UNIT 4

Que 1. Write the significance of switches and multiplexers in automated system.(2M)

OR

Explain the functionality of switches, OP-amp & multiplexers in testing only op amp.(3M)

Ans:

Switches in Automated Systems

Switches are fundamental components used to control the flow of electrical signals in an
automated system. They enable or disable the connection between different parts of the
system, allowing manual or automatic control of processes such as turning machines on or
off.

Multiplexers (MUX) in Automated Systems

A multiplexer is a digital switching device that selects one input from multiple inputs.In
automation, multiplexers help reduce the number of data paths required by allowing multiple
signals to share a single communication line, which simplifies circuit design and lowers
hardware costs.

Op-Amps under test are checked for different parameters like input offset voltage, gain,
bandwidth, and slew rate. The test system applies signals and checks if the op-amp gives the
correct output.

Que 2 Need for automatic testing of electronic components (2 Marks)

OR

Justify the need of automatic testing of electronic components?(2M)

Ans: 2 Automatic testing of electronic components is needed because it saves time and gives
accurate results. Manual testing is slow and can have mistakes, especially when testing many
parts. Automatic testing helps find problems quickly, works faster, and is more reliable

Que 3 How the digital ICs can be tested automatically?(3M)

OR

How to test digital ICs automatically?(2M)

Ans. Digital ICs can be tested automatically using special machines called Automatic Test
Equipment (ATE). These machines send different input signals to the IC and check if the
output is correct. Some ICs have a feature called Built-In Self-Test (BIST), which allows them
to test themselves. Another method is Boundary Scan, which helps test ICs on a circuit board
without using physical test probes. These methods save time, reduce errors, and are very
useful for testing large numbers of chips quickly and accurately.

Que 4 How virtual instrumentation is significant in automation industry. Explain the basic
components of virtual instrumentation using an example. List its advantages & applications

Ans

Introduction:
Virtual Instrumentation (VI) represents a paradigm shift in measurement and control systems
by replacing traditional hardware instruments with software-defined solutions. In the
automation industry, VI has become indispensable due to its ability to provide flexible, cost-
effective, and highly customizable solutions for various industrial applications.

Significance in Automation Industry:

1. Enhanced Flexibility: Unlike fixed-function hardware instruments, VI allows engineers to

modify functionality through software changes, adapting quickly to new requirements.
2. Cost Reduction: Eliminates the need for multiple dedicated instruments by consolidating
functions into a single software platform.
3. Improved Efficiency: Enables real-time data acquisition, processing, and control
decisions with high precision.
4. Seamless Integration: Facilitates connectivity with industrial networks, IoT devices, and
enterprise systems.
5. Remote Capabilities: Supports distributed monitoring and control across multiple
locations through network connectivity.

Basic Components with Example:

A complete VI system comprises four fundamental components working in tandem:

1. Measurement Hardware:
Includes sensors (e.g., thermocouples, RTDs, accelerometers)
Data acquisition devices (e.g., NI CompactDAQ, USB DAQ modules)
Signal conditioning circuitry
2. Computing Platform:
Industrial PCs or embedded controllers
Provides processing power for data analysis and control algorithms
3. Application Software:
Development environments like LabVIEW, MATLAB, or Python
Implements measurement, analysis, and control logic
4. User Interface:
Customizable graphical displays
Interactive controls and visualization tools
Practical Example: Vibration Monitoring System
In an industrial plant, a VI-based vibration monitoring system would:

1. Use accelerometers to measure machine vibrations

2. Employ a DAQ device to digitize analog signals
3. Process data through LabVIEW software implementing FFT analysis
4. Display vibration spectra and trends on a human-machine interface
5. Trigger alarms when vibration levels exceed thresholds
6. Optionally integrate with PLCs to initiate shutdown procedures

Advantages:

1. Customization: Tailor measurement and control algorithms to specific needs

2. Upgradability: Easily update software without hardware changes
3. Data Management: Advanced logging, reporting, and database integration
4. Multifunctionality: Single system can replace multiple instruments
5. Future-proofing: Adaptable to emerging technologies and standards

Applications in Automation:

1. Process Control:
Continuous monitoring of temperature, pressure, and flow variables
Closed-loop control of industrial processes
2. Predictive Maintenance:
Vibration analysis for rotating equipment
Thermal imaging for electrical systems
3. Quality Testing:
Automated test sequences for product validation
Statistical process control implementation
4. Energy Management:
Power quality monitoring
Load profiling and optimization
5. Smart Manufacturing:
Integration with industrial robots
Digital twin implementations

Que 5 Describe the basic components of Instrumentation amplifier switches in test system.
List its advantages & applications. (7M)

Ans: Significance:

Virtual Instrumentation (VI) is very useful in the automation industry because it replaces
traditional hardware instruments with computer-based systems. Instead of using separate
devices like voltmeters or signal analyzers, VI allows us to do everything—like measuring,
displaying, and controlling—on a single computer using software and some basic hardware.

This makes the system more flexible, cost-effective, and easier to manage. Engineers can
quickly change settings, test new conditions, and handle multiple tasks at once. VI is
especially helpful in industries where fast and accurate monitoring and control are needed.

Basic Components:

1. Computer – This is the main part of the system. It runs the software, controls the
process, and displays the results.
2. DAQ (Data Acquisition) Hardware – This connects the sensors and devices to the
computer. It collects signals (like temperature, voltage, etc.) and sends them to the
software.
3. Sensors and Actuators – Sensors measure physical values like pressure, speed, or
temperature. Actuators control devices like motors, heaters, or fans.
4. Software (like LabVIEW) – The software controls everything. It reads sensor data,
displays it in real time, analyzes it, and sends commands to control devices.

Example:

Imagine a system that controls room temperature. A sensor checks the temperature and
sends the data to the computer through the DAQ device. The software shows the
temperature on the screen. If the room is too hot, it turns on a fan. If it’s too cold, it turns on a
heater. This whole system works through virtual instrumentation, without needing separate
devices for each task.

Advantages:

Saves money and reduces hardware usage

Easy to change, upgrade, or customize
Real-time monitoring and control
Less wiring and simpler setup
Can handle multiple tasks using the same setup
Works well with other automation systems like PLC or SCADA

Disadvantages:

Requires skilled users to design and operate the system

Initial setup cost can be high (DAQ devices and software like LabVIEW)
System depends on the computer and software—if it crashes, everything stops
Not ideal for very rough or industrial environments without proper protection

Applications:

Industrial process control and automation

Product testing in R&D labs
Medical systems like ECG monitoring
Environmental monitoring (e.g., air and water quality)
Training and simulation in education

Que 6: Automated testing of operational amp?(7M)

Ans:

Automated testing of operational amplifiers, or op-amps, means checking if the op-amp is

working properly using machines instead of testing it by hand. Since op-amps are used in
many electronic circuits, it’s important to make sure they meet performance standards.
Automated testing is faster, more accurate, and is commonly used in industries where a large
number of op-amps need to be tested.

Example

Let’s say a company is making thousands of op-amps every day. Testing each one manually
would take a lot of time. So, they use Automatic Test Equipment (ATE). This machine sends
input signals to the op-amp and measures the output to see if it’s working as expected.

Some of the things it checks are:

Input offset voltage – how accurate the op-amp is

Gain – how much it can amplify a signal
Bandwidth – what range of signal frequencies it can handle
Slew rate – how quickly it responds to changes
CMRR – how well it can ignore unwanted signals or noise

In this setup, switches and multiplexers are used to test many op-amps one by one
automatically, without changing wires manually. The entire process is controlled by software.

Applications

In factories to test op-amps during mass production

In research labs for checking new op-amp designs
In quality control departments to ensure good performance
In colleges and training labs to teach students how op-amps work
In testing electronic products that use op-amps

Advantages

Saves time – can test hundreds of op-amps quickly

Reduces human error – more accurate than manual testing
Repeatable results – every device is tested the same way
Multi-parameter testing – checks many things in one setup
Perfect for large-scale testing

Disadvantages

Expensive setup – ATE and software can cost a lot

Needs trained staff – not everyone can run the system
System can crash – testing stops if the software fails
Not ideal for small batches – too costly for low-volume testing
PC Based: