DEPARTMENT OF MECHANICAL ENGINEERING

B.e / B.tech –INDUSTRIAL AUTOMATION

LABORATORY MANUAL
(Regulation 2017)
Prepared by

M.SARAVANAN
FACULTY OF MECHANICAL ENGINEERING, AVIT
 DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
NAME OF THE LAB : INDUSTRIAL AUTOMATION LAB

MANUAL REFERENCE NO : W.I.

PREPARED BY :

M.SARAVANAN
AUTOMATION LAB INCHARGE

APPROVED BY :

PROF.L.PRABHU,
HEAD OF THE DEPARTMENT
 SYLLABUS

INDUSTRIALAU Category L T P Credit

17MECC91
TOMATIONLAB CC 0 0 4 2
Preamble
Totrainthestudentsinhydraulicandpneumaticcircuitdesignusingdifferentcontroldevices
PrerequisiteNIL

CourseObjective

1 Design HydraulicandPneumaticcircuitsforlowcostautomation
Tounderstandtheworkingoflogicalcircuits
2

3 Tounderstandtheoperationofbasicelectropneumaticcircuits

4 Todesignopenloopand closedloopcontrolcircuitofACservomotor

5 ApplicationofPLCtodesignasystem.

CourseOutcomes:On thesuccessfulcompletion of thecourse,studentswillbeableto

Understandprinciples,strategiesandadvantagesofindustrial Understand
CO1. automation
Designmaterialhandlingandmaterialstoragesystemsforanautomatedfactor Analyze
CO2. y

Deviseautomatedshopfloorcontrolsandpartidentificationmethods Understand
CO3.
Outlinethe IoTTechnologies usedinamanufacturingplant andtheir Understand
CO4. rolein Industry
CO5. Understandthebasicsofvehiclecollisionanditseffects. Understand

MappingwithProgrammeOutcomesandProgrammeSpecificOutcomes
CO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 PSO3

CO1 S S M L M L

CO2 S S S S M S S L

CO3 S M L L L

CO4 S M L L L L

CO5 S S M L M L L

S-Strong;M-Medium; L-Low
LISTOFEXPERIMENTS:
1. TodesignaSpeedcontrolcircuitsfordoubleactingcylinder.
2. Todesign aSynchronizationcircuitfortwocylinders.
3. Todesign aContinuousreciprocationofdoubleactingcylinder.
4. TodesignaSequencingoftwocylindercircuits.
5. Todesign aCascadingcircuitfortrappedsignals-2groups
6. ImplementationofLogicCircuits:AND,OR
7. DesignofBasicElectroPneumaticCircuits:Continuousreciprocationofcylinder(withtimer
and counter)
8. Design andtestingof Force,VelocitycalculationsinHydraulic Linearactuation
9. AutomaticbottlefillingMachine
10. DesignandsimulationofPLCControlPneumatic/Hydrauliclinearactuatorcircuits.
11. TodesignaWater LevelControllerusingPLC.

12. Todesign aPLCControlledMaterialHandlingSystem.

TextBooks

1 INDUSTRIALAUTOMATIONLABManual

CourseDesigners
Department/Na
S.No FacultyName Designation Emailid
meoftheCollege
1 M.SARAVANAN ASST.PROF MECH./AVIT [email protected]
 INDEX

EXPT.NO DATE NAME OF THE EXPERIMENT PAGE.NO SIGN

1 INTRODUCTION OF AUTOMATION SYSTEM

AND SYMBOLS
2 INTRODUCTION ABOUT PLC SYSTEM AND
ITS PROGRAMMING
3 DESIGN OF CIRCUITS WITH LOGICAL
SEQUENCE(AND GATE ) USING ELECTRO
PNEUMATIC TRAINER KITS
4 DESIGN OF CIRCUITS WITH LOGICAL
SEQUENCE (OR GATE ) USING ELECTRO
PNEUMATIC TRAINER KITS
5 AUTOMATION OF MULTIPLE CYLINDERS
IN SEQUENCE (A+B+B-A-) USING PLC
6 ACTUATION OF HYDRAULIC CYLINDER TO
FIND OUT FORCE Vs PRESSURE
7 ACTUATION OF HYDRAULIC CYLINDER TO
FIND OUT SPEED VS. DISCHARGE

8 SIMULATION OF SINGLE ACTING

CYLINDER BY USING
AUTOMATION SOFTWARE
9 SIMULATION OF DOUBLE ACTING
CYLINDER BY USING
AUTOMATION SOFTWARE
10 AUTOMATIC BOTTLE FILLING MACHINE
USING PLC.
EX.NO:1 DATE:

INTRODUCTION OF AUTOMATION SYSTEM AND SYMBOLS

AIM:

To study about the important features ,about Automation system and symbols

Introduction to Automation system:

Introduction ELECTRICAL power is one of the most important infrastructure inputs necessary for the
rapid economic development of a country. The ever-rising demand of electrical energy has led to the
installation and incorporation of a large number of electrical power generation units, with increased
capacities in a common power grid, making the operation of the entire system sensitive to the
prevailing conditions. Therefore, the extensive and complex power systems have become
unmanageable using the conventional instrumentation and control schemes. Intelligent systems based
on microprocessors and computers have been employed for online monitoring and control of modern
large-scale power systems, in generation, transmission and distribution, thereby overcoming the
complexities and drawbacks of the conventional instrumentation schemes.

The term “Automation”

Automation is the use of scientific and technological principles in the manufacture of machines that
take over work normally done by humans. This definition has been disputed by professional scientists
and engineers, but in any case, the term is derived from the longer term “automatization” or from the
phrase “automatic operation”. Delmar S. Harder, a plant manager for General Motors, is credited with
first having used the term in 1935.

History of Automation Ideas for ways of automating tasks have been in existence since the time of the
ancient Greeks. The Greek inventor Hero (fl. about A.D. 50), for example, is credited with having
developed an automated system that would open a temple door when a priest lit a fire on the temple
altar. The real impetus for the development of automation came, however, during the Industrial
Revolution of the early eighteenth century. Many of the steam-powered devices built by James Watt,
Richard Trevithick, Richard Arkwright, Thomas Savery, Thomas Newcomen, and their
contemporaries were simple examples of machines capable of taking over the work of humans.

One of the most elaborate examples of automated machinery developed during this period was the
draw loom designed by the French inventor Basile Bouchon in 1725. The instructions for the operation
of the Bouchon loom were recorded on sheets of paper in the form of holes. The needles that carried
thread through the loom to make cloth were guided by the presence or absence of those holes. The
manual process of weaving a pattern into a piece of cloth through the work of an individual was
transformed by the Bouchon process into an operation that could be performed mindlessly by merely
stepping on a pedal. Automation Applications Manufacturing companies in virtually every industry are
achieving rapid increases in productivity by taking advantage of automation technologies. When one
thinks of automation in manufacturing, robots usually come to mind.

The automotive industry was the early adopter of robotics, using these automated machines for
material handling, processing operations, and assembly and inspection. Donald A. Vincent, executive
vice president, Robotic Industries Association, predicts a greater use of robots for assembly, paint
systems, final trim, and parts transfer will be seen in the near future. One can break down automation
in production into basically three categories: fixed automation, programmable automation, and flexible
automation. The automotive industry primarily uses fixed automation. Also known as "hard
automation," this refers to an automated production facility in which the sequence of processing
operations is fixed by the equipment layout. A good example of this would be an automated
production line where a series of workstations are connected by a transfer system to move parts
between the stations. What starts as a piece of sheet metal in the beginning of the process, becomes a
car at the end.

Programmable automation is a form of automation for producing products in batches. The products
are made in batch quantities ranging from several dozen to several thousand units at a time. For each
new batch, the production equipment must be reprogrammed and changed over to accommodate the
new product style. Flexible automation is an extension of programmable automation. Here, the variety
of products is sufficiently limited so that the changeover of the equipment can be done very quickly
and automatically.

The reprogramming of the equipment in flexible automation is done off-line; that is, the programming
is accomplished at a computer terminal without using the production equipment itself. Computer
numerical control (CNC) is a form of programmable automation in which a machine is controlled by
numbers (and other symbols) that have been coded into a computer. The program is actuated from the
computer's memory.

The machine tool industry was the first to use numerical control to control the position of a cutting
tool relative to the work part being machined. The CNC part program represents the set of machining
instructions for the particular part, while the coded numbers in the sequenced program specifies x-y-z
coordinates in a Cartesian axis system, defining the various positions of the cutting tool in relation to
the work part.

Automation tools:

• ANN – Artificial neural network

• DCS – Distributed Control System
• HMI – Human Machine Interface
• SCADA – Supervisory Control and Data Acquisition
• PLC – Programmable Logic Controller
• Instrumentation
• Motion control
• Robotics

Advantages and Disadvantages:

• Increased throughput or productivity.

