MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

EXPERIMENT LIST

Name of Subject:MECHATRONICS (304185)

Marking Scheme: In Sem-30 Marks End Sem -70 Marks Prac: 50 Marks
Term Work-50 Marks

CLASS: T.E.- E&TC Subject In charge:Prof Wadekar.V.R.

List of Experiments
1. LINEAR OR ANGULAR POSITION USING SERVOMECHANISM
WITH PHOTOELECTRIC.

2. DISPLACEMENT AND VELOCITY MEASUREMENT USING

ENCODERS

3. STUDY OF LIQUID FLOW MEASUREMENT

4. WEIGHT MEASURE MEASUREMENT USING LOAD CELL(STRAIN

GAUGE)

5. STUDY OF LIQUID LEVEL MEASUREMENT

6. INTERFACING OF ANY 2 SENSORS WITH DATA ACQUISITION

SYSTEMS

7. DEMONSTRATION OF ELECTRO-PNEUMATIC COMPONENTS CIRCUITS

8. DEMONSTRATION OF ELECTRO-HYDRAULIC COMPONENTS

CIRCUITS

9. CASE STUDY WITH DEMONSTRATION A) COIN COUNTER

ASST.PROF. Wadekar.V.R PROF.DIGHE D.D.

(DEPT. OF E & TC) (HOD E & TC)

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TITLE:OPTICAL PICKUP TRAINER

Experiment No:1

Date of Performance: Date of Submission: Remark:

Roll. Practical (5) Oral (5) Total (10) Remark Sign. with date
No.

: To study the Optical pickup, its principle of operation &

Aim characteristics.
Apparatus : a) Optical pickup Trainer.
Oscilloscope with probes. (Optional)
230 VAC, 1Ø, 50 Hz mains supply.
THEORY:
Need of modern automated industry is to sense motion, which can be of rotary or
linear, to control the displacement. The rotary motion is most commonly used in the
form of motors, gearboxes, wheels & in various industries like chemical, automobile,
mechanical etc.
The importance of accurate measurement & control of motion, speed, displacement,
velocity is increasing day by day.
The Optical pickup is the basic & very reliable, widely used motion sensing
device. The pickup generates train of electrical pulses proportional to rotary
motion/speed.
It operates on the principle of cutting optical signal, resulting pulse train generation.
The optical light is incident on the gear tooth and the reflected light from gear
tooth is sensed. The electrical pulse is generated upon receipt of reflected light back at
the sensor. These generated pulse train is proportional to the speed of motor. The gear
may have one or ‘n’ no. of teeth’s on which resolution of speed measurement depends.
Photo Electric Pick Sensor :-
A Phototransistor is an electronic switching and current amplification component

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which relies on exposure to light to operate. When light falls on the junction, reverse
current flows which is proportional to the luminance. Phototransistors are used
extensively to detect light pulses and convert them into digital electrical signals. These
are operated by light rather than electric current. Providing large amount of gain, low
cost and these phototransistors might be used in numerous applications.
It is capable of converting light energy into electric energy. Phototransistors work in a
similar way to photo resistors commonly known as LDR (light dependent resistor) but
are able to produce both current and voltage while photo resistors are only capable of
producing current due to change in resistance. Phototransistors are transistors with the
base terminal exposed. Instead of sending current into the base, the photons from
striking light activate the transistor. This is because a phototransistor is made of a bipolar
semiconductor and focuses the energy that is passed through it. These are activated by
light particles and are used in virtually all electronic devices that depend on light in
some way. All silicon photo sensors (phototransistors) respond to the entire visible
radiation range as well as to infrared. In fact, all diodes, transistors, Darlington’s, triacs,
etc. have the same basic radiation frequency response. The structure of the
phototransistor is specifically optimized for photo applications. Compared to a normal
transistor, a photo transistor has a larger base and collector width and is made using
diffusion or ion implantation. In this setup 2n5777 photo transistor is used and Led light
source is
used. Special arrangement with DISK and hole is also done. Once any hole comes in
front of light source , light is falls on phototransistor and it gives output is again Fed to 2
stage amplifier before given to Microcontroller input (as Feedback)

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PHOTO TRANSISTOR POSITION FEEDBACK CIRCUIT

2 QUDRANT MOSFET BASED PWM DRIVE :-

In this setup microcontroller generates PWM signal for one of mosfet in either forward
quadrant or Reverse quadrant and accordingly bridge generates +ve or –ve voltage which
is then fed to the motor, which in turn rotates forward or reverse. This is modern Servo
drive technique where precise voltage control is possible with PWM drive and also
regenerative braking is possible for large loads.

CLOSED LOOP POSITION CONTROL TECHNIQUE USING

PIC16F870 MICROCONTROLLER

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This unit has used Pic microcontroller 16F870 as CLOSED LOOP position control of the
motor . This IC accepts Pulses from photoelectric pick initially from index sensor. Once
Index pulse is received then it READS SET positions and then calculates error in term of
position. Then it starts generating pulses for 2Q drive for motor accordingly sense of
Error .Depending upon error either Forward or reverse rotation is enabled. Now
controller keeps on counting each pulse from Photoelectric pick -2 and accordingly
estimates the actual position. Once error counted is zero, it stops PWM drive from
generating voltage Motor will stop immediately at the desired position.

Description of the setup:

1) SET POTENTIOMETER (P1)

2) PHOTOELECTRICK PICK UP SENSOR-1and LIGHT source -1
(LED) for indexing purpose.
3) PHOTOELECTRICK PICK UP SENSOR -2 and LIGHT source -2
(LED) for position counting purpose.

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4) PIC MICROCONTROLLER BASED POSITION CONTROL SYSTEM

forming closed loop system with SET position from P1 and actual position from PHOTO
ELECTRICK PICK UP-2.
5) 12v,1 AMP , geared DC motor with special Disk with 20 holes for position
measurement is coupled to motor shaft.
6) Scale of 360 Deg is printed on top of disk.
7) Disk also carries 1 hole separately, which is used for indexing purpose.
8) LCD DISPLAY 16*2 CHARACTER with facility to show Actual position, Set
position and Estimated Angle .
9) Inbuilt regulated power supply +5V .
10)Inbuilt 2 quadrant Mosfet based PWM Servo Drive For running the motor in Forward
or Reverse Direction .
11) Opto isolator 4n35 based isolation card between Microcontroller based Firing circuit
and Mosfet Based Drive.
12) MS powder coated box with Polycarbonate Front panel.

