Jawaharlal Nehru Engineering CollegeICE)CSE-I lab manual.pdfJawaharlal Nehru Engineering College ......

Jawaharlal Nehru Engineering College

Laboratory Manual

CONTROL SYSTEM ENGINEERING-I

For

Third Year Students

Prepared By: Ms.Sunetra S Suvarna

Assistant Professor

Author JNEC INSTRU. DEPT., Aurangabad

1

SUBJECT INDEX

Title

1.Do’s and Don’ts in Laboratory

2. Instruction for Laboratory Teachers:

3. Lab Exercises

1. Study of different types of control systems

2. Implementation of Logic Gates using relays.

3. Study of Hydrulic components and simple hydraulic

circuits

4. Study of pneumatic control valve.

5. Study of Synchro transmitter and receiver system

6. Study of Pressure / temperature/level / flow Switches

(any two).

7. Study of I/P and P/I converter.

8. Stepper motor control

9. Study ofA.c. Servo motor and its characteristics

4. Conduction of viva voce examination

2

1. DOs and DON’Ts in Laboratory:

1. Do not handle different kit without reading the instructions/Instruction manuals.

2. Go through through the procedure and precautions given in manual

4. Strictly observe the instructions given by the teacher/Lab Instructor

.

2 Instruction for Laboratory Teachers::

1. Lab work completed during prior session ,should be corrected during the next lab session.

2. Students should be guided and helped whenever they face difficulties.

3. The promptness of submission should be encouraged by way of marking and evaluation patterns that

will benefit the sincere students.

3

Exercise No 1: ( 2 Hours) – 1 Practical

Study of different types of control systems.

Aim: Study of different types of control systems.

Theory: The five types of control systems namely Open loop control system, Closed loop control system,

feedback control system, feed forward control system, Linear control system.

1. Schematic diagram of Control systems

2. Elements of control system

3. Specifications of control system

4. Applications of control system

4


IMPLEMENTATION OF LOGIC GATES USING RELAYS

Aim: To implement different types of logic gates using relays.

Apparatus:

Relays, power supply, connecting wires, breadboard.

Theory:

The physical implementation of Boolean logic is to use relays. This is, in fact, how the very first

computers were implemented. No one implements computers with relays anymore -- today, people use

sub-microscopic transistors etched onto silicon chips. These transistors are incredibly small and fast,

and they consume very little power compared to a relay. However, relays are incredibly easy to

understand, and they can implement Boolean logic very simply. Because of that simplicity, you will be able

to see that mapping from "gates on paper" to "active gates implemented in physical reality" is possible

and straightforward. Performing the same mapping with transistors is just as easy.

Let's start with an inverter. Implementing a NOT gate with a relay is easy: What we are going to do is

use voltages to represent bit states. We will define a binary 1 to be 5 volts and a binary 0 to be zero

volts (ground). Then we will use a 6-volt battery to power our circuits. Our NOT gate will therefore look

like this:

5

Here you can see that if you apply 5 volts to A and B, Q will have 5 volts. Otherwise, Q will have

zero volts. That is exactly the behavior we want from an AND gate. An OR gate is even simpler -- just

hook two wires for A and B together to create an OR. You can get fancier than that if you like and use

two relays in parallel.

You can see from this discussion that you can create the three basic gates -- NOT, AND and OR --

from relays. You can then hook those physical gates together using the logic diagrams shown above to

create a physical 8-bit ripple-carry adder. If you use simple switches to apply A and B inputs to the

adder and hook all eight Q lines to light bulbs, you will be able to add any two numbers together and

read the results on the lights ("light on" = 1, "light off" = 0).

Boolean logic in the form of simple gates is very straightforward. From simple gates you can create

more complicated functions, like addition. Physically implementing the gates is possible and easy. From

those three facts you have the heart of the digital revolution, and you understand, at the core, how

computers work.

Conclusion:

In this way we have studied and implemented different types of logic gates using relays.

6


STUDY OF HYDRUALIC COMPONENTS AND SIMPLE HYDRULICCIRCUITS

Aim: To study the different hydraulic components and hydraulic circuits

Apparatus: setup of hydraulic trainer, connecting pipes etc.