• Improved quality or increased predictability of quality.
• Improved robustness (consistency), of processes or product.
• Increased consistency of output.
• Reduced direct human labor costs and expenses.
• Installation in operations reduces cycle time.
• Can complete tasks where a high degree of accuracy is required.
• Replaces human operators in tasks that involve hard physical or monotonous work (e.g., using one
forklift with a single driver instead of a team of multiple workers to lift a heavy object)[43]
• Reduces some occupational injuries (e.g., fewer strained backs from lifting heavy objects)
• Replaces humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear
facilities, underwater, etc.)
• Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
• Reduces operation time and work handling time significantly.
• Frees up workers to take on other roles.
• Provides higher level jobs in the development, deployment, maintenance and running of the
automated processes.
The main disadvantages of automation are:

• Possible security threats/vulnerability due to increased relative susceptibility for committing

errors.
• Unpredictable or excessive development costs.
• High initial cost.
• Displaces workers due to job replacement.
• Leads to further environmental damage and could compound climate change.

Hydraulic System
 Schematic Layout of Hydraulic System

BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Reservoir (or air tank):

A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid (usually oil).

Pump:
The pump is used to force the liquid into the system.

Prime mover:
A Prime mover, usually an electric motor, is used to drive the pump.

Valves:
Valves are refitted in the system to control liquid direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the liquid energy into mechanical force or torque to do useful work.
The actuator is the actual working element of the system. The actuators can be either cylinders (to
provide linear motion) or hydro motors (to provide rotary motion).
Fluid-transfer piping:
The hydraulic Piping is provided to carry the compressed liquid from one place to another.

Schematic Layout of Pneumatic System

Compressor:
The compressor is used to compress the atmospheric air so as to increase the pressure of the air.

Prime mover:
A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:
Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the air energy into mechanical force or torque to do useful work.

Fluid-transfer piping:
Piping is provided to carry the compressed air from one place to another.
BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

Reservoir (or air tank):

An air tank is provided to store the compressed air required for the operations.

Compressor:
The compressor is used to compress the atmospheric air so as to increase the pressure of the air.

Prime mover:
A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:
Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the air energy into mechanical force or torque to do useful work.

Fluid-transfer piping:
Piping is provided to carry the compressed air from one place to another.
RESULT:
Thus the important feature Automation system was studied.
EX.NO:2 DATE:

INTRODUCTION OF PROGRAMMABLE LOGIC CONTROLLER(PLC)

The programmable logic controller (PLC) is a solid state electronic device designed to replace
electromechanical relays, timers, counters and sequences, by using a programmable memory for the
internal storage of user oriented instructions for implementing specific functions such as logic
sequencing timing, country and arithmetic control through digital or analog inputs and outputs,
various types of machines or processes.

Major advantages of using PLC are as follows:

1. The PLC is a hardened industrial computer designed to withstand the harsh

factoryenvironment.
2. PLCsarereusabletheycontainachangeableprogramthateliminatorsextensiveand
component changes and that makes them cost effective
3. PLCs offer easytroubleshooting
4. PLCs feature easy installation and smallsize.
5. Increaseproductivity.
6. Ease ofprogramming.
7. Ability to communicate withcomputer.

PROCESS

INPUT DEVICES SENSORS

DATA MEMORY
PROCESS
PROCESSING
PROGRAM MODULE ACTUATORS
OUTPUT DEVICES
MEMORY

PROGRAMMING
MODULE or PC

Fig.1.1 ARCHITECHTURE OF PLC

PROGRAMMING
MODULE or PC
Some of the used Instructions Bit
Instructions
The following instructions are used with fixed, SLC 5/01, SLC 5/02, SLC 5/03, and SLC 5/04
processors.

If you want to: Use this Instruction:

Examine a bit for an On conditions XIC
Examine a bit for an Off conditions XIO
Turn a bit On or Off OTE
Turn a bit On OLT
Turn a bit Off OUT

Trigger a one time event OSR

Examine if Closed (XIC)

Use the XIC instruction in your ladder to determine if a bit is on. Whenthe
][
instruction is executed, if the bit addressed is on (1), then the instruction is
evaluated as true. When the instruction is executed, if the bit addressed off (0),
then the instruction is evaluated asfalse.
Examine if Open (XIO)

][ Use an XIO instruction in your ladder program to determine if a bit is off. When
theinstructionisexecuted,ifthebitaddressedisoff(0),thentheinstructionis
evaluated as true. When the instruction is evaluated as false.

