1. Introduction
In industrial processes, precise control of liquid levels and flow between multiple tanks is essential across various sectors, including power generation, biochemical and petrochemical industries, and water distribution systems. Accurate regulation of liquids stored, transferred, or mixed within tanks is crucial for ensuring operational efficiency, safety, and reliability. Among the most widely used systems for such applications are coupled tanks, consisting of interconnected vertical tanks that share orifices. These setups typically employ electrical pumps and motorized valves as actuators, while pressure sensors and flowmeters provide real-time monitoring of liquid levels and flow rates. However, managing coupled tank systems comes with unique challenges, primarily due to their nonlinear characteristics. These arise from the dynamic behaviour of pumps, valves, and fluctuations in system parameters. When it comes to industrial process control, attaining accurate as well as steady regulation is critical, particularly for systems exhibiting complex and dynamic tendencies. Because of their simplicity and efficiency, the traditional control methods, which include proportional–integral–derivative (PID) controllers, have been widely adopted. PID control is well-suited for single-input, single-output systems and provides satisfactory performance in environments with minimal disturbances and well-understood dynamics. In a liquid level system, PID controllers are often used to maintain the desired level by adjusting the input flow based on the error between the setpoint and the actual level. However, the effectiveness of PID controllers diminishes when applied to nonlinear systems or systems subject to significant external disturbances [
1]. In such cases, the controller may struggle to maintain stable and precise control, leading to oscillations, overshoots, or slow response times.
However, these controllers often fail to meet requirements in cases where there is significant nonlinearity, time delays, and external disturbance processes involved [
2]. One of the main problems in real-time control is ensuring that the controller can respond fast enough to dynamic changes in the process [
3,
4,
5,
6,
7,
8]. The speed must be supported by not only processing power but also a way of predicting and compensating for time delays and disturbances applied to the system undergoing control [
9]. In some such cases, more advanced control methodologies are required to satisfy demanding performance specifications, especially under real-time conditions. To address the limitations of traditional PID control, more advanced control techniques, such as the cascade nonlinear feedforward proportional integral retarded (CNPIR) controller, have been developed [
10]. The CNPIR controller builds upon the foundational principles of PID control by incorporating a cascade control architecture, where an inner loop manages fast system dynamics while the outer loop regulates slower dynamics. This structure enables more effective disturbance rejection and improved control over nonlinear processes like liquid level systems [
11]. Additionally, the feedforward component in CNPIR control anticipates disturbances before they affect the system, further enhancing stability and performance [
12,
13]. Cascade control structures have always been preferred in automation methods based on their capability to decouple various process objectives and handle multiloop systems. The retarded (time-delay) element incorporated into this control scheme allows the system to handle time delays common in industrial processes, such as those caused by sensor lags or actuator delays [
14,
15,
16]. Despite these advantages, the CNPIR controller still has limitations when dealing with highly nonlinear or unpredictable dynamics, as well as when external disturbances are severe [
17,
18,
19,
20]. While the controller improves upon PID control in terms of stability and disturbance rejection, it can still struggle with maintaining optimal performance under varying operational conditions [
21].
To address these challenges, advanced control methods are needed to provide more robust performance and finer control accuracy under varying operational conditions [
22]. For example, a fractional order (FO) control introduces the concept of fractional calculus into the control strategy, which allows for the tuning of non-integer order derivatives and integrals [
23]. This flexibility gives FO controllers the ability to handle more complex dynamics and long-term system behaviours, making them particularly well-suited for systems with memory or history effects. In the context of liquid level control, FO controllers provide smoother transitions and more precise control over nonlinearities compared to traditional integer-order controllers like PID [
24]. The ability of FO controllers to model and control dynamic processes with more accuracy allows them to outperform conventional control methods in systems with significant time delays and nonlinearities [
25,
26].
In addition to the above controller, the adaptive control technique has emerged as a powerful technique for managing systems with unknown or time-varying parameters. Adaptive PID controllers adjust their control parameters in real-time based on the observed behaviour of the system, which allows them to maintain effective control even when the system undergoes significant changes [
27,
28,
29]. For liquid level systems, where flow rates, valve characteristics, and other system parameters can change over time, adaptive PID control ensures that the controller can dynamically respond to these variations [
30]. By continuously updating its parameters, adaptive PID control offers improved robustness and flexibility over standard PID and CNPIR controllers, particularly in environments where system dynamics are uncertain or subject to frequent changes [
31].
Another important controller technique in the literature is the SMC control method. sliding mode control (SMC) is widely recognized for its robustness in handling systems with uncertainties and external disturbances [
32]. The SMC approach works by driving the system’s state trajectory onto a predefined sliding surface and keeping it there, ensuring that the system behaves in a desired manner regardless of disturbances [
33]. However, a significant drawback of classical SMC is the phenomenon known as “chattering”, which refers to the high-frequency oscillations that occur near the sliding surface due to the discontinuous control action [
34]. These oscillations can lead to undesirable effects, such as increased wear and tear on actuators or degraded control performance. To address this issue, modifications to SMC, such as higher-order sliding modes or incorporating fractional-order elements, have been introduced [
35,
36].
Within the scope of this study, APIDSMC combines the benefits of both adaptive PID control and sliding mode control [
37]. This hybrid approach allows for real-time adaptation of the control parameters, ensuring that the system can handle time-varying dynamics and disturbances, while the sliding mode component guarantees robustness against uncertainties [
38]. The adaptive nature of the controller allows it to continuously adjust to changing conditions, providing more consistent performance in complex systems like liquid level control. Furthermore, by integrating adaptive control with sliding mode techniques, APIDSMC offers the potential for reduced chattering compared to traditional SMC methods [
39,
40].
The proposed FO-APIDSMC controller combines the strengths of fractional order calculus, adaptive PID, and sliding mode control into a unified framework. This novel control approach is specifically designed to address the challenges of nonlinear, time-delayed, and dynamically uncertain systems such as liquid level control in industrial processes. By incorporating fractional-order calculus, the FO-APIDSMC controller gains enhanced flexibility and precision, enabling it to more effectively manage long-term system behaviours and nonlinearities. The adaptive PID component continuously adjusts the control parameters in real-time, ensuring that the controller remains robust in the face of system changes. Meanwhile, the sliding mode control component guarantees that the system remains stable and resilient against disturbances while also mitigating the chattering effect that typically plagues traditional SMC approaches [
41].
As far as we know from a detailed literature survey, no study has been found in which the FO-APIDSMC controller is applied to a dual tank level system, which is a process system, in real-time. Taking this gap in the literature into account, the FO-APIDSMC method based on the system model has been created and applied to a process system in real-time within the scope of this article.
In a real-time comparison of the FF-PI and CNPIR controllers, FO-APIDSMC presents significant improvements in control accuracy, external disturbance resistance, and robustness. The fractional order calculus allows for smoother control actions and better handling of nonlinearities, while the adaptive PID component ensures real-time responsiveness to changing system conditions. The sliding mode control provides the necessary robustness to external disturbances, making FO-APIDSMC the ideal solution for complex industrial systems like liquid level control.
In the next section, firstly, the system modelling is performed; then, the mathematical equations of FF-PI, CNPIR, and FO-APIDSMC control laws are created based on the system model. In the experimental results section, real-time results are reported. A list of topics that require further research concludes this study.
2. Dynamic Model of Liquid Level and System Description
Figure 1 depicts the closed recirculating test system used for a connected tank. The system comprises two interconnected liquid tanks, an electrically operated pump, a level monitoring aperture at the bottom of each tank, and a pressure sensor. Tank 1 is supplied by the electric pump, and
Figure 1 shows how both liquid tanks are mounted on the front plate. Tank 2 receives the outflow from Tank 1. Two pressure-sensitive sensors located at the base of each tank measure the liquid levels in both reservoirs.
The mathematical basis of the interconnected tank system can be found in [
41]. The rate of change of the liquid level in each separate reservoir is as follows:
The variable
represents the liquid level in the reservoir, measured in centimeters.
represents the cross-sectional area of the reservoir, measured in square centimetres.
and
represent the inflow and outflow rates of the
i-th tank, measured in cubic centimetres per second. The rate at which liquid flows into tank 1 is precisely proportional to the voltage that is applied to the pump. This means that as the voltage increases, the inflow rate into the tank also increases.
