rate, angle of heel, etc.) and therefore require sensors to convert the given quantities into electrical signals. Since here explicit results take on foreground importance, these experiments are particularly well suited for a basic introduction to this thematic.

Advanced Course Advanced courses in control technology employ pure electronic devices as controlled systems. Sensors are no longer necessary here because only electrical signals occur in the entire control circuit. Since electrical signals are easily managed, these experiments stand out as a consequence of their convincingly quantifiable results. The results assessed here also stand up to critical interpretation.

Symbols: Experiment literature included

Battery required

Software included

COM3LAB compatible

Accessories required

Bus-capable (USB, Profibus, ...)

T8.2 Equipment Set Configuration

CONTROL TECHNOLOGY

LEYBOLD DIDACTIC GMBH

CONTROL TECHNOLOGY


Temperature ControlT 8.2.1.1

T 8.2.1.1

Training Objectives

➔ Temperature control with two-point controller

➔ Hysterisis of two-point controller

Temperature control with DDC controller under WinFACT.

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Temperature ControlT 8.2.1.1

T 8.2.1.1

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Some like it hotInstead of the oven model 734 38 from T 8.1.3 Process Instrumentation Tech-nology, the thermally quicker Temperature Controlled System 734 12 is used here. This increases the dynamics of control and shortens measurement time.

EQUIPMENT LIST T8.2.1.1

Temperature ControlQUANTITY CAT. NO. DESCRIPTION

1 734 01 Two Position Controller

1 734 02 Reference Variable Generator

1 734 12 Temperature Controlled System

2 734 13 Power Amplifier

1 524 016 Profi-CASSY

1 734 48 WinFACT 6-COM3LAB / CASSY-Edition

1 568 222 Book: Fundamentals of Automatic Control Technology II, Vol. 2

Foundries must maintain exacting, prescribed,

temperature profiles for the molten mass.

Basic Course: Technical Systems

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Liquid Level ControlFlow Rate Control

T 8.2.1.2T 8.2.1.3

Liquid level control with DDC controller under CASSYLab.

Training Objectives

➔ Control of fill level height on single tank model

➔ Control of fill level height on dual tank model

➔ Control of liquid flow rate

➔ Disturbance behavior in the Liquid Controlled System

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T 8.2.1.2T 8.2.1.3

T 8.2.1.2T 8.2.1.3

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Liquid Level ControlFlow Rate Control

T 8.2.1.2T 8.2.1.3


Basic experiment: Liquid level control on a single tank modelQUANTITY CAT. NO. DESCRIPTION

1 734 262 Liquid Controlled System


1 734 81 Differential Pressure Transducer

1 734 876 Immersion Tube



1 568 1012 Book: Experiments with the Liquid Controlled System T 8.1/8.2

Supplementary experiment: Liquid level control on a dual tank model

The basic experiment can be extended for the dual tank model. The probes listed below can also be used in the basic experiment

1 734 264 Additional reservoir

1 727 68 C/F-, L/F- and F/U-Converter

1 734 861 Capacitive Bar-Type Probe

1 734 881 Level Switch with Float

1 734 89 Capacitive Level Switch

1 734 901 Gravimetric Level Meter


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Flow Rate ControlQUANTITY CAT. NO. DESCRIPTION

1 734 262 Liquid Controlled System





Two in a boatLiquid level and flow can both be measured with one instrument. The illus-trated experiment uses the same liquid level measurement as T 8.1.3.2 to maintain a pre-selected fill level height with a closed loop controlled system. The experiment is quite clear and demonstrates, in an instructional manner, the interrelationship between reference value and actual value in feedback loops.


T 8.2.1.2T 8.2.1.3

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Gas Flow ControlT 8.2.1.4

Flow Control with blower and windmill type anemometer.

Training Objectives

➔ Control of a technical system with a moderate time constant

➔ Evaluation of the step response

➔ Determination of system time constants

T 8.2.1.4

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


They don‘t all have the same timeA system‘s responsiveness to state changes is determined by its time con-stants. Technical systems can exhibit significantly different time constants:

temperature : very slow

flow : slow

rotary speed : moderately fast

brightness : very fast

The control techniques investigated here are used for process control and in air conditioning systems.

