Mechatronics & Control Engineering Dept.
, UET, Lahore Fall 2024
MCT-334L: Industrial Automation
Instructor: Muhammad Rzi Abbas
muhammadrziabbas@uet.edu.pk
Assignment: Semester Project
Assigned On: Tuesday, Nov. 12, 2024
Due Date: Tuesday, Dec. 17, 2024
INTRODUCTION
Students have learned about programming a PLC in multiple lectures through PLC simulators as well as on
hardware. Furthermore, complete instruction set of the SLC series has been provided so that students may
learn instructions on their own. Using the gained knowledge and learning a few things on their own,
students are being assigned a semester project to gauge their level of understanding and readiness for
clearing the practical portion of Industrial Automation.
COURSE LEARNING OUTCOME ADDRESSED
CLO2: Build PLC interfaces of different I/O devices for implementing and testing sustainable automation
solutions.
CLO3: Present their findings and data in the form of a viva/presentation.
CLO4: Conform to ethical values related to presentation of experimental data.
SEMESTER PROJECTS
There are five different projects designed as Semester Projects. The details of each project are explained
below. All projects containing hardware shall be assigned to a two-student group, whereas other projects
will be assigned to individual students.
PROJECT # 1:
The stamping machine stamps 10
parts in one cycle. The program
cycle starts by a push button S1.
The proximity switch B7 signals
“Part in magazine”. A part is fed
towards the machine by means of
Cylinder 1.0, a double solenoid-
actuated cylinder, and is clamped.
Proximity switches B1 and B2
gives the retracted and extended
position of the Cylinder 1.0,
respectively. After the part has
been clamped, Cylinder 2.0, a
spring return solenoid actuated
cylinder, stamps the part. The
retracted position of the cylinder 2.0 is signaled by a proximity switch B3 and extension by a proximity
switch B4. The Cylinder 2.0 is pressed against the part for 4 seconds so that stamp leaves a good impression
on the part. After this the Cylinder 2.0 is retracted and once it has retracted fully, Cylinder 3.0, a spring
return solenoid actuated cylinder, is actuated to push the part towards the outlet container. The retracted
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
Mechatronics & Control Engineering Dept., UET, Lahore Fall 2024
and extended position of the Cylinder 3.0 is signaled by proximity switches B5 and B6. Once the Cylinder
3.0 has pushed the part and has retracted fully, the Cylinder 1.0 retracts and wait for 2 seconds before
pushing the next part in the clamping position and the process repeats. After 10 parts have been stamped,
the whole machine should rest for 30 seconds before starting the next cycle via push button S1.
Cylinder 1.0 use coil Y1 for clamping or extension and Y2 for unclamping or retracting.
Cylinder 2.0 use coil Y3 for extension.
Cylinder 3.0 use coil Y4 for extension.
Students should develop a Ladder Diagram and an FBD for this stamping machine. Students may use
OpenPLC or RSLogix for Ladder Diagram, whereas FBD must be created on OpenPLC as there is no option of
FBD in RSLogix.
Deliverables
This project has three deliverables listed below.
1. Ladder Diagram file implemented on either RSLogix or OpenPLC.
2. Function block implementation of the solution, made on OpenPLC.
3. Report on Semester Project. The details of how to write the report are given in a later section.
PROJECT # 2:
Design a PLC program for a traffic signal installed at an intersection of two roads. The four sides of the
intersection should have traffic lights that allows traffic to move from one of the four sides at a time only.
Sequence of lights to be followed is given below.
A latching start button S1 should start the traffic signal light and the sequence should continue for as long
as the start button is latched. Moreover, if another latching button S2 is pressed, the traffic light cycle stops
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
Mechatronics & Control Engineering Dept., UET, Lahore Fall 2024
and emergency YELLOW light sequence should start. In this sequence, all the YELLOW lights should turn
ON for 1.5 seconds and remain OFF for 1.5 seconds. This sequence should continue for as long as button
S2 is latched.
Students should develop a Ladder Diagram of RsMicroLogix software and implement this on 34-500 PLC
Trainer Board. The traffic lights present on the trainer board should follow the defined sequence. Whereas
any suitable buttons available on the trainer board may be used as S1 and S2.
Deliverables
This project has three deliverables listed below.
1. Ladder Diagram file implemented on RSMicroLogix readily useable with 34-500 Trainer Board.
2. Completely wired traffic signal demonstration on 34-500 Trainer Board.
3. Report on Semester Project. The details of how to write the report are given in a later section.
PROJECT # 3:
Design a PLC program for a traffic signal installed at an intersection of two roads. The four sides of the
intersection should have traffic lights that allows traffic to move from one of the four sides at a time only.
Sequence of lights to be followed is given below.
A latching start button S1 should start the traffic signal light and the sequence should continue for as long
as the start button is latched. Moreover, if another latching button S2 is pressed, the traffic light cycle stops
and emergency YELLOW light sequence should start. In this sequence, all the YELLOW lights should turn
ON for 1.5 seconds and remain OFF for 1.5 seconds. This sequence should continue for as long as button
S2 is latched.
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
Mechatronics & Control Engineering Dept., UET, Lahore Fall 2024
Students should develop an FBD program on OpenPLC and implement it on Arduino microcontroller.
Furthermore, a low-cost demonstration of traffic lights must be developed using LEDs, switches, etc.
attached to a platform showing road intersection.
Deliverables
This project has three deliverables listed below.
1. An FBD file, implemented on OpenPLC.
2. Completely wired traffic signal demonstration on a platform.
3. Report on Semester Project. The details of how to write the report are given in a later section.
PROJECT # 4:
Consider the use of electric servo motors to operate car park barriers. The in-barrier is to be opened when
the car is present at the entrance (signaled by a proximity IR sensor, B1) and the correct money is inserted
in the collection box signaled by a momentarily pressed, non-latching, push button. Whereas the out-
barrier is to open when a car is detected at the exit side (signaled by a proximity IR sensor B2). The servo
motors operate when a high signal is given to them and return to home position when a low signal is
provided. The open and closed position of the barriers is signaled by micro-switches that are pressed by
the barriers when they are fully opened or closed. Additionally, green and red LEDs should show the open
or close status of the barriers respectively. Furthermore, a counter keeps track of the number of cars
present in the parking lot and displays the occupancy through a 5-LED bar graph. Each LED of the bar graph
will display the presence of 5 cars, hence if 15 cars are present then 3 LEDs will be ON, whereas if 22 cars
are parked, 4 LEDs will glow, and 25 cars will make all LEDs glow.
Students should develop a Ladder Diagram or an FBD for this parking lot and implement it on Arduino
microcontroller. Furthermore, a low-cost demonstration must also be built using IR proximity sensors,
micro-switches, servo motors, and LEDs.
Deliverables
This project has three deliverables listed below.
1. Ladder Diagram/FBD file, implemented on OpenPLC.
2. A working demonstration made using required electronic components.
3. Report on Semester Project. The details of how to write the report are given in a later section.
PROJECT # 5:
In a certain packing industry packages are conveyed past a linear measuring device on a roller conveyor to
establish their size. There are two different package sizes: short and long packages. The linear measuring
device (LM1) supplies a 0-signal for a short package and a 1-signal for a long package.
The sequence starts by means of a START button S1. After going past the linear measuring device, the
packages reach a lifting platform. The packages are lifted by a lifting cylinder 1.0. The packages are then
sorted: Short packages are transferred to a second conveyor via transfer cylinder 2.0, and long
packages onto a third conveyor via cylinder 3.0. Lifting cylinder 1.0 is to retract only after cylinders 2.0 or
3.0 have reached their end position.
The cylinder positions are monitored by means of proximity switches from B1 to B6. Cylinder 1.0 is
advanced and retracted by means of a double solenoid valve via coils Y1 and Y2. Cylinders 2.0 and 3.0 are
spring return cylinders and are advanced and retracted by means of solenoid valves (coils Y3 and Y4).
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
Mechatronics & Control Engineering Dept., UET, Lahore Fall 2024
Students should develop a Ladder
Diagram and an FBD for this
stamping machine. Students may use
OpenPLC or RSLogix for Ladder
Diagram, whereas FBD must be
created on OpenPLC as there is no
option of FBD in RSLogix.
Deliverables
This project has three deliverables
listed below.
1. Ladder Diagram file
implemented on either
RSLogix or OpenPLC.
2. Function block
implementation of the
solution, made on OpenPLC.
3. Report on Semester Project. The details of how to write the report are given in a later section.
REPORT
A report shall describe the project, its working and the results. The report must include at least the
following things.
• Well-structured format like IEEE Conference Paper format. Template file may be downloaded from
IEEE website.
• Abstract: An executive summary of the project, highlighting the problem, method, and end result
in around 200 words.
• Introduction: This section must introduce the project along with what was required. Don’t just
copy-paste the paragraphs that are already given to you through this document as introduction to
the project. Students should write in their own words what the project is and its practical
importance, both with respect to the industry/practical life and learning.
• Methods: This section must explain how you implemented the solution. A flow diagram of your
solution would be most desirable. You should provide details of the simulation development
and/or hardware development.
• Results: This section must present results in a suitable format. For example, a timing diagram can
represent which output would be ON or OFF when certain input devices are giving high or low
signal. Students may use images, graphs, timing diagrams etc. to clearly present the results. The
instructor is going to use this section during evaluation to judge how the implemented solution is
working.
• Suggestions: This section should provide suggestions for improving any aspect of the Industrial
Automation Lab that you think needs improvement. Also present how that aspect can be improved
practically.
• References: References must be provided in IEEE format. Use of ChatGPT or any other AI Language
Model is allowed, but you should cite ChatGPT wherever text has been generated by it. Anything
not properly referenced will be considered plagiarized. Keep in mind that copy-pasting is the
worst form of plagiarism, whether it is from a friend or an AI Language Model.
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
Mechatronics & Control Engineering Dept., UET, Lahore Fall 2024
SUBMISSION
RSMicroLogix, RSLogix, and/or OpenPLC along with the report in MS Word or PDF format must be zipped
into a single folder named SemesterProject_2021MCXX or SemesterProject_2021IMXX and submitted
through Google Classroom. A viva voce examination shall be conducted along with the submission.
Hardware components should be presented during the viva.
GRADING RUBRICS
The following rubrics shall be used for marking the semester project. Please note that Projects # 1 and 5 do
not contain any hardware demonstration, however, two different PLC programming software will be used
in these projects. On the contrary, Project # 2 to 4 contains one PLC programming software and a hardware
demonstration. Therefore, appropriate rows from the following rubrics table shall be used.
Most importantly, a viva voce examination shall be conducted when the semester project is submitted. The
performance in this examination will greatly influence the marking of the semester project. A student
exhibiting a high level of understanding of a partially working project will get higher marks than a student
failing to exhibit any understanding of a fully functional project.
Deliverable Component Level of Achievement Marks
Completeness of No implementation objective was achieved. 0
the implemented 50% objectives were achieved. 4
solution. 75% objectives were achieved. 8
[CLO2, PLO3 – C6] More than 90% of objectives were achieved. 12
The student was not able to demonstrate an acceptable
Deliverable 1 and 2 [CLO2 and CLO4]
PLC programming 0
level of software usage.
proficiency
The student knows the basics of PLC programming. 4
(RSLogix) [CLO2,
PLO3 – C6] The student has proficiently used the programming
8
software.
The student was not able to demonstrate an acceptable
PLC programming 0
level of software usage.
proficiency
The student knows the basics of PLC programming. 4
(OpenPLC) [CLO2,
PLO3 – C6] The student has proficiently used the programming
8
software.
The student has not prepared any hardware demonstration. 0
Hardware The hardware demonstration has errors and needs
4
demonstration improvement.
[CLO2, PLO3 – C6] The hardware demonstration presents all aspects of the
8
project successfully.
Ethical Values Pass/F
Students presented their original work.
[CLO4, PLO8 – A2] ail
Deliverable 3 [CLO3 and
Ethical Values Pass/F
Plagiarism was less than 19%.
[CLO4, PLO8 – A2] ail
Did the student compiled the report as per the format? 4
Were all required components presented in the report? 2
Report [CLO3,
Quality of abstract. 4
PLO10 – A2]
Quality and completeness of methods. 6
CLO4]
Quality of discussion and presentation of results. 6
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
Mechatronics & Control Engineering Dept., UET, Lahore Fall 2024
Document drafted by Muhammad Rzi Abbas, Dated: 6 November 2024
