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Level control (Tank 1) of Coupled Tank Liquid Level System Using Integral Control State Feedback Controller

AHMAD SYAUQI BIN ADNAN

This thesis is submitted as partial fulfillment of the requirement for the award of the Bachelor Degree of Electrical Engineering (Power Systems)

Faculty of Electrical & Electronic Engineering University Malaysia Pahang (UMP)

MEI, 2009

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All the trademark and copyright use herein are property of their respective owner. Reference of information from other sources is quoted accordingly; otherwise the information presented in this report is solely work of the author.

Signature

: _____________________

Author

: AHMAD SYAUQI BIN ADNAN

Date

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Specially dedicated to My beloved family Thanks For all their support, motivation and caring During the course of this project

iv ACKNOWLEDGEMENT

Firstly, thank to God throughout all His Almighty kindness and loveliness for letting me to finish my final year project. Secondly, I wish to hand a million thank to this final year project supervisor Mr. Mohd Syakirin Bin Ramli for his encouragement, guidance and consistent supports in finishing this project. I am also very thankful to my academic advisor Mr. Syahrulnaim Bin Mohammad Nawi for guidance and motivation.

I would like to extend my thank to UMP associates that contribute in the project progress either directly or indirectly. Also, thank to Mr Salmizan because help me to obtain all components was needed for the project.

My great thanks to my family especially my beloved father and mother who give a very good support to me to complete the project. For all of that, I am very thankful to the cooperation and contributions from everyone that has driven me to accomplished of this project especially my friend. To wrap it, thank you for everything. May Allah bless you all.

v ABSTRACT

This paper presents the design and modeling for coupled tank Liquid level system using Integral Control State Feedback Controller (ICSF). The ICSF have found wide acceptance and applications in the industries for the past few decades. ICSF controllers are proven to be sufficient for many practical control problems. The modeling for couple tank system, CTS-001 will be done before the designing controller begins. These coupled tank liquid level systems are in second order system. The ICSF Controller will be designed to control the liquid level at tank 1 and design techniques of the ICSF Controller is derived by using pole placement method that are conducted based on developed model. SIMULINK/MATLAB has been used to simulate and verified the mathematical model of the controller. Visual Basic 6 has been used to implement the graphic user interface (GUI) and implementation issues for the controllers algorithms will also be discussed. The DAQ card has been used to interfacing between hardware and software. Finally, the simulated result will be compared with the implemented result.

vi ABSTRAK

Projek ini memaparkan cara-cara untuk mereka dan membina pengawal Integral Control State Feedback Controller (ICSF) untuk mengawal paras cecair di dalam sistem tangki berkembar pada amnya dan mengawal paras cecair pada tangki 1 secara khususnya. Sistem pengawal ICSF ini diguna pakai secara meluas dalam industri di masa kini, Sistem pengawal ini telah di buktikan kebolehannya secara praktikal untuk mengawal pelbagai masalah sistem pengawal. Sebelum sistem ini pengawal ICSF dibina, ciri-ciri dan diskripsi sistem tangki air berkembar CTS-001 haruslah dikenal pasti terlebih dahulu. Model matematik sistem pengawal ini didapati dengan menggunakan teknik Pole Placement berdasarkan model yang dikehendaki. Perisian SIMULINK/MATLAB digunakan untuk menjalankan simulasi dan mengesahkan model matematik pengawal ICSF ini. Perisian Visual Basic 6 digunakan untuk

mengaplikasikan sistem pengguna berkomunikasi dengan computer (GUI) dan melaksanakan isu model matematik sistem pengawal ICSF akan dibincangkan. Kad DAQ di gunakan sebagai penghubung antara perisian dengan perkakasan. Akhirnya, hasil keputusan antara simulasi dan eksperimen akan dibandingkan.

vii TABLE OF CONTENTS

CHAPTER

CONTENTS TITLE DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENTS LIST OF FIGURES LIST OF TABLES LIST OF ABBREVIATIONS LIST OF APPENDICES

PAGE i ii iii iv v vi vii xi xii xiii xiv

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1 1.1 1.2 1.3 1.4 1.5

INTRODUCTION Background of project Problem Statement Objective Scope of Project Summary

1 1 2 3 3 4

2 2.1 2.2 2.2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.6 3.6

LITERATURE REVIEW Overview Article Summary METHODOLOGY Overview Project Flow Chart Modeling of Coupled Tank System Controller Design MATLAB Visual Basic 6 DAQ card Summary

5 5 5 7 8 8 10 12 16 20 22 26 27

RESULT, ANALYSIS AND DISCUSSION

28

4.1 4.2 4.3

Overview MATLAB Simulation result Real Time Result

28 28 30

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4.4

Comparison between simulation and real time experiments with controller

32

4.4

Summary

32

CONCLUSION AND FUTURE RECOMMENDATION 5.1 5.2 5.3 Conclusion Future Recommendation Costing and commercialization

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33 34 35

REFERENCE

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APPENDIX A APPENDIX B APPENDIX C

37 38 45

APPENDIX D APPENDIX E

55 56

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LIST OF FIGURE

FIGURE 3.1 3.2 3.3

TITLE Overall flow chart work of progress Flow chart for software and hardware development Block Diagram of integral control feedback controller combines with Plant

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20 20 23 24 24 26

3.4 3.5 3.6 3.7 3.8 3.9

Integral Control Feedback Controller The first GUI The second GUI The third GUI Advantech USB DAQ 4716 card Advantech USB DAQ 4716 card connection between computer and plant

