Automation and Control Lab

IE 0906544

Experiment 2: Block Diagram Reduction

Dr. Eng. Baha’eddin Alhaj Hasan

Department of Industrial Engineering
System Modelling Diagrams
Building Blocks
Building Blocks
Building Blocks
Series and Parallel Structure
Series and Parallel Structure
Series and Parallel Structure
Negative Feedback and Unity
Feedback
Negative Feedback and Unity
Feedback
Negative Feedback and Unity
Feedback
Negative Feedback and Unity
Feedback
Block Diagram Reduction &Transformation
Block Diagram Reduction &Transformation
Block Diagram Reduction &Transformation
Block Diagram Reduction &Transformation
 Automation and Automatic Control Lab

Experiment 1

Introduction to SIMULINK

Objectives:
By the end of this experiment, the student should be able to:
1. Build and simulate simple system model using Simulink
2. Use Simulink test and measurement tools.

1. Introduction
Simulink is a program for simulating signals and dynamic systems. Simulink has two phases of use: model
definition and model analysis. It provides an interactive graphical environment and a customizable set of block
libraries that let you design, simulate, implement, and test a variety of time-varying systems, including
communications, controls, signal processing, video processing, and image processing.
Simulink provides toolboxes for designing, simulating, and analysing communications systems. The Simulink
enables source coding, channel coding, interleaving, analogue and digital modulation, equalization,
synchronization, and channel modelling.
A typical session starts by either defining a new model or by recalling a previously defined model, and then
proceeds to analyse that model. In order to facilitate the model definition, Simulink has a large library of
blocks. Models are created by combining proper blocks from the library and edited in the model window
principally using mouse-driven operation ( Drag and Drop ) . An important part of mastering Simulink is to
become familiar with manipulations of various model components in these windows.
After you create (or define) a model, you can analyse it either by choosing options from the Simulink menus in
the model window or by entering commands in the Matlab command window. The progress of an ongoing
simulation can be viewed while it is running, and the results can be made available in the Matlab workspace
when the simulation is complete.
Simulink is a visual programming interface designed to make modelling systems intuitive. It offers a
way to solve equations numerically using a graphical user interface, rather than requiring code.

Models contain blocks, signals and annotation on a background:.

 Blocks are mathematical functions, they can have varying numbers of inputs and outputs.
 Signals are lines connecting blocks, transferring values between them. Signals are different
data types, for example numbers, vectors or matrices. Signals can be labelled.
 Annotations of text or images can be added to the model, and while not used in the
calculations they can make it easier for others to understand design decisions in the model.
 Text Annotation
Blocks

Signal and Label

1.1 Open the Simulink Library Browser:

You need MATLAB® running before you can open the Simulink® Library Browser.
1. In the MATLAB Command Window, enter simulink.
A short delay occurs the first time you open the Simulink Library Browser. The figure 1 shows
the Library Browser with the Out1 block selected in the Simulink/Commonly Used Blocks sub
library. A block description that appears when you hover over it.

2. The Library Browser keeps a repository of all the libraries it shows. If your library has missing
repository information, a notification bar appears above the Libraries pane when you refresh
the Library Browser. To prevent this notification from appearing again, click on Fix in the
notification bar and choose Resave libraries in SLX file format. This saves all libraries in .slx
format with Enable Repository property set to on. You can also open the Simulink Library
Browser from the MATLAB Tool strip, by clicking
the Simulink Library button. To keep the Library Browser above all other windows on your
desktop, in the toolbar, select the Stay on top button.

Figure 1.1: Simulink Library

1.2 Create a New Simulink Model
Create a new Simulink model from the Simulink Library Browser.

1. From the Simulink Library Browser toolbar, click the New Model button . An empty
model diagram figure 1.2 opens in the Simulink Editor.
 Figure 1.2: Simulink New Model

Example 1: Model the differential Equation (Time Domain)

x·(t) = 2x(t) + u(t) (1)

where u(t) is a square wave with an amplitude of 1 and a frequency of 1 rad/sec, use an integrator
block and a gain block.

The Integrator block integrates its input x· (t) to produce x(t). Other blocks needed in this model include
a Gain block and a Sum block. To generate a square wave, use a Signal Generator block and select the
Square Wave form but change the default units to radians/sec. Again, view the output using a Scope
block. Gather the blocks and define the gain.

