I have an application where we are trying to control level in a reservoir tank based on running of four 55 gal drum unloader pumps. The drum unloader pumps are VFD controlled and we monitor the drum level of each. We currently operate these pumps by sequencing on/off based on the tank level percentage. We would like to control using a level PID control that would also monitor the drum levels and cascade control the pumps on the drum unloaders based on the level of material in the drum. Lowest level would run faster to try and empty the drum, next lowest level would run slightly slower, etc. This is so that we can empty the drum and then have time to change the drum before a second drum empties. All the while maintain the level in the reservoir. Looking for control ideas I can implement in PLC to provide more efficient and reliable control of the drum unloader pumps and better regulate the level control in the reservoir.
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