SECTION-A

BASIC PROCESS CONTROL TRAINER

Experiment No. 1
To Calibrate the Float Level Sensor and Transmitter by using Basic Process Control
Trainer.
Theory:
In this practical the FLT will be calibrated to zero ('zero' being the lowest reading, i.e. 4 mA)
without the sensor connected. The sensor is then connected with the level in the tank at the
zero indicator and its screw adjusted until the DDM reads 4mA again. The zero reading of
the sensor and transmitter has now been calibrated against an empty tank.
The tank is now filled until the level is at the 100 (full) indicators. This is the highest level
that will be reached in the tank. At this level the signal output should be maximum, 20 mA.
The span of the transmitter is adjusted so that the DDM does read 20 mA at the top of the
tank.

Apparatus Diagram:

Figure 1 Process Control Unit

Practical procedure:
1. Open manual valve MV2, so that the upper tank is filled to above the zero level. Close
MV2 and then briefly open MV3 until the water level is exactly on zero.
2. Remove float level sensor cable from the float level transmitter. Adjust the zero screw on
the float level transmitter with a small screwdriver so that the DDM
reads exactly 4.0 mA. This is now calibrated to zero.
3. Reconnect the cable from the float level sensor to the Sensor input of the float level
transmitter, and ensure that the tank level is at 0 on the tank scale. Adjust the screw in the
center of the float level sensor wheel so that the DDM reads 4mA again. This has
calibrated the sensor potentiometer to zero. A 4 mA current will signal an empty (zero
level) tank.
4. Close manual value MV3 and open MV2 so that the tank fills, lifting the level sensor.
Allow the level to reach 100 (maximum value) on the tank scale. Close MV2 and adjust
the span screw on the float level transmitter so that the DDM is reading 20 mA. This is
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 the maximum current corresponding to the maximum water level in the tank.
5.
6. The float level sensor and transmitter are now calibrated against the upper tank. A current
between 4 mA and 20 mA will be produced which is directly proportional to the water
level in the tank.
Table:

Sr. No Height (cm) Current (mA)

1 100 20
2 95 19.1
3 90 18.3
4 85 17.5
5 80 16.9
6 75 16.2
7 70 15.5
8 65 14.5
9 60 12.3
10 55 11.5
11 50 10.7
12 45 9.9
13 40 9.1
14 35 8.4
15 30 7.4
16 25 6.5
17 20 5.7
18 15 4.9
19 10 4.4
20 05 4

Graph between Liquid level and current.

25
Liquid Level vs Current

20
Current (mA)

15
current
10 Linear (current)

0
0 20 40 60 80 100 120
Liquid Level (cm)

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Flat Level Sensor:
Is float level sensor a discrete-level sensor or continuous level measurement sensor?
A float level sensor typically falls under the category of continuous level measurement
sensors. These sensors work by utilizing the position of a floating object (such as a float)
to determine the level of a liquid or bulk solid substance. As the level of the substance
changes, the position of the float changes correspondingly, providing continuous feedback
on the level. This is in contrast to discrete-level sensors, which provide information about
whether the level is above or below a certain threshold but do not give continuous
information about the exact level.

Is it a contact type sensor?

Yes, a float level sensor is generally a contact type sensor. It operates by physically
contacting the substance being measured. The float attached to the sensor rises and falls
with the level of the substance, making contact with the substance at various levels and
thereby providing feedback on the level. The contact between the float and the substance
is what enables the sensor to determine the level accurately.

Applications of Float Level Sensors

Some applications of float level sensors:
 Industrial tanks for monitoring liquids like water, oil, and chemicals.
 Wastewater treatment plants to prevent overflow.
 HVAC systems for maintaining proper water levels.
 Automotive fuel tanks for fuel level indication.
 Food and beverage processing for ingredient level control.
 Medical equipment such as dialysis machines.
 Water management in reservoirs and dams.
 Pump control systems for maintaining desired levels.

Hazards associated with Basic Process Control Trainer

 Electrical hazards from exposed wires and faulty components.
 Potential chemical exposure during experiments.
 Risks of injury from moving mechanical parts.
 Danger of over pressurization in pneumatic or hydraulic systems.
 Risks of burns from hot surfaces or fluids.
 Possibility of equipment failure leading to hazards.
 Fire or explosion risks due to flammable materials.
 Hazard if safety interlocks or shutdown systems fail.

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Controls for Hazards:
Controls for Hazards:
 Electrical: Insulation, grounding, and enclosures.
 Chemical: Fume hoods, gloves, ventilation.
 Mechanical: Safety guards, lockout/tagout.
 Pressure: Relief valves, gauges, maintenance.
 Temperature: Thermal barriers, PPE.
 Equipment: Inspections, maintenance, shutdown procedures.
 Fire/Explosion: Proper storage, spark-resistant equipment, extinguishers.
 Interlock: Regular testing, backup systems, operator training.

Comments:
 Developed hands-on expertise in instrument calibration, emphasizing
accuracy and safety protocols.
 Enhanced problem-solving, collaboration, and communication skills
through teamwork and addressing real-world challenges.
 Gained practical experience in data collection, analysis, and technical report
writing, strengthening data literacy and communication.

2021-me427 Hassan Zahid

 Experiment No. 2

To calibrate Variable Area Flow Meter/Rotameter on Basic Process Control Trainer.

Theory:
In this practical you will measure the 'fill' times for various volumes of water, calculate in
each case the flow rate in liters/min and take the average of all these flow rate values.
Finally, you will compare this average flow rate value with the value indicated by the visual
flow meter.
If liquids of high viscosities are used, the limiting factors to calibration are the drainage
characteristics of the tank, which must be such that the residue liquid left after draining has
an insufficient volume to affect the accuracy of the next calibration.
Note however that the resolution of the flow meter is 0.2 l/min, its range is 0.4 l/min to 4.0
l/min, and water should be used as the liquid.
DIAGRAM:

Figure 2 Process Control Unit

Practical Procedure:
1. Completely empty the upper tank, and then close all manual valves connected to the
upper tank. Note that you do not need to worry about the state of the solenoid valves,
since they are normally fully closed. You do need however to make sure that the servo
valve is fully open, as discussed in the Flow/Level rig familiarization assignment.
2. Switch on the pump with the switched ac switch on the front of the Process Interface.
3. Adjust MV2 to give a nominal flow of approximately 1.2 liters/min, as shown on
the visual flow meter.
4. Switch off the pump and empty the upper tank using MV3. When the tank is empty,
close MV3.
5. Now, simultaneously start the pump and the stop-watch and measure the time taken for
the level in the tank to reach the 20 mark.
6. Stop the pump and calculate the flow rate, using the level to volume correspondence you
found in the previous practical.
7. Empty the upper tank and repeat the above procedure to obtain the time to reach the 40
mark. Calculate the flow rate for this.
8. Repeat the procedure for levels of 60, 80 and 100 and then calculate the average flow
rate from your five readings. Compare this average with the reading from the visual flow
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 meter.

9. Now, repeat the whole procedure for nominal flow rates of 2.4 liters/min and 3.6
liters/min and compare again your calculated averages with the actual visual flow meter
readings.
10. Calculate the average flow rate and compare it with the reading from the visual flow-
meter.

Calculation for Volume Filled in Tank:

 Sr. No. 1: Volume Filled (L) = 0.630

 Sr. No. 2: Volume Filled (L) = 1.342

 Sr. No. 3: Volume Filled (L) = 2.013

 Sr. No. 4: Volume Filled (L) = 2.643

 Sr. No. 5: Volume Filled (L) = 3.232

Table:
Sr. No Volume filled (L) Time (mints) Flow rate (L/min)
1 0.630 0.49 1.29
2 1.342 0.98 1.36
3 2.013 1.28 1.57
4 2.643 1.57 1.68
5 3.232 1.86 1.74
Average flow rate 1.528

Applications of Rotameter:
 Chemical processing for measuring flow rates of liquids and gases.
 HVAC systems for monitoring fluid flow in heating and cooling processes.
 Pharmaceutical industry for precise measurement of liquid ingredients.
 Water treatment plants for monitoring water flow rates.
 Oil and gas industry for measuring flow rates of various fluids.
 Laboratory experiments requiring accurate fluid flow measurement.
 Food and beverage processing for controlling ingredient flow rates.
 Industrial manufacturing processes for monitoring and controlling fluid flow.

Comments:
 Gained hands-on expertise in Variable Area Flow Meter calibration, focusing on
interpreting calibration curves, ensuring accurate setup, and understanding the
correlation between flow rate and meter readings.

2021-me427 Hassan Zahid

  Collaborated with peers to facilitate shared learning and applied theoretical knowledge
in a real-world context, highlighting the industrial relevance of precise flow
measurement.

Experiment No. 3
To Control Level of water in a tank through Pump switching (ON/OFF) on Basic
Process Control Trainer.
Theory:
 On/off control will be used to control the water level in the tank by automatically
turning on and off the centrifugal pump.
 The on-off control section of the PI includes a comparator and Schmitt trigger
arrangement with variable hysteresis control and logic inputs to control the switched
power supplies.
 The output from the Schmitt Trigger, which will be in one of two states depending on
the deviation of the measured signal from the reference signal, is controlling the
supply to the centrifugal pump by providing a logic signal to input D.
 The reference signal is connected to the inverting input of the comparator, so that
while the measured level is less than the desired level the deviation is negative. When
the measured value has passed the desired level, the deviation becomes positive.
Considering the hysteresis curve of a Schmitt trigger, this is an inverted action, since
the output will switch from positive to negative as the deviation is moving from
negative to positive.
 Care should be taken when setting manual valve MV3, connected to the upper tank.
This should be open enough for the level in the upper tank to increase when the pump
is on and decrease when the pump is off.
 This valve is controlling the times taken to rise and to fall between the two limits set
by the hysteresis level.
Apparatus Diagram:

Figure 3 Process Control Unit

Practical Procedure:
1) Servo valve should be fully open. If not, connect the current source to the servo valve
and supply 20 mA to open it, then replace the leads.
2) Set the manual valve MV3 (below the upper tank) to approximately 50% open. Fully
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 open manual valve MV2 (before the visual flow meter). Set the ac supply output switch,
on the front panel of the PI, to the logic input position. Set the DDM to current (mA).
3) Set the current source to an intermediate position and the hysteresis control to the
minimum position.
4) Switch on the PI. When the behavior of the process has become steady, vary the
hysteresis level in steps and observe the effect on the operation of the system. Set the
hysteresis level back to a low value and now vary the current source output in steps and
observe the effect on the system.
Block diagram:

Comments:
 Gained hands-on experience in level control implementation using pump switching,
emphasizing the relationship between water level and pump operation, and the
importance of calibration for accuracy.
 Developed troubleshooting and problem-solving skills through addressing real-world
control challenges, while collaborating with peers for shared learning.
 Reinforced the importance of safety protocols when working with pumps and related
equipment.

2021-me427 Hassan Zahid

 Experiment No. 4
To Control level of liquid in a tank by witching (ON/OFF) Solenoid valve on basic
process control trainer.
Theory:
 A better way of controlling the tank level is to use a different 2-state device a solenoid
valve. The solenoid valve is designed with repeated switching in mind and is much
more suitable for on/off control. This will be investigated now.
 Solenoid valve SV1 could replace the pump as the device that cuts the flow on and off.
The valve must be open when the tank level is below desired level, and closed when
above desired level.
 But there is another way of controlling level which exhibits a non-inverting action.
This is to use solenoid valve SV2, connected to the upper tank. It lets water flow from
the upper to the sump tank.
 Now, when the actual tank level is above the desired level the valve should switch on,
open, so that more water can flow out. When the actual level is below the desired level
it should switch off, close, so the water level can rise.
 To accomplish this the reference signal from the current source is fed into input A
(which is the non-inverting input to the comparator) and the measured signal from the
FLT is fed into input B. Now, while the measured level is less than the desired level
the deviation is positive and will become negative when the measured level is greater
than desired. This is the reverse of the last practical.
 Translating this to the action of the comparator and Schmitt trigger together, the output
should switch from negative to positive as the deviation changes from negative to
positive. This is a non-inverting action.
 Since the solenoid valve is to be controlled, the output of the Schmitt trigger will now
feed the logic input E of the switched 24Vdc output to SV2.
 As before, care must be taken when setting the position of manual valve MV3. For the
operation of this on/off control example to be as expected, the level in the tank should
go up when SV2 is closed and down when it is open. It may take a little trial and error
to get this right.

Apparatus Diagram:

Figure 4 Process Control Unit

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Perform Practical:
1) Ensure that manual valve MV2 is fully open. Initially set manual valve MV3 to be
approximately 50% open.
2) When the practical is running you will have to adjust this to get the correct behavior; the
tank level should rise when SV2 is closed, and fall when it is open. Set the 24Vdc o/p
switch to logic input E, and the ac supply output switch to ON. Set the current source
output to an intermediate value and the hysteresis to the minimum.
3) Switch on the PI. SV2 will be closed initially. Once the behaviour of the process has
settled down and the correct position of MV3 has been found, vary the hysteresis level in
steps and observe the effect on the operation of the system.
4) Set the hysteresis back to minimum and now vary the current source output in steps and
observe the effect on the system.
5) Set the current source to an intermediate level and the hysteresis to minimum. Swish
around the water in the upper tank (with a spoon, ruler or the like) and observe the effect
on the process. Increase the hysteresis in small steps and repeat for each step.

Block diagram:

Comments:

 You gained a solid understanding of fundamental process control concepts and their
practical applications in real-world scenarios.
 Hands-on experience with the process control trainer equipped you with the ability to
design and implement a simple control system using an ON/OFF solenoid valve.
 The experiment highlighted the importance of various aspects of process control,
including calibration, tuning, and feedback mechanisms for optimal performance.

2021-me427 Hassan Zahid

 Experiment No. 5
To control the liquid level in a tank by using the Float Level Switch on Basic Process
Control Trainer.
Theory:
The Float Switch:
 The float switch is binary in operation: open or closed. It can give no clue as to how
much over or under the desired level the water in the tank is. This makes it a device
suitable for on/off control only.
 It will take the place of the float level sensor, which produced a current signal
proportional to the actual tank level. The solenoid SV1 will be used to switch flow on
and off. This exhibits the same action (inverted) as the pump, from the point of view of
the Schmitt trigger.
 The float switch uses the FLT to convert its signal into the 4-20 mA format. The FLT,
then, must be recalibrated for this new device. The calibration for the float switch is
very simple and should be carried out as follows before beginning the practical.
 The float switch is connected to the FLT with the barrel in its lowest position (this
means that the reed relay is open) and the zero screw on the FLT adjusted to read 4 mA
on the DDM. The barrel is then held in its highest position (this will close the relay) and
the span screw on the FLT adjusted to read 20 mA on the DDM.
What is difference between float level switch and float level sensor?
A Float Level Switch and a Float Level Sensor are both used for liquid level detection, but
they serve different purposes and have distinct characteristics:
Float Level Switch:
 A discrete device that triggers an ON/OFF signal when the liquid level reaches a
predetermined point.
 Typically used for controlling pumps, valves, or alarms.
 Provides a binary output (e.g., 0/1, YES/NO, or ON/OFF).
 Often used for simple on/off control or alarm applications.
Float Level Sensor:
 A continuous device that measures the liquid level and provides an analog output
proportional to the level.
 Typically used for monitoring and controlling liquid levels in tanks or vessels.
 Provides a continuous output signal (e.g., 0-10V, 4-20mA, or digital values).
 Often used for precision level control, monitoring, and automation applications.
Apparatus Diagram:

Figure 5 Process Control Unit

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Practical Procedure:
 Calibrating all necessary equipment (the current source, and the float level transmitter)
Set the manual valve MV3 (below the upper tank) to approximately 50% open. Fully
close MV2 and fully open MV1 so that all the flow passes through SV1. Set the ac
supply output switch to ON and the 24 V dc switch to the logic input position. Set the
DDM to current (mA). Switch on the PI. Adjust MV3 so that the system operates
correctly: the level rises when SV1 is open and falls when it is closed.
 Set the hysteresis level back to a low value and now vary the current source output in
steps and observe the effect on the system. Set the current source back to its initial
position, and now give the upper tank a gentle shake while the system is operating.
Observe the effect.
Block diagram:

Applications of Float Level Switch

Float Level Switches have a wide range of applications in various industries, including:
 Controlling liquid levels in storage tanks, processing tanks, and silos.
 Automatically starting and stopping pumps based on liquid levels.
 Controlling the opening and closing of valves to regulate liquid flow.
 Triggering alarms when liquid levels reach a predetermined point.
 Controlling chemical levels in processing tanks and reactors.
 Monitoring and controlling water levels in treatment tanks and reservoirs.
 Monitoring liquid levels in storage tanks and processing vessels.
 Controlling liquid levels in storage tanks, processing vessels, and packaging lines.

Comments
 The Temperature Control experiment provided a hands-on introduction to PID control
and its implementation in maintaining stable temperatures.
 I learned how to tune a PID controller to achieve optimal performance, minimizing
overshoot and oscillations.
 The experiment highlighted the importance of sensor sensitivity and controller
responsiveness in precise temperature control.
 I gained practical experience working with thermocouples and the Basic Process
Control Trainer.
SECTION-B
2021-me427 Hassan Zahid
 PNEUMATIC & ELECTRO PNEUMATIC CONTROL TRAINERS
Experiment No. 6
The Use of Pneumatic Control Trainer for Assembly Fixture and Foundry Ladle

Figure 6 Assembly Fixture

Figure 7 Foundry Ladle

Theory:
 Splined shafts are to be assembled into bushes, the assembly requires a press fit. The
shafts are placed manually into the bush a push button is than actuated to extend a
single acting cylinder through a linkage as the cylinder extends the shaft is pressed
home. The cylinder is to retract as soon as the push button is released.
 In a foundry molten metal is to be poured from a ladle a double acting cylinder is used
to lift the ladle. To extend the cylinder a push button must be actuated to retract the
cylinder a second push button must be actuated. The cylinder will remain in the last
position that it is sent to until the opposite push button is actuated.
Equipment Required at Assembly fixture:
 1 off single acting cylinder
 1 off 3/2 way push button operated, spring return direction control valve
 1 off distribution manifold with ON/OFF valve
 4 mm pneumatic tubing as required
Equipment Required at foundry ladle:
 1 off double acting cylinder.
 2 off 3/2 way push button operated spring return direction control valves
 1 off one-way flow control valve
 1 off pneumatic on/off slide valve.
 Pneumatic tubing as required.

2021-me427 Hassan Zahid

 Figure 8 Pneumatic Circuit Diagram for Assembly fixture

Figure 9 Pneumatic Circuit Diagram for Foundry ladle

Note: Label the diagram.
Operational procedure:
 Ensure that the ON/OFF valve is in the OFF position.
 Connect tubing between the manifold and port 1 f the push button valve.
 Connect tubing between the port 2 of the push button and the inlet port of the single
acting cylinder.
 Fit the blanking plugs into all unused manifold ports.
 Check your assembled circuit against the circuit diagram.
 Select the ON/OFF valve to the ON position.
 Operate and hold down push button observe what happens.
 Release the push button and again observe what happens.
 Compare your observation with written circuit explanation for assembly fixture.
 Following the pneumatic circuit diagram connect tubing between the ON/OFF valve air
distribution manifold and port 1 of the two push button valves for foundry ladle.
 Connect tubing between the port 2 of the push buttons and the inlet port of the single
acting cylinder.
 Fit the blanking plugs into all unused manifold ports.
 Set the flow control valve to its maximum position by turning the knurled adjuster anti-