Figure 1.3: Blocks representation of equation 1

An important concept in this model is the loop that includes the Sum block, the Integrator block, and
the Gain block.
In this equation, x(t) is the output of the Integrator block. It is also the input to the blocks that compute
x· (t), on which it is based. This relationship is implemented using a loop.
The Scope displays x(t) at each time step. For a simulation lasting 10 seconds, the output shows in
figure 4:
 Figure 1.4: The simulation result of x(t)

Example .2: Model the differential Equation (Frequency Domain- Transfer Function)
x· (t) = 2x(t) + u(t) (2)

The equation you modeled in this example can also be expressed as a transfer function. The model
uses the Transfer Fcn block, which accepts u as input and outputs x(t).

So, the block implements (s)/U(s) . If you substitute sX(s) for x· (t) in the above equation, you get
sX(s) = -2X(s) + U(s)
Solving for X(s) gives
U(s)
X(s) =
s+2
Or
The Transfer Fcn block uses parameters to specify the numerator and denominator coefficients. In
this case, the numerator is 1 and the denominator is s+2. Specify both terms as vectors of coefficients
of successively decreasing powers of s
In this case the numerator is [1] (or just 1) and the denominator is [1 2].

Figure 1.5: Transfer Fcn block parameter

Figure 1.6: Transfer function representation of equation 2

 Exercise 1: Build the following block diagram using SIMULINK

Exercise 2:

Take R = 0.01; L= 0.01

Exercise 3: Consider the general second order equation below.

Use SIMULINK to generate the output of the second order differential equation above.
 Automation and Automatic Control Lab
IE 0906544

Experiment 2: Block Diagram Reduction

Objective: The objective of this exercise will be to learn commands in MATLAB that would
be used to reduce linear systems block diagram using series, parallel and feedback
configuration.

List of Equipment/Software
Following equipment/software is required:

• MATLAB

Category Soft-Experiment

Deliverables
A complete lab report including the following:

• Summarized learning outcomes.

• MATLAB scripts and their results for examples, exercises and Dorf (text book)
related material of this lab should be reported properly.

Series configuration: If the two blocks are connected as shown below then the blocks are
said to be in series. It would like multiplying two transfer functions. The MATLAB
command for the such configuration is “series”.

The series command is implemented as shown below:

Example 1: Given the transfer functions of individual blocks generate the system transfer
function of the block combinations.
The result is as shown below:

Parallel configuration: If the two blocks are connected as shown below then the blocks
are said to be in parallel. It would like adding two transfer functions.

The MATLAB command for implementing a parallel configuration is “parallel” as shown

below:

Example 2: For the previous systems defined, modify the MATLAB commands to obtain the
overall transfer function when the two blocks are in parallel.

Feedback configuration: If the blocks are connected as shown below then the blocks are
said to be in feedback. Notice that in the feedback there is no transfer function H(s) defined.
When not specified, H(s) is unity. Such a system is said to be a unity feedback system.

The MATLAB command for implementing a feedback system is “feedback” as shown below:
When H(s) is non-unity or specified, such a system is said to be a non-unity feedback system
as shown below:

A non-unity feedback system is implemented in MATLAB using the same “feedback”

command as shown:

Example 3: Given a unity feedback system as shown in the figure, obtain the overall transfer
function using MATLAB:

The result is as shown below:

Example 4: Given a non-unity feedback system as shown in the figure, obtain the overall
transfer function using MATLAB:

The result is as shown below:

Poles and Zeros of System: To obtain the poles and zeros of the system use the MATLAB
command “pole” and “zero” respectively as shown in example 5. You can also use MATLAB
command “pzmap” to obtain the same.

Example 5: Given a system transfer function plot the location of the system zeros and poles
using the MATLAB pole-zero map command.

For example:
Exercise 1: For the following multi-loop feedback system, get closed loop transfer function
and the corresponding pole-zero map of the system.

1 1 s2 + 1 s+1 s+1
Given G1 = ;G = ;G = ; G4 = ; H1 = ; H2 = 2;
(s + 10) 2
(s + 1) 3 (s + 4s + 4)
2
(s + 6) (s + 2)
H3= 1
 Automation and Control Lab
IE 0906544

Experiment 3: Performance of First order and second order

systems

Dr. Eng. Baha’eddin Alhaj Hasan

Department of Industrial Engineering
System’s Response
System’s Order
Transient Response and Steady-State
Response.
The time response of a control system consists of two parts:
- the transient response
- and the steady-state response.
By transient response, we mean that which goes from the initial
state to the final state.
By steady-state response, we mean the manner in which the
system output behaves as t approaches infinity. Thus the system
response c(t) may be written as
c(t) = ctr(t) + css(t)
Laplace Transform of Standard Functions
Laplace Transform of Standard Functions
Laplace Transform of Standard Functions
 FIRST-ORDER SYSTEMS

 Consider the first-order system shown in Figure 5–1(a).