26 28 30

4.1 4.2

MATLAB simulink model Output for tank 1

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LIST OF TABLE

TABLE 3.1 3.2 5.1

TITLE Parameter Values Parameter Values Total estimation cost

PAGE 14 15 36

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LIST OF ABBREVIATIONS

PID DAQ GUI CTS-001 V USB RC VB PSM

Proportional-Integral-Derivative Data acquisition Graphic User Interface Coupled Tank Liquid Level System Voltage Universal Serial Bus Resistor-Capacitor Circuit Visual Basic Projek Sarjana Muda

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LIST OF APPENDICES

APPENDIX A B C D E

TITLE M-file coding First GUI coding Second GUI coding Third GUI coding DAQ card Datasheet

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Chapter 1

Introduction

1.1 Background of project

Coupled tank water level system consists of double tank mounted on a reservoir for water storage. In the centre of the double tank placed a baffle to divide it into two different small tanks. At the base of each tank there are a flow valve connected to reservoir. Each of the small tanks has water pump to pump water from reservoir. Capacitance sensor is used to detect the level of the water and as visual a scale placed in front of the tank. This equipment widely use in the food processing and chemical industries. Using State Feedback control system to control the level of the water return to the reservoir as wanted. State feedback will control the water pump so that water in tank 1 in is maintained as required. The DAQ card is used as the interface between the controller and the coupled tank system. As suggestion, use software such as Visual Basic 6 and MATLAB/SIMULINK has been used as graphic user interface and as simulation.

1.2 Problem Statement

Nowadays, many of countries in this world facing the same problem because of the world economy are down. So to overcome this problem, many of factories must cut cost in term of workforce to maintain the same price or to reduce the price of their product. The thing that can overtake human responsibility is a computer. But the computer cannot working itself without human setting the suitable program for it, so the program that been used is called controller. All equipment in this world wanted to be automatically operated without human observation. To do this, we use a controller, so that the machine or equipment can run itself according to what we want. To do this we must have a medium to control so that it can run automatically. Normally controller such as PID and Fuzzy Logic are widely used to control many of the instrument or machines, but in this project the controller that have been used is the Integral Control State Feedback Controller. The Integral Control State Feedback Controller will control the liquid level at tank 1 at real time. This plant system are in second order system and the Integral Control State Feedback Controller will be derived directly from the plant using pole placement method, by using this method we can not manipulate anything of the controller value that we get. It is different between PID or LQR controller because it can simply be tuned to get the result as desired. We need continuous data from the plant as the feedback. Therefore, to overcome this problem, an Advantech DAQ card has been used as the interfacing between the hardware and software.

1.3 Objectives
There are several objectives that must be achieved in order to make this project successful: i. To control Coupled Tank liquid Level (Tank 1) Using Integral Control State Feedback Controller. ii. To compare result between experiment and simulation

1.4 Scope of The Project

i. ii. iii. iv. v. vi. To design Integral Control State Feedback Controller To analyze system performance using MATLAB/SIMULINK To use MATLAB to verify modeling. To develop GUI using Microsoft Visual Basic 6 To Implement controller using VB on couple tank water level system To assemble the coupled tank until it working.

1.5 Summary
This section provides insight of the overall project and explains the objectives and the scope of the project.

CHAPTER 2

LITERATURE REVIEW

2.1 Overview This chapter is about the explanation for some article that will refer to gets the information or some knowledge that will apply to make the project run successfully. 2.2 Articles

[1] Elke Laubwald., Coupled Tank System, Control System Principles.Co.uk This is one of series of papers on modeling, analysis and control to give insight into important principle and process [2] Seil Aydn1 Sezai Tokat1 Sliding Mode Control of a Coupled Tank Systemwith a State Varying Sliding Surface Parameter, 1Computer Engineering Department, Pamukkale University, 20017, Denizli, Turkey This paper presents a special purpose approach with a state dependent moving algorithm for the control of the coupled tank system where the state variables are defined as the liquid levels of the tanks.

[3] Hugues Bersini ADAPTIVE FUZZY CONTROLLER FOR STATE-FEEDBACK OPTIMAL CONTROL, ADAPTIVE FUZZY CONTROLLER FOR STATE-FEEDBACK OPTIMAL CONTROL This paper first discusses how to provide fuzzy models with the capacity to automatically self-tune their parameters by using wellknown gradientbased algorithms. Then the temporal extension of the gradient-based method which allows the automatic tuning of the fuzzy controller parameters over a temporal horizon will be presented and illustrated for an optimal control and a time-minimization simple problems.

2.3 Summary Literature reviews discuss about usage of this controller at different system or plant and also same system or plant with different controller. This chapter is also about the explanation for some article that will refer to gets the information or some knowledge that will apply to make the project run successfully.

CHAPTER 3: METODHOLOGY

3.1 OVERVIEW To help this project run smoothly, the draft of work has been organized so that this project will finish on time. There are several part work progress can be divided. The PSM flow chart showed the flows of this from the study case until it finish with demo and summit final report. The Project flow chart at sub-section 3.3 shown about how the progress works between software and hardware is done.

PSM FLOW CHART.

Figure 3.1 Overall flow chart work of progress.

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3.2 PROJECT FLOW CHART

Figure 1.2 Flow chart for software and hardware development

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Figure 3.2 show about the overall progress for both software and hardware development that will be discuss later. For the software part, modeling for the controller must be obtain and verify it with MATLAB before it can be implemented in Visual Basic 6 as GUI. MATLAB also has been used to run this plant simulation. A simple communication must be done between plant and computer using DAQ card, the DAQ card itself must be analyzed to make the interfacing easier. Both operations at this point need to refer to their respective manual. After make sure that both part software and hardware do not have problem, both of them must be integrated in order to test the designed controller. At this point, the simulation result that has been tested using MATLAB must be compared with the real time result. If there are some errors or miscalculation, troubleshooting was performed to obtain better result.