EXPERIMENTATION /OBSERVATIONS FOR STUDENTS :-

IS INTIAL INDEX DONE = YES/ NO
THEN OBSERVE THE FOLLOWING

Sr. No. SET POSITION ACTUAL ESTIMTED

IN POSITION ANGLE IN
TERMS OF IN TERMS OF DEG
HOLES HOLES

TEST POINTS TO BE OBSERVED ON CRO :-

1) TP1 :- PHOTO ELECTRICK SENSOR1 (INDEX SENSOR)
2) TP2:- PHOTO ELECTRICK SENSOR 2 (POSITION SENSOR)
3) MOTOR (V) :- WAVEFORM OF PWM CHOPPER OUTPUT TO
MOTOR

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Conclusion :

Self-Assessment Questions:
Which are the types of encoders?
What type of transducers is used in encoders?
How direction is sensed using optical encoder?
What is the use of Home pulse?
Can encoder be interfaced to computer?

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TITLE :OPTICAL ROTARY ENCODER TRAINER

EXPERIMENT NO: - 2

Date of Performance: Date of Submission: Remark

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

Aim: To study rotaryencoder, it’s principle of operation &

characteristics.
Apparatus:
i) Optical Rotary Encoder Trainer
ii) Frequency Counter / Oscilloscope with probes.
iii) 230 V AC 1Ø, 50 Hz mains supply.
Theory:
Need of modern automated industry is to sense motion which can be of rotary or
linear, to control the displacement. The rotary motion is most commonly used in the
form of motors, gearboxes, and wheels & in various industries like chemical,
automobile, mechanical etc. The importance of accurately measurement & control of
motion, speed, displacement, velocity is increasing day by day.
The Rotary encoder is the basic & very reliable, widely used motion-sensing
device. The rotary encoder generates electrical pubes proportional to rotary
motion/speed/Angular Velocity. It operates on the principles of optical transmitter,
receiver interrupted by a slotted disc. The disc rotates along with rotary shaft & optical
sensors are aligned in such a way the receiver observes interruptions generated by
slotted window on rotation of disc. Optical receiver converts this interruption into
electrical pulses; pulses are amplified and processed as per requirement. The disk may
have ‘n’ no. of slots on which resolution of speed measurement depends.

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The rotary encoder trainer setup consists of rotary encoder driven by dc motor &
dc drive with speed regulator and provision for change in motor direction of rotation.
The encoder is covered with transparent cover. The setup also consists of
programmable RPM & total revolution electronic indicator for direct digital readout.
The encoder pulses are brought out on cover for study purpose. The LED indicates
0
pulses on each channel. Encoder has two channels, which are 90 in phase to each
other. It may also have one home pulse channel, giving one pulse per revolution. All
channels are buffered & are with open collector output.
An incremental encoder can be used to extract three pieces of information about
a rotating shaft.
1. By counting the number of pulses received and multiplying the count by the encoder’s
resolution, the angular rotation angle of the shaft can be determined.
2. By viewing the phase relationship between the phase A and phase B outputs, the
direction of shaft rotation can be found.
3. By counting the number of pulses received from either output during a fixed time
period, the angular velocity of the shaft (in either radians per second or revolutions per
second) can be found.
When an incremental encoder is switched on, it simply outputs a1 to 0 on its phase A and
phase B output lines. This dies not provide any initial information about the angular
position of the encoder shaft. In other words the incremental encoder gives relative
position information, with the reference position being the angle of the shaft when the
encoder was energized. The only way an incremental encoder can be used to provide
absolute position information is for the encoder shaft to be homed after power is applied.
This requires some other external device (such as slotted disc) to provide this home
position reference. Some
incremental encoders have a third output signal named home, which provides one pulse
per revolution and can be used for homing the encoder.
Description of the set-up:
The Set up is housed in a two parts .
PART –I :- Main Panel houses all controls, Microcontroller ,LCD display and test

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points for CRO .

PART- II :- This houses the variable speed DC motor (12 volt, 1 Amp) that is coupled to
the optical encoder with the help of a special coupling and arrangement to measure
angular displacement with special scale provided vertically.
PART- I
A variable power supply drive for DC motor is derived from a Regulator IC 7812.
Switch Sw1 is used an ON/OFF switch to control the DC supply for DC motor. By
interchanging the direction of the armature terminals the direction of the DC motor& in
turn for optical encoder is also changed. This is done by switch Sw2. The pot P1 is used
to control the speed of DC motor by controlling the armature voltage in the range of 1 to
10volt. The test points A, B, Z, are with respect to ground. Switch Sw3 is used to select
the indication for frequency or RPM. RPM is indicated directly, but for frequency
measurement a multiplier of 10 is required to be used. If the optical encoder is 360 Pulse
Per Revolution i.e. 360 PPR, for 1000 RPM, (Which corresponds 25rev/sec), the o/p
frequency is 6000 Hz. Near test point B a terminal is provided.. The test point A o/p is
used to frequency or speed measurement. Normally o/p at Z test point is produced as 1
Pulse Per revolution and is used for indexing purpose. Switch SW2 decides direction of
rotation for motor. Inside the unit PIC microcontroller 16F870 used to detect the
frequency of rotation and then speed is calculated. A LCD display 16*2 characters is
used for RPM and Frequency indication.
Switch SW3 decides mode of indication either SPEED/FREQUENCY or Position in
(deg).
In Speed mode ,also direction of rotation is detected with the help of phase angle
difference of channel A and Channel B output. If A is leading it is clockwise direction
and if B is leading it is anticlockwise direction.
It is detected and indicated in terms of ‘CW’ or ‘CCW’.
If SW3 is switched to Position side, then position of the shaft in Degrees is indicated.
You may use SW4 switch as indexing switch to make count / position ’0’ at 0 position.
To measure the angle, pulse from channel A is given to interrupt of the microcontroller
and no of pulses are counted. Angle can be measured by moving shaft of the motor in

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slow speed manually or moving motor in slow speed. For higher motor speed position
measurement may be inaccurate.

