DEPARTMENT OF MECHANICAL ENGINEERING

m.e/m.tech - Automation LABORATORY

MANUAL (Regulation 2017)
Prepared by

M.SARAVANAN
FACULTY OF MECHANICAL ENGINEERING,AVIT
 DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
NAME OF THE LAB : AUTOMATION LAB

MANUAL REFERENCE NO W.I.

:

PREPARED BY :

M.SARAVANAN
AUTOMATION LAB INCHARGE

APPROVED BY :

PROF.L.PRABHU,
HEAD OF THE DEPARTMENT
 SYLLABUS
AUTOMATION LAB LTPC0042

AIM: To impart knowledge in the area of hydraulics and pneumatic components and its functions.

OBJECTIVE:

 To make the students to learn the basic concepts of hydraulics and pneumatics and its applications
in the area of manufacturing process.

 To simulate the various hydraulics and pneumatics circuits.

1 Simulation of single and double acting cylinder circuits

2 Simulation of Hydraulic circuits

3 Simulation of electro pneumatic circuits

4 Simulation of electro hydraulic circuits
5 Simulation of PLC circuits
6 Exercises on linear and angular measurements
7 Exercises on speed measurements
8 Exercises on Vibration measurements
9 Exercises on Motion controller using servo motors, encoders, etc.
10 Exercises on fiber optics transducers.
11 Exercises on stepper motor
12 Exercises on microprocessor based data acquisition system.
13 Software simulation of fluid power circuits using Automation studio.
 INDEX

EXPT.NO DATE NAME OF THE EXPERIMENT PAGE.NO SIGN

1 INTRODUCTION OF AUTOMATION SYSTEM
AND SYMBOLS

2 INTRODUCTION OF PROGRAMMABLE
LOGIC CONTROLLER (PLC)

3 SIMULATION OF SINGLE ACTING

CYLINDER BY USING
AUTOMATION SOFTWARE

4 SIMULATION OF DOUBLE ACTING

CYLINDER BY USING
AUTOMATION SOFTWARE

5 DESIGN OF CIRCUITS WITH LOGICAL

SEQUENCE (AND GATE ) USING ELECTRO
PNEUMATIC TRAINER KITS

6 DESIGN OF CIRCUITS WITH LOGICAL

SEQUENCE (OR GATE ) USING ELECTRO
PNEUMATIC TRAINER KITS

7 AUTOMATION OF MULTIPLE CYLINDERS

IN SEQUENCE (A+B+B-A-) USING PLC

8 ACTUATION OF HYDRAULIC CYLINDER

TO FIND OUT SPEED VS. DISCHARGE

9 WATER LEVEL CONTROLLER USING Date:

PROGRAMMABLE LOGIC CONTROLLER
10
LIFT CONTROL SYSTEM USING PLC
EX.NO:1 DATE:

INTRODUCTION OF AUTOMATION SYSTEM AND SYMBOLS

AIM:

To study about the important features ,about Automation system and symbols

Introduction to Automation system:

Introduction ELECTRICAL power is one of the most important infrastructure inputs necessary for the
rapid economic development of a country. The ever-rising demand of electrical energy has led to the
installation and incorporation of a large number of electrical power generation units, with increased
capacities in a common power grid, making the operation of the entire system sensitive to the
prevailing conditions. Therefore, the extensive and complex power systems have become
unmanageable using the conventional instrumentation and control schemes. Intelligent systems based
on microprocessors and computers have been employed for online monitoring and control of modern
large-scale power systems, in generation, transmission and distribution, thereby overcoming the
complexities and drawbacks of the conventional instrumentation schemes.

The term “Automation”

Automation is the use of scientific and technological principles in the manufacture of machines that
take over work normally done by humans. This definition has been disputed by professional scientists
and engineers, but in any case, the term is derived from the longer term “automatization” or from the
phrase “automatic operation”. Delmar S. Harder, a plant manager for General Motors, is credited with
first having used the term in 1935.

History of Automation Ideas for ways of automating tasks have been in existence since the time of the
ancient Greeks. The Greek inventor Hero (fl. about A.D. 50), for example, is credited with having
developed an automated system that would open a temple door when a priest lit a fire on the temple
altar. The real impetus for the development of automation came, however, during the Industrial
Revolution of the early eighteenth century. Many of the steam-powered devices built by James Watt,
Richard Trevithick, Richard Arkwright, Thomas Savery, Thomas Newcomen, and their
contemporaries were simple examples of machines capable of taking over the work of humans.