Theory: 1 Principle of hydraulic systems

2.Different symbols used for construction of hydraulic systems

3.Specification of different hydraulic components

4.Application of hydraulic circuits

Procedure: 1.First of all study different hydraulic components

2. Connect the hydraulic circuits according to circuit diagram

3. Start the hydraulic system pump and observe the pressure buildup to standard

pressure

4. Slowly vary the position of directional control valve and obser the output of

hydraulic circuits

5.Repet the same procedure for different hydraulic circuits.

7

Conclusion: In this exercise we have studied different hydraulic components and different hydraulic

circuits. It is observed that as hydraulic supply varies the motions of different components varies in

hydraulic circuit.

8


STUDY OF PNEUMATIC CONTROL VALVE

Aim: Study of pneumatic control valve (spring actuator type)

Apparatus: Closed loop flow measurement system setup/valve trainer trainer.

Theory: 1. Principle of pneumatic control valve

2. Construction of pneumatic control valve

3. Specification of pneumatic control valve

4. Application of pneumatic control valve

Procedure: 1. Observe the stem displacement of valve

2. Observe the percentage of flow passing through the valve

3. Observe the flow and stem displacement of valve

Construction:

Conclusion: It is observed that as input pressure applied to pneumatic control valve increased or

decreased (Depending on valve type) the flow through the valve is controlled.

9


SYNCHRO CHARACTERISTICS

Aim: Study of synchro characteristics.

a) Study of synchro transmitter characteristics.

b) Study of synchro transmitter / receiver characteristics.

Apparatus: Synchro transmitter / receiver set-up, multimeter comnnecting wires etc.

Theory:

Principal: A synchro is an electromagnetic transducer commonly used to convert an angular position of a

shaft into an electric signal.

The basic synchro unit is usually called a synchro transmitter. Its construction is similar to that of a

three- phase alternator. The stator is of laminated silicon steel and is slotted to accommodate a

balanced three phase winding which is usually of concentric coil type and is Y-connected. The rotor is of

dumb-bell construction and is wound with a concentric coil. An a.c. voltage is applied to the rotor winding

through slip rings.

Constructional features of synchro transmitter:

Stator

Rotor

Coil

Stator

Stator

Winding

10

~

Operation: Let an a.c. voltage

Vr (t) = Vr sin wct

Be applied to the rotor coil which produces a sinusoid ally time varying flux directed along its axis and

distributed nearly sinusoid ally in the air gap along the stator periphery. As the air gap flux is sinusoid

ally distributed, the flux linking any stator coil is proportional to the cosine of the angle between the

rotor and stator coil axes and so is the voltage induced in each stator coil.

Let Vs1n, Vs2n and Vs3n.

Be the voltage induced in the stator coil S1,S2 and S3 with respect to the neutral.

Vs1n = KVr sin wct cos ( 0-120)

Vs2n = = KVr sin wct cos 0

Vs3n = KVr sin wct cos / ( 0+240)

The three terminal voltages of the stator are.

Vs1s2 = Vs1n – Vs1n = / 3KVr sin ( 0+ 240) sin wct.

Vs2s3 = Vs3n – Vs3n = / 3KVr sin ( 0+120 ) sin wct.

Vs3s1 = Vs3n – Vs1n = / 3KVr sin 0 sin wct.

Procedure:

(A):

1. Connect the system in main supply.

2. Starting from zero position note down the voltage between stator terminal i.e. Vs2s1,Vs1s3

and Vs2s3 in a sequential position.

3. Plot the graph of angular position Vs voltage of three winging i.e. terminal voltage.

(B):

1. Connect the system to the main supply .

2. Make connections between corresponding terminals of transmitter and receiver i.e. connect

S1 – S1, S2 – S2 and S3 – S3 of transmitter and receiver.

3. Switch on SW1 and SW2.

4. Move the graph of angular displacement of transmitter to angular displacement in receiver.

11

Nature of characteristics :

(A):

Vs1s2 Vs3s1 Vs2s3

RMS

Voltage

0

Angular

Displacement

(in degrees)

0

Part-b diagram.

12

Observation tables: -

(A)

(B)

Conclusion: -(a) If angular displacement is changed depending on rotor position the voltages are induced

in stator coils.

(b)If Transmitter position is changed then receiver position is changed accordingly.