Gas Flow ControlT 8.2.1.4


Gas Flow ControlQUANTITY CAT. NO. DESCRIPTION

1 666 630 Blower

1 666 631 Venturi Tube

1 666 632 Windmill Type Anemometer



1 568 342 Book: Flow-Through Measurement of Gases T 8.1.3.4

T 8.2.1.4

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While wind force and direction are constantly being measured

in wind power generators, the availability of wind can’t be

controlled by man.

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Brightness ControlSpeed Control

T 8.2.1.5T 8.2.1.6

T 8.2.1.5 Training Objectives

➔ Brightness Control with PI controller

➔ Dynamic properties of fast closed loop control

T 8.2.1.5T 8.2.1.6

Small but super!Light controlled system and mini-machine system. The motor-

generator set consists of two coupled DC machines and an optical tacho-generator.

T 8.2.1.6 Training Objectives

➔ Speed control of a motor-generator set with PID controller

➔ Voltage control with the motor-generator set

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Brightness ControlSpeed Control


Brightness ControlQUANTITY CAT. NO. DESCRIPTION

1 578 51 Si Diode 1N 4007


1 734061 PID Controller


1 734 16 Manual/Automatic Switch

1 734 31 Light Control System




T 8.2.1.5T 8.2.1.6

T 8.2.1.5T 8.2.1.6

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Light-VelocityBrightness control is a practical example for the control of „fast“ systems. This finds application in large lighting systems in sports arenas, halls, etc.Speed control is another daily life application. In the experiment the con-trolled system (= motor) provides the non-electric controlled variable „speed“. The generator coupled to the motor acts as a sensor that converts the motor‘s rotary speed into an electrical voltage signal.


Speed ControlQUANTITY CAT. NO. DESCRIPTION

3 505 23 Lamp 24 V / 5 W


1 734 061 PID Controller

1 734 11 Motor-Generator Set, 24V


2 734 19 Gain and Offset Adjust

1 734 39 Load Switch





CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Listing controllers ensure a balanced course tracking for big transportation vessels.

Listing ControlT 8.2.1.7

Training Objectives

➔ Putting listing control into service

➔ Control parameter settings for stable stationary operation

➔ Creating oscillating instabilities

T 8.2.1.7

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Listing ControlT 8.2.1.7

T 8.2.1.7

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Ship shape in bad shapeThe list (heeling over) of a container ship or ferry changes as it is loaded. Difficulties can also arise, for example, in keeping the pitch of railroad tracks aligned while moving railroad cars onto a ferry. The appropriate filling of ballast tanks can help to compensate for such undesirable ship list and pitch-angles.

Profi-CASSY and its CASSYLab software combine to serve as a convenient controller.

Controller parameters, as well as the controlled, manipulated

and reference quantities are visible at a glance.



Listing ControlQUANTITY CAT. NO. DESCRIPTION



1 734 300 Listing Controlled System



1 510 48 Pair of Magnets


CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Air conditioning system with fuzzy controller.The controlled system can be electrically heated with a halogen lamp and cooled by a fan.

Fuzzy ControlT 8.2.2

Training Objectives

➔ Implementation of an electronic gas pedal (drive by wire)

➔ Control of an air conditioning system with fuzzy algorithm

➔ Speed control of vehicles with differing loads

➔ List control with fuzzy algorithm

T 8.2.2

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Fuzzy ControlT 8.2.2

Of approximate values andmembership functionsFuzzy describes an approach to the control of technical systems which avo-ids sophisticated mathematical modeling. The control strategy is defined in terms of conditional language. Fuzzy control is particularly well suited for systems with multiple controlled variables and is used frequently today in many common appliances, from washing machines to cameras.

EQUIPMENT LIST T8.2.2

Fuzzy ControlQUANTITY CAT. NO. DESCRIPTION



1 734 10 Servo Set point Generator

1 734 11 Motor-Generator Set, 24V



1 734 14 DC-Servo

1 734 56 Tensile Test Bar

1 734 300 Listing Controlled System


1 734 4722 WinFACT 6-Student License Type B

1 510 48 Pair of Magnets


T 8.2.2

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Fuzzy techniques can even be found in automotive

engineering. The „drive by wire“ technology transmits the

driver‘s wish to change speed to a fuzzy controller.