One of the most elaborate examples of automated machinery developed during this period was the
draw loom designed by the French inventor Basile Bouchon in 1725. The instructions for the operation
of the Bouchon loom were recorded on sheets of paper in the form of holes. The needles that carried
thread through the loom to make cloth were guided by the presence or absence of those holes. The
manual process of weaving a pattern into a piece of cloth through the work of an individual was
transformed by the Bouchon process into an operation that could be performed mindlessly by merely
stepping on a pedal. Automation Applications Manufacturing companies in virtually every industry are
achieving rapid increases in productivity by taking advantage of automation technologies. When one
thinks of automation in manufacturing, robots usually come to mind.

The automotive industry was the early adopter of robotics, using these automated machines for
material handling, processing operations, and assembly and inspection. Donald A. Vincent, executive
vice president, Robotic Industries Association, predicts a greater use of robots for assembly, paint
systems, final trim, and parts transfer will be seen in the near future. One can break down automation
in production into basically three categories: fixed automation, programmable automation, and flexible
automation. The automotive industry primarily uses fixed automation. Also known as "hard
automation," this refers to an automated production facility in which the sequence of processing
operations is fixed by the equipment layout. A good example of this would be an automated
production line where a series of workstations are connected by a transfer system to move parts
between the stations. What starts as a piece of sheet metal in the beginning of the process, becomes a
car at the end.

Programmable automation is a form of automation for producing products in batches. The products
are made in batch quantities ranging from several dozen to several thousand units at a time. For each
new batch, the production equipment must be reprogrammed and changed over to accommodate the
new product style. Flexible automation is an extension of programmable automation. Here, the variety
of products is sufficiently limited so that the changeover of the equipment can be done very quickly
and automatically.

The reprogramming of the equipment in flexible automation is done off-line; that is, the programming
is accomplished at a computer terminal without using the production equipment itself. Computer
numerical control (CNC) is a form of programmable automation in which a machine is controlled by
numbers (and other symbols) that have been coded into a computer. The program is actuated from the
computer's memory.

The machine tool industry was the first to use numerical control to control the position of a cutting
tool relative to the work part being machined. The CNC part program represents the set of machining
instructions for the particular part, while the coded numbers in the sequenced program specifies x-y-z
coordinates in a Cartesian axis system, defining the various positions of the cutting tool in relation to
the work part.
Automation tools:

 ANN – Artificial neural network

 DCS – Distributed Control System
 HMI – Human Machine Interface
 SCADA – Supervisory Control and Data Acquisition
 PLC – Programmable Logic Controller
 Instrumentation
 Motion control
 Robotics

Advantages and Disadvantages:

 Increased throughput or productivity.

 Improved quality or increased predictability of quality.
 Improved robustness (consistency), of processes or product.
 Increased consistency of output.
 Reduced direct human labor costs and expenses.
 Installation in operations reduces cycle time.
 Can complete tasks where a high degree of accuracy is required.
 Replaces human operators in tasks that involve hard physical or monotonous work (e.g., using one
forklift with a single driver instead of a team of multiple workers to lift a heavy object)[43]
 Reduces some occupational injuries (e.g., fewer strained backs from lifting heavy objects)
 Replaces humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear
facilities, underwater, etc.)
 Performs tasks that are beyond human capabilities of size, weight, speed, endurance, etc.
 Reduces operation time and work handling time significantly.
 Frees up workers to take on other roles.
 Provides higher level jobs in the development, deployment, maintenance and running of the
automated processes.
The main disadvantages of automation are:

 Possible security threats/vulnerability due to increased relative susceptibility for committing

errors.
 Unpredictable or excessive development costs.
 High initial cost.
 Displaces workers due to job replacement.
 Leads to further environmental damage and could compound climate change.

Hydraulic System
 Schematic Layout of Hydraulic System

BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Reservoir (or air tank):

A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid (usually oil).

Pump:
The pump is used to force the liquid into the system.

Prime mover:
A Prime mover, usually an electric motor, is used to drive the pump.

Valves:
Valves are refitted in the system to control liquid direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the liquid energy into mechanical force or torque to do useful work.
The actuator is the actual working element of the system. The actuators can be either cylinders (to
provide linear motion) or hydro motors (to provide rotary motion).

Fluid-transfer piping:
The hydraulic Piping is provided to carry the compressed liquid from one place to another.

Schematic Layout of Pneumatic System

Compressor:
The compressor is used to compress the atmospheric air so as to increase the pressure of the air.

Prime mover:
A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:
Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the air energy into mechanical force or torque to do useful work.
Fluid-transfer piping:
Piping is provided to carry the compressed air from one place to another.

BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

Reservoir (or air tank):

An air tank is provided to store the compressed air required for the operations.

Compressor:
The compressor is used to compress the atmospheric air so as to increase the pressure of the air.

Prime mover:
A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:
Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:
An actuator is provided to convert the air energy into mechanical force or torque to do useful work.

Fluid-transfer piping:
Piping is provided to carry the compressed air from one place to another.
RESULT:
Thus the important feature Automation system was studied.
EX.NO:2 DATE:

INTRODUCTION OF PROGRAMMABLE LOGIC CONTROLLER (PLC)

The programmable logic controller (PLC) is a solid state electronic device designed to replace
electromechanical relays, timers, counters and sequences, by using a programmable memory for the
internal storage of user oriented instructions for implementing specific functions such as logic
sequencing timing, country and arithmetic control through digital or analog inputs and outputs,
various types of machines or processes.

Major advantages of using PLC are as follows:

1. The PLC is a hardened industrial computer designed to withstand the harsh

factory environment.
2. PLCs are reusable they contain a changeable program that eliminators extensive and
component changes and that makes them cost effective
3. PLCs offer easy troubleshooting
4. PLCs feature easy installation and small size.
5. Increase productivity.
6. Ease of programming.
7. Ability to communicate with computer.

PROCESS

INPUT DEVICES SENSORS

DATA MEMORY
PROCESS
PROCESSING
PROGRAM MODULE ACTUATORS
OUTPUT DEVICES
MEMORY

PROGRAMMING
MODULE or PC

Fig.1.1 ARCHITECHTURE OF PLC

Some of the used Instructions Bit
Instructions
The following instructions are used with fixed, SLC 5/01, SLC 5/02, SLC 5/03, and SLC 5/04
processors.

If you want to: Use this Instruction:

Examine a bit for an On conditions XIC
Examine a bit for an Off conditions XIO
Turn a bit On or Off OTE
Turn a bit On OLT
Turn a bit Off OUT

Trigger a one time event OSR

Examine if Closed (XIC)

Use the XIC instruction in your ladder to determine if a bit is on. When the
] [
instruction is executed, if the bit addressed is on (1), then the instruction is
evaluated as true. When the instruction is executed, if the bit addressed off (0),
then the instruction is evaluated as false.
Examine if Open (XIO)

] [ Use an XIO instruction in your ladder program to determine if a bit is off. When
the instruction is executed, if the bit addressed is off (0), then the instruction is
evaluated as true. When the instruction is evaluated as false.

Output Energize
Use an OTE instruction in your ladder program to turn on a bit when rung
( )
conditions are evaluated as true.

Output Latch (OTL)

The OTL instruction is a retentive output instruction that can only turn on a bit. It
(L) cannot turn off a bit. This instruction is traditionally used in pairs with an Output
Unlatch (OUT) instruction, with both instructions addressing the same bit. You
can also use this to initialize data values at the bit level.

Output Unlatch (OTU)

The OTU instruction is a retentive output instruction that can only turn off a bit. If
(U) cannot turn on a bit. This instruction is traditionally used in pairs with an Output
Latch (OTL) instruction, with both instructions addressing the same bit. You can
use this to initialize data values at the bit level.
One Short Rising (OSR)

The OSR instruction is a retentive input instruction that triggers an event to occur
] OSR [ one time. Use the OSR instruction when an event must start based on the change
of state of the rung from false to true, not on the resulting status. Applications
include starting events triggered by a pushbutton switch. An example is freezing
rapidly displayed LED values.
Timer and Counter Instructions

Timers and counters are output instructions. Use the following instructions with fixed, SLC 5/01,
SLC 5/02, SLC 5/02, SLC 5/03, and SLC 5/04 processors.

If you want to: Use this instruction:

Count time base intervals when the instruction is true TON

Count time base intervals when the Instruction is false TOF

Count time base intervals when the instruction is true and
retain the accumulated