The constant
represents the pump’s conversion factor in cubic centimetres per volt-second (
. The control input,
, also known as the voltage pump
in volts (
), is utilized to attain the desired levels in either tank 1 or tank 2, as follows:
The contributions of the cascade rule and the feedforward action are denoted by
, respectively, in Equation (3).
Moreover, Equation (4) provides the outflow velocity from the orifice at the bottom of each unique tank using Bernoulli’s law.
Next, using Equation (5), the outflow percentage of a separate liquid tank is calculated, where
is the cross-sectional area of the outflow orifice (
) at the bottom of the
-th tank, and
is the gravitational acceleration (
). Tank 2’s inflow is determined as follows:
Thus, the following mathematical expression for the liquid level in the connected tanks can be produced by applying the mass balance principle and Equations (1)–(6):
The steady-state pump voltage,
, that leads to the steady-state level,
, in reservoir 1 is determined by using Equation (7) when the system is at equilibrium (
). Equation (8) is employed to determine the value of
in reservoir 1 when the system is at equilibrium (
). This value represents the desired constant level in reservoir 2, referred to as the planned steady-state level.
The relationships are specified in Equations (9) and (10). Deviation variables can be defined by utilizing the operational range that corresponds to small departure voltages (
) and heights (
)
The cascade control is denoted by
in Equation (11). Thus, it is possible to translate the dynamic equations of Equations (7) and (8) as follows:
The liquid level system’s dynamic equations are nonlinear due to the characteristics of the pump and valve, as well as variations in the system’s parameters, as shown by Equations (12) and (13). In order to execute the suggested cascade for the connected tank system, it is necessary to linearize the linked tank system model around the operational point
. Applying the first-order Taylor series approximation at the points (
and
)) to Equations (12) and (13) results in the following [
42]:
where
After analysing the subsystem decomposition of Equations (14) and (15), the task of regulating the level in Tank 2 (i.e., achieving set-point control of
) is established. In this particular context,
and
symbolize the output and input of the subsystem, respectively, as mentioned in Equation (15).
In addition, the subsystems in Equations (14) and (15) are modelled as transfer functions, and the Laplace transforms of these equations are given in Equations (17) and (18), where
,
,
, and
. It is evident that Equations (17) and (18) can be applied to both cascade and traditional PI.
Table 1 displays the parameters of the connected tank system.
6. Conclusions
This study evaluated the effectiveness of three advanced control strategies in real-time applications: the cascade nonlinear feedforward proportional integral retarded (CNPIR) controller, the feedforward–proportional integral (FF-PI) controller, and the fractional order adaptive PID-type sliding mode control (FO-APIDSMC) method. The CNPIR controller, applied to an industrial liquid level system for the first time, showed improvements in control accuracy and disturbance handling compared to the classical PI controller. However, while the FF-PI controller improved response time, it displayed limitations in handling external disturbances and nonlinearities. Although the FF-PI controller produced faster responses, its performance fell short when compared to the more advanced CNPIR and FO-APIDSMC techniques, particularly in dynamic scenarios.
The FO-APIDSMC controller, which was introduced as a more advanced option, used fractional calculus and adaptive sliding mode control to perform a better job than both the CNPIR and FF-PI controllers. This method provided chattering-free control, finite-time convergence, and significantly increased trajectory tracking accuracy. The adaptive component of FO-APIDSMC automatically adjusted to system uncertainties, further enhancing robustness. The tests showed that FO-APIDSMC not only worked better than the CNPIR and FF-PI controllers but also provided a more accurate and dependable way to manage complex dynamic systems in real-time. In addition, the proposed FO-APIDSMC controller integrates fractional-order and adaptive techniques simultaneously. For the first time, we have applied this proposed strategy in real-time to a liquid level system. This approach allows for superior performance in both tracking precision and disturbance rejection control for nonlinear and uncertain dynamic processes. Future studies will concentrate on developing and implementing hybrid control strategies that integrate artificial intelligence (AI) or machine learning (ML) techniques into the FO-APIDSMC framework.