13


STUDY OF PRESSURE/TEMPERATURE/LEVEL/FLOW SWITCHES (ANYTWO)

Aim: Study of various pressure/temperature/level/flow switches.

Apparatus: Level and flow switches.

Theory:

Level Switches:

Single point and multi-point level switches, visual indicators and continuous liquid level sensing

products. Each senor type is offered in multiple technologies from low cost proven reed switch based

floats, compact solid-state electro-optics, no moving parts conductivity switches and controls, capacitive

to ultrasonic and non-intrusive piezo-resonant.

1. Single Point Level Switches:

1.1 Float Level Switches:

In most models, a float encircling a stationary stem is equipped with powerful, permanent magnets. As

the float rises or lowers with liquid level, the magnetic field generated from within the float actuates a

hermetically sealed, magnetic reed switch mounted within the stem. The stem is made of non-magnetic

metals or rugged, engineered plastics. When mounted vertically, this basic design provides a consistent

accuracy of ±1/8 inch. Multi-station versions use a separate reed switch for each level point being

monitored.

Side-mounted units use different actuation methods because of their horizontal attitude. The basic

principle, however, is the same: as a direct result of rising or falling liquid, a magnetic field is moved into

the proximity of a reed switch, causing its actuation.

14

1.1.1 LS-3 Series Single-Point Level Switch:

• Engineered Plastics

• Ideal for Shallow Tanks

• Low Cost/High Volume Use

The durable construction of these reed switch designs ensures long, trouble-free service. Because

the effects of shock, wear and vibration are minimized, these hermetically sealed switches provide

precise repeatability with no more than 1% deviation. The switch actuation points remain constant

over the life of the unit.

1.1.2 LS-1700 Series Single-Point Level Switch:

• Rugged Durability

• Ideal for Oils and Water

• Broad Heat and Pressure Capabilities

15

Ideal for shallow tanks or restricted spaces, or for low-cost, high volume use. Offers broad chemical

compatibility for general purpose use. Also ideal for oils and water.

Flow switches:

1. Piston type flow switches:

For Low Flow Rates in Liquids and Gases

Models for liquid flow rates as low as 50 cc/min. and gas flow rates as low as 2 SCFH.

Small, compact housings with port sizes from 1/4" NPT

Precision built for superior accuracy

Applications:

Protect your expensive electronic equipment from coolant flow failure on:

Laser Heads • Welders • Power Supplies • High Speed Spindles • X-Ray Tubes • Semiconductor

Equipment

Assure proper lubrication flow to critical bearings or gears to prevent system downtime on:

Presses • Rotating Equipment • Conveyors • Machine Tools • Robotics

Ensure system integrity in processing and dispensing equipment on:

Water Purification and Filtering • Beverage Dispensing • Chemical Additives • Gas Sampling • Distilling.

1.1.FS-380 Series Flow Switch:

• Flow Rate Settings: 0.25 GPM to 2.00 GPM

• Port Size: Multiple

• Primary Construction Material: Brass or Stainless Steel

• Setting Type: Fixed

These rugged inline flow switches use 100 micron filtration and are less susceptible to clogging than

other high-pressure inline flow switches. The one-piece magnetic PPS composite piston makes the FS-

16

380 ideal for high-pressure applications such as industrial cleaning equipment. The FS-380 is also an

excellent choice for semicon cooling applications where simple design and reliable operation are

required.

Applications:

• Electronic Equipment: Laser Heads, Welders, Power Supplies, High Speed Spindles, X-Ray Tubes,

Semiconductor Equipment

• Bearings or Gears: Presses, Rotating Equipment, Conveyors, Machine Tools, Robotics

• Processing & Dispensing Equipment: Water Purifications and Filtering, X-Ray Film Processing,

Beverage Dispensing, Chemical Additives, Gas Sampling, Distilling.

1.2 FS-925 Series Flow Switch:

• Flow Rate Settings: Liquids - 0.1 GPM to 1.5 GPM; Air/Gases - see chart

• Port Size: 1/4" NPT

• Primary Construction Material: Brass or Stainless Steel


This series of precision-calibrated switches provide reliable and consistent performance; repeatability

is within 1%. FS-925 units are factory preset for actuation at specified flow rates.

