Design And Modeling Of Multiple Tank Control For Fluid Circulation System Using Fuzzy Controller.
DESIGN AND MODELING OF MULTIPLE TANK
CONTROL FOR FLUID CIRCULATION SYSTEM USING
FUZZY CONTROLLER
GWEE CHIOU CHIN
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Design and Modeling of Multiple Tank Control for Fluid
Circulation System Using Fuzzy Controller
Thesis submitted in accordance with the partial requirement of the
Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Robotic & Automation) with Honours
By
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UTeM Library (Pind.1/2007)
GWEE CHIOU CHIN
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FAKULTI KEJURUTERAAN PEMBUATAN
Rujukan Kami (Our Ref) : 30 April
2008
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA Karung Berkunci 1200, Ayer Keroh, 75450 Melaka
Tel : 06-233 2421, Faks : 06 233 2414 Email : fkp@kutkm.edu.my
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iii
DECLARATION
I hereby, declared this thesis entitled “Design and Modeling of Multiple Tank Control for Fluid Circulation System Using Fuzzy controller” is the results of my
own research
except as cited in references.
Signature : ……….
Author’s Name : Gwee Chiou Chin
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APPROVAL
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Robotic and
Automation) with Honours. The members of the supervisory committee are as follow:
……… Main Supervisor
En Muhamad Arfauz Bin Abdul Rahman Faculty of Manufacturing Engineering
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v
ABSTRACT
A tank level control is one of the important systems which are used widely in industry. This control system keeps developing from time to time to replace the ordinary system which applies mechanical functions in its control in order to improve the system reliability. There are many applications in industries that are utilizing this system such as water dam, water treatment system, industry tank control and also boiler. In order to develop a successful tank fluid level control system, full understanding on the function and principle of the system is required. In this project, Matlab Simulink will be used as a main platform in developing the simulation of the exact control system for the Lamella Filtration system. The system that been study in this project is the Lamella Filtration system of Bukit Sebukor Water Treatment Plant. This study is to upgrade the mechanical water level control system of the Lamella Filtration system to an automatic system. The automation of the system can reduce the burden of the technicians on shift and prevent human error on manual operation. The system will be tested to gain the desired control function. The end result of this project will be a smooth and low error water level control system for the Lamella Filtration system.
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ABSTRAK
Pengawalan paras tangki merupakan salah satu sistem penting yang luas digunakan dalam industri pada masa kini. Sistem ini terus membangun untuk menggantikan sistem biasa yang mengaplikasikan fungsi mekanik dalam pengawalan untuk memperbaiki kebolehpercayaan sistem. Terdapat banyak aplikasi dalam industri yang menggunakan sistem ini seperti empangan air, sistem rawatan air, kawalan tangki industri dan juga pemanas air. Untuk membangun suatu sistem kawalan paras air yang berjaya, pemahaman yang menyeluruh terhadap fungsi dan prinsip sistem tersebut diperlukan. Dalam projek ini, Matlab Simulink akan digunakan sebagai alat uatama dalam menghasilkan simulasi sistem kawalan yang tepat and betul untuk Sistem Penapisan Lamella. Sistem yang dikaji dalam projeck ini adalah Sistem Penapisan Lamella Loji Air Bukit Sebukor Melaka. Kajian ini adalah bertujuan untuk menaik tarafkan sistem mekanikal kawalan air yang ada pada Sistem Penapisan Lamella yang sedia ada kepada sistem automasi. Pengautomasian sistem tersebut dapat mengurangkan beban teknisian yang bertugas dan mengurangkan kesilapan manusia dalam operasi manual..Sistem tersebut akan diuji untuk mendapat fungsi kawalan yang diingini. Hasil daripada projek ini merupakan satu sistem kawalan paras air untuk Sistem Penapisan Lamella yang lancar dan rendah kesalahan.
