Controls Lab
Lab Report Number: 05
“Study and plotting Characteristic Curve for Flow Control
Training System
Section: ME-14 (C)
Name CMS ID
Muhammad Ahmad Nadeem 416175
Objectives: -
• To learn about Circuit Building.
• To study the relationship between Flow rate and Sensor Voltage (signal) reading.
• To plot the characteristic curve between Flow rate and Sensor Voltage.
Equipment: - Pressure sensor
Float
Process tank
Control panel
Release valve
Rotameter
Storage
Tank
Pump
Flow Control Training System
Procedure: -
1) First, the circuit was constructed, and the control system was powered.
2) Any excess water in the process tank was removed firsthand before starting the experiment by
opening the release valve.Then the voltage was applied to the driver to turn on the water pump.
3) Every value of the voltage after an increasing interval of 0.5L/min was measured through the
sensor by connecting the multimeter to the output of the Flow sensor interface.
4) After that, the flow rate was reduced and the decreasing value of voltage at each interval was
measured.
5) Finally, a graph was made between the Sensor Voltage and the flow readings for both rise and
fall in the flow rate.
Circuit Representation: -
Circuit diagram for sensor and Water Pump driver
Readings:
For Rising Temperature: -
Voltage data for increasing and decreasing flowrate
S# Flowrate (LPM) Voltage forward (v) Voltage backward (v)
1 1.5 0.85 1.01
2 2 1.5 1.8
3 2.5 2.3 2.56
4 3 3.08 3.5
5 3.5 3.5 4.06
6 4 4.32 4.61
Graph: -
Graph for increasing and Decreasing Voltage
5
4.5
4
Voltage (V)
3.5
2.5
1.5
1 1 1.5 2 2.5 3 3.5 4 4.5
Flow rate (L/min)
Forward Voltage Backward Voltage
Graph for increasing and decreasing voltage
Applications
A Flow controlled training system has several real-world applications across industries.
• Hydraulic systems:
Training systems simulate the flow of fluids in hydraulic machinery and allow technicians to
understand how to adjust flow rates and pressures in systems like hydraulic presses, lifts,
and cranes.
• Piping and pumping systems:
Flow control training systems are used to train operators and engineers working with
industrial piping systems, where controlling the flow of fluids is critical.
• Research and Development (R&D)
Used in laboratories to simulate and control fluid flow in experiments, essential for
research in fields like materials science, chemical engineering, and biomedical
technology.
Discussion:
In this experiment, we familiarized ourselves with the Flow Control Training System and observed
the relationship between flow rate and voltage readings on the Digital Multimeter. As the flow rate
increased, the voltage displayed on the multimeter also increased, demonstrating a direct
correlation. A similar trend was observed when the flow rate decreased, though minor discrepancies
and a slight hysteresis effect were noted.
The sensor detects the flow through the pipe and translates it into a varying voltage signal, which is
sent to the controller. The Digital Multimeter captures this output voltage signal for analysis.
Discrepancies between the increasing and decreasing flow rates can be attributed to hysteresis,
where the system's response lags the input changes. Mechanical factors such as elastic deformation,
system inertia, and internal friction can also influence these deviations. Additionally, non-linearities
in the flow-voltage relationship or temperature variations during the experiment may contribute to
these inconsistencies.
Despite these factors, the system effectively demonstrated how flow rate influences output voltage,
providing valuable insights for flow regulation applications where precise control is essential.
Conclusion
In this experiment, we demonstrated the working principles of the Flow Control Trainer and
identified a clear linear correlation between flow rate and the voltage generated. This relationship
can be highly beneficial in applications requiring accurate flow control. However, discrepancies
between increasing and decreasing flow rates were observed, likely due to hysteresis, mechanical
inertia, sensor calibration errors, and other system inefficiencies.
Overall, the experiment confirmed a generally linear relationship between the flow rate and the
output voltage detected by the multimeter, while highlighting the importance of understanding and
mitigating factors that can introduce slight errors in real-world applications.
Safety Precautions
• Personal Protective Equipment (PPE): Ensure that all lab personnel wear appropriate PPE, including
safety goggles, lab coats, gloves, and closed-toe shoes to protect against chemical splashes, electrical
hazards, or mechanical injuries.
• Equipment Inspection: Regularly inspect all lab equipment and apparatus for any signs of damage or
wear. Report any defects immediately and ensure that faulty equipment is taken out of service until
repaired or replaced.
• Emergency Procedures: Familiarize all lab members with emergency procedures, including the location
of fire extinguishers, eyewash stations, safety showers, and emergency exits. Conduct regular safety
drills.
• Hazardous Materials Handling: Follow proper procedures for handling, storing, and disposing of
hazardous materials, such as chemicals and solvents. Use fume hoods and ventilation systems as
needed.
• Electrical Safety: When working with electrical circuits and equipment, ensure that power sources are
disconnected before making connections or adjustments. Avoid contact with exposed wires and use
insulated tools.
• First Aid Kit: Maintain a well-equipped kit in the lab and ensure lab personnel are trained in basic first
aid procedures. Display emergency contact numbers and locations prominently.
• Equipment Safety: Follow the manufacturer's guidelines and instructions for operating lab equipment
and machinery. Ensure that the equipment is properly grounded and that safety interlocks are
functional.
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