Basic Course

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Continuous ControlT 8.2.3

Training Objectives

➔ Transient functions from P-controller and I-controlled systems

➔ Feedbacks in transfer elements

➔ Output quantities in an open loop control chain

➔ Simulation of a pneumatic pressure closed loop control

➔ Pneumatic pressure closed loop control

➔ Step-responses of PT1 and PT2 elements

➔ Characteristic of a temperature closed loop control

➔ Dead time element

➔ Transient function of various controls:

PI-control, PIP-control with 1st order delay,

PIDP-control with 1st order delay

T 8.2.3

Experimental set-up of an electronic control loop.

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


A cybernetic base modelThe set-up photo shows a typical course T 8.2.3 experiment configuration. The electronic control loop is made of discrete components. This type of structure is ideal for the simulation of technical control loops. The advantage to this approach is its simple mastery of electrical quantities in comparison to (somewhat more complex) physical process quantities.


Continuous ControlQUANTITY CAT. NO. DESCRIPTION


2 734 03 P Controller

1 734 04 Integral-Action Element

1 734 05 Derivative-Action Element

1 734 07 Summing Point, 2 Inputs


1 734 089 Dead Time Element

2 734 09 Simulated Controlled System



1 734 40 Test Function Generator




Continuous ControlT 8.2.3

T 8.2.3

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Advanced Course

Control loop odels: 1 controller 2 actuator 3 controlled system 4 sensor

The upper block diagram shows a closed loop control in general

form. The controlled variable X and the reference variable W

are different physical quantities and must be transformed for compatibility to one another by way of sensor technology.

The actuator provides the control loop with the necessary power. The lower block diagram

illustrates a simplified closed loop control. The actuator is

integrated into the controller or the controlled system. Here

the controlled variable and the reference variable are of

the same physical nature, this makes sensors unnecessary.

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Discontinuous ControlT 8.2.4

T 8.2.4

Advanced CourseTraining Objectives

➔ Temperature control with a two point controller

➔ Discontinuous control with feedback

The steam iron is a classic example of an application with a two-point

controller.

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY



Discontinuous ControlQUANTITY CAT. NO. DESCRIPTION

1 734 01 Two Position Controller




1 734 095 Second Order Transfer Element







Discontinuous ControlT 8.2.4

T 8.2.4

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Discrete stepsThe temperature of a steam iron will rarely take on directly the desired refe-rence value. In contrast to continuous control systems, the controlled system (heater) here can only be turned on or off. There are no intermediate values. There isn‘t even an active cooling mechanism available.

Advanced Course

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Controlled System ClassesT 8.2.5

T 8.2.5

Experimental set-up for computer-aided recording of step responses.

Training Objectives

➔ Simulation of fill level control

➔ Investigation of reference behavior

➔ Investigation of oscillation behavior

➔ Control of a controlled system with start-up time and dead time by a PID-controller

➔ Discussion of disturbance transient function

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY



Controlled system ClassesQUANTITY CAT. NO. DESCRIPTION




1 734 063 PID Controller, 10 Turn








Class reunionsControlled systems which are important from a technical point of view will be systematically classified here according to their recorded time behavior characteristics. Experiments with 10-turn PID-controllers achieve astonishing quantitative correlation between theory and measurements. For anyone who places value on theoretically quantifiable control techniques, this controller is a recommendable alternative to the standard design (734 061).

Controlled System ClassesT 8.2.5

T 8.2.5

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Advanced Course

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Recording the locus diagram on a system with dead time.

Electronic SystemsT 8.2.6

T 8.2.6

Training Objectives

➔ Step response

➔ Frequency response

➔ Systematic of controlled systems

➔ Systematic of controllers

➔ Digital controllers

➔ Systematic and frequency behavior of closed loop controls

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


T 8.2.6 Electronic Systems

Idea and realityElectrical control systems that replace their physical counterparts while maintaining the same system behavior are investigated here.

pressure closed loop control

temperature closed loop control

T 8.2.6


Electronic SystemsQUANTITY CAT. NO. DESCRIPTION



1 734 41 Sample and Hold Element










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Control and evaluation with the PC.

In DDC (Direct Digital Control) mode, the Profi-CASSY acts as the interface between the control loop

and the PC. Together with CASSY Lab or WinFACT software, the

computer can take over various tasks:

to provide a freely-configurable digital controller

taking over of recording tasks as an XY/Yt recorder or step response

plotter

This also allows experiments to be performed in the time

and frequency domain, e.g. the recording of step responses or the

presentation of locus diagrams.