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vii
DEDICATION
I dedicate this PSM thesis to my beloved parents, Gwee Tee san and Yew Be Bee, my beloved brothers, Gwee Chen Ee and Gwee Chen Shang, and my friends, Jannatunnaim Harun and Noorhayati Shaharudin.
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ACKNOWLEDGEMENTS
With the helps and blessing from God, I managed to complete this project successfully. First of all, I would like to thank my parent, for their concern and support, all over the time. Not forgotten my brothers, who had helped me a lot in supporting me physically and morally.
I also want to thank Mr. Muhamad Arfauz Bin Abdul Rahman from Fakulti Kejuruteraan Pembuatan, Universiti Teknikal Malaysia Melaka, for supervising me all along this project, and provide helps, guides, ideas, and suggestions to accomplish this project. All the supports and motivation that been given to me are greatly appreciated.
Also not forgotten, Mr. Salleh and Mr. Asmadi from Bukit Sebukor Water Treatment Plant, for giving a permission to conduct the case study at the Water Treatment Plant.
With a deep sense of gratitude, I would also like to express my sincere thank to my colleague, Jannatunnaim and Noorhayati for the help and supports that been shown by them.
Last but not least, thanks to all my friends who had helped me directly or indirectly in completing this project and thesis in time.
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ix
TABLE OF CONTENTS
Declaration………...iii Approval………..………iv Abstract………..………...………....v Abstrak……….vi Dedication………...vii Acknowledgements………...……viii
Table of Contents ………....ix
List of Figures……….xii
List of Tables...xiii
List of Abbreviations, Symbols, Specialized Nomenclature………... .xiv
1. INTRODUCTION ………..1
1.1Project Introduction ………...1
1.2Problem Statement ...………..………...2
1.3Objective...………..3
1.4Scopes ……….3
2. LITERATURE REVIEW ……….5
2.1 Introduction ………....5
2.2 Control system ………6
2.2.1 Open Loop and Closed Loop System ………..………….9
2.2.2 Fuzzy Logic ………..……..12
2.3 Level Controllers ………..13
2.4 Flow Controllers ………...14
2.5 Water Level and Flow Control Devices ………16
2.5.1 Level Sensor ………16
2.5.2 Flow Meter ………..17
2.5.3 Water Valve ………18
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2.6 Fuzzy Logic Controller ……….21
2.6.1 Structure of a Fuzzy Controller ………..24
2.6.2 Fuzzy Logic Toolbox ……….24
2.7 Fuzzy Controller versus PID Controller ………...25
2.8 Water Filter ………...28
2.9 Concluding Remarks ………... 29
3. METHODOLOGY ……….………...31
3.1 Introduction ………..31
3.2 Project Design ……..………...31
3.3 System Design .……….33
3.4 Project Methodology .………...35
3.4.1 Case Study …………..………35
3.4.2 Research ………..35
3.4.3 Interview ……….35
3.4.4 Observation ……….36
3.5 Project Tools ……….36
3.5.1 Books ………..36
3.5.2 Papers ………..36
3.5.3 Internet ………37
3.5.4 Software ………..37
3.6 Project Planning ………38
3.6.1 Project Planning for PSM 1 ………38
3.6.2 Project Planning for PSM 2 ………41
4. CASE STUDY ………..43
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xi
5. DESIGN SIMULATION ...………...50
5.1 Introduction ...50
5.2 System Development ...50
5.3 Development of SIMULINK Block Diagram ...51
6. RESULTS & DISCUSSION……...……….56
6.1 Introduction ...56
6.2 Results ...56
6.3 Concluding Remarks ... 60
7. CONCLUSION & SUGGESTIONS ...61
7.1 Introduction ...61
7.2 Summary ...61
7.3 Conclusion ...63
7.4 Suggestions & Recommendations ...74
REFERENCES APPENDIX
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LIST OF FIGURES
2.1 Simplified Description of a Control System 6
2.2 Elevator Response 8
2.3 Open Loop System 9
2.4 Closed Loop System 10
2.5 Direct Control 22
2.6 Feed Forward Control 23
2.7 Fuzzy parameter adaptive control. 23
2.8 Blocks of a Fuzzy Controller 24
2.9 Fuzzy Logic Based Control System 27
3.1 Flow of the Project Design 32
3.2 Flow of the System Design 34
4.1 Bukit Sebukor Water Treatment Plant 42
4.2 PLC Monitoring 46
4.3 Filter Control Panel 46
4.4 Lamella Filtration Tank 47