Output Energize
Use an OTE instruction in your ladder program to turn on a bit when rung
()
conditions are evaluated astrue.

Output Latch (OTL)

The OTL instruction is a retentive output instruction that can only turn on a bit. It
(L) cannot turn off a bit. This instruction is traditionally used in pairs with an Output
Unlatch (OUT) instruction, with both instructions addressing the same bit. You
can also use this to initialize data values at the bitlevel.

Output Unlatch (OTU)

The OTU instruction is a retentive output instruction that can only turn off a bit.If
(U) cannotturnonabit.ThisinstructionistraditionallyusedinpairswithanOutput
Latch (OTL) instruction, with both instructions addressing the same bit. You can
use this to initialize data values at the bit level.
One Short Rising (OSR)
The OSR instruction is a retentive input instruction that triggers an event to occur
] OSR [ one time. Use the OSR instruction when an event must start based on the change
of state of the rung from false to true, not on the resulting status. Applications
include starting events triggered by a pushbutton switch. An example is freezing
rapidly displayed LEDvalues.
Timer and Counter Instructions

Timers and counters are output instructions. Use the following instructions with fixed, SLC 5/01,
SLC 5/02, SLC 5/02, SLC 5/03, and SLC 5/04 processors.

If you want to: Use this instruction:

Count time base intervals when the instruction is true TON

Count time base intervals when the Instruction is false TOF

Count time base intervals when the instruction is true and
retain the accumulated value when the instruction RTO
goes false
Increment the count at each false–to–true transition. CTU
Decrement the count at each false-to-true transition CTD
Count high-speed pulses from a fixed
HSE
Controller High-speed input
Reset the accumulated value and status bits of a timer or
RES
counter. Do not use with TOF timers.

Timer On-Delay(TON)

Use the TON instruction to turn an output on or off after the timer
TON
has been on for a preset time interval. The TON instruction begins
to count time base intervals when rung conditions become true. As
long as rung conditions remain true, the timer adjusts its
TIMER
Timer ON DELAY
T4: 0 accumulated value (ACC) each evaluation until it reaches thepreset
Timer Base 0.01 value (PRE). The accumulated value is reset when rung conditions
go false, regardless of whether the timer has timedout.
Timer Off-Delay(TOF)

Use the TOF instruction to turn an output on or off after is rung has
TOF
been off for a preset time interval. The TOF instruction begins to
TIMER OFF DELAY count time base intervals when the rung makes a true-to-false
transition. As long as rung conditions remain false, the timer
Timer T4:1
increments its accumulated value (ACC) each scan until it
Time base 0.01 reachesthe preset value (PRE). The accumulated value is reset
when rung conditions go true the timer has timed out.

Retentive Timer (RTO)

RTO Use the RTO instruction to turn an output on or off after its timer
has been on for a preset time interval. The RTO instruction is a
RETENTIVE TIMER
retentive instruction that begins to count time base intervals when
ON
rung conditions become true. As long as rung conditions remain
Timer T4: 2 true, the timer increments its accumulated value (ACC) until it
reaches the preset value (PRE).
Time base 0.01
Using counters
Counter instructions have three word data file elements. Word 0 is
the control word, containing the status bits of the instructions. Word
1 is the preset value; word 2 is the accumulatedvalue.

How Counters Work: The figure below demonstrates how a

counter works. The count value must remain in the range of –
32768, a counter status overflow (OV) or underflow (UN) bit isset.
 Count Up (CTU)

CTU
The CTU is a retentive output instruction that counts false-to-true
COUNT UP
rungtransitions.Rungtransitionscanbecausedbyeventsoccurring in
the program such as parts traveling past a detector or actuating a
Counter C5:0 limitswitch.
Prese 120
t

Count Down (CTD)

CTD The CTD is a retentive output instruction that counts false-to-true

rung transitions Rung transitions can be caused by events occurring
COUNT DOWN
in the program such as parts traveling past a detector or actuating a
limit switch.
Counter C5:1
Preset 120

High-Speed Counter (HSC)

HSC

HIGH SPEED The High-Speed Counter is a variation of the CTU counter. The
COUNTER HSC instruction is enabled when the rung logic is true and disabled
Counter when the rung logic is false.

C5:0 Departme
n
Preset 120
 Reset (RES)

Use a RES instruction to reset a timer or counter. When the RES

instruction is enabled, it resets the retentive on-delay timer, count
up, or countdown instruction having the same address as the RES
instruction.
Math Instruction

The following output instruction allows you to perform computation and math operations on
individual words. Use these instructions with fixed. SLC 5/01, SLC 5/02, SLC 5/03, and SLC
5/04 processors, except where noted.

If you want to: Use this instruction

Add two values ADD
Subtract two values SUB
Multiply one value from another MUL
Divide one value by another DIV
Perform a double divide DDV
Change the sign of the
NEG
source value and place it in the destination
Set all bits of a world to zero CLR
Convert an integer to BCD TOD
Convert a BCD value to an integer value FRD
Multiplex data DCD
Find the square roof of a value SQR
Scale a value SCL

Add (ADD)

Use the ADD instruction to add one value (source A) to another value
ADD
(source B) and place the result in the destination.
Source A

Source B
Subtract (SUB)

SUB

Subtract Use the SUB instruction to subtract one value (Source B) from another
(Source A) and place the result in the destination.
SourceA

SourceB

Multiply (MUL)

MUL
Use the MUL instruction to multiply one value (source A) by another (source
Multiply
B) and place the result in the destination.
Source A

SourceB

Dest

Divide (DIV)

DIV

Divide Use the DIV instruction to divide one value (source A) by another (source
B). The rounded quotient is then placed in the destination. If the remainder
Source A is0.5orgreater,roundupoccursinthedestination.Theunroundedquotient is
stored in the most significant word of the math register. The remainderis
SourceB
placed in the least significant word of the mathregister.
Dest
Scale Data (SCL)

SCL
When this instruction is true, the value at the source address is multiplied
Scale
by the rate value. The rounded result is added to the offset value and
Rate [/10000] placed in the destination. Use this instruction with SLC 5/02, SLC 5/03,
and SLC 5/04processors.
Offset

Comparison Instructions

Following input instructions allow you to compare values of data, Use these instructions with
fixed, SLC 5/01, SLC 5/02, SLC 5/03, and SLC 5/04 processors.

If you want to: this instruction:

Test whether two value is not equal EQU
Test whether one value is not equal to EQ
Test whether one value is less than a second value LES
Test whether one value is less than or equal to a second value LEQ
Test whether one equal to second value is greater than another GRT
Test whether one value is greater than or equal to a second value GEQ
Test portions of twovaluesto see whether they areequal MEQ
Test whether one value is within the limit range of two other LIM
values
Equal (EQU)

EQU

EQUAL Use the EQU instruction to test whether two values are equal. If source
AandsourceBareequal,theinstructionislogicallytrue.Ifthesevalues are
Source A
not equal, the instruction is logicallyfalse.
Source B

Not Equal (NEQ)

NEQ

NOT EQUAL Use the NEQ instruction to test whether two values are not equal. If
source A and source B are not equal, the instruction is logically true. If
the two values are equal, the instruction is logically false.
Source A

Source B

Less Than (LES)

LES
UsetheLESinstructiontotestwhetheronevalue(sourceA)islessthan
LESS THAN another (source B). If source A is less than the value at source B the
instruction is logically true. If the value at source A is greater than or
Source A
equal to the value at source B, the instruction is logicallyfalse.
Source B

Less Than or Equal (LEQ)

LEQ

LESS THAN OR Use the LEQ instruction to test whether one value (source A) is less
EQUAL than or equal to another (source B). If the value at source A is less
than or equal to the value at source B, the instruction is logically
SourceA
Depar
SourceB
 true. If the value at source A is greater than the value at source B, the
instruction is logically false.

Greater Than (GRT)

GRT
Use the GRT instruction to test whether one value (source A) is
GREATER THAN
greaterthananother(sourceB).IfthevalueatsourceAisgreaterthan the
value at source B. The instruction is logically true. If the value at
Source A source A is less than or equal to the value at source B, the instruction
is logicallyfalse.
Source B
Greater Than or Equal (GEQ)

GEQ
Use the GEQ instruction to test whether one value (source A) is
GREATER THAN greater than or equal to another (source B). If the value at source A is
OR EQUAL greater than or equal to the value at source B, the instruction is
logically true. If the value at source A is less than the value at source
Source A
B, the instruction is logically false.
Source B

Masked Comparison for Equal MEQ)

MEQ

MASKED EQUAL Use the MEQ instruction to compare data at a source address with
data at a reference address. Use of this instruction allows portions of
Source the data to be masked by a separate word.

Mask

Limit Test (LIM)

LIM

LIMIT TEST Use the LIM instruction to test for value within or outside a specified
range, depending on how you set the limits. Use this instruction with
Test 5/02 and 5/03 processors.

