World Academy of Science, Engineering and Technology 1 2007

Level Control in Horizontal Tank by Fuzzy-PID Cascade Controller

Satean Tunyasrirut, and Santi Wangnipparnto
performances [1,2]. On the other hand, the fuzzy controller is also popularly implemented in many practical industrial automation applications. II. THEORY A. Cylindrical Horizontal Tank System The structure of the liquid volume in horizontal tank is shown in Fig. 1.

to control the level of horizontal tank that has diameter 300 mm and 480 mm long. Interface card module PCI-6024E in computer and Lab View software program is used for built the cascade controller. Structure of its where the inner loop is a PID controller for regulating flow rate of system and outer loop is a Fuzzy logic controller for control the level. The response time, steady state error, load disturbance, and control valve action of cascade are tested and compared with the simple controller. The experimental shows that at the same water level 50% set-point, the rising time to set-point of cascade controller is less than the simple controller about 1750 ms, and it has steady state error less than simple controller about 1% . The load disturbance on the plant has no affect when using the cascade controller. The control valve action of the cascade controller has operation high frequency than the simple controller so the water level in horizontal tank is smoothly constant. Overshoot affect on cascade and simple controller has not occurred. the cascade controller that consist of the PID and the fuzzy logic control to improve the dynamic characteristic of the level control in horizontal tank. The performance of it will comparing with the simple loop or fuzzy logic controller.

AbstractThe paper describes the FuzzyPID cascade controller

KeywordsFuzzy PID, level control, horizontal tank.

Fig. 1 The horizontal tank model

I. INTRODUCTION OWADAYS, the various parameters in the process of industrial are controlled such as temperature, level, and etc. Some process needs to keep the liquid level in the horizontal tank such as oil, chemical liquid in its. The level control is a type of control method for common in process system. The level control system must be controlled by the proper controller. The objective of the controller in the level control is to maintain a level set point at a given value and be able to accept new set point values dynamically. The conventional proportional-integral-derivative (PID) is commonly utilized in controlling the level, but the parameter of those controllers must be turned by tuning method either in time response of frequency response to meet their required

The continuity equation is essentially the equation for the conservation of mass as follows;

Where m = V = Mass of water, kg o = Volume flow rate, inlet and outlet respectively. Qio , Qo = Water density = 1000 kg/m3

dm o o = Q i Q o dt

(1)

dV o o =Q i Q o dt
o dh Q Qo = i o2 dt 2(Dh h )

(2)

Manuscript received November 30, 2006. The research has been supported in part by Faculty of Engineering, Pathumwan Institute of Technology, Bangkok 10330, Thailand and Research Center for Communications and Information Technology, King Mongkut's Institute of Technology Ladkrabang (KMITL), Bangkok 10520, Thailand. Satean Tunyasrirut is with Asst. Prof at Pathumwan Institute of Technology, Thailand. His research interests include modern control, intelligent control, Power Electronics, Electrical Machine, and Drives (email: satean2000@gmail.com). Santi Wangnippranto is with Asst. Prof. at Department of Electrical Engineering, Faculty of Engineering, Pathumwan Institute of Technology, Bangkok 10330, Thailand. His research interests include sensor technology, control system, enhance heat transfer, and energy conversion. (e-mail:nipparnto@gmail.com).

When dV = 2(Dh-h2)dh and Dh = 2Rh are substituted in Eq.(2) and given as; (3)

Where Q o = Cv h and Cv = value constant are substituted in Eq.(3) and given as;
o

o dh Q Cv h o i = = f (h,Q i) 2 2 dt 2(Dh h ) 2(Dh h )

(4)

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World Academy of Science, Engineering and Technology 1 2007

Taylor-series expansion and Laplace transform are used, and we get:

H(s) 1 K = = o s s+ 1 Q i (s) 2A ((Dh h2 ) + 1 A

where K= -1/(2A(Dh-h2)) and = -1/A.

(5)

fuzzification, control rule and defuzzification stages. To create the membership function, Membership function editor is used for expressing input and output variables. The input variable is the level error. The number of membership functions for each input variable is designated in seven ranges. The setting level of the horizontal tank is defined as the fuzzy controller output, which has 49 membership functions.

From the transfer function shows that K and as a function of nonlinear h. III. PID, FUZZY, AND CASCADE CONTROLLER A. PID Controller The most industrial process can be controlled with PID control (Proportional-Integral-Derivative) provided in equation:
t 1 (t) de ( ) ( ) u(t) = K e t e t dt Td + + Ti dt 0

(a)

(6)

Where u is the control variable and e is the control error (e=ysp-y). The parameters of its can be determined by ultimate sensitivity method that using Kc=4.5 and received the data from Fig. 2. All data is used for calculated the parameters of PID controller as shown in Table I.

Pu = 25 ms

Kc = 4.5 PBu = 22.22

(b)

Delay Time = 300 ms

Fig. 2 Data result from the ultimate sensitivity method

TABLE I PARAMETERS OF PID CONTROLLER Type of control P PI PID Kc 2.25 2.045 2.647 Ti 0.1037 0.0625 TD 0 0 0.01562

B. Fuzzy Logic Controller Fuzzy control uses a list of rules than complicated mathematical expressions. These rules are modeled after decisions previously made by humans through the process control system. The inputs of fuzzy logic controller are the level error between the actual level and target level of the level in horizontal tank. The fuzzy logic controller consists of

(c) Fig. 3 Membership function of input and output variables for the level control; (a) error, (b) CE, and (c) output assumption

The form of all input and output membership functions is selected to be triangle-shaped functions for simplicity. In fuzzification stages, the input variables, the level is converted into fuzzy variables by using the membership function as shown in Fig. 3 where e and ce of level is the fuzzy subsets in the universe. The linguistic rules are shown in Table II.

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World Academy of Science, Engineering and Technology 1 2007

ce e NB NM NS ZE PS PM PB

TABLE II CONTROL RULES FOR INPUT AND OUTPUT VARIABLES NB DE0 DE1 DE2 DE3 DE4 DE5 DE6 NM DE0 DE1 DE2 DE3 DE4 DE5 DE6 NS DE0 DE1 DE2 DE3 DE4 DE5 DE6 ZE DE0 DE1 DE2 DE3 DE4 DE5 DE6 PS DE0 DE1 DE2 DE3 DE4 DE5 DE6 PM DE0 DE1 DE2 DE3 DE4 DE5 DE6 PB DE0 DE1 DE2 DE3 DE4 DE5 DE6

C. Cascade Control Cascade control can be used for improved disturbance rejection when there are several measurement signals and one control variable. Cascade control is built up by two control loop as shown in Fig. 4. The inner loop is called the secondary loop that using the PID controller, the flow transmitter is used for sending the feedback signal. The outer loop is called the primary loop that using the fuzzy logic controller, the level transmitter is used for sending the feedback signal.
HV5

Fig. 5 Plant level control set up

A/D 0 - 10V

D/A

Interface card PCI-6024E

Controller

TANK 2 PI FT CV1

V. EXPERIMENTAL RESULTS In this paper shows level control from 10-90% of the horizontal tank by cascade controller. There are three types of the experimental as the response time, load disturbance, and control valve action are investigated. A. The Response Time The process response or response time of the level control system, when changing the step set point from 0 to 10, 25, 75 and 90 are tested. At the step set point from 0 to 50%, the response time of the simple loop or fuzzy controller and Cascade controller are compared and shown in Fig. 6.

Terminal block CB-68LP

0 - 10V

HV6 HV4 HV3 HV2

H LT

HV1

I/V
4-20mA

V/I
4-20mA MOTOR PUMP

SUPPLY TANK 1

4-12mA

Fig. 4 Plant model of cascade control system

IV. EXPERIMENTAL SETUP The simplified of the level control system is shown in Fig. 5. It consists of a microcomputer, interface card, level transmitter, Flow transmitter, and linear control valve. The microcomputer is a cascade controller that used for controls the level in horizontal tank. The outer loop, the fuzzy controller is received the level signal, computation and sending control signal as the set point of PID controller. The inner loop, PID controller is received the flow signal, computation and sending control signal to the control valve in order to keep the water level at the set point in the horizontal tank.

