(CLO_1): (C4, Analyzing) (PLO_2, Problem Analysis)

1. Analyze the different aspects of factory automation and evaluate the function and
operation of PLC ladder logic to design solutions for factory automation applications.
Discuss how PLC ladder logic can be utilized effectively in various industrial settings to
automate processes and enhance productivity.

2. Explain the various components and technologies involved in factory automation, such as
sensors, actuators, controllers, and communication protocols.

3. Explain the benefits of factory automation, including increased productivity, improved

4. Explain what PLC (Programmable Logic Controller) ladder logic is and its role in factory
automation. Detail the principles of ladder logic programming, including logic gates,
timers, counters, and other instructions. Discuss the advantages of using ladder logic for
controlling industrial processes, such as its simplicity, reliability, and ease of
troubleshooting.

5. Analyzing different aspects of sensors and actuators in the context of factory automation
requires a comprehensive understanding of their roles, types, integration challenges, and
future trends. Here's a structured approach to answering this exam question:

6. Define sensors and actuators and their significance in factory automation.

7. Explain how sensors gather data about the physical environment, while actuators execute
actions based on that data.

8. Design a ladder logic program for a traffic light control system with the following
specifications: The system controls traffic lights at a four-way intersection.

 Each direction (North-South and East-West) has its own set of traffic lights: red,
yellow, and green.
 The traffic lights should operate in a sequence:
 North-South green -> North-South yellow -> North-South red -> East-West green ->
East-West yellow -> East-West red -> Repeat.
 Each light should stay green for 10 seconds, yellow for 3 seconds, and red for 10
seconds.
 There should be a 2-second all-red interval between the changing of lights from one
direction to another to allow for clearing the intersection.

9. Design a ladder logic program for controlling a bottling plant conveyor system with the
following specifications:
 The conveyor system consists of a main conveyor belt and three separate filling
stations: Station A, Station B, and Station C.
 Each filling station has its own sensor to detect the presence of a bottle.
  The conveyor should stop when a bottle is detected at any filling station.
 Once a bottle is filled at a station, the conveyor should resume operation after a
delay of 5 seconds.
 The conveyor should continue operating until all stations are empty.
 If no bottles are detected at any station, the conveyor should continue running at
normal speed.

10. Design a ladder logic program to control the conveyor system according to the above
specifications. Ensure proper handling of bottle detection, delays, and continuous
operation of the conveyor.

11. Three IR sensors are installed at various locations on a conveyor belt, i.e. one each at the
ends and one in the middle, to detect the presence of an object. If the object appears on
the left side, the conveyor motor starts rotating clockwise. If the object appears on the
right side, the conveyor motor starts rotating anticlockwise. The conveyor stops when
the object reaches the middle. Furthermore, if objects appear on both ends
simultaneously, an alarm is activated. The power to the system is controlled via start and
stop push buttons. Analyze the scenario and develop the Ladder Logic Diagram for this
system.

12. Analyze the scenario and develop the logic in PLC using the Ladder Diagram
programming language. Making of an ATS Circuit, with the help of the PLC Program.
This circuit is widely used in industries. The trainees have to make such a circuit with the
following options. When the main supply goes down, The Generator Will Turn ON
automatically after 5 Min. When the Generator is Turned ON, the load shifts to the
Generator after 3 min. automatically. When the main supply becomes available, shift load
immediately on the main while the Generator will then run without load for 3 min. and
then turn it OFF automatically.

13. A PLC has three inputs and one output. Inputs X1 and X2 are momentary contacts that
normally open push button switches. X3 is a normally closed push button switch. Output
Y1 is a coil for the control circuit of a meat grinder motor. For safety, the PLC is to be
programmed so that a person must press both X1 and X2 (one with each hand) to start the
grinder. The grinder is to remain running once both buttons are pressed and released. The
grinder is to stop if X3 is momentarily pressed.
(CLO_2): C5 (Evaluation) (PLO_4, Investigate)

14. Compare and contrast NTC (Negative Temperature Coefficient) and PTC (Positive
Temperature Coefficient) thermistors in terms of their temperature-sensing characteristics,
applications, advantages, and limitations. Discuss scenarios where one type may be
preferred over the other and provide examples of practical applications for each.

15. Recommend a sensor topology including signal conditioning to achieve the functionality
of a Temperature Switch using a Resistance Temperature Detector RTD. Use PT100 and
assume switching to take place at 1250C. Defend your response with proper justification.

16. Optical Encoder is a digital sensor that is widely used in Electrical Systems to measure
Position. Your task is to summarize its Construction, Working, and Applications as a
Position Sensor.

17. Interlocking mechanisms are integral components in various engineering systems. Explain
the concept of interlocking mechanisms and provide examples of their applications in
different fields. Evaluate the effectiveness of interlocking mechanisms in enhancing safety
and efficiency within these systems, considering factors such as reliability, complexity, and
maintenance requirements.

18. Evaluate why we use a 4-20mA signal instead of 0-10V.

19. Compare and contrast the two-wire and three-wire RTD (Resistance Temperature
Detector) systems used for temperature measurement.

