Description

AL-E187E LEVEL / FLOW / PRESSURE / TEMPERATURE CONTROL BENCH WITH CASCADE

AL-E187E LEVEL / FLOW / PRESSURE / TEMPERATURE CONTROL BENCH WITH CASCADE

1. Product Description

The AL-E187E Level / Flow / Pressure / Temperature Control Bench with Cascade is a comprehensive process-control training system designed for practical study of PID control, flow control, level control, pressure control, temperature control, ratio control, cascade control and multi-loop regulation.

The system consists of a transparent process tank, heating and cooling circuits, pumps, sensors, proportional valves, flow measurement, pressure and temperature measurement, and computer-based supervision and data-acquisition software. It is suitable for laboratory training in process instrumentation, industrial automation, control engineering and mechatronics.

2. Educational Operations

The trainer shall support practical implementation and demonstration of:

1. PID regulation — Proportional, Integral and Derivative control
2. Flow regulation
3. Level regulation
4. Pressure regulation
5. Temperature regulation
6. Ratio regulation
7. Cascade regulation
8. Master Level / Slave Flow control
9. Multi-loop regulation
10. Interactive regulation loops

3. Technical Specifications

4. Transparent Process Tank

The main process tank shall be transparent and equipped with:

• Coil heat exchanger
• Agitator
• Vent valve
• Pressure sensor with 0–10 V DC output
• Level sensor with 0–10 V DC output
• PRT temperature sensor with 0–10 V DC output
• Drain valve
• Process connections for heating and cooling circuits

5. Heating Loop

The heating circuit shall include:

• Heating tank
• Electrical heating resistor
• Heating control with 0–10 V DC control/output
• Low-level safety protection using float switch
• Temperature sensor
• Circulation pump with 0–10 V DC control/output
• Heat exchanger / temperature-sensor return arrangement
• Temperature measurement at tank return
• Flow-rate sensor in the heating loop
• Over-temperature safety system
• Suitable piping and process connections

6. Cooling Loop

The cooling circuit shall include:

• Cooling radiator
• Cooling fan
• Cooling tank with low-level safety
• Circulation pump with 0–10 V DC control/output
• PRT temperature sensor at cooling-radiator inlet
• PRT temperature sensor at cooling-radiator outlet
• Both temperature sensors with 0–10 V DC output
• Flow sensor with 0–10 V DC output
• Proportional control valve with 0–10 V DC control/output
• Regulation bypass valve
• Suitable piping, hoses and process connections

7. Control & Regulation Functions

PID Control

The system shall permit independent adjustment of:

• Proportional gain
• Integral gain
• Derivative gain

The PID system shall be usable for level, flow, pressure and temperature control experiments.

Ratio Control

The system shall support ratio regulation between selected process variables, allowing students to study the relationship between master and slave process signals.

Cascade Control

The trainer shall support cascade regulation with Master Level / Slave Flow Rate, allowing practical study of master-slave control loops.

Multi-Loop Control

The system shall support simultaneous operation and study of multiple interacting control loops.

8. Supervision & Data Acquisition Software

The system shall be supplied with supervision and data-acquisition software having a graphical interface.

The software shall provide:

• Real-time process monitoring
• Real-time curve display
• Measurement and recording of process variables
• Configuration of control loops
• Virtual instruments
• Signal simulation
• Mathematical and control blocks
• PID parameter adjustment
• Process-response analysis
• Data acquisition and visualization

9. Simulated Signal Blocks

The software shall provide signal-generation functions including:

Signal Generator

• Sinusoidal waveform
• Square waveform
• Sawtooth waveform
• Variable frequency
• Variable amplitude
• Variable offset

DC Level

• Fully variable DC level

10. Virtual Instruments

The software shall include the following virtual instruments:

• Digital measuring device
• Bar graph
• Analog measuring device
• Oscilloscope
• Chart recorder

11. Regulation Blocks

The software shall provide configurable control blocks:

12. Simulation Blocks

The software shall include process simulation blocks for:

• Integer
• First-order system
• Double integrator
• Second-order system
• First-order system with integrator
• Second-order under-damped system

13. Additional Functional Blocks

The software shall provide:

• Gain
• Voltage-to-frequency converter
• Delay
• Discrete transfer function
• Saturation
• Summing junction

ü  Three inputs

• Multiplier

ü  Three inputs

• Switch
• Relay

14. Fuzzy Logic Blocks

The software shall include fuzzy-logic functions for advanced control studies:

• Fuzzy potentiometer
• Fuzzification
• Defuzzification
• Fuzzy multiplexer
• Fuzzy demultiplexer
• Fuzzy AND
• Fuzzy OR
• Fuzzy NOT
• Fuzzy lookup/table function
• Combined fuzzy measuring device
• Simple fuzzy measuring device

15. Safety Features

The system shall incorporate suitable safety provisions including:

• Low-level safety for heating tank
• Low-level safety for cooling tank
• Over-temperature protection
• Controlled heating operation
• Process drain arrangement
• Central electrical protection
• Safe process connections
• Properly enclosed electrical/control sections

16. Mechanical Construction

• Robust laboratory bench/table-top construction.
• Transparent process vessels for easy observation of process operation.
• Industrial-grade piping and fittings.
• Clearly identified process components.
• Easily accessible sensors, valves and measurement points.
• Suitable arrangement for repeated student experiments.
• Compact construction suitable for laboratory installation.

17. Power Supply

220 V AC, 50 Hz

The electrical system shall include appropriate protection and switching provisions for the trainer, pumps, heater, control system and associated instrumentation.

18. Dimensions & Weight

19. Documentation & Training Material

The equipment shall be supplied with:

• User Manual — Paper Version
• User Manual — Digital Version
• Practical Work / Experiment Manual — Paper Version
• Practical Work / Experiment Manual — Digital Version
• Software installation and operating documentation
• Control-system experiment documentation
• Necessary software for supervision, data acquisition and simulation

20. Recommended Experiments

The trainer is suitable for experiments such as:

1.      Study of PID control characteristics.

2.      Level control using PID controller.

3.      Flow control using PID controller.

4.      Pressure control.

5.      Temperature control using heating and cooling loops.

6.      Study of proportional control.

7.      Study of integral control.

8.      Study of derivative control.

9.      Ratio-control experiment.

10.   Cascade control — master level/slave flow.

11.   Multi-loop process control.

12.   Interactive control loops.

13.   Study of process response using real-time graphs.

14.   Study of first- and second-order systems.

15.   Study of fuzzy-logic control.

16.   Simulation and analysis of control-system response.

Technical Details