2021-me427 Hassan Zahid

 clockwise.
 Operate and hold down push button 1.1 to extend the cylinder.
 Release the push button1.1then operate and hold button 1.2 to retract the cylinder.
 Now using push buttons 1.1 and 1.2 alternately to operate the cylinder adjust the flow
control valve clockwise to obtain a cylinder extend travel time of 3 seconds.
 Compare your observation with written circuit explanation.
 Turn off the air supply at the manifold.
 Remove all tubing.
Circuit Explanation:
 The push button valve controlling the single acting cylinder is of the 3/2 way,
normally closed type. In the at rest condition the air supply to the valve is closed the
output which is connected to the cylinder is open to exhaust thereby allowing the
cylinder to be retracted due to the internal return spring.
 Upon operation of the push button the supply is connected to the output and the
exhaust is closed this allows compressed air to travel into the cylinder, the piston and
piston rod will now extended. Immediately the push button is released it reverts to its
initial position, the air supply is closed and the air in the cylinder is allowed to flow to
exhaust the cylinder is now free to retract.
 When the push button 1.1 is released and push button 1.2 is opearted and held air
flows into the front chamber of the cylinder via the by pass of the on-way flow contro
1.3 at a no-restricted rate..
 On-way flow control valves are available as in line units or as units that can be fitted
directly into the cylinder port. The closer that the valve is palced to the cylinder the
better the controlling will be.
What was the pressure at which the operation is performed pneumatically?
Typical pneumatic systems operate at a pressure range of 80-120 psi (5.5-8.3 bar). So,
pressure was 5 bar.
Comments:
 The Pneumatic Control Trainer experiment provided hands-on experience in designing
and building pneumatic circuits, emphasizing their role in automation tasks like
assembly fixtures and foundry ladles.
 Gained practical knowledge of pneumatic system design, component selection, and
troubleshooting techniques.
 Reinforced the importance of understanding pneumatic principles and safety practices
for effective system implementation in industrial settings.

2021-me427 Hassan Zahid

 Experiment No. 7
To analyze the use of electro Pneumatic control trainer in foundry ladle and assembly
Fixture

Figure 10 Assembly fixture

Figure 11 Foundry Ladle

Theory:
Splined shafts are to be assembled into bushes, the assembly requires a press fit. The shafts
are placed manually into the bush a push button is than actuated to extend a single acting
cylinder through a linkage as the cylinder extends the shaft is pressed home. The cylinder is
to retract as soon as the push button is released. In a foundry molten metal is to be poured
from a ladle a double acting cylinder is used to lift the ladle.

Equipment Required for assembly fixture.

 1 off single acting spring return cylinder.
 1 off 3/2 way solenoid actuated spring return direction control valve.
 1 off Electric push button
 1 off pneumatic on/off slide valve.
 1 off 24V D.C. Power supply.
 Pneumatic tubes as required.
 Red and blue electric lead as required.
Equipment Required for Foundry ladle.
 1 off double acting cylinder.
 1 off 5/2 double solenoid actuated directional control valve.
 2 off electric push button with normally open contacts and momentary operation.
 2 off electric relay.
 1 off pneumatic on/off slide valve.
 1 off 24V D.C power supply.
 Pneumatic tubing as required.
 Red and blue electric leads as required.

2021-me427 Hassan Zahid

 Figure 12 Electric Circuit diagram for assembly fixture and foundry ladle

Figure 13 Pneumatic Circuit Diagram for foundry ladle and assembly fixture
Operational Procedure:
 Connect a compressed air supply regulated to between two and three bar pressure to the
inlet port of the on/off slide valve.
 Connect 24V D.C power supply to the electric distribution manifold.
 Actuate the air on/off slide valve to the off position.
 Ensure that the electric power supply is switched off.
 Following the pneumatic circuit diagram connect tubing between the on/off valve air
distribution manifold, 3/2 solenoid operated spring return valve and the single acting
cylinder.
 Now following the electric circuit diagram connect electric leads between the red/blue
electric manifolds, electric push button and the solenoid on the 3/2 directional control
valve.
 Check the assembled circuits against the circuit diagrams.
 Switch on the 24V DC power supply.
 Actuate the air on/off valve to the on position.
 Depress and hold down the electrical push button and observe the action of cylinder.
 Release the push button and observe the action of the cylinder.
 Switch off both the electric power supply and the compressed air supply.
 Remove all pneumatic tubing and electric leads.
 Compare our observation with the written circuit explanation.
 Connect a compressed air supply regulated to between two and three bar pressure to the
inlet port of the on/off slide valve.
 Connect 24V D.C power supply to the electric distribution manifold.
 Actuate the air on/off slide valve to the off position.
 Ensure that the electric power supply is switched off.
 Following the pneumatic circuit diagram connect tubing between the on/off valve air
distribution manifold, 5/2 solenoid operated valve and the double acting cylinder.
 Now following the electric circuit diagram connect electric leads between the red/blue
2021-me427 Hassan Zahid
 electric manifolds, electric push button and the solenoid on the 5/2 directional control
valve.
 Check the assembled circuits against the circuit diagrams.
 Switch on the 24V D.C power supply.
 Actuate the air on/off valve to the on position.
 Depress and release the electrical push (S1) button and observe the action of cylinder.
 Depress and release the electrical push (S2) button and observe the action of cylinder.
 Switch off both the electric power supply and the compressed air supply.
 Remove all pneumatic tubing and electric leads.
 Compare your observation with the written circuit explanation.
Circuit Explanation:
 In this exercise the switch (S1) is connected direct to the solenoid (Y1) when the
switch is operated and the contacts are closed the current will flow to the solenoid,
which is then energise and 3/2 way valve is therefore actuated and air passes to the
rear of the cylinder. The cylinder extends and remains extended until the solenoid Y is
de-energised allowing the 3/2 way valve to reset and exhaust the cylinder which will
then retract by means of an internal spring.
 When S2 is operated it energises relay K2 closing the contacts of this relay, current
will then flow via these contacts and energise the solenoid Y2 which resets the 5/2
way valve to the condition as drawn, the cylinder subsequently and rear of the cylinder
exhausting.

What was the pressure at which the operation is performed pneumatically?

Typical pneumatic systems operate at a pressure range of 80-120 psi (5.5-8.3 bar). So,
pressure was 5 bar.

What are the Jigs and Fixtures and their applications?

Jigs and fixtures are manufacturing aids used to hold and position parts for subsequent
operations. Jigs are used to guide a cutting tool and are most often used for drilling,
reaming and tapping operations. Fixtures are devices that support and position workpieces
during manufacturing processes such as machining, grinding, fabrication, broaching and
milling Some of the applications of jigs and fixtures include :
 Mass production of automobile parts.
 Inspection of parts in continuous production in manufacturing industries.
 Cutting the ingots in the steel plant.
 In the refrigeration industry.
 Pump assembling process.
 For drilling the flanges and drilling holes to any required angles.
 For multi-spindle machining.
 Jigs used for mass drilling, reaming and tapping.
 For guiding the tools for machining contours.
 Fixtures used for milling, mass turning and grinding operations.

2021-me427 Hassan Zahid

Differentiate between Single acting cylinder and Double acting cylinder?
Single acting cylinder and Double acting cylinder are two types of pneumatic cylinders
used in industrial automation. The main difference between them is:
Single Acting Cylinder:
 Has one piston and one rod
 Air pressure is applied only on one side of the piston
 The piston returns to its original position due to a spring or gravity
 Movement is in one direction only (extension or retraction)
 Typically used for applications requiring a simple push or pull motion
Double Acting Cylinder:
 Has one piston and two rods (one on each side)
 Air pressure is applied on both sides of the piston
 Movement is possible in both directions (extension and retraction)
 No spring or gravity is required for return motion
 Typically used for applications requiring precise control and bidirectional motion

Comments:
 Gained hands-on experience with the Electro-Pneumatic Control Trainer, designing
and building circuits for precise control of industrial tasks like foundry ladles and
assembly fixtures.
 Developed practical knowledge of electro-pneumatic systems, component integration,
and the importance of accurate sequencing in automated processes.
 Reinforced my understanding of how electro-pneumatic systems enhance precision and
efficiency in industrial settings.

2021-me427 Hassan Zahid