These switches provide accurate detection of excessive or insufficient flow rates in such applications

as: protecting against loss of fluid flow in hydraulic systems, assuring proper coolant flow in

semiconductor processing equipment, monitoring high pressure lubrication systems, and ensuring proper

air flow in water/waste systems.

17

Applications:

• Electronic Equipment: Laser Heads, Welders, Power Supplies, High Speed Spindles, X-Ray Tubes,

Semiconductor Equipment

• Bearings or Gears: Presses, Rotating Equipment, Conveyors, Machine Tools, Robotics

• Processing & Dispensing Equipment: Water Purifications and Filtering, X-Ray Film Processing,

Beverage Dispensing, Chemical Additives, Gas Sampling, Distilling.

2.Shuttle Type Flow Switches:

For Moderate to High Liquid Flow Rates

Models for flow rate settings from .5 GPM to 100.0 GPM

Rugged housings with port sizes ranging from 3/4" NPT to 3" NPT

Efficient flow paths assure low line pressure drop at full flow

Typical Applications:

Protect bearings or gears from loss of lubricant flow

Switches can reduce maintenance costs on:

Oil Separators • Fuel Systems • Pumps • Compressors • Presses

Provide instant, automatic shutdown if coolant flow falls off in electronics or machinery, such as:

Heat Exchangers • Semiconductor Manufacturing Equipment • Induction Furnaces • Radio Transmitters

Assure efficient operation of process systems, including:

Water Filtration and Reverse Osmosis • Chlorinators • De-icers • Sterilizers • Evaporators

2.1 FS-400 Series Adjustable Flow Switch:


18

• Port Size: 3/4"

• Primary Construction Material: Bronze

• Setting Type: Adjustable

Provides accurate flow detection in water and oil with 1% repeatability. Flow settings on the adjustable

version can be easily changed without disassembly. A shuttle by-pass vane inside the housing is

controlled externally using an ordinary flat-blade screwdriver. These switches are ruggedly constructed

of non-corrosive materials and resist shock and vibration. Suitable for triggering alarms on interlocking

shutdown circuitry when flow rate is improper to protect bearings, gears and cooling systems.

Applications:

Protect Bearings or Gears: oil separators, fuel systems, pumps, compressors, presses

Electronics or Machinery: heat exchangers, semiconductor manufacturing equipment, induction furnaces,

radio transmitters

Process Systems: water filtration and reverse osmosis, chlorinators, de-icers, sterilizers, evaporators.

3.Plastic shuttle flow switches:

3.1 FS-500 Series Flow Switch:


• Port Size: 3/4" NPT

• Primary Construction Material: Polypropylene


The FS-500 offers low cost flow monitoring with a variety of switch actuation points and low pressure

drop. All wetted parts are polypropylene or stainless steel, making this switch ideal for a wide range of

chemical and temperature requirements. The materials are also NSF or FDA approved for potable water

treatment applications including chlorinators, purifiers and heaters. The FS-500 is ideal for equipment

cooling including welders, lasers, etc. A J-box version with a 5 amp relay is also available for direct

control of higher electrical loads, such as chlorinator pumps.

19

Applications:

•••• Protect Bearings or Gears: oil separators, fuel systems, pumps, compressors, presses

•••• Electronics or Machinery: heat exchangers, semiconductor manufacturing equipment, induction

furnaces, radio transmitters

•••• Process Systems: water filtration and reverse osmosis, chlorinators, de-icers, sterilizers,

evaporators.

Conclusion:

In this way we have studied different level and flow switches.

20


Study of I/P and P/I converter.

Aim: Study of I/P and P/I converter.

Apparatus: I/P, P/I converters, air regulator, current source, compressor for air supply, pressure guage

etc

Theory:

1. Working principle of I/P converter

2. Working principle of P/I converter.

3. Applications of these converters

I/P converter diagram:

21

P/I converter diagram:

Procedure:

Part A: P/I converter

1. Power on the supply to the set-up.

2. Current source/sink should be in a sink mode

3. Adjust air-regulator to give 3 psi pressure.

4. Note down the current it should be 4 mA

5. Vary the pressure in steps of 2 psi and note down the corresponding values of current

6. Enter the reading in the observation table.

Observation Table:

Sr No. Pressure(psi) Current(mA)

1.