4.5 Lamella Filtration Tank structure (Architecture Drawing) 48
4.6 Lamella Filtration Tank Structure (Simplified Drawing) 49
5.1 Simulink Library Browser 51
5.2 Empty Simulink Window 52
5.3 Block Diagram for the new system. 52
5.4 Water Tank Block Parameters Window 53
5.5 Penstock Block Parameter Window 54
5.6 Rule Editor Window 54
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xiii
LIST OF TABLES
3.1 Gantt chart for PSM 1 40
3.2 Gantt chart for PSM 2 42
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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
AWWA - American Water Works Association
CPVC - Chlorinated PVC
DP - Differential pressure
GUIs - Graphical user interfaces
I/O - Input/Output
P - Proportional
PD - Proportional plus derivative / Positive displacement
PI - Proportional plus integral
PID - Proportional, integral, and derivative
PSM - Projek Sarjana Muda
PTFE - Polytetrafluoroethylene
PV - Photovoltaic
PVC - Polymers, polyvinyl chloride
UV - Ultraviolet
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1
CHAPTER 1
INTRODUCTION
1.1
Project Introduction
Level and flow control system is a technique used to control the level and flow of circulation system for variety of purpose. It can be used to control either fluid or even air for pneumatic or hydraulic system. There are few types of process that use the level and flow control system, such as water treatment centre, water dam, tank level control, and liquid flow control and circulation system.
In this project, the Lamella Filtration system of Bukit Sebukor Water Treatment Plant is studied. The objective of this project was to upgrade the mechanical water level control system of the Lamella Filtration system to an automatic system. The automation of the Lamella Filtration system can help reducing the burden of the technicians on shift and prevent human error on manual operation.
Previous study on fluid level control using SIMULINK was carried out by previous student. [15] In his study, the design and modeling tank control for fluid circulation system using SIMULINK had been designed. Unfortunately, the system is not suitable to be applied at the current Lamella Filtration system.
Level and control system for Lamella Filtration system will be discussed in this report. By conducting a case study that implement this system, problem that been faced by the system were carefully taken into consideration. New proposed system will be develop and evaluate to find the best solution for the problem faced.
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1.2
Problem Statement
Nowadays, most of the fluid level and flow system are still applying the mechanical control to control the circulation system. [15] Floating limit switch, diaphragm valve and solenoid which connected by simple wiring are the examples of main control device that normally used in mechanical control.
The current Lamella Filtration system of Bukit Sebukor Water Treatment Plant uses a mechanical control system. Technicians are required on shift to monitor the control system twenty four hours a day.
The main criterion that needs to be controlled in level and flow of a fluid circulation is the rate of the main supply and the distribution system. Complete system with suitable control need to be considered to achieve this.
The mechanical control system’s device is subjected to tear and wear itself. For the example, floating limit switch has a cycle rate which will turn to be malfunction after the cycle rate. At the same time it is also subjected to tear and wear caused by the movement of the switch.
Over flow is another problem that regularly been faced by this system, which caused by insufficient control of the inlet. The reason for system overflow can be failure of the device to calculate the level of the main tank before signaling the inlet device. Other problems such as supply drainage cause by the device failure, which in return can affect the production process.