Advanced Course

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Stability & OptimizationT 8.2.7

Training Objectives

➔ Simulation of electric motor speed control

➔ Stability testing a 3rd order control system

➔ Stability testing a simulated gas flow controller

➔ Controller settings for a controlled system with dead time

➔ Nyquist evaluation of a control system

➔ Nyquist evaluation of an oscillating closed loop control

➔ Experimental optimization by means of ISE criteria

➔ Optimizing according to Ziegler / Nichols

➔ Optimizing according to Chien / Hrones / Reswick

➔ Fundamental stability investigations

➔ Higher order systems

➔ Stability test on an open loop control

➔ Integral criteria for system optimization

➔ Controller optimization

T 8.2.7

Locus diagrams of an open loop control system forstability evaluation per Nyquist.

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CONTROL TECHNOLOGY


CONTROL TECHNOLOGY



Stability & OptimizationQUANTITY CAT. NO. DESCRIPTION


1 734 063 PID Controller, 10 Turn





1 734 19 Gain and Offset Adjust



1 727 71 Function Module


Stability & OptimizationT 8.2.7

On the swingControl loops are feedback coupled systems. As such, they tend to oscillate under certain conditions. This effect is generally undesirable and demands all of the engineer‘s talents to create a design that is adequate for its dynamic behavior yet does not lead to parasitic oscillations that could endanger the system or the process.

T 8.2.7

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Advanced Course

Some have their own intuitive notions about stability and

process optimization. For the technician, this subject

is a more somber matter but certainly no less interesting.

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


COM3LAB Course Control Technology ICOM3LAB Course Control Technology II

7008270083

Training Objectives 70082

➔ Everyday open and closed loop control

➔ Analysis of controlled systems

➔ Plants with/without compensation

➔ Higher order systems

➔ PID and PI control

➔ Digital control

➔ Performance criteria

➔ PID controller settings

➔ Temperature control

➔ Rotary speed control

➔ Light Control

➔ Control with discontinuous controllers

➔ Fault simulation

Training Objectives 70083

➔ Control system stability

➔ Controller design per Ziegler / Nichols

➔ Systems with deadtime

➔ Reference variable limitations

➔ Cascade control

➔ Introduction to frequency response

➔ Frequency responses of individual basic elements

➔ Frequency response of combined elements

➔ Controller design in the frequency domain

➔ Fuzzy control

➔ Adaptive Control

COM3LAB: master unit and course board are the only training materials required to conduct the computer-aided experiments.

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7008270083

CONTROL TECHNOLOGY


CONTROL TECHNOLOGY


Measuring in the virtual laboratoryCOM3LAB frees you of the inconvenience associated with obsolete measu-ring instruments. PC and master unit are all that is required – and then the course‘s software unfolds on any pupil‘s desk into a richly equipped instru-ment laboratory with the following instruments:

static characteristic plotter

step response plotter (for analog control)

DDC plotter (for sampling control)

controller design computer for calculating optimal controller parameters from specified system parameters

two multimeters

function generator (synthesizer)

oscilloscope

frequency analyzer

logic analyzer

COM3LAB Course Control Technology ICOM3LAB Course Control Technology II

7008270083

EQUIPMENT LIST

COM3LAB Control Technology I/IIQUANTITY CAT. NO. DESCRIPTION

1 700 82 COM3LAB Course: Control Technology I

1 700 00 COM3LAB Master Unit

recommended:

1 700 83 COM3LAB Course: Control Technology II

The COM3LAB Control Technology II course is a supplementary course to 700 82. It uses the

same experiment board and can be released by a dongle on course I.

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The control process is recorded on the DDC plotter versus

the time axis. The reference variable is red, the manipulated

variable is green and the controlled variable is blue. The

example shows the rotary speed control of a fan motor as affected by a PID controller for

various reference variables.

Multimedia

7008270083


Modern educational systems

for the future

Cost effective system solutions

Computer-assisted measurement

and evaluation systems

Interactive multimedia training

Literature with exercise sheets

Comprehensive counseling

Commissioning and seminars

Global references

Hotline for problem solving

ISO 9001 quality management system

Educational SystemsPractical and Efficient

Motivating and Fun

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