Physically, this system may represent an RC circuit, thermal
system, or the like

 Unit-Step Response of First-Order Systems. Since the

Laplace transform of the unit-step function is 1/s, substituting
R(s)=1/s into Equation, we obtain


 for the unit-ramp input the output c(t) is

 For the unit-step input, which is the derivative of unit-ramp input, the
output c(t) is

 Finally, for the unit-impulse input, which is the derivative of unit-step

input, the output c(t) is
 First-Order Systems: Y (s) k
G ( s) = =
 Step Response: U (s) τ s + 1
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
©2010 John Wiley & Sons, Inc. M P Groover, Principles of Modern Manufacturing 4/e SI Version
 Automation and Automatic Control Lab
IE 0906544
Experiment 3
Performance of First order and second order systems

Objective: The objective of this exercise will be to study the performance characteristics of first and
second order systems using MATLAB.

List of Equipment/Software
Following equipment/software is required:

• MATLAB

Category Soft-Experiment

Deliverables
A complete lab report including the following:

• Summarized learning outcomes.

• MATLAB scripts and their results for Exercise 1 & 2 should be reported properly.

Overview First Order Systems:

An electrical RC-circuit is the simplest example of a first order system. It comprises of a resistor and
capacitor connected in series to a voltage supply as shown below on Figure 1.

E(t) Vc(t)

Figure 1: RC Circuit

If the capacitor is initially uncharged at zero voltage when the circuit is switched on, it starts to charge
due to the current ‘i' through the resistor until the voltage across it reaches the supply voltage. As soon
as this happens, the current stops flowing or decays to zero, and the circuit becomes like an open circuit.
However, if the supply voltage is removed, and the circuit is closed, the capacitor will discharge the
energy it stored again through the resistor. The time it takes the capacitor to charge depends on the time
constant of the system, which is defined as the time taken by the voltage across the capacitor to rise to
approximately 63% of the supply voltage. For a given RC-circuit, this time constant is Hence τ =RC its
magnitude depends on the values of the circuit components.
 The RC circuit will always behave in this way, no matter what the values of the components. That is,
the voltage across the capacitor will never increase indefinitely. In this respect we will say that the
system is passive and because of this property it is stable.
For the RC-circuit as shown in Fig. 1, the equation governing its behavior is given by

where Vc(t) is the voltage across the capacitor, R is the resistance and C is the capacitance. The constant τ =RC is
the time constant of the system and is defined as the time required by the system output i.e. Vc(t) to rise to 63% of its
final value (which is E). Hence, the above equation (1) can be expressed in terms of the time constant as:

Obtaining the transfer function of the above differential equation, we get

Where τ is time constant of the system and the system is known as the first order system. The performance measures
of a first order system are its time constant and its steady state.

Exercise 1:
a) Given the values of R and C, obtain the unit step response of the first order system.
a. R=2KΩ and C=0.01F
b. R=2.5KΩ and C=0.003F
b) Verify in each case that the calculated time constant (τ =RC) and the one measured from the figure as
63% of the final value are same.
c) Obtain the steady state value of the system.

Overview Second Order Systems:

Consider the following Mass-Spring system shown in the Figure 2. Where K is the spring constant, B
is the friction coefficient, x(t) is the displacement and F(t) is the applied force:
x(t)

M F(t)

Figure 2. Mass-Spring system

The differential equation for the above Mass-Spring system can be derived as follows
Applying the Laplace transformation, we get

Provided that, all the initial conditions are zeros. Then the transfer function representation of the system is
given by

The above system is known as a second order system.

The generalized notation for a second order system described above can be written as

For which the transient output, as obtained from the Laplace transform table (Table 2.3, Textbook), is

Where 0 < ζ < 1. The transient response of the system changes for different values of damping ratio, ζ. Standard
performance measures for a second order feedback system are defined in terms of step response of a system.
Where, the response of the second order system is shown below.
The performance measures could be described as follows:

Rise Time: The time for a system to respond to a step input and attains a response equal to a percentage
of the magnitude of the input. The 0-100% rise time, Tr, measures the time to 100% of the magnitude of
the input. Alternatively, Tr1, measures the time from 10% to 90% of the response to the step input.

Peak Time: The time for a system to respond to a step input and rise to peak response.