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3
1.3
Objective
The main objective of this project is to control and model multiple tank fluid level control system using Fuzzy Controller. In order to achieve the main objective, following are some additional objectives to be completed:
a) To evaluate the current fluid level control.
b) To design and propose an automatic fluid level control system that can replace the current mechanical system.
c) To control and simulate the designed Lamella Filtration tank fluid control system.
1.4
Scopes
The scopes of this project are:
a) Data Collection
A case study will be conducted to collect data about the current Lamella Filtration system at Bukit Sebukor Water Treatment Plant Malacca. In this case study, a few visits will be pay to the Bukit Sebukor Water Treatment Plant, and the technician on duty will be interview for the data collection purpose. After that limitation of the current system will be identify and carefully taken into consideration for the further improvement. Besides that, data for literature review will be collect from internet, books, and previous student’s research.
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b) Design and Simulation
New automation control system will be designed to improve the current system. The new control system will be design by using Fuzzy Logic Toolbox in Matlab. The designed system will then be simulated.
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5
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
The literature review that have been done to gain more information on the project that been carried out is describes in this chapter. Firstly, the basic explanation on the control system is discussed. After that, it is followed by the discussion of the lamella filtration tank fluid level control and the devices that needed in controlling this system. Finally is the control application using the Fuzzy Logic Toolbox with the aid of Matlab is discussed.
Mechanical controls are used to control the simple level and flow system, for the examples: limit switches, mechanical valve, and electro-pneumatic valve. However, mechanical system could not give an accurate and precise output in controlling. Further more, the mechanical control performance are affected by the tear and wear process. Automation control by the application of control system can be used to achieve a better performance.
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2.2
Control System
According to Wikipedia [1], a control system is a device or set of devices to manage, command, direct or regulate the behavior of other devices or systems.
Control systems are an integral part of modem society. Nowadays, there are many applications using control system. Lots of example can be found in daily life, such as washing machine, air-conditioner, and microwave.
There are also control systems that exits in the naturally. For the example, pancreas which regulates human blood sugar level and photosynthesis by plants.
A control system consists of subsystem and processes assembled for the purpose of controlling the outputs of the processes [2]. The air-conditioner that produces more cool air as the result of the room temperature increase is an example. Air conditioner use thermostat to measure the temperature of the room. Thermostat is as a subsystem that will be the input for the system. The control system will provide an appropriate output or response for the given input or stimulus. Figure 2.1 [2] shows the process.
Figure 2.1: Simplified Description of a Control System
Input; stimulus Desired response
Output; response Actual response Control
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7
Control system where built for four primary reasons:
a) Power amplification.
A control system can produce the needed power amplification, or power gain. For example, a radar antenna, positioned by the low-power rotation knob at the input, requires a large amount of low-power for its output rotation. By using the control system, the power that needed can be produce by amplifying the power needed.
b) Remote control.
Robot design by control system principles can compensate for human disabilities. Control systems are also useful for remote at dangerous location. For example, a remote controlled robot arm can be used to pick up material in a radioactive environment.
c) Convenience of input form.
Control system can be used to provide convenience by changing the form of the input. A temperature control system as an example. The position on the thermostat is the input, while the output is the heat. Thus, a convenient position input yields a desired thermal output.
d) Compensation for disturbance.
The ability to compensate for disturbance is typically to control such variable as temperature in thermal system, position and velocity in mechanical system, and voltage, current, or frequently in electrical systems. The system must be able to yield the correct output even with disturbance. For example, an antenna system that point in commanded direction. If wind forces the antenna from its commanded
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position, or if noises enter internally, the system must be able to detect the disturbance and correct the antenna’s position. The system’s input is obviously will not change to make correction. Consequently, the system itself must measure the amount that the disturbance has repositioned the antenna and then return the antenna to the position commanded by the input.
A control system provides n output or response for a given input or stimulus. The input represents a desired response, and the output is the actual response. For example, when the fourth-floor button of an elevator is pushed on the ground floor, the elevator rises to the fourth-floor button of a speed and floor-leveling accuracy designed for passenger comforts is shown in Figure 2.2 [2].