2.

3.

4.

5.

22

Part B: I/P converter

1. Power on the supply to the set-up.

2. Current source/sink should be in a source mode

3. Adjust the supply pressure to 20 psi.

4. Adjust the current to 4 mA, output pressure should be 3 psi

5. Vary the current in steps of 2 mA and note down the corresponding values of pressure

6. Enter the reading in the observation table.

Observation Table:

Sr No. Pressure(psi) Current(mA)

1.

2.

3.

4.

5.

Plot the graph of pressure vs current for readings of P/I converter.

Plot the graph of pressure vs current for readings of P/I converter

Conclusion: It is observed that if the valve opening is kept undisturbed and flow rate is varied, the valve

co-efficient remains constant for different flow rates.

23


STEPPER MOTOR CONTROL

Aim: Study of stepper motor control.

Apparatus: Stepper motor control kit, power supply, UJT Oscillator, translator & stepper

motor. conceiting wires

Theory:

Principle:

A Stepper motor is an electro mechanical device, which actuates a train of step angular, or

linear moment in response to train of input pulses one to one basis. One step actuation for each pulse

input.

Types of stepper motors:

α) Variable reluctance type,

β) Permanent magnet stepper motor

The operation of stepping motor can be understood from the simple model shown in above fig-

1which has 90 per step .In this motor the rotor is an permanent magnet which driven by

particular set of electromagnets .In the position shown the system is in equilibrium

electromagnets .The switch are in solid state devices such as transistor, SCR etc. The switch

sequence will direct the switches will a sequences of positions as the pulses are received.

The next pulse in fig-1 will change S2 from c to d resulting in poles of that electromagnet

reversing fields

Now, because the pole north /south orientation is different, the rotor is repelled and attracted

so that it moves to the new position of equilibrium as shown in fig. 2 with the next pulse S is

changed to B canting the same kind of pole reversal & rotation of PM S2. To switch to C again

and PM rotor again steps to new equilibrium position as shown in fig. D, the next pulse will send

the system back to original position. This sequence is

then repeated.

Steps/revaluation (s) = m Nr

Where m = phases

Nr = no of rotor teeth.

Angle/step=360/m

N = 360/s

Specifications:

1) Step angle =1.8°

2) Operating voltage= 12 v d.c.

3) Current rating =1.2 Amp

4) Torque 3 Kg.cm

24

Properties:

1) When driven with digital pulses it moves one & only one step per pulse.

2) Self-starting no external means is required.

3) It Starts/Stops & reverse instantaneously.

4) It is bi-directional motor and can rotate in either direction.

Applications of stepper motor:

1) Pulse converter on production lines.

2) Remote indicator.

3) Numerically controlled machine tool drive.

4) Line spacing controls for point out m/c.

5) Punch tape drives.

7) In optical & medical equipments.

8) Focus control of camera & filmstrip projector.

9) Automatic servo operated AC voltage regulator.

10) Ac drives, it can be used, strip chart recorder & curve tracer.

11) For recording instrument.

Operation of stepper motor:

Fig. a fig. b

fig c

fig d

25

90°/step.

Permanent magnet stepper motor

Driving circuit for stepper motor: -(Open Loop Control)

-

Elementary diagram of stepper motor:

Conclusion: In this way we studied the operation of stepper in open loop mode.It is observed that as

frequency is changed the spped of motor is also changed and direction of motor can be

changed by changing the pulses to bifiller windings.

26


STUDY OF A.C. SERVOMOTOR & ITS CHARATERSTICES

Aim: Study of A.C. Servomotor

a) Control characteristics of servomotor. by amplitude control ( control voltage verses

speed )

b) Speed torque characteristics.

Apparatus: Servomotor kit, Multimeter, connecting wires etc.

Theory:

1 Principle of A.C. servomotor

2.Specification of A.C. servomotor

3.Application of A.C. servomotor

4.compeare A.C. servo motor and two phase induction motor

Procedure:

Part-A:

1. Keep the switch SW3 off so that the armature circuit of D.C. machine is

not connected to auxiliary power supply.

2. Sw2 should be in OFF position.

3. Ensure P2 and P1 are fully anticlockwise position.

4. Now switch Sw1 and Sw2 ON.

5. You can observe that a.c. servomotor starts rotating and speed will

indicated by `M` on front panel.

6.Vary speed of a.c. servomotor by rotating P1 in clockwise direction and

note the emf generated by a.c. machine,

7.Enter the result in table- 1

Part-B

1 Now switch OFF Sw3 and switch ON Sw2.

2. Now set the control winding voltage at 54Volt and reference winding voltage will be all-

out Voltage.

3. Note down the speed of A.C. servomotor

4. Now switch ON Sw2 and start a.c. servomotor in slow fashion and note down the

corresponding values of Ia (Armature current).

5. Set the control winding voltage to new value of after switching Sw3 again repeat.

6. Plot the speed torque characteristics for different values of the control voltage.

Observation table:

Part-A

Sr No. Speed ( RPM ) Control Voltage (V) Eb = Volts.

1.

2.

27

Part-B

Sr.No. Speed (M)

( RPM )

Eb

Volts.

Ia

( Milliamp)

Torque =

EbIa/2πη

1.

2.

Nature of characteristics:

Part-B

Part-A

Torque VC=30V

Vc=0

Control

Voltage

Speed Speed

Reference

winding

Actuating

signal _

control winding q

Fig.-1 schematic diagram of two phase induction motor

28

Servo amplifier

TMI,F

Charters tics of 2 phase A.C.servomotor and Induction motor

X1/R1 > X2/R2 > X3/R3

Torque

(N-M)

(1)

(2)

(3)

Speed(RPM)

Fig.-2

Torque speed characteristics of induction motor

Conclusion: In part A it is observed that as control winding voltage increases the speed of motor

increases and part B as load increases the speed of motor decreases.

29

DOs and DON’T in Laborary:

1. Do not handle any equipment before reading the instructions/Instruction manuals

2. Read carefully the power ratings of the equipment before it is switched on whether ratings 230 V/50

Hz or 115V/60 Hz. For Indian equipments, the power ratings are normally 230V/50Hz. If you have

equipment with 115/60 Hz ratings, do not insert power plug, as our normal supply is 230V/50 Hz,

which will damage the equipment.

3. Observe type of sockets of equipment power to avoid mechanical damage

4. Do not forcefully place connectors to avoid the damage

5. Strictly observe the instructions given by the teacher/Lab Instructor

Instruction for Laboratory Teachers::

1. Submission related to whatever lab work has been completed should be done during the next lab

session. The immediate arrangements for printouts related to submission on the day of practical

assignments.

2. Students should be taught for taking the printouts under the observation of lab teacher.

3. The promptness of submission should be encouraged by way of marking and evaluation patterns that

will benefit the sincere students.

5. Conduction of Viva-Voce Examinations:

Teacher should oral exams of the students with full preparation. Normally, the objective questions with

guess are to be avoided. To make it meaningful, the questions should be such that depth of the students

in the subject is tested Oral examinations are to be conducted in co-cordial environment amongst the

teachers taking the examination. Teachers taking such examinations should not have ill thoughts about

each other and courtesies should be offered to each other in case of difference of opinion, which should

be critically suppressed in front of the students.

30

4. Quiz on the subject:

Questions to be prepared for viva voce examinations

1. Comp ear open loop and closed loop systems

2. State the applications of control system engineering

3 Define the terminology used in control system engineering

5. What significance of positive and negative feedback in control system

6. What is matamatical modeling, enlist the steps of modeling

7. Give the analogy of different systems

8.state specifications and applications of different components of control system.

9.compare Electrical, pnumetic, and hydraulic systems.

10.what is actuator? How actuator are claasified.listout different actuator

11 what is control valve? How control valves are classified

12.Define control valve size, disharge coefficient, Rangeability.

13.Give the selection criteria for control valve

14.what are the different converters? State its applications

15.what are the different transmitters? State its applications

10. What are the different types of Relays, state its specifications.

6. Evaluation and marking system:

As per JNEC format/University marking scheme.

31

Jawaharlal Nehru Engineering CollegeICE)CSE-I lab manual.pdfJawaharlal Nehru Engineering College ......

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Transcript of Jawaharlal Nehru Engineering CollegeICE)CSE-I lab manual.pdfJawaharlal Nehru Engineering College ......