Overshoot: The amount by which the system output response proceeds beyond the desired response. It
is calculated as
M pt − f υ
P.O.= ×100%
fυ
where MPt is the peak value of the time response, and fv is the final value of the response. Settling
Time: The time required for the system’s output to settle within a certain percentage of the input
amplitude (which is usually taken as 2%). Then, settling time, Ts, is calculated as

Exercise 2: Effect of damping ratio ζ on performance measures. For a single-loop

second order feedback system given below

E(s)
R(s) Y(s)

Find the step response of the system for values of ωn = 1 and ζ = 0.1, 0.4, 0.7, 1.0 and
2.0.

ζ Rise time Peak Time % Overshoot Settling time Steady state value
0.1
0.4
0.7
1.0
2.0
 Experiment 2
Performance of First order and second order systems

Data Sheet

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Automation and Control Lab
IE 0906544

Lecture 4: Introduction to PID Controller

Dr. Eng. Baha’eddin Alhaj Hasan

Department of Industrial Engineering
Introduction
Introduction
PID Controller
PID Controller
P - Controller
D- Controller
D- Controller
D- Controller
PD- Controller
PD- Controller
I - Controller
I - Controller
PI - Controller
PID - Controller
The Characteristics of P, I, and D controllers

A proportional controller (Kp) will have the effect of reducing the

rise time and will reduce, but never eliminate, the steady-state
error.

An integral control (Ki) will have the effect of eliminating the

steady-state error, but it may make the transient response worse.

A derivative control (Kd) will have the effect of increasing the

stability of the system, reducing the overshoot, and improving the
transient response.
Proportional Control
By only employing proportional control, a steady state error
occurs.

Proportional and Integral Control

‫تذبذبي‬
The response becomes more oscillatory and needs longer to
settle, the error disappears.

Proportional, Integral and Derivative Control

All design specifications can be reached.
The Characteristics of P, I, and D controllers

CL RESPONSE RISE TIME OVERSHOOT SETTLING TIME S-S ERROR

Kp Decrease Increase Small Change Decrease

Ki Decrease Increase Increase Eliminate

Kd Small Change Decrease Decrease Small Change

Tips for Designing a PID Controller

1. Obtain an open-loop response and determine what needs to be improved

2. Add a proportional control to improve the rise time
3. Add a derivative control to improve the overshoot
4. Add an integral control to eliminate the steady-state error
5. Adjust each of Kp, Ki, and Kd until you obtain a desired overall
response.
Lastly, please keep in mind that you do not need to implement all three
controllers (proportional, derivative, and integral) into a single system, if not
necessary. For example, if a PI controller gives a good enough response (like the
above example), then you don't need to implement derivative controller to the
system. Keep the controller as simple as possible.
Introduction to PID controller

Consider the following unity feedback system:

Figure 1: Block diagram of closed loop control system.

Plant: A system to be controlled.

Controller: Provides excitation for the plant; Designed to control the overall system
behavior. The three-term controller: The transfer function of the PID controller looks
like the following:

KP = Proportional gain

KI = Integral gain

KD = Derivative gain

First, let's take a look at how the PID controller works in a closed-loop system using
the schematic shown above. The variable (e) represents the tracking error, the
difference between the desired input value (R) and the actual output (Y). This error
signal (e) will be sent to the PID controller, and the controller computes both the
derivative and the integral of this error signal. The signal (u) just past the controller is
now equal to the proportional gain (KP) times the magnitude of the error plus the
integral gain (KI) times the integral of the error plus the derivative gain (KD) times
the derivative of the error.

1
This signal (u) will be sent to the plant, and the new output (Y) will be obtained. This
new output (Y) will be sent back to the sensor again to find the new error signal (e).
The controller takes this new error signal and computes its derivatives and its internal
again. The process goes on and on.

Example:

Suppose we have a simple mass, spring, and damper problem.

Figure 2: Spring Mass Damper System.

The transfer function between the displacement X(s) and the input F(s) then becomes:

Let

M = 1kg, b = 10 N.s/m, k = 20 N/m, F(s) = 1

Plug these values into the above transfer function

The goal of this problem is to show you how each of Kp, Ki and Kd contributes to
obtain

 Fast rise time

 Minimum overshoot
 No steady-state error

2
Open-loop step response:

Let's first view the open-loop step response.

Figure 3: open-loop step response

Proportional control:

The closed-loop transfer function of the above system with a proportional controller
is:

Let the proportional gain (KP) equal 300:

3
 Figure 4: step response with a proportional controller at Kp=300.

Proportional-Derivative control:

The closed-loop transfer function of the given system with a PD controller is:

Let KP equal 300 as before and let KD equal 10.