HighLim
Depar

11
 Move and Logical Instructions

The following output instructions allow you to perform move and logical operations
on individual words. Use these instructions with fixed. SLC 5/01, SLC 5/02, SLC
5/03, and SLC 5/04processors.

If you want to: Use this instruction:

Move the source value to the destination MOV

MVM
Move data from a source location to a
selected portion of the destination
Perform an AND operation AND
Perform an inclusive OR operation OR
Perform an Exclusive Or operation XOR
Perform a NOT operation NOT
Move (MOV)

MOV

MOVE This output instruction moves the source value to the

destination location.
Source

Masked Move (MVM)

MVM
The masked move instruction is a word instruction that
MASKED MOVE moves data from a source location to a destination, and
allows portions of the destination data to be masked by a
Source
separate word.

RESULT:
Thus the important feature Programmable Logic Controller was studied.

28
EX.NO:3 DATE:

DESIGN OF CIRCUITS WITH LOGICAL SEQUENCE (AND GATE ) USING

ELECTRO PNEUMATIC TRAINER KITS
Aim
To construct a pneumatic circuit to control the single acting cylinder control by Two-way
pressure valve using electro pneumatic trainer kits.

Apparatus Required

➢ Compressor air
➢ FRL
➢ Two-way pressure valve
➢ Single acting cylinder

Figure. 1. Circuit Diagram of the AND Logic in the Single Acting Cylinder
Procedure
1. Draw the circuit diagram.

2. Connect the compressor air supply to FRL unit.

29
 3. Any two of the outputs of FRL unit directly connected to 3/2 push button valve inlet
first and second.

4. Both 3/2 push button valves outputs to give AND Gate input.

5. Check the all circuit.

6. Open the hand slide valve. The air passes in both 3/2 pushbutton valves input port.

7. When both push buttons is press the cylinder should be activated.

Truth table
Input 1 Input 2 Output

ON ON ON

OFF OFF OFF

OFF ON OFF

ON OFF OFF

Result

The pneumatic circuit of two way pressure valve was simulated

30
EX.NO:4 DATE:

DESIGN OF CIRCUITS WITH LOGICAL SEQUENCE (OR GATE ) USING ELECTRO

PNEUMATIC TRAINER KITS

Aim

To construct a pneumatic circuit to control the single acting cylinder using electro pneumatic
trainer kits.

Apparatus Required

➢ Compressor air
➢ Tube
➢ 3/2 push button valve
➢ Shuttle valve
➢ Single acting cylinder

Figure. 2. Circuit Diagram of the OR Logic in the Single Acting Cylinder.

31
Procedure

1. Draw the circuit diagram ( Refer Fig. 2)

2. Connect the compressor air supply to FRL unit.
3. Any two of the output of FRL unit to first 3/2 push button valve inlet and second 3/2
push button valve inlet.
4. Both 3/2 push button valves outputs to give shut the valve inlet ports.
5. Check the all circuits.
6. Open the hand slide valve. The air passes in both 3/2 push button valve inlets.
7. Press any one push button valve. The cylinder will be activated.

Truth table
Input 1 Input 2 Output

OFF OFF OFF

ON OFF ON

OFF ON ON

ON ON ON

Result

Thus the single acting cylinder controlled by OR Gate.

32
EX.NO:5 DATE:

AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+B+B-A-) USING PLC

Aim:

To perform sequencing of two pneumatic cylinders (A and B) in the order of A+B+ B-A-
using PLC.

Apparatus Required:

1. FRL Unit
2. Flow Control valve
3. 5/3 solenoid operated directional control Valve
4. 5/2 solenoid directional control Valve
5. PLC pneumatic trainer
6. Double Acting Pneumatic Cylinder
7. Polyurethane Tubes and Electrical wires

ACTUATED POSITION

Figure.3

33
Procedure:

1. Connect the FRL unit, Control valves, directional control valves and cylinders as shown
in the circuit.
2. Draw the functional block diagram using PLC software and save it in the computer.
3. Give connections between PLC and PC using USB port and download the program to the
PLC.
4. Give connections from the reed switches to the PLC input and from the PLC output to the
respective solenoid valves.
5. Adjust the FRL and set the pressure as 6 bars.
6. Switch on the electric supply.
7. Execute the program from the PLC and observe the sequencing of cylinders being carried
out automatically.

RESULT:
Thus the single cycle automation of multiple cylinders is operated in sequence (A+B+B-
A-) using PLC.