SPECIFICATIONS IN GLANCE :-

1) DC MOTOR :- 1000 RPM ,12V MAX , 1 AMP

2) OPTICAL ENCODER :- 360 PPR ( PULSES PER REVOLUTION)
3) POWER SUPPLY :- 2N3055 BASED VARIBALE DC 0- 5V ,1 A
4) PIC 16F870 MICROCONTROLLER
5) LCD DISPLAY :- 16*2 CHARACHETER
6) POT P1 FOR SPEED CONTROL
7) SW1 FOR MOTOR ON/OFF
8) SW2 FOR MOTOR DIRECTION CONTROL
9) SW3 POSITION OR SPEED MEASUREMENT
10)SW4 FOR PUSH FOR ZERO POSITION .

EXPERIMENT NO :-A
ANGLE MEASUREMENT USING OPTICAL ENCODER OPTICAL ENCODER GENRATES 360
PULSES PER REVOLUTION OF 360 DEG. SO ITS RESOLUTION IS 1 PULSE/ DEG .
We have connected channel A of optical encoder to interrupt port of microcontroller. So
this detects every pulse and counts it accordingly.

PROCEDURE :-
1) Keep Switch SW1 in off Position so that motor will not run .
2) Now you can change SW3 to position in Deg side.
3) Take pointer to Zero position and press SW4.This should make position value as ‘0’
indicated.
4) Now move pointer slowly in CLOCKWISE direction. Position measurement is to be
done for clockwise movement only.
5) See the position measured by microcontroller vs Angle shown on the Scale in deg .

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6) Compare both the readings and estimate the accuracy of measurement.

7) Also you can connect CRO across ground and OUTPUT A.
8) You can observe each square wave output pulse on CRO for angle
measurement.

EXPERIMENT NO 2:-B

SPEED MEASUREMENT AND DIRECTION SENSE USING OPTICAL

ENCODER .

For Speed measurement Frequency of pulses generated by Channel A is measured

by Microcontroller and then speed is estimated based on that . AT 1000 RPM =
(16.66 rotation/second ) * 360 ppr = 5997 hz is output frequency
1) Ensure that Pot P1 is in min position, i.e. most anticlockwise position & switch Sw1 in
OFF position.
2) Now Switch ON the main supply & Switch Sw1 should also be thrown in downward
position. Sw2 may be in forward position.
3) Keep Switch SW3 in Speed position
4) Now move the pot P1 slowly in clockwise direction for increasing the applied
armature voltage slowly. The DC Motor starts rotating along with optical encoder. The
DPM indicates the rpm of motor & resultant frequency generated by optical encoder
output. i.e. DC Motor speed is slightly changes & hence the indication for RPM &
frequency also
changes.
5) Observe waveform at points A, B & Z on CRO with respect to ground. The sensitivity
selection may be in the range of 2V/div & time sweep 1 to 2 msec/div.
6) You may enter the reading for rpm & frequency in a tabular form. Note that optical
encoder is of 360 PPR type.
7) Also you can observe that direction of rotation is also indicated on the LCD.
8) Students can measure Frequency of Channel A wrt ground on CRO.

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9) Also Students can observe the phase difference of CHANNLE A and CHANNEL B on
dual channel CRO.
10) Phase Difference helps to detect the direction of rotation .

SPEED MEASUREMENT

Sr. No. Speed RPM Frequency in Hz. Direction

Precautions:
1) Do not tamper with optical Encoder & its coupling. It is a very delicate system.
2) Before starting the motor always ensure Pot P1 is in fully anticlockwise position.
When motor is running do not operate switch Sw2 i.e. do not change motor direction.

Conclusion:

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TITLE:STUDY OF LIQUID FLOW MEASUREMENT

EXPERIMENT NO :- 3

Date of Performance: Date of Submission: Remark:

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

: To measure water flow using

Aim rotameter
Apparatus: 1) Flow transducer characteristics trainer (TURBINE FLOW SENSOR)

2) Water Supply & Electric 230VAC mains Supply.

Theory:
Values of pipe flow rate are needed for many purposes. Pipe flow measurement
can be done with various types of flow meter, including the rotameter, which is covered
in this article. The principle of operation and advantages and disadvantages of the
rotameter for pipe flow measurement are discussed.
Experimental Procedure:

1) Measure sensor output frequency at tp1 and gnd on cro and draw relation between
frequeuncyvs
actual flow measured with stop watch and measuring tank.
2) Calibrate the indicator with the help of measuring tank and stop watch.
3) Now take down the reading of actual flow vs indicated flow calculations

CALCULATIONS –

We will take readings as ‘Time taken in seconds to fill 5 cm height (H) of

measuring tank
Size of measuring tank L = 17.5 cm
B = 21.0 cm
Volume of the water at 5 cm (H) of tank = 17.5*21.0*5
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= 1837 cm^3
= 1.83 liter
A)
If Time T = 23.3 sec for 5 cm water height change
Flow = (1.83*60) / 23.3
Flow = 4.71 litres /minute
Where T is time for 5cm change

OBSERVATIONS:
Sr. no Flow indicated Time ‘T’ in Flow
by TURBINE seconds for 5 calculated
FLOW in LPM cm height F=
change (1.83*60) /
T
F = (109) /
T

Conclusion:

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

TITLE:LOAD CELL TRAINER

EXPERIMENT NO: - 4

Date of Performance: Date of Submission: Remark:

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

Aim: To study Load Cell Trainer.