Figure 5: step response with a PD controller at Kp=300, Kd=10.

4
This plot shows that the derivative controller reduced both the overshoot and the
settling time, and had a small effect on the rise time and the steady-state error.

Proportional-Integral control:

Before going into a PID control, let's take a look at a PI control. For the given system,
the closed-loop transfer function with a PI control is:

Let's reduce the KP to 30, and let KI equal 70.

Figure 6: step response with a PI controller at Kp=30, Ki=70.

We have reduced the proportional gain (Kp) because the integral controller also
reduces the rise time and increases the overshoot as the proportional controller does
(double effect). The above response shows that the integral controller eliminated the
steady-state error.

Proportional-Integral-Derivative control:

Now, let's take a look at a PID controller. The closed-loop transfer function of the
given system with a PID controller is:

5
After several trial and error runs, the gains Kp=350, Ki=300, and Kd=50 provided the
desired response. To confirm, enter the following commands to an m-file and run it in
the command window. You should get the following step response.

Figure 7: step response with a PID controller at Kp=350, Kd=5500, Ki= 300.

Now, we have obtained a closed-loop system with no overshoot, fast rise time, and no
steady state error.

The characteristics of P, I, and D controllers:

The proportional controller (KP) will have the effect of reducing the rise time and will
reduce, but never eliminate, the steady state error. An integral controller (KI) will
have the effect of eliminating the steady state error, but it may make the transient
response worse. A derivative control (KD) will have the effect of increasing the
stability of the system, reducing the overshoot and improving the transient response.

6
Effect of each controller KP, KI and KD on the closed-loop system are summarized
below

Note that these corrections may not be accurate, because KP, KI, and KD are
dependent of each other. In fact, changing one of these variables can change the effect
of the other two. For this reason the table should only be used as a reference when you
are determining the values for KP, KI, and KD.

Exersice:

Consider a process given below to be controlled by a PID controller,

 Obtain the unit step response of Gp(s) Try PI controllers with (Kp=2, 10, 100),
and Ki=Kp/10. Investigate the unit step response in each case, compare the
results and comment.
 Let Kp=100, Ki=10, and add a derivative term with (Kd=0.1, 0.9, 2).
Investigate the unit step response in each case, compare the results and
comment.
 Based on your results in parts above what do you conclude as a suitable PID
controller for this process and give your justification.

7
Automation and Control Lab
Experiments 5: Introduction to Pneumatics

Dr. Eng. Baha’eddin Alhaj Hasan

Department of Industrial Engineering
 ‫ما هي املواد الهوائية؟‬

What are pneumatics

 Mechanisms which use

Retracted
air pressure to apply
Cylinder
mechanical force and
displacement (work)
 The pneumatic devices
we use are basically
binary actuators – either
retracted or extended
Extended
Cylinder
 What are pneumatics good for?

 Mechanisms requiring (2) discrete states

 Gear shifters
 Gripper articulation
 Lifters
 Brakes
 …and a significant force or displacement
 Strengths

 High durability and reliability

 Simple design and Easy to control
 High effectiveness : can apply a lot of force from a
small, light package, and force is limited by air
pressure and cylinder diameter
 High adaptability to harsh environment
 Safety aspects
 Drawbacks

 Relatively low accuracy

 Not well suited for non-binary actuation
 Low loading
 Noise
 Processing required before use.
 Uneven moving speed – As air can easily be
compressed, the moving speeds of the pistons are
relatively uneven.
 Pneumatic Actuators

‫مشغل‬
 An actuator is an output device for the conversion of
supply energy into useful work.
 The output signal is controlled by the control system, and
the actuator responds to the control signals via the control
element.
 The pneumatic actuator can be described under two
groups, linear and rotary :
 Linear motion: Single-acting cylinders and Double-acting
cylinders.
 •Rotary motion : Air motor, Rotary cylinders and Rotary
actuators.
 Single Acting cylinders

 With single-acting cylinders compressed air is applied on

only one side of the piston face. The other side is open to
atmosphere.
 The cylinder can produce work in only one direction.
 The return movement of the piston is effected by a built-in
spring or by the application of an external force.
 The spring force of the built-in spring is designed to return
the piston to its start position with a reasonably high speed
under no load conditions.
Single Acting cylinders
 Single Acting cylinders

