Cascade Control Trainer | Prozessi PX 18
The Cascade Control Trainer Prozessi PX 18 teaches advanced industrial process control through flow, level and cascade control experiments. This Cascade Control Trainer integrates a water circulation loop, electronic transmitters, an orifice meter, a pneumatic control valve and NI USB-6001 data acquisition with LabVIEW software. Ten structured experiments cover open loop control, ON/OFF, proportional, integral, derivative and PID control, plus controller tuning and system stability analysis. Closed loop circulation and non-corrosive parts ensure reliable operation for continuous classroom use.
The Cascade Control Trainer Prozessi PX 18 is designed to teach advanced process control methods used in industrial applications. This Cascade Control Trainer allows students to configure and study flow, level and cascade control experiments with water circulation, transmitters, an orifice meter, a pneumatic control valve and data acquisition.
Product Overview
The Cascade Control Trainer Prozessi PX 18 consists of a water supply tank, submersible pump, level transmitter, transparent acrylic level tank, orifice meter with differential pressure transmitter, rotameter, pneumatic control valve (1/4″ size, air to close), I/P converter and NI USB-6001 data acquisition device. All units are mounted on a tabletop support housing with necessary piping. Process signals from the level transmitter and flow transmitter connect to the Multifunction I/O and NI-DAQMX module via USB communication to a computer. Non-corrosive wetted parts ensure long service life. A specially developed LabVIEW-based software provides flexible experiment selection, trend plots, data logging, printing and data export functions.
Cascade Control Trainer Prozessi PX 18 — Technical Specifications
| Specification | Value |
|---|---|
| Product Code | 315 |
| DAQ Device | NI USB-6001, 14 bit, 20KS/S Multifunction I/O and NI-DAQMX |
| Analog Input | 4 channels |
| Analog Output | 2 channels |
| Communication | USB port |
| Overall Dimensions | 550W x 475D x 520H mm |
Technical Data
Transmitters and Sensors
| Component | Specification |
|---|---|
| Level Transmitter | Electronic, Two wire, Range 0-250 mm, Output 4-20mA |
| DP Transmitter | Capacitance, Two wire, Range 0-200 mm, Output 4-20mA, Square root |
| Rotameter | 10-100 LPH |
| Process Tank | Transparent acrylic with 0-100% graduated scale |
| Flow Measurement | Orifice meter |
Control Components
| Component | Specification |
|---|---|
| I/P Converter | Input 4-20mA, Output 3-15 psig |
| Control Valve | Pneumatic, Size 1/4″, Input 3-15 psig, Air to close, Linear characteristic |
| Pump | Fractional horse power, Submersible type |
Power and Pneumatics
| Component | Specification |
|---|---|
| Power Supply | Model S-15-24, Output 24 VDC, 0.7 A |
| Air Filter Regulator | Range 0-2.5 kg/cm2 |
| Pressure Gauge 1 | Range 0-2.5 kg/cm2 (1 No.) |
| Pressure Gauge 2 | Range 0-7 kg/cm2 (1 No.) |
Key Features
- Cascade Control Trainer: flow, level and cascade control capability
- ON/OFF and PID operation modes
- Closed loop water circulation system
- Non-corrosive wetted parts for durability
- NI USB-6001 DAQ device with 14-bit resolution and 20KS/S sampling rate
- LabVIEW-based software with trend plots and data logging
Experiments
- Study of open loop (Manual control)
- Study of on/off controller
- Study of proportional controller
- Study of proportional integral controller
- Study of proportional derivative controller
- Study of PID controller
- Tuning of controller (Open loop method)
- Tuning of controller (Closed loop method)
- Study of stability of the system (Bode plot)
- Study of cascade control system
Construction and Design
The Cascade Control Trainer Prozessi PX 18 features a tabletop support housing measuring 550W x 475D x 520H mm. A transparent acrylic process tank with 0-100% graduated scale allows direct observation of liquid level. The fractional horse power submersible pump circulates water from the supply tank through a 1/4″ pneumatic control valve and returns via an orifice meter for flow measurement. An electronic level transmitter measures level across 0-250 mm with 4-20mA output. A capacitance-type differential pressure transmitter measures flow across the orifice meter with 0-200 mm range and square root output. The 3-15 psig pneumatic control valve is driven by an I/P converter accepting 4-20mA input. All process signals connect to the NI USB-6001 data acquisition device, which interfaces with computer-based LabVIEW software via USB communication for real-time monitoring and control.
Software
LabVIEW-based software is provided with the Cascade Control Trainer to teach control principles. Features include:
- Easy experiment selection and study
- Flexible interface with multiple operating modes
- Data access and real-time monitoring
- Trend plots for visualization
- Data logging for analysis
- Printing and data export functions
- Manual, ON/OFF, P, PI, PD and PID control modes
Scope of Delivery
- Cascade Control Trainer Prozessi PX 18 assembly with support housing
- Water supply tank with submersible pump
- Level transmitter and differential pressure transmitter
- Transparent acrylic process tank
- Orifice meter with necessary piping
- Pneumatic control valve and I/P converter
- DAQ device
- Air filter regulator and pressure gauges
- LabVIEW-based software
- USB cable for computer connection
- User documentation and experimental manual
Q1: What types of control can be studied on the Cascade Control Trainer Prozessi PX 18?
A: The Cascade Control Trainer supports flow control, level control and cascade control using ON/OFF and PID operational modes.
Q2: How does the Cascade Control Trainer connect to a computer?
A: Process signals from the transmitters connect to the NI USB-6001 data acquisition device, which interfaces with the computer through a USB port connection.
Q3: What is the range of the level transmitter?
A: The level transmitter has a range of 0-250 mm with a 4-20mA output signal.
Q4: Can I tune the controller on the Cascade Control Trainer?
A: Yes, the Cascade Control Trainer provides both open loop and closed loop controller tuning methods, and includes Bode plot analysis for system stability.
Q5: What data can the software export from the Cascade Control Trainer?
A: The LabVIEW software allows data logging, trend plot generation, printing and data export for analysis and documentation.
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