(a)

Fig. 6 The process response result at the step set point 0-50% when (a) the fuzzy logic controller only, (b) the cascade controller

(b)

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From the Fig. 6 shows that the response time of the cascade controller is less than the fuzzy logic controller about 7.9% and it has steady state error less than the fuzzy logic controller too. B. Level Control with Interrupt Load At water level 50%, interrupting load by decrease water to level 25% and off valve quickly. The response time of the fuzzy controller only and the cascade controller are compared and shown in Fig. 7. It is seen from the Fig. 7 that the fast responses can also be obtained, the response time of the cascade controller is less than the fuzzy controller only about 4.6%.
(a)

(a)
(b) Fig. 8 The action of control valve at level set point 50% when (a) the fuzzy logic controller only, (b) the cascade controller

Fig. 7 The process response result at interrupting load when (a) the fuzzy logic controller only, (b) the cascade controller.

(b)

C. Control Valve Action Control valve action of the fuzzy controller only and the cascade controller are compared and shown in Fig. 8. It is seen from the Fig. 8 that the control valve of the cascade controller operates at high frequency and keep level nearly the set point.

VI. CONCLUSION PID and fuzzy controller are used for built the cascade controller in order to control the level in the horizontal tank. It has been shown that the speed of responses of the level control system with and without load interrupt in the tank are fast. Hence, it can be conclusion that; 1. The response time of the cascade controller less than the single loop or fuzzy logic controller about 7.9% at the step level set point 0 to 50%. 2. Both of the fuzzy logic controller and the cascade controller give the smallest state error. 3. The interrupt load has slightly effect to the fuzzy logic controller and the cascade controller. 4. The control valve action of the cascade controller is operated at high frequency than the single loop so the water level in the tank is smoothly ACKNOWLEDGMENT The authors gratefully acknowledge the Mr. KampolPrompornchai and Mr. Watee Kaewpet who work hardly and testing this research. REFERENCES
[1] J. G. Ziegler and N. B. Nichols, Optimum settings for automatic controller, ASME Trans. Vol64, 1942, pp.759-768.

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[2] [3] [4]

W. K. Ho, C. C. Hang, and J. H. Zhou, Performance and gain and phase margins of well-known PI Tuning formulas, accepted for publication in IEEE Trans. Contr. Syst. Technol., 1995. Jacob, J.Michael., Industrial Control Electronics, New Jersey: Prentice-Hall, 1988. Passino, Kevin M., and Yurkovich, Stephen., Fuzzy Control, Sydney: Addison-Wesley, 1998.

1995 he was awarded with the Japan International Cooperation Agency (JICA) scholarship for training the Sensor Technology at Nara National College of Technology, Japan. Since 2005, he has been a Asst. Prof at Department of Electrical Engineering, Pathumwan Institute of Technology, Thailand.. His research interests include Sensors, Control system, Energy conversion, and Enhance heat transfer .

Satean Tunyasrirut received in B.S.I.Ed. in Electrical Engineering and M.S.Tech.Ed in Electrical Technology from King Mongkuts Institute of Technology North Bangkok(KMITNB),Thailand in 1986 and 1994, respectively. In 1995 he was awarded with the Japan International Cooperation Agency (JICA) scholarship for training the Industrial Robotics at Kumamoto National College of Technology, Japan. Since 1995, he has been a Asst. Prof at Department of Instrumentation Engineering, Pathumwan Institute of Technology, Thailand. His research interests include adaptive control, intelligent control, electric drives. Santi Wangnipparnto received in B.S.I.Ed. in Electrical Engineering from King Mongkuts Institute of Technology North Bangkok(KMITNB) ,Thailand in 1988 and M.eng and D.eng in Energy Technology from King Mongkut University of Technology Thonburi (KMUTT),Thailand in 1994 and 2001, respectively. In

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