Apparatus: Load cell trainer consisting of
1) Load cell
2) Mechanical stand and pan with cantilever strip.
3) Electronics exciter with digital indicator.
4) Weight ranging from 20gm to 1000grams.
Theory -
Transducer play very important role in the engineering. applications. It is
essential to measure parameter like weight, force, pressure, temp and so on frequently,
for which transducer is required. Study of various transducers is important.
Strain gauge is one of the prime transducer widely used in industry for
measurements of weight, load force, pressure, displacement, indirectly for torque, stress
and strain. Strain gauge is nothing but a non-conductive paste clad on a high-grade
plastic strip in such a way that it can be easily bent and stressed/strained. The property of
material is it change it’s resistance when expose to mech./physical change in it’s shape.
The strain gauge foils are available with different resistance valves, different size and
different gauge factors. (Gauge factor is the ratio of change in resistance with elongation
or strain). Normally strain gauges are available with 120Ω, 240Ω, and 350Ω resistance

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values. Resistance wire stain gauges are transducers applied to the surface of structural
members under test in order to sense the elongation or strain due to applied loads. The
setup consists of mild steel structural strip duly ground from both the side ensuring
smooth surface rigidly mounted on a sturdy solid square bar supported on heavy stable
base structure. The sturdy structure stands ensure better result.
Strain gauge sensor of plastic foil type with 120Ω resistance and 8mm gauge length,
5mm width, compensated for mild steel type are pasted to steel strip. The pasting
procedure is very important as it is directly related to elongation of strain gauges when
load is applied. Perfect surface contact shall give better and consistent change in
resistance linear to load applied to it. The strain gauges changes it’s resistance with
variation of temp. Hence gauge are selected are mild steel compensated. The change in
resistance is too small in value which makes it difficult in sensing the change in view of
this the strain gauges are used in the form of bridge circuitry and electronic signal
generated is processed by instrumentation amplifier.
Bridge may have only one arm or two arm or four-arm strain gauge as active
element and balance resistance as passive element. The 4-arm strain gauge bridge is the
most preferred on performance basis. Load cell uses 4 strain gauges as active bridge
element. The strain gauge are pasted to steel strip in such a way two strain gauge sensor
are compressed while other elongated, resulting differential change in resistance
increasing (doubles) sensitivity. Two strain gauges pasted from top to the strip and
another exactly below from bottom all the 4 strain gauges are wired in the form of bridge
and terminated at bottom plate on a connector makes it easy for connection. Small pan
hooked up to the dead end cantilever with weights.
Procedure:
1) Connect load cell to the 4 binding posts provided on the front side
. of the panel.Follow the colour code of binding post and load cell
Wires.
2) Red & black are excitation wires whereas yellow & blue wires
produce O/P voltage.Keep the gain of the amplifier around 100.
3) Now switch on the power supply & get NULL on the DPM by
adjusting the coarse &fine controls ,after allowing a warm up time of
about 5 minutes.
4) Now keep a weight of 200 GM on the weight pan & adjust the gain

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control to get an indication of 0.20 kg on the DPM.Again check

back for zero.Repeat this process of zero adjustment & gain
adjustment until you get proper indications at zero & full load.
5) Now you can check for the intermediate weights like 100GM, 300
GM ,500 GM ,1000GM .You may check for repeatability of the
instruments also.
Take the readings as per SAMPLE TABLE GIVEN
6) To ALSO can study performance characteristics of the load
indicator you may study the effects of the following parameters.
a) Change in I/P supply voltage in the range 210- 245 V.
b) Effect of change in ambient temp.(this can be studied by
continuous operation of the unit.
c) Zero stability of the unit.
d) Effect of change in humidity.

OBSERVATION TABLE:
a) Increasing weight response: 1mV output for 1gm of load
SR.NO. MEASURED (KG) INDICATED(KG)

(b) Reducing Weights response:

SR.NO. MEASURED(KG) INDICATED(KG)

 PRECAUTIONS:
1) Do not overload the load cell.Maximum safe capacity is 6 kg.
2) Do not stretch the sensor cable.
3) Operate the gain control pot very carefully& gently.

Conclusion:

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

TITLE: WATER LEVEL CONTROL MEASUREMENT

EXPERIMENT NO : - 5

Date of Performance: Date of Submission: Remark:

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

AIM: Study of Overhead Tank Water Level Control.

OBJECTIVES:
1) To study the various steps involved in design of Overhead Tank Water Level
Control.
2) Prepare flow chart and then ladder diagram to run Overhead Tank Water Level
Control.
3) To verify the operation of the Overhead Tank Water Level Control.

APPARATUS:
1) Overhead Tank Water Level Control trainer model.
2) PLC Trainer
3) Ladder logic programming software platform.
THEORY:
INTRODUCTION:
In industrial as well as the commercial application the Water level controller
plays a vital role. For ex. In industries related to boiler applications, it is necessary to
maintain a specific level on the tank. As well as in housing societies the upper tank
should be maintained with a constant level of water. Hence water level controlling is
necessary.
Pressure Transducer:

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The pressure sensor id designed to produce of an output of 4mA to 20mA for a pressure
range 0
to 1 bar. The pressure sensor is then used to convert the current signal into voltage signal
using
an op- amp with calibration control MIN & MAX. the output voltage
Is generated by passing this 4 mA to 20 mA current through a fix resistance of 360 ohms
(nominal value).
The instrument produces direct read out for level in cms. when the MIN & MAX pots are
adjust
properly. The current signal can be monitored when an ammeter (using DMM) is
connected
across the terminals marked as link or can be calculated from the voltage drop across a
fixed
resistance of 360 Ω, when switch Sw2 is in downward direction. In upward direction the
DPM
indicates the level in cms directly. The output of this unit can be interfaced with PC using
the
terminals on the rear panel of the set-up.
The two wire 4 – 20 mA current loop is one of the most widely utilized transmission
signals for use with transducers in industrial applications. A two wire transmitter allows
signal
and power to be supplied on a single wire-pair. Because the information is transmitted as
current,
the signal is relatively immune to voltage drops from long runs and noise from motors,
relays,
switches and industrial equipment. The use of additional power source is not desirable
because
the usefulness of this system is greatest when a signal has to be transmitted over a long
distance
with the sensor at a remote location. Therefore, the 4 mA minimum current in the loop is
the
maximum usable current to the power entire control circuitry.
Figure 1 is a block diagram of a typical 4 -20 mA current loop system which illustrates
a simple two chip solution to converting pressure to a 4 – 20 mA signal. This system is
designed
to be powered with a 12V to 24 Vdc supply. Pressure is converted to a differential
voltage by the
sensor. The voltage signal proportional to the monitored pressure is then converted to the
4 – 20
mA current signals with the precision two wire transmitter. The current signal can be
monitored
by a meter in series with the supply or by measuring the voltage drop across Rl. A key
advantage
to this system is that circuit performance is not affected by a long transmission line.

