Mathematical Model of Control Valves of Three-Tank System: Petr Chalupa, Jakub Novák, Vladimír Bobál
Mathematical Model of Control Valves of Three-Tank System: Petr Chalupa, Jakub Novák, Vladimír Bobál
Mathematical Model of Control Valves of Three-Tank System: Petr Chalupa, Jakub Novák, Vladimír Bobál
Manuscript received June 29, 2010: This work was supported by the
Ministry of Education of the Czech Republic under grant 1M0567.
Petr Chalupa is with Tomas Bata University in Zlin, nám. T. G. Masaryka
5555, 760 01 Zlín, Czech Republic (phone: +420576035204; e-mail:
[email protected]).
Jabub Novák is with Tomas Bata University in Zlin, nám. T. G. Masaryka
5555, 760 01 Zlín, Czech Republic (e-mail: [email protected]).
Vladimír Bobál is with Tomas Bata University in Zlin, nám. T. G.
Masaryka 5555, 760 01 Zlín, Czech Republic (e-mail: [email protected]). Fig. 1. Amira DTS200 – three tank system
Pumps are controlled by analogue signal in range from - and q represents inflow as change of water level in time:
10V to 10V. Heights of water level are measured by pressure
qi
sensors. Each valve is operated by two digital signals which qi i 1, 2 (5)
control motor of particular valve. First signal orders to start ST
closing of the valve while the second signal is used for Similar equations can be derived for the other two tanks.
opening of the valve. If none of the signals is activated the The model obtained by using ideal properties and behaviour of
valve remains in its current position. Each valve also provides plant parts if further referred as “ideal model”. This model of
three output signals: analogue voltage signal correspond to the whole three tank system is successfully used in many control
current position of the valve and two informative logical system studies as a demonstration example [9], [10], [11].
signals which states that the valve is fully opened or fully
closed respectively. IV. CHARACTERISTICS OF THE VALVES
The overall number of inputs to the modeled plant DTS200
is 14: As stated in Section 2, each of plant’s 6 valves is driven by
• 2 analogues signals controlling the pumps, two dedicated logical signals. These signals are used for
• 12 digital signals (2 for each of the 6 valves) for opening starting valve’s motor in closing or opening direction
/ closing of the valves. respectively. If none signal is activated the valve remains in its
The plant provides 21 measurable outputs which can be current position. Activation of both signals at in a particular
used as a control feedback or for measurements of plant time represents an invalid state and valve motor is stopped.
characteristics: Each valve provides three output signals. The current valve
• 3 analogue signals representing level heights in the three position is determined by analogue signal. Higher values of
tanks, signal represent closed valve and lower values represent
• 6 analogues signals representing position of the valves, opened valve. The other two signals are logical and state that
• 12 logical signals (2 for each of the 6 valves) stating that valve is opened or closed respectively.
corresponding valve is fully opened / closed.
A. Valve limits and speed draining of a tank to the reservoir situated below the tanks is
Process of opening all valves at once from fully closed state described by differential equation based on (3):
dh t
to fully opened state is presented in Fig. 3.
k h t (7)
dt
full close => full open
k2 2
0.2 h t t k h 0 t h 0 (8)
4
valve pos [MU]
Valve positions corresponding to hard constraints and It is obvious that parabola depicted in Fig. 4 would continue
validity of “opened” and “closed” state are summarized in below zero contrary to (8). A term corresponding to the
Table I. vertical length of outflow pipe h0 was added to the model. The
vertical length h0 is depicted in Fig. 5.
Table I
Valve positions for important states
tank
full “closed” signal “opened”
Valve full open
closed change signal change
no. [MU]
[MU] [MU] [MU]
1 0.5199 0.4066 -0.6065 -0.6945 valve
h
2 0.4550 0.3880 -0.5719 -0.7493
3 0.5462 0.3996 -0.5423 -0.6501
4 0.4926 0.3594 -0.5751 -0.7151
5 0.4868 0.3296 -0.5157 -0.6718 reservoir
6 0.5242 0.4416 -0.5698 -0.6525 h0
Due to mechanical configuration of the plant, the value of This relation for one set of experiment on valve V4 is
h0 for outflow valves V3, V4, V5, and V6 cannot be measured presented in Fig. 7 where circles represent individual
directly. But it can be identified from draining course (Fig. 4). experiments. The characteristic is not strictly linear. It
To encapsulate h0 into model, equations (7) and (8) were contains saturation of fully closed and fully opened valve.
superseded: Transitions to saturation states are smooth.
Experiments with the same configuration were performed
dh t
k h t h0 for all outflow valves. The results obtained from measurement
dt (9) of valve V6 are presented in Fig. 8. The upper graph depicts
k2 the course of k6 and values of corresponding h0 are shown in
h t t 2 k h 0 h0 t h 0 the lower graph.
4
valve 6 - opening
A second order polynomial (parabola) was fitted to an 0.3
appropriate interval of draining data in least mean squares
sense. The MATLAB function polyfit was used for this task. 0.2
Parabola fitting is presented in Fig. 6.
k6
0.1
parabola fitting of draining through valve V 4
h1=0.0086*t 2-4.95*t+622
700 0
-0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5
h1
valve position V 6 [MU]
600 parabola
200
500
0
400 h06
h1 [mm]
-200
300
200 -400
-0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 0.5
valve position V 6 [MU]
100
Fig. 8. Relation between valve position and k6 and h06
0
The values of h06 for the four rightmost experiments (i.e.
-100 valve position greater than 0.2 MU) are irrelevant because the
0 20 40 60 80 100 120 140 160 180 200
time [s] valve was closed and no outflow was observed. The remaining
Fig. 6. Parabola fitting to the draining course experiments resulted in almost the same values of h06 which
was expected as the values of h0 are physical values of the
Values of k and h0 can be easily obtained from polynomial Amira DTS200 model.
coefficient according to (9). Valve can be closed to different C. Valve flow parameter for interconnection valves
positions at the beginning of draining experiment and relation
Similar approach to obtaining values of k as presented in
between valve position and value of k can be achieved.
previous subsection can be used also for valves V1 and V2
valve opening which interconnects tanks T1 and Ts, and Ts and T2,
0.3
respectively. Flow from the full tank T1 to the empty tank Ts
was used to measure valve constant k1. The other valves were
0.25 closed during the experiment. According to (3), the flow can
be described by two differential equations:
0.2
dh1 t
k1 h1 t hs t sign h1 t hs t
dt
(10)
0.15
dhs t
k4
k1 h1 t hs t sign h1 t hs t
dt
0.1
Since the value of h1 is always higher or equal to hs, the
term inside absolute values is always nonnegative. As the
0.05
water flow just from T1 to Ts and the geometry of both tanks is
the same, according to mass conservation law the sum of h1
0 and hs remain the same during the experiment. Then the
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
position of valve V 4 [MU] course of draining T1 and filling Ts can be described by two
Fig. 7. Relation between valve position and k4
independent differential equations.
dh1 t
k1 2h1 t h A similar approach as presented for valve V1 was used to
dt
measure characteristics of valve V2. Resulting course of k2 is
dhs t (11)
k1 h 2hs t depicted in Fig. 11.
dt valve 2 - opening
h h1 t hs t 0.3
k12 2
h1 t t k1 2h1 0 h t h1 0
0.2
2 (12)
k2
hs t 1 t 2 k1 h 2hs 0 t hs 0
0.15
k2
2
An example of courses and corresponding parabolas are 0.1
depicted in Fig. 9.
0.05
parabola fitting of flow through valve V 1
h1=0.0209*t 2 -4.95*t +570
hs =-0.0212*t 2 +5.01*t -20
600 0
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
h1 valve position [MU]
500 hs
Fig. 11. Relation between valve position and k2
parabola h1
400 parabola hs
D. Valve hysteresis
300 The experiments presented in previous subsections were
h [mm]
0.2
0.25
0.15
k2
0.2
0.1
0.15
k1
0.05
0.1
0.05 0
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU]
presented in Fig. 12. The figure shows that hysteresis plays a Similar experiments were performed also for outflow valves
big role in the experiments. The value of position itself does V3, V4 V5, and V6. Corresponding figures contain courses of
not give sufficient information about current value of parameter k as well as values of h0 obtained from individual
parameter k2. For example, if the position is 0 MU the value of experiments.
k2 can be anywhere in range 0.03 to 0.13. Especially in case of Four sets of experiments and corresponding characteristics
using the valve as an actuator the hysteresis should be taken of valve V3 is shown in Fig. 15.
into account. Otherwise control process can easily become valve 3
0.3
unstable.
closing 1
Consequently, extensive set of experiments was performed 0.25 closing 2
to measure hysteresis characteristics. The resulting courses of openig 1
0.2 openig 2
valve parameters are shown of following figures.
Three sets of experiments for opening and another three sets 0.15
k3
for closing of valve V1 were performed. Results shown in Fig. 0.1
13 provided consistent data and the hysteresis was lower
0.05
comparing to Fig. 12.
valve 1 0
0.3 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU]
closing 1
closing 2
0.25 closing 3
200
openig 1
openig 2
0.2 openig 3 150
h03
0.15 100
k1
closing 1
50 closing 2
0.1
openig 1
openig 2
0
0.05 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU]
Fig. 15. Characteristics of valve V3
0
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU] Twelve sets of experiments and corresponding
Fig. 13. Characteristics of valve V1 characteristics of valve V4 is shown in Fig. 16.
closing 1
valve 4 closing 2
Four sets of experiments for closing of the valve performed 0.3
closing 3
in various time concerning valve V2 are depicted in Fig. 14. 0.25
closing 4
Individual experiments correspond to stars in the figure. Three closing 5
0.2 closing 6
set of experiment are presented for closing of the valve where opening 1
individual experiments are represented by circles. 0.15 opening 2
k4
opening 3
valve 2 opening 4
0.3 0.1
opening 5
closing 1 opening 6
0.05
closing 2
0.25 closing 3 0
closing 4 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
openig 1 valve position [MU]
0.2 openig 2
closing 1
openig 3
200 closing 2
closing 3
0.15 closing 4
k2
150 closing 5
closing 6
opening 1
0.1
h04
100 opening 2
opening 3
opening 4
0.05 50 opening 5
opening 6
0 0
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU] valve position [MU]
Fig. 16. Characteristics of valve V4
Fig. 14. Characteristics of valve V2
Five sets of experiments and corresponding characteristics valve V2. Experiments performed on valves V3 and V6 resulted
of valve V5 is shown in Fig. 17. in more consistent values of h0 when comparing with
valve 5 experiments performed on V4 and V5.
0.3
Since the shape of curves corresponding to opening and
closing 1
0.25 closing 2 closing of the valve is similar, an average difference between
opening 1 them in direction of position axis can be computed. This value
0.2 opening 2
can be used as measure of hysteresis. Values of hysteresis, h0
opening 3
0.15 as well as maximal value of k for each valve is presented in
k5
0.1
Table II.
0.05
Table II
0 Valve characteristics
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
Valve hysteresis
valve position [MU] maximal k h0 [mm]
no. [MU]
1 0.0219 0.2180 -
200
closing 1
2 0.1783 0.2237 -
closing 2 3 0.0310 0.2601 126.6
150 opening 1 4 0.0426 0.2976 127.9
opening 2
opening 3 5 0.1307 0.2735 121.2
h05
100
6 0.0800 0.2688 97.1
50
E. Modeling of valve characteristics
0
The course of relation between valve position in MU and k
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU]
is similar to step responses of dynamical system and therefore
it was modeled in similar way. Other types of approximation
Fig. 17. Characteristics of valve V5 functions, like sigmoids, were also tested, but did not achieve
better results. A model based on transfer of 4 th order aperiodic
Five sets of experiments and corresponding characteristics system produced satisfactory results. Thus relation between
of valve V6 is shown in Fig. 18. position and k was as follows:
valve 6
0.3 1 b b3 3b2 a 6ba 2 6a3
closing 1 pos pos0 : k kmax 1 e a
0.25 closing 2
6 a3
opening 1
0.2 opening 2 b pos0 pos (13)
opening 3
0.15 pos pos0 : k 0
k6
0.1
where pos is valve position in MU and parameters a and pos0
0.05 were obtained by nonlinear regression.
Values of parameters kmax for each valve as well as pos0 and
0
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 a both for opening and closing are summed in Table III.
valve position [MU]
Table III
200 Valve characteristics
closing 1
closing 2
Valve opening closing
kmax
150 opening 1 no. pos0 a pos0 a
opening 2 1 0.2180 0.2673 0.0818 0.2892 0.0825
opening 3
h06
Values of pos0 correspond to position of the curve in the It can be stated that the parameter k does not change its
valve position axis (x-axis). Therefore greater difference value till it reaches a border of hysteresis area, i.e. the curve of
between pos0 for opening and for closing was achieved for either opening or closing of the valve.
valves with greater hysteresis.
Values of parameter a correspond to the slope of the curves. V. CONCLUSION
Higher values represent steeper slope while lower values The paper presented a development of the model of valves
represent softer slope. of a hydraulic system. The Amira DTS200 three tank system
The regression for valve V2 is presented in Fig. 19. was considered but used techniques can be easily generalized
to wide set of hydraulic systems. The real system contains
0.25
data close
several nonlinearities which incorporate complexity to the
model close system. Total number of experiments concerning valves
0.2
data open reached 433 taking altogether more than 113 hours.
model open
Resulting model includes all major nonlinearities and can
be integrated into a Simulink model of whole three tank
0.15 system.
k2
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0.15
k2
0.1
0.05
0
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4
valve position [MU]