 For single-acting cylinders with built-in spring, the stroke is limited

by the natural length of the spring.
 Single-acting cylinders are therefore only available in stroke lengths
of up to approximately 80 mm.
 The construction and simplicity of operation of the single-acting
cylinder makes it particularly suitable for compact, short stroke
length cylinders for the following types of applications:
a.Transferring
b.Branching
c.Clamping
d.Ejecting
 Double Acting cylinders

 The construction principle of a double-acting cylinder is similar to

that of the single-acting cylinder. However, there is no return
spring, and the two ports are used alternatively as supply and
exhaust ports.
 The double-acting cylinder has the advantage that the cylinder is
able to carry out work in both directions of motion. Thus,
installation possibilities are universal.
 The force transferred by the piston rod is somewhat greater for the
forward stroke than for the return stroke as the effective piston
surface is reduced on the piston rod side by the cross-sectional area
of the piston rod.
Double Acting cylinders
The pneumatic system
Directional Control Valves
Directional Control Valves
3/2 way DCV –NC ( Normally Closed)
3/2 way DCV –NC ( Normally Closed)
3/2 way DCV –NC ( Normally Open)
3/2 way DCV –NC ( Normally Open)
3/2 way Roller Lever Valve ( N/C)
3/2 way Roller Lever Valve ( N/C)
3/2 way DCV –NC ( Normally Open)
3/2 way Selector Valve
Different Types of Actuators
Manual Actuators
Mechanical Actuators
Electrical Actuators
Pneumatic Actuators
5/2 way Directional Control Valve
5/2 way Directional Control Valve
5/2 way SelectorValve
5/2 way Single PilotValve
5/2 way Double PilotValve
 Automation and Automatic Control
Lab
IE 0906544
Experiment 5

Introduction to Pneumatics
Simulation of Single Acting and Double acting Cylinders using Automation
Studio

Introduction
In this experiment, you will study about the pneumatic circuits for the linear movement of an
actuator. More precisely, we will study about the single-acting and double acting pneumatic
cylinder.

Objectives
 To learn about pneumatic power characteristics, applications, advantages and
disadvantages;
 To investigate a basic pneumatic circuit.

Components Required
Automation Studio software

Discussion
Fluid power systems convert mechanical energy into fluid energy, and then convert this fluid
energy back into mechanical energy to do useful work. The fluid power devices that convert
the energy of a pressurized fluid into mechanical energy to do work are called actuators. The
two basic types of actuators are cylinders, which generate linear motion, and motors or rotary
actuators, which generate rotary motion.
Most pneumatic circuits contain a source of compressed air, a pressure control device,
conductors such as pipe or tubing, an actuator, and a directional control valve to control the
operation of the actuator. The power source comes from a motor or engine, called a prime
mover, that operates a compressor having its inlet port connected to the atmosphere. The
mechanical energy is converted into fluid power when this air is compressed. In addition to a
prime mover and a compressor, a pneumatic power source includes an air storage tank called
a receiver. The receiver stores the compressed air until this energy is needed elsewhere in the
system.
A pneumatic circuit is a fluid power circuit that uses gas to transmit power. Air is commonly
used as a gas in pneumatics because it is readily available, inexpensive, and can be returned
to the atmosphere after use.
Air is extremely compressible and elastic. It is capable of absorbing large amounts of
potential energy. These properties of compressed air make possible smooth acceleration and
deceleration and reversal of direction of mechanical motions, with relative freedom from
shock.
As a power medium, compressed air has numerous distinct advantages such as:
 Easy to transport and store;
 Unlimited conductive geometry;
 Offers little risk of explosion or fire;
 Is a very fast working medium and enables high working speed to be obtained;
 Provides flexibility in the control of machines;
 Provides an efficient method of multiplying force; C no return lines necessary; C
efficient and dependable.

The main disadvantages of compressed air are:

 Safety precautions are necessary in handling;
 Expensive compared to some mechanical, electrical or hydraulic means for a given
application;
 Generally suitable for relatively low power requirements;
 Pressure limits;
 Leakages must be controlled to maintain usable pressures; C dirt and humidity must
not be present.
Compressed air finds wide use in transportation and industry fields: air brakes, air cylinder,
tools, die casting, etc. Figure 1-1 shows some typical applications.

Figure 1-1. Compressed Air Applications.

Figure 1-2 illustrates the flow of air through a fundamental pneumatic circuit. Air is drawn
from the atmosphere by the compressor and compressed in the receiver. When the directional
control valve (DCV) is operated, air flows through the valve and to side A of the cylinder. This
causes the cylinder to extend and the air from side B is exhausted and returned to atmosphere.

Figure 1-2. Fundamental Circuit Flow.

Procedure:
Part 1: Single –acting Cylinder
A. Simulation of single acting cylinder using direct method.
1. Draw the pneumatic circuit diagram for direct triggering of single acting cylinder in Figure
3 using Automation Studio Software.
2. Simulate the circuit using Automation Studio Software.

Figure 1- 3 Single acting Cylinder circuit using direct method.

B. Simulation of single acting cylinder using indirect method.
1. Draw the pneumatic circuit diagram for direct triggering of single acting cylinder in Figure
4 using Automation Studio Software.
2. Simulate the circuit using Automation Studio Software.

Figure 1- 4 Single acting Cylinder circuit using indirect method.

C. Simulation of single acting cylinder using two push Button switches.
1. Draw the pneumatic circuit diagram for direct triggering of single acting cylinder in Figure
5 using Automation Studio Software.
2. Simulate the circuit using Automation Studio Software.

Figure 1- 5: Single acting Cylinder circuit using two push Button switches.

Part 2: Double –acting Cylinder

D. Simulation of double acting cylinder using direct method.

1. Draw the pneumatic circuit diagram for direct triggering of double acting cylinder in
Figure 6 using Automation Studio Software.
2. Simulate the circuit using Automation Studio Software.
 Figure 1-6: Double acting cylinder using direct method.

E. Simulation of double acting cylinder using two push button switches.

1. Draw the pneumatic circuit diagram for direct triggering of double acting cylinder in
Figure 7 using Automation Studio Software.
2. Simulate the circuit using Automation Studio Software.
Figure 1- 7: Double acting Cylinder circuit using two push Button switches.
 Automation and Control Lab
Experiment 5
Data Sheet: Pneumatic Logic Circuits

A.
1. Construct the pneumatic circuit in the Figure 2.
2. Fill the table below with the state of the cylinder if the stroke is return or forward
according to the states of valve 1 and valve 2 ( ON or OFF).
3. What is the logic function this circuit represents?

Valve 1 Valve2 Cylinder

OFF OFF
OFF ON
ON OFF
ON ON
B.
1. Construct the pneumatic circuit in the Figure 2.
2. Fill the table below with the state of the cylinder if the stroke is return or forward
according to the states of valve 1 and valve 2 ( ON or OFF).
3. What is the logic function this circuit represents?

Valve 1 Valve2 Cylinder

OFF OFF
OFF ON
ON OFF
ON ON
 Automation and Control Lab
Experiment 6
Data Sheet: Pneumatic Logic Circuits 2

1. Construct the pneumatic circuit in the Figure 1.

2. Fill the table below with the state of the cylinder if the stroke is return or forward
according to the states of valve 1 and valve 2 ( ON or OFF).
3. What is the logic function this circuit represents?

Figure 1

Valve 1 Valve2 Cylinder

OFF OFF
OFF ON
ON OFF
ON ON
 Automation and Control Lab
Experiment 5
Exercise: Pneumatic Logic Circuits (2)

1. Construct the pneumatic circuit in the Figure 2.

2. Fill the table below with the state of the cylinder if the stroke is return or forward
according to the states of valve 1 and valve 2 ( ON or OFF).
3. What is the logic function the shuttle valve represents?

Figure 2

Valve 1 Valve2 Cylinder

OFF OFF
OFF ON
ON OFF
ON ON
 Automation and Control Lab
Experiment 5
Exercise: Pneumatic Logic Circuits (3)

1. Construct the pneumatic circuit in the Figure 3.

2. Fill the table below with the state of the cylinder if the stroke is return or forward
according to the states of valve 1 and valve 2 ( ON or OFF).
3. What is the logic function the other valve represents?

Figure 3

Valve 1 Valve2 Cylinder

OFF OFF
OFF ON
ON OFF
ON ON
Automation and Control Lab
Experiments 6: PLC for Pneumatic Cylinder

Dr. Eng. Baha’eddin Alhaj Hasan

Department of Industrial Engineering
 PLC for Pneumatic Cylinder

 Pneumatic cylinder is a binary actuator ( ON/OFF)

 Any Pneumatic Cylinder can be controlled by The PLC by
controlling the solenoid value that supplies cylinder with
pressed air Q1.
 Two position sensors
(X1 and X2)
are needed to read
the position of the
cylinder rod if it is
extended or retracted

.
 PLC for Pneumatic Cylinder

 Pneumatic cylinder is a binary actuator ( ON/OFF), Any Pneumatic Cylinder

can be controlled by The PLC by controlling the solenoid value that supplies
cylinder with pressed air Q1.
 A general procedure for controlling a pneumatic cylinder by PLC is as follows:
1. An ON / OFF switch can start the process.
2. Two position sensors
(X1 and X2) are needed to read
the position of the cylinder rod
if it is extended or retracted.
3. When X1 is high, an output signal
activities Q to push the rod out of
the cylinder.
4. When the rod’s piston reaches the forward position switch X, X1 will be high and
Q1 ( output of the solenoid will be off too), the rod will retracted inside the
cylinder and X1 will be off again.
5. And when the rod piston reaches backward position switch X2, X2 will be high
and Q1 will be high again. Pushing forward the rod again.
6. This cycle of movement will be repeated several times according to a counter
reading (C1).
7. The counter will counts the number of times the cylinder’s rod energised, and
when the number reaches to C1 ( for example 5 times) it will disable the over all
process.
 Question
 Draw the ladder diagram to control the pneumatic cylinder shown
in the Figure below. The system is composed of a double acting
pneumatic cylinder that has to push a product immediately after
fallen to the conveyer.
 The cylinder rod will be
extracted forward and
retracted backward again to the
cylinder.
 This movement cycle has to
be repeated for 5 times.
 Solenoid Valve

 In order to solve the problem in the previous slides, the working

mechanism of the soleniod valve, which control the supply of the
pressure to the pneumatic double acting cylinder must be explained.

https://www.youtube.com/watch?v
=bXXL-0sf8gs
 Solenoid Valve

 Soleniod valve is composed of ports that

supply the air pressure in and out of the
acting cylinder.
 Solenoid Valve

 The moving part that open and close ports

( and controlling the inlet and outlet of the
air pressure) is performed by a moving
part called spool.
 This moving part is controlled by an
electric solenoid.
 The electric soliniod which is another ON
/ Off actuator will be controlled by an
signal comming out from the PLC ports.
 Solenoid Valve

 The first Figure represent the rest position

of the spool ( the soliniod is not
energized).

 When the signal comes from PLC and

energized the soleniod, the soleniod will
push spool and this it will squeez the
spring to the other side.
 As a result of moving the spool the the air
path will be changed as illustrated in the
Figure beside. This will cause the rode of
the double acting cylinder to retrive inside
the cylinder.

 As soon as the PLC removes the

command the spring will retrun back to
it’s original position causing the direction
of the air path to be reveresed.

 As a result of that, the rod of the cylinder

will extend again ( the pressreized air will
be behind the piston force the rode to
exted as illustrated un the Figure beside.
 Suggested Ladder Diagram

 Based on understanding the electric solinoid, a suggested

ladder diagram is proposed next slide.
 Two complementry outputs are suggested : Y1 to keep the rode
in the extraction position for 4 sec, and Y2 to retrive the rode
inside the cylinder. Both Y1 and Y2 are controlled by the PLC
activation signal Q.
 X1 ( forward position sensor) will indicate the extraction of the
rode, so it will inatiate both a timer T1 to keep extraction position
for 4 sec, and accounter C1 to count the required repitation of
the extraction process.
 When the counter counts up to 5, it will disapple the overall
process.
 Any other suggestion to solve the problem ? Try to find another
solution !.
 Automation and Control Lab
Experiment 7
Data Sheet: PLC for Pneumatic Circuits

1. Construct the pneumatic circuit in the Figure 1.

Figure 1
2. With your supervisor, built the AB PLC ladder diagram in Figure 2, please notice the name
of the libraries from which you can select the components.

Figure 2
3. With your supervisor, built the AB PLC ladder diagram in Figure 3, please notice the name
of the libraries from which you can select the components.

Figure. 3
5. Rebuilt the AB PLC ladder diagram in Figure 3 by using a counter that will counts up to 10
( Figure 6) , please notice the name of the libraries from which you can select the
components.

Figure. 6
Exercise: Compare between the outputs of the different timers and the counter you have
simulated in the previous steps.
 Automation and Control Lab
Experiment 8
Data Sheet: PLC for Pneumatic Circuits (2)

1. Construct the pneumatic circuit in the Figure 1.

Figure 1
2. With your supervisor, built the AB PLC ladder diagram in Figure 2, please notice the name
of the libraries from which you can select the components.

Exercise: Compare between the outputs of the different timers and the counter you have
simulated in the previous steps.
Figure 2