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PROCEDURE:
1) Keep the level tank on a suitable stool with bucket below the ½″ cock provided on the
tank.
2) Connect the 5 pin Amphenol cable to the socket on the instrument. With Sw2 in
upward
(level) position. Switch on the supply & give a warm up time above 10 minutes for the
system is to stabilize. Ensure that a link is in place across the terminals marked link on
the rear panel.
3) With valve close, pour water from the top into the tank so that datum level of 5cm is
reached.
4) Adjust MIN pot (P2) so that water level is indicated as 5.0 cm on DPM.
5) Now pour water into the tank carefully so that a level of 60 cm is reached. Adjust the
reading on DPM by max Pot P1, so that DPM reading is 60.0 cm.
6) You may have to repeat steps 3 & 4 alternately so that you get proper readings at 5 cm
and at 60.0 cm level.
7) Now you can check calibration at intermediate points. Start from 60 cm level & enter
the
results in tabular form.
While taking readings you may note that when switch sw2 is in downward position DPM
indicates the voltage in mV. Produce by sensor current which in range of 4 to 20 mA for
a pressure range of 0 to 1Kg/cm². (ie for 10 meters of water head.). thus current flows
through a resistance of 360 ohms which in turn produces a voltage drop of 360 * 4 mA
=1440 mV. Thus the current signal is change into voltage for further processing before
indication. You may also measure the current directly by inserting DMM in current range
of 0 to 20 mA for measurement purpose. In case ammeter is not used a shorting link is a
must.
8) you may plot the graph of i/p vs o/p for this instrument and check for linearity.
Precautions:
1) While pouring water into the tank ensure that water is not dropped on the
instrument or on the sensor itself.
Effect level changes carefully.

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2) Do not tamper with the sensor or the sensor cable.

CONCLUSION:Thus we have studied the Overhead Tank Water Level Controller and
observed the operation of the same.

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

TITLE: DATA ACQUISITION SYSTEM

EXPERIMENT NO: - 6

Date of Performance: Date of Submission: Remark:

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

Aim :To study the data Acquisition & data Logging.

Apparatus :
1) Data Logger Trainer.
2) Temp transmitters for RTD PT100, J & K Thermocouples
3) PC Pentium with RS 232 interface connection.
4) RS232c Computer communication Cable.
Theory:
Data acquisition (DAQ) is the process of measuring an electrical or
physicalphenomenon such as voltage, current, temperature, pressure, or sound with a
computer. A DAQ system consists of sensors, DAQ measurement hardware, and a
computer with programmablesoftware.
The block diagram of a general Data Acquisition System (DAS) is shown below
1) Transducer is require in it
2) Signal conditioner is require in it
3) Multiplexer (MUX) is require in it
4) A-D Converter is require in it
5) Recorders devices and Display devices are require in it
a) Transducer:-
A transducer is used to convert the physical parameters corning from the field
into electrical signals or it is used to measure directly the electrical quantities such as
resistance, voltage, frequency, etc.
b) Signal Conditioner:-

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Usually the output signals of the transducer will be of very low level (weak)
signals which cannot be used for further processing. In order to make the signals strong
enough to drive the other elements signal conditioners are used such as amplifiers,
modifiers, filters etc.
c) Multiplexer:-
The function of the multiplexer is to accept multiple analog inputs (after signal
conditioning) and provide a single output sequentially according to the requirements.

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. A/D Converter:-
The analog-to-digital (A/D) converter is generally used to convert the analog data
into digital form. The digital data is used for the purpose of easy processing,
transmission, digital display and storage.
Processing involves various operations on data such as comparison, mathematical
manipulations, data is collected, converted into useful form and utilized for various
purposes like for control operation and display etc.
The transmission of data in digital form is possible over short distances as well as
long distances of and has advantages over transmission in analog form. The data can be
stored permanently or temporarily and can be displayed on a CRT or digital panel.
1) Recorders and Display Devices:-
In display devices the data is displayed in a suitable form in order to monitor the
input signals. Examples of display devices are oscilloscopes, numerical displays, panel
meters,etc.In order to have either a temporary or permanent record of the useful data
recorders are used and analog data can be recorded either graphically or on a magnetic
tape. Optical recorders, ultraviolet recorders, styles-and-ink recorders are some of its
examples.
The digital data can be recorded through digital recorders. The digital data is first
converted into a suitable form for recording by means of a coupling unit and then
recorded on a magnetic tape, punched cards or a perforated paper tape.
DATA LOGGER:
A data logger (also data logger or data recorder) is an electronic device that
records data over time or in relation to location either with a built in instrument or sensor
or via external instruments and sensors. Increasingly, but not entirely, they are based on a
digital processor (or computer). They generally are small, battery powered, portable, and
equipped with a microprocessor, internal memory for data storage, and sensors. Some
data loggers interface with a personal computer, and use software to activate the data

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logger and view and analyze the collected data, while others have a local interface device
(keypad, LCD) and can be used as a stand-alone device.
Data loggers vary between general purpose types for a range of measurement
applications to very specific devices for measuring in one environment or application
type only. It is common for general purpose types to be programmable; however, many
remain as static machines with
only a limited number or no changeable parameters. Electronic data loggers have
replaced chartrecorders in many applications.
One of the primary benefits of using data loggers is the ability to automatically
collect data on a 24-hour basis. Upon activation, data loggers are typically deployed and
left unattended to measure and record information for the duration of the monitoring
period. This allows for a comprehensive, accurate picture of the environmental
conditions being monitored, such as air temperature and relative humidity.
The cost of data loggers has been declining over the years as technology improves and
costs are reduced. Simple single channel data loggers cost as little as $25. More
complicated loggers may costs hundreds or thousands of dollars.
SOFTWARE FOR DATA ACQUISITION SYSTEM :-

Powerful data acquisition software USB DAQ is provided which runs on windows XP or
WINDOWS 7 (32 bit operating system). This is powerful software with facility to
acquire data for analog input / digital input and also control digital outputs and PWM
control/DC output control.