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1.3
Objective
The main objective of this project is to control and model multiple tank fluid level control system using Fuzzy Controller. In order to achieve the main objective, following are some additional objectives to be completed:
a) To evaluate the current fluid level control.
b) To design and propose an automatic fluid level control system that can replace the current mechanical system.
c) To control and simulate the designed Lamella Filtration tank fluid control system.
1.4
Scopes
The scopes of this project are:
a) Data Collection
A case study will be conducted to collect data about the current Lamella Filtration system at Bukit Sebukor Water Treatment Plant Malacca. In this case study, a few visits will be pay to the Bukit Sebukor Water Treatment Plant, and the technician on duty will be interview for the data
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b) Design and Simulation
New automation control system will be designed to improve the current system. The new control system will be design by using Fuzzy Logic Toolbox in Matlab. The designed system will then be simulated.
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CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
The literature review that have been done to gain more information on the project that been carried out is describes in this chapter. Firstly, the basic explanation on the control system is discussed. After that, it is followed by the discussion of the lamella filtration tank fluid level control and the devices that needed in controlling this system. Finally is the control application using the Fuzzy Logic Toolbox with the aid of Matlab is discussed.
Mechanical controls are used to control the simple level and flow system, for the examples: limit switches, mechanical valve, and electro-pneumatic valve. However, mechanical system could not give an accurate and precise output in controlling. Further more, the mechanical control performance are affected by the tear and wear process. Automation control by the application of control system can be used to achieve a better performance.
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2.2
Control System
According to Wikipedia [1], a control system is a device or set of devices to manage, command, direct or regulate the behavior of other devices or systems.
Control systems are an integral part of modem society. Nowadays, there are many applications using control system. Lots of example can be found in daily life, such as washing machine, air-conditioner, and microwave.
There are also control systems that exits in the naturally. For the example, pancreas which regulates human blood sugar level and photosynthesis by plants.
A control system consists of subsystem and processes assembled for the purpose of controlling the outputs of the processes [2]. The air-conditioner that produces more cool air as the result of the room temperature increase is an example. Air conditioner use thermostat to measure the temperature of the room. Thermostat is as a subsystem that will be the input for the system. The control system will provide an appropriate output or response for the given input or stimulus. Figure 2.1 [2] shows the process.
Figure 2.1: Simplified Description of a Control System Input; stimulus
Desired response
Output; response Actual response Control
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Control system where built for four primary reasons:
a) Power amplification.
A control system can produce the needed power amplification, or power gain. For example, a radar antenna, positioned by the low-power rotation knob at the input, requires a large amount of low-power for its output rotation. By using the control system, the power that needed can be produce by amplifying the power needed.
b) Remote control.
Robot design by control system principles can compensate for human disabilities. Control systems are also useful for remote at dangerous location. For example, a remote controlled robot arm can be used to pick up material in a radioactive environment.
c) Convenience of input form.
Control system can be used to provide convenience by changing the form of the input. A temperature control system as an example. The position on the thermostat is the input, while the output is the heat. Thus, a convenient position input yields a desired thermal output.
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position, or if noises enter internally, the system must be able to detect the disturbance and correct the antenna’s position. The system’s input is obviously will not change to make correction. Consequently, the system itself must measure the amount that the disturbance has repositioned the antenna and then return the antenna to the position commanded by the input.
A control system provides n output or response for a given input or stimulus. The input represents a desired response, and the output is the actual response. For example, when the fourth-floor button of an elevator is pushed on the ground floor, the elevator rises to the fourth-floor button of a speed and floor-leveling accuracy designed for passenger comforts is shown in Figure 2.2 [2].
Figure 2.2: Elevator Response
The input is the push of the forth-floor button and it’s represented by a step command. The input represents the desire output after the elevator stop; the elevator itself follow the displacement describes by the curve marked elevator response.