Brewery tank controls

Hello all -
I'm looking to develop a system for controlling the Fermentation tanks
in our brewery using LabView controls. We currently use the standard
tempermental fuzzy logic PID microcontrolers (Partlow, Watlow, etc). I
believe these are overly expensive for the functionality they provide,
and being a both a professional Brewer and a LabView/systems guy I am
always seeking better ways to control the process. Programatically, I
realize all the flexible advantages LabView would have for our system,
however I'm evaluating the feasibility ( on a cost basis) of replacing
these with a custom LabView controlled system.
Our current process: A type K thermocouple monitors the tank
temperature via the fuzzy logic controller. The controller's alarm
relay (rated 5 amps at 110 VAC) responds based on a setpoint and will
either send coolant thru the jacketed tank or not. The controller alarm
relay activates a seperate solid state relay (20 mA) which then sends
an electrical signal to a circulating pump (single phase, 115 Volt,
ranging 0.5-2.0 amps) and a solenoid valve (120 Volt coil) with their
own power sources.
We currently use this system as an on/off controller. The tanks are
either cooling or not - and control beyond that is manual. I realize
that soaking, ramping, and other functions can be set with these
controllers but not only do we have numerous controller brands with
different parameters, but the programming is beyond the scope of many
of the people that operate the system. I'm looking to build in user
friendly functionality and operate all the tank controls from one
central computer hub.
So the question is, how do I replace the controllers and wire for
LabView control of the motors and solenoids? Is the solution to just
run wires to a big Data Acquisition board connected to a central computer? Or
is building a wireless network of tanks feasible? (My budget will be
relatively small) We've got 14 tanks to control spaced evenly over
about 4,000 sq. ft. Any idea's, experience, hardware suggestions, etc. - I'd love
to hear. Thanks in advance for all your help!
- John Rehm
Brewer in Chief, Philadelphia Brewing Co.
LabView Instructor, La Salle University
From McMaster Carr supply (www.mcmastercarr.com):
Autotuning P-I-D Temperature Controllers
1/16 DIN
   These
autotuning controllers with fuzzy logic calculate the optimal P-I-D
(Proportional-Integral-Derivative) parameters for a particular process
and store them in memory for future use. Controllers accept input from
RTDs and thermocouple types J (-58° to +1832°  F/-50° to +1000°  C), K
(-58° to +2498°  F/-50° to +1370°  C), and T (-454° to
+752°  F/-270° to +400°  C). Units are easy to program using menu and
keypad. Each has selectable auto/manual control modes, two limit alarm
relays with eight programmable modes, and ramp/soak programming ("ramp"
for length of time to reach a temperature and "soak" for length of time
a temperature is maintained).
   Controllers are ° F/° C selectable,
and dual LED displays show present temperature and setpoint
simultaneously. Top LED is red, and bottom LED is green. Units accept
probes with bare lead wires (probes sold separately).
Operate on 90 to 264 VAC. All include screw terminal connections and
mounting brackets. Accuracy is ±0.36°  F (±0.2°  C) for RTDs and
±1.8°  F (±1°  C) for thermocouples. CE approved.
    1/16 DIN size units have one control and two alarm relays with SPST contacts that are wired normally open and rated 5 amps at 110 VAC. Top LED is 3/8" high, and bottom LED is 5/16" high.
    1/4 DIN size units have two control and two alarm relays with SPST contacts that are wired normally open and rated 5 amps at 110 VAC. Top LED is 9/16" high, and bottom LED is 3/8" high.

Hi John. A couple of suggestions:
1) If there is any way to remotely program your existing controllers, building your system on them may
have several advantages. Lets you use your existing hardware and wiring, reduces new stuff to buy,
and gives you a fall-back position if problems crop up with the master controller. Also can be
implemented in stages, a few tanks at a time.
2) Replacing your existing controllers with remotely programmable ones still gives you the other advantages
of the architecture above, just you have to buy new controllers.
3) Fieldpoint hardware is certainly capable of doing what you want, and gives you independence from
a PC, i.e. you can download your process parameters to the Fieldpoint controller and disconnect the
PC, or leave it running as a monitor. Gives you the reliability of an industrial controller with the option
of a PC GUI. You could run all 14 tanks with one controller.
For a 4000 ft^2 facility, I wouldn't expect wireless to be worth the trouble unless there are other
considerations like mobile equipment.
I am in Jenkintown. I'd be happy to trade tips for a tour. Are you involved with the ISBT program?
Matt

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Control wrote in message
news:[email protected]..
> Hi, I'm trying to control the water level of a spherical tank model
> using PID in labview. The model is a non-linear equation a
s follows:
> Qi(t-L)-Qo=pi*R^2(1-(R-y)^2/R^2)dy/dt
> where Qi=inlet flow
> Qo=Outlet flow
> R=tank radius
> y=height of water
> t=time
> In order to get y, i have shifted the right hand side to the left and
> integrating it. However, i can't implement the integration of this
> non-linear equation in labview. Pls advise. Thank you.
> Attached are the files that i've tried.

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a lab view VI to control a tank system which is controlled via 3 solenoid valves

Perhaps he's asking for bids for the job. If so, perhaps posting in the LabVIEW Job Openings would garner more responses.

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