20. Compare and contrast NTC (Negative Temperature Coefficient) and PTC (Positive
Temperature Coefficient) thermistors used in temperature sensing applications

21. Compare and contrast hydraulic, electrical, and pneumatic actuators in terms of their
performance, applications, advantages, and limitations.

(CLO_3): (C5, Evaluation) (PLO_3, Design and Development)

22. Evaluate the Car Parking System with a limited capacity of 20 cars. Implement a ladder
logic for a car parking system with a limited capacity of 20 cars to be parked. There are
two position sensors one at the entrance and the other one at the exit to detect the
entrance or exit of the car in the parking area.

23. When a car enters in parking area there is an increment of 1 in the counter after a delay of
2 seconds and when a car leaves the parking area there is a decrement of 1 in the value of
the counter after a delay of 2 seconds. If 20 cars are already parked then a red light will
be on which will show that the parking area is full else a green light will be on. If there is
 a car at the exit gate then the car at the entrance will wait; a yellow light will be on until
the car at exit leaves.

24. Compare and contrast the functionality and applications of DCNT (Discrete Cosine
Transform) counters with other types of counters used in signal processing. Detail the
operational differences between DCNT counters and their counterparts, highlighting the
advantages and disadvantages of each. Provide examples of real-world scenarios where
DCNT counters excel in comparison to alternative counters, and elucidate how these
differences influence their effectiveness in signal processing tasks.

25. Analyze the scenario and develop the Ladder Logic Diagram for this system. An
automated coffee dispenser is designed to provide freshly brewed coffee at the touch of a
button, ensuring safety and convenience in a workplace environment. The system
incorporates a Programmable Logic Controller (PLC) to control its operation.
Inputs:
 X1: Momentary contact, normally open push button switch labeled
"Start/Stop."
 X2: Momentary contact, normally open push button switch labeled "Brew."
 X3: Normally closed push button switch labeled "Emergency Stop."
 Output: Y1: Solenoid valve controlling the flow of hot water to brew coffee.
Operation:
 To start the coffee brewing process, a person must press both X1 and X2
simultaneously, ensuring safety and preventing accidental operation. These
buttons are strategically placed to be easily accessible, requiring one hand each
to press. Once both X1 and X2 are pressed and released, indicating the start
command, the PLC activates Y1, allowing hot water to flow through the
brewing mechanism, resulting in freshly br
 ewed coffee.
 The coffee dispenser remains operational even after releasing X1 and X2,
ensuring continuous brewing until the desired amount of coffee is brewed.
 In the event of an emergency or the need to halt the brewing process, pressing
X3 will trigger the emergency stop function.
26. Analyze the equation and convert the simplified equation into ladder logic diagram

27. Analyze the scenario and develop the Ladder Logic Diagram for this system. Consider
a conveyor belt system with two motors, Motor A and Motor B, controlled by two separate
start and stop buttons, StartA, StopA, StartB, and StopB. The system is designed such that
both motors cannot run simultaneously. Implement an interlocking mechanism using
ladder logic to ensure that only one motor can be started at a time. If Motor A is running,
Motor B should not start, and vice versa. Additionally, both motors should stop if either
 StopA or StopB is pressed. Design the ladder logic diagram to achieve this interlocking
mechanism.

28. Analyze the scenario and develop the Ladder Logic Diagram for this system
 When the push button (X0) is pushed, a light will flash for 10 times.
 The flashing light (Y0) will be on for 2sec and off for 1 sec.
 By pressing button X1 or If button (X0) has been pushed for 5 times the system
will be reset

29. Analyze the scenario and develop the Ladder Logic Diagram for this system. You are
tasked with designing an automated car wash control system using a PLC. The system
should operate according to the following sequence:
 The car wash starts when a car triggers the entry sensor (X0).
 The water spray (Y0) turns on immediately when the car is detected.
 After 100 seconds, the soap dispenser (Y1) activates for 50 seconds while the
water spray remains on.
 Once the soap cycle is complete, the water spray continues for another 10
seconds to rinse the car.
 The dryer (Y2) activates for 15 seconds after the rinse cycle completes.
 An emergency stop button (X1) should halt all operations immediately and
require a manual reset to restart.

30. Analyze the scenario Convert the following ladder diagram mode to instruction mode.
31. Evaluate the 24-hour Clock Operated by 3 Counters. Implement a ladder logic diagram
Using 3 counters together with the flag of M1013 (1s clock pulse) to operate a 24-hour
clock.

32. Analyze the scenario and develop the Ladder Logic Diagram for this system. In the
following scenario, a tank will be filled with two chemicals, mixed, and then drained.
When the Start Button is pressed the program starts pump 1 which runs for 5 seconds,
filling the tank with the first chemical, then shuts off. The program then starts pump 2
which runs for 3 seconds filling the tank with the second chemical. After 3 seconds pump
2 shuts off. The program starts the mixer motor which mixes the two chemicals for 30
seconds. The program then opens the drain valve and starts pump 3. Pump 3 and drain
valve shuts off after 8 seconds and the process stops. A manual Stop switch is also provided
to stop the process when needed.