1) User Need to first install Device Drivers for the data acquisition card (arduino) , Once
drivers for device are installed then only user should Connect USB INTERFACE
CABLE provided on the back side of the panel to the USB port of the PC and Power on
the unit.
2) This will start the Device recognisation and Virtual com port generation Process. Wait
until process is completed and then goto Device manager >> PORT and note down the
COM PORT FOR ARDUINO DEVICE .
3) If COM port for the Device is More than COM 5 , then select the device and Goto
advanced settings and CHANGE the COM port to any value
between COM -1 and COM-5
4) Then User is now ready to install Main PC based DAQ SOFTWARE
(DAQ_MECHATRONICS_8.0)
5) Once it is installed goto the menu and start the software .
6) Goto the Menu where you can select the COM port .

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7) Select the appropriate COM port as observed in the Device manager .

8) Now Connect the Model Process Unit to the Main unit.
9) Now user can Press START communication button so that communication is started
and MENU button for DAQ is enabled .
10) In The main DAQ menu you can use and test the system as general purpose DAQ
system and you can use it for STUDY of interfacing of 2 sensors to DAQ and ON/OFF
temperature
controller application .
ON/

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ON/OFF TEMPERATURE CONTROLLER APPLICATION :-

1) Simply select the SET TEMP with + / - . Buttons.
2) Also user needs to select the Dead band with the help of dead
band selector switch .
3) Then Press the start button.
4) User can observe characteristics of ON/OFF temperature
controller.
5) Also GRAPH of controlled actual temperature also can be observed
by selecting graph.

SPECIFICATIONS OF THE GIVEN SYSTEM:-

1) ANALOG INPUT 6 NO (0- 1.1 V)

a) CHANNEL 1:- TEMEERATURE SENSOR (RTD) (A0)
b) CHANNEL 2:- LOAD CELL SENSOR (A1)
c) Channel 3 to 6 ( A2 to A4) are general purpose input
channels .
System is based on 10bit ADC with overall accuracy of
+/ - 2 % with 1.1 V as ref voltage.

2) DIGITAL INPUT 6 NO.

a) INPUT 1 to INPUT 5 ( I1 TO I 5 ,toggle switches)
b) INPUT 6 :- EXTERNAL DIGITAL PULSE CAN BE

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CONNECTED. (0 -5 V RANGE) ,ALSO OPTIONALLY

STUDENTS CAN CONNECT INDUCTIVE PROXIMITY
SWITCH TO I 6 by putting link across I 6 AND Inductive
proximity Switch output.

3) DIGITAL OUTPUT 4 NO
a) OUTPUT 1 to OUTPUT 3 are general purpose OUTPUTS.
b) OUTPUT 4 (O4) is connected permanently to buzzer.
c) OUTPUT NO 5 is also provided and it is dedicatedly
connected to SOLID STATE RELAY connected inside which
is to be used for MODEL PROCESS HEATER , REQUIRED
FOR ON/OFF TEMPERATURE CONTROLLER .

4) DC OR OUTPUT
a) This channel generates PWM signal w.r.t count provided.
(RANGE 0- 255)
b) If user selects DC output through switch , then internally RC
circuit is connected across the output and pure DC is
observed at terminal marked as DC output.
c) If user selects PWM output through switch , then DC
MOTOR is connected in the circuit , to form the PWM
3 HEM \DATA ACQUISITION SYSTEM
CHOPER mode and DC motor’s SPEED is controlled
through that.

5) USB COMMUNICATION :-
For communication with PC, USB port is provided on the backside
of the panel . Connect the USB cable correctly with PC and system
port and then switch on the system.
6) INBUILT SIGNAL CONDITIONING :-
RTD SECTION :- ( CHANNEL A0)

The system has inbuilt measurement section for RTD-PT-100

temperature sensor and industrial load cell section.
RTD (TEMEPRATURE MEASUREMENT SECTION) has inbuilt min and max
gain adjustment . User need not adjust any values and it directly gives output of
2000 mv at 200 DEG C.
Floating DPM (digital panel meter , 0-2 V) range is provided which can be used
to measure the temperature indicated by RTD section. You can connect RTD
section’s output to DPM by using patch across RTD and DPM input .
If you want to connect RTD section to Data acquisition part then connect RTD
section output to channel ‘A0’ of the analog input section.
For connecting RTD PT-100 sensor to signal conditioning , dedicated 3 pin
socket is provided on board.

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The Sensor is required to inserted inside the M ODEL PROCESS PROVIDED

with Aluminum rod and Heater bulb .
With This Sensor and Model Process connected to Digital output , ON/OFF
temperature controller application can be studied with the help of DAQ software
1. .
Conclusion:

Self-Assessment Questions:
1) What is the difference between Data Acquisition & Data Logger?
2) How will you differentiate the scan time & log time?
3) What happens when the position of decimal point is changed from one digit to
other digit
?
4) What is 2 Wire transmitter & 3 Wire transmitter?
5) Why 4 – 20 mA is the 2 Wire transmitter current ranges?

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

TITLE:ELECTRO-HYDRAULIC TRAINER
EXPERIMENT NO : -8

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

Aim : To study the Electro hydraulic trainer.

Apparatus : a) Hydraulic trainer.

Theory:
Hydraulic components provided:
1) Power pack (hydraulic):oil filter, gear pump,3phase induction motor, pressure relief valve.
Starter for 3phase induction motor with control panel and connection. Power pack with oil level
indicator, drain ,,6 no. of holes for drains from the valves.
Hydraulic :cut oil is also provided.
2) Pressure relief valve:¼ ” connection with port P,A,T
3) Manifold/distributor :4 way oil distributor is provided with ball valve(1/4” connection)
4)4/3 manual Lever valve: This is with P,A,B,T ports.(1/4” connection )in this setup is
dedicatedly connected to hydraulic motor for forward and reverse control.
5)flow control valve:this will be used control flow of the air METERIN and METEROUT circuit
for double or single acting cylinder and hydraulic motor.this is without any non-return action.so
if this valve is installed in series of any of the port of the cylinder\motor ,it will control speed of
the both METERIN & METEROUT flow.
6) Single acting cylinder: forward movement of the piston will be controlled by hydraulic
pressure in incoming METERIN circuit.so control is only for forward movement(single
acting).This is having inbuilt spring fitted inside for return action.( Maximum pressure is 50bar
,stroke:50mm)
7)Double acting cylinder: Forward and reverse movement of piston will be controlled by
hydraulic pressure in incoming METERIN & METEROUT circuit. (Maximum
pressue50bar,stroke: 125mm)

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8)Hydraulic motor: This motor generates rotating torque when applied max pressure of 50bar.At
30psi it will run at 300rpm at no load.(1/4’’ connection)
9)Pressure Gauge :It is given to measure pressure in any given circuit (max at 100bar psi)

Electro-pneumatic components provided:-

1)4/3 double solenoid valve(coil 230V AC) :- This is provided for double acting cylinder.
solenoid valve is controlled from PLC(by switching coil on and off according to program).ports
available are P,T,A,B.
Coil A is controlled for forward movement
Coil B is controlled for reverse movement
If both coil are OFF then valve will completely close.
2)4/2 single solenoid valve(coil 230V ac):- This is provided for single acting cylinder. Solenoid
valve is controlled from PLC(by switching coil on and off according to program),it is having
ports P,A,T,B.
PORT A:- is controlled for forward movement
Reverse movement is by using SPRING.
PORT B & PORT T are 2 drain ports.
PORT P :- is INLET port.
3)Inductive proximity switch:- For detecting positions (start or end) of single acting and double
acting cylinder. Total 4 no. of sensors are provided.
4) Programmable logic controller (PLC):- This is the main controller for Electro-pneumatic
circuit or control.
ALLEN-BRADELY MICRO820 PLC with 11 digital inputs,7 digital output ,1 analog input
and 1 analog output. 24 volt SMPS based power supply is also provided. Also input, start
switches. Proximity switches on the panel are connected to PLC for various control actions.
Always keep switch on INTERNAL PULSE SIDE for using with the given setup. There is
provision made for using the PLC for any other external system .For using it externally you have
to keep switch on EXTERNAL PULSE SIDE and then you can connect wires for the respective
input very carefully.

PLC INPUT/OUTPUT CONNECTIONS

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I1-start
I2-stop
I4,I5,I6 –application selection switches
I8-Proxy 1
I9-Proxy 2
I10-Proxy 3
I11-Proxy 4
00=4/2 single solenoid single acting cylinder
02=4/3 double solenoid double acting cylinder (PORT B)
03=4/3 double solenoid double acting cylinder (PORT A)
For conducting electro-pneumatic experiment you need to do the application selection switches
I4,I5,I6 as per the table below.

Sr no. Application selection I4 I5 I6

1 Sequence(both cylinder) 0 0 0

2 AND gate 0 0 1

3 Single acting cylinder 0 1 0

with flow
control(continuous)
4 Double acting cylinder 0 1 1
control(continuous)
5 Single acting cylinder 1 0 0
with counter

DESCRIPTION OF THE MODES

Always press stop before you change mode.
1)Sequence:-(Application selection as per table above)
Proxy1 ON, Proxy3 ON ,both the cylinder at start position, press start=single acting forward :-
Proxy2 ON then reverse cycle complete ,then double acting cycle will start:- Double acting
forward ON :-Proxy ON, then reverse cycle complete, Proxy3 ON, end of cycle.
2) AND gate :- (Application selection as per table above)

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Proxy1 & Proxy2 ON, both must be at start position , Press start:-both cylinder should start
forward ,both should complete forward cycle & then only both will start reverse cycle, once then
reach start position ,this is the end of cycle.
3) Single acting cylinder continuous mode :- (Application selection as per table above)
Proxy1 ON, then press start ,Single acting will start continuous mode ,it will continue till you
press stop.
4)Double acting cylinder continuous mode :- (Application selection as per table above)
Proxy1 ON ,then press Start, double acting will start continuous mode,it will continue till you
press stop.
5) Single acting cylinder with counter:- (Application selection as per table above)
Proxy1 ON ,then press Start, single acting will start continuous mode,it will continue till 5 cycle
completed.
Precautions
1)Adjust max pressure at 30 bar with the help of pressure relief valve.
2) All hydraulic connections are fixed with hose pipes. Make sure that are properly tightened.
3) Always make sure that (6 no)from valve /motor are inserted properly in power pack to avoid
oil spill.
4)Single and double acting cylinder can be controlled manually as well as from PLC. Please
make sure that proper switch selection is done.
5)Always connect and handle 3phase connections very carefully
(System require 3phase,440volt,50hz supply for 3phase induction motor.)

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Conclusion:

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

TITLE:ELECTRO-PNEUMATIC TRAINER

EXPERIMENT NO : - 7

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

Aim : To study the electro-pneumatic trainer.

Apparatus: a) Electro-pneumatic trainer.
d) Air compressor
e) PLC Trainer
Theory:Introduction to Electro-pneumatics
Pneumatic circuits can be controlled by electric circuits. The interface between
these two circuits is a solenoid valve. Solenoid valves perform the same function as
normal pneumatic valves but there are operated electrically.
Inside the solenoid valve, there is a coil of wire through which an electric current
is passed. It produces a magnetic field which attracts an iron armature. The movement of
the armature operates the valve.
Solenoid Operation Off: When the electric current is not flowing, a spring
pushes theiron armature out of the coil. A seal connected to the armature blocks port 1.
Air can flow between ports 2 and 3.

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Solenoid Operation On: When current flows, the iron armature is attracted into the
coilby a magnetic field. The spring pressure is overcome and the seal moves to block port
3. Air can flow between port 1 and 2.

When the solenoid valve is on, an electric current will flow through the coil.
When current flows through the coil, the iron armature is attracted by magnetism. The
solenoid has control of the valve. Port 1 is connected to port 2 and air flows to inflate the
soft robot.When the solenoid valve is off, the coil is de-energized and the spring has
control of the valve. Port 2 is connected to port 3 and air flows out of the soft robot.

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Manual expriment1:
Single acting meter in and meter out

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

Manual experiment 2:
Double acting meteter out

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

Manual experiment 3: And gate using 3/2 and 5/2

for double acting meter in and meter out

Manual expriment4:
Study of pheumatic motor

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Precautions: Ensure following point for proper functioning of the trainer.

1) Ensure the compressor is of proper rating
2) Ensure the compressor is with safety devices like pressure relief valve,
spring-loaded safety valve, isolation valve etc.
3) Ensure the proper connection of air inlet using proper size.

Conclusion:

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 MECHATRONICS ,DEPARTMENT OF ELECTRONIC AND TELECOMMUNICATION

TITLE:CASE STUDY COIN COUNTER AND SEPARATER

EXPERIMENT NO : - 9

Roll. No. Practical (5) Oral (5) Total (10) Remark Sign. with date

AIM: Study of Mechatronics System: Coin counter.

OBJECTIVES:
1. To study the various steps involved in design of coin counter.
2. Prepare flow chart and then ladder diagram to run coin counter
3. To verify the operation of the coin counter.
APPARATUS:
Coin counter trainer model, Allen Bradley makes PLC loaded with program.
THEORY:
INTRODUCTION:
In the coin counter trainer there are two optical sensors for the sensing of coins.
The sensors sense the 1 Rs coin as well as 50 Paise coin separately. we are found the
counted coin of 1 Rs& 50 Paise in the ladder programming software of PLC. Also in the
ladder we are found the total number of coins.
1. Size
Most counting machines use the size of the coins to determine which coins go
where.
Usually, there is an opening at the top where you put bunches of mixed-up coins
through, and there is a slant on which the coins slide down. The first hole built into the
slant is the dime hole. Because the dimes are the smallest, only they will fall into the
hole, while all the rest skip by. The penny hole is next, followed by the nickel hole, the
quarter hole and finally the half dollar hole. So if you put in a quarter, it will not fit into
the dime, penny or nickel hole; it will slide over them and fall into the first hole that it
fits into, which is the quarter hole.

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2. Weight
Many machines today can measure how many coins are in each slot by their
weight.
After the scale calculates the weight and determines the value, it sends the
information to a processing unit, which displays the total value.
3. Sight
Today, many machines are using newer technology that can determine which coin
is
which faster and more accurately. Modern machines use beams of light and light receptors
that are adjacent each other. When a coin passes by, the light is obstructed, thus verifying
that a coin
has been dropped. The machines then use weight and size to confirm their calculations,
and the totals are sent to a processing unit, where they displayed for the person using
the machine.
In the coin counter trainer there are two optical sensors for the sensing of coins.
The sensors sense the 1 Rs coin as well as 50 Paise coin separately. we are found the
counted coin of 1 Rs& 50 Paise in the ladder programming software of PLC. Also in the
ladder we are found the total number of coins.
Basic components involved in coin counter are as follows:
First optical sensor (S0). – Input number 0 of the
PLC Second optical sensor (S1). - Input number 1
of the PLC
Optical Sensors:
For sensing the coins optical type switches are used. If the coin cuts the optical
rays of the sensors it gives the output signal to the PLC as a input in the form of input 0
or input 1 i.e. which coin we are inserted in the coil slot.
Inductive proximity sensors are used for non-contactdetection of metallic objects. Their
operating principle is based on a coil and oscillator that creates an electromagnetic field
in the close surroundings of the sensing surface. The presence of a metallic object
(actuator) in the operating area causes a dampening of the oscillation amplitude. The rise

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or fall of such oscillation is identified by a threshold circuit that changes the output of the
sensor. The operating distance of the sensor depends on the actuator's shape and size and
isstrictly linked to the nature of the material

SPECIFICATION OF THE SYSTEM :-

1) MECHANICAL SEPERATOR OF TWO COIN USING SIMPLE

DIAMETER BASED SLOTS.
2) 2 NO OF INDUCTIVE PROXIMITY SENSORS TO DETECT THE
SEPERATED COINS.
3) PIC16F870 MICROCONTROLLER BASED COIN COUNTER.
4) COUNT RESET BUTTON.
5) BUZZER FOR COUNT RESET ALARM.
6) +12V,2A SMPS BASED SUPPLY
7) SYSTEM IS DESIGNED TO COUNT AND SEPARATE 1 RS AND 2
RS COINS.
8) LCD DISPLAY 16*2 CHARACTER FOR DISPLAY OF COUNT .
9) STURDY MS POWDER COATED BOX AS ENCLOSURE.
10)COIN INSERT SLOT TO INSERT COIN IN SPECIALLY ARRANGED
CHANEL FOR THE SPERATOR AND INDUCTIVE PROXIMITY BASED
SENSING.
11) ZENER DIODE BASED VOLTAGE REGULATION IS DONE TO
GIVE SENSING PULSE TO PIC 16 F870
12) SENSOR-1 AND SENSOR-2 OUTPUT (+12V) IS DIRECTLY
PROVIDED FOR CONNECTION OF ANY CONTROLLER FOR
COUNTER APPLICATION (COMPATIBLITY WITH PLC)
13) LED LIGHT IS PROVIDED INSIDE FOR THE VISIBLITY OF THE
TOTAL PROCEDURE INSIDE.

PROCEDURE:
1) Power on the unit. See that Power on switch is on and LCD is
glowing.
2) It will be showing COIN1 and COIN 2 count as zero on every
power on.
3) Now locate the Coin insert slot.
4) Make sure that sensors are in place and Coin collector tray is
correctly placed below.
5) Then any one coin from the given set of coins can be inserted
one by one in the slot.
6) As soon as coin is inserted , it should travel down the rail
provided for the separator .
7) It should fall down in correct slot and while following down it will
come in the proximity of the sensor,which will send sensing
pulse to the Microcontroller.

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8) Coin should be inserted inside slot with proper method.

9) Now observe the respective count is increasing on the LCD (coin
– 1 and coin-2).
10)Also check that how accurately Coin is separated and counted.
11) if user wants to reset the count , he can simply press RESET
button provided .
12) COIN-1 AND COIN-2 SENSOR OUTPUTs are provided on the
side of the panel where students can see the waveform of
sensor
to anyonexternal
CRO or else
PLCcanwith
carefully connect
voltage the sensor
levels withinoutput
the range.

CONCLUSION:
Thus we have studied the coin counter and observed the operation of the same.

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