34
EX.NO:6 DATE:

ACTUATION OF HYDRAULIC CYLINDER TO FIND OUT FORCE Vs PRESSURE

Aim

To actuate the hydraulic cylinder and find out the force vs. pressure

Apparatus required

Oil tank, single-phase motor, gear pump, pressure relief valve, 4/3 double solenoid valve, double
acting cylinder, load cell, and data actuation card than lab view software.

Procedure

1. Switch on the electrical power supply with motor.

2. Switch on the power supply to the control unit.

3. Open the lab view software in the system.

4. Inter face hydraulic trainer with system using RS-232.

5. Open the force. Go to operate, click the run. Than power on (below).

6. Now extend the system by pressing the up button.

7. Load cell indicate the force value in the monitor.

8. Now adjust the pressure regulator and set the maximum pressure as 25kg/cm2.

9. Retract the cylinder.

10. Once again forward the cylinder; you have adjusted the pressure in pressure
regulator.

11. You have seen the force value in monitoring.

12. Repeat the force value for different pressure.

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Figure.4

36
HYDRAULIC LINEAR ACTUATION TRAINER

Tabulation
S. No Pressure Force ( displayed) Calculated force % of Errors
(kg)
(kg/m2) (kg)

Calculation

W. K. T.

Force
➢ Pressure =
Area
• PRESSURE in ‘kg/m2’
• FORCE in ‘kg’
• AREA in ‘m2’

π 2
➢ Area = D
4
➢ D = Cylinder diameter
• Cylinder diameter = 50mm.
• Cylinder rod diameter = 28mm.
• Cylinder stroke length = 150mm.
• Error = Displayed Force – Calculated Force / Displayed Force

Display forces − Calculated Forces

% Error =  100
Displayed Forces

37
MODEL CALCULATION:

GRAPH:
Pressure VS Force

38
MODEL GRAPH:

Result

The actuation of double acting cylinder was carried out

39
EX.NO:7 DATE:

ACTUATION OF HYDRAULIC CYLINDER TO FIND OUT SPEED VS. DISCHARGE

Aim

To actuate the double acting hydraulic cylinder to find out speed vs. discharge

Apparatus required

Oil tank, single-phase motor, gear pump, pressure relief valve, 4/3 double solenoid valve, flow
control valve, double acting cylinder, load cell, and data actuation card than lab view software.

40
Procedure

1. Switch on the electrical power supply with motor.

2. Switch on the power supply to the control unit.

3. Open the lab view software in the system.

4. Inter face hydraulic trainer with system using RS-232.

5. Open the speed. Go to operate, click the run then power on (below).

6. Now extend the system by pressing the up button.

41
 7. Now regulate the flow control valve, contract the system by pressing down position after
seen monitor in velocity cm/sec.

8. Now adjust the flow control valves and set the maximum flow, to find the up and
velocity.

9. Repeat the velocity values for different flows

HYDRAULIC LINEAR ACTUATION TRAINER

Tabulation
S. No Velocity in UP ( Velocity in DOWN Discharge in UP Discharge in
cm/sec) ( cm/sec) FLOW ( L/sec) DOWN FLOW
( L/sec)

Calculation

W. K. T.

➢ Velocity Speed = Flow

Area
• SPEED in ‘cm/sec’
• FLOW( DISCHARGE) in ‘L/sec’
• AREA in ‘m2’

42
 π 2
➢ Area = D
4
➢ Flow = velocity × Area

MODEL CALCULATION:

D Diameter of Cylinder cm
Cylinder diameter = 50mm
Cylinder rod diameter = 30mm
Cylinder stroke length = 150mm

GRAPH:

Speed VS Discharge

MODEL GRAPH:

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Result

The actuation of hydraulic cylinder was carried out.

44
EX.NO:8 DATE:

SIMULATION OF SINGLE ACTING CYLINDER BY USING

AUTOMATION SOFTWARE

Aim

To perform the simulation of single acting cylinder with use of automation software.

Apparatus required

1.Automation software

2.Computer

Procedure

1. Open the file automation software and open a new file.

2. Then the select the required circuit using the library tool bar.

3. Then pick the required cylinder and valves required.

4. Then drag it and place it is the file.

5. Then give the connections as given in the circuit.

6. Then save the circuit and then select the simulation option.

45
 Diagram:

Result:

Thus the simulation operation of a single acting cylinder was done.

46
EX.NO:9 DATE:

SIMULATION OF DOUBLE ACTING CYLINDER BY USING

AUTOMATION SOFTWARE

Aim

To perform the simulation of Double acting cylinder with use of automation software.

Apparatus required

1.Automation software

2.Computer

Procedure

1. Open the file automation software and open a new file.

2. Then the select the required circuit using the library tool bar.

3. Then pick the required cylinder and valves required.

4. Then drag it and place it is the file.

5. Then give the connections as given in the circuit.

6. Then save the circuit and then select the simulation option.

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 Diagram:

Result:

Thus the simulation operation of a single acting cylinder was done.

48
EX.NO:10 DATE:

AUTOMATIC BOTTLE FILLING MACHINE USING PLC.

AIM
To execute a PLC program for a conveyor system.
APPARATUS REQUIRED
1. PLC Trainer kit.
2. PC with Siemens LOGO! Software.
3. Ethernet cable.
4. Patch chords.
5. Power supply.
6. Conveyor system setup.
PROCEDURE
STEP 1: Switch ON the power supply to PC and PLC Trainer kit.
STEP 2: Patch the power chords. (24v Positive to inputs and 24v
Positive to outputs)
STEP 3: Click File >Click Open>Conveyor Program.
STEP 4: Download and Run the program. (Refer CREATE NEW A
PROGRAM STEP 4 in PROGRAMMING METHODS).
STEP 5: Connect the patch as per the connections given below.
STEP 6: Enable the Start input I2; conveyor starts to move in forward
direction if Direction input is not enabled in the conveyor
setup.
STEP 7: When the specified count is reached from detection of metal
piece by sensor, the conveyor will come to stop.

STEP 8: If direction input is enabled, the conveyor will start to run inreverse direction.
STEP 9: If stop input I3 is enabled, conveyor comes to stop.

49
CONNECTIONS:

SUPPLY PLC TRAINER KIT CONVEYOR SETUP

INPUT
24V Q1 PORT 1 24V
Q2 PORT 2
GND GND
I5 DIRECTION SWITCH
I6 SENSOR INPUT
Q1 PORT 2 FORWARD
Q2 PORT 2 REVERSE
PROGRAM

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DESCRIPTION

INPUTS/OUTPUTS DESCRIPTION
I2 START
I3 STOP
I5 DIRECTION
I6 SENSOR INPUT
I7 COUNTER RESET
Q1 FORWARD
Q2 REVERSE

RESULT:
Thus PLC program for conveyor system is executed

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 VIVA – VOCE QUESTIONS
1. What is meant by sensor?
2. What are the various types of control system?
3. Distinguish between closed loop system and open loop system.
4. What are the types of strain gauges?
5. Define -LVDT
6. What is meant by fluid power?
7. What is a check valve?
8. What is a solenoid valve?
9. Define – FRL unit
10. Define –DCV
11. Differentiate between meter-in and meter-out controls.
12. What is the function of an unloading valve?
13. What is the function of a sequence valve?
14. What is the function of a shuttle valve?
15. What is the function of a spool valve?
16. What is the function of a process control valve?
17. What is the function of a 2-way pressure valve?
18. Why hydraulic power is especially used in heavy works?
19. Where are pneumatic system spreferred?
20. Name the basic components of a hydraulic system.
21. What is the function of a relief valve in a hydraulic system?
22. Draw the symbols for a pressure relief valve and a pressure reducing valve.
23. What is meant by NC and NO contacts?
24. What is meant by an actuator?
25. What are the types of actuators?
26. What is a control valve?
27. What are the types of control valves?
28. What is a circuit control valve?
29. What is the function of flow control valve?
30. Distinguish between flow control and needle valve.

52
 31. What is the function of time delay valve?
32. What is the function of pilot operated valve?
33. What is a quick exhaust valve?
34. What is the difference between a strainer and a filter?
35. Distinguish between hydraulics and pneumatics?
36. What is the purpose of a pressure regulator?
37. Why lubricator is used in pneumatic systems?
38. What are the advantages of hydro-pneumatics?
39. What is meant by logic control?
40. Name the different pneumatic position sensors.
41. How do you rate a compressor?

42. What is a programmable logic controller?

43. What are the basic elements of a PLC?
44. What are the various approaches for entering the program for PLC?
45. What is a ladder diagram?
46. What is the purpose of an electrical timer?
47. Draw the general ladder rungs to represent a latch circuit.
48. How does a PLC differ from relay logic?
49. What are the features of a PLC?
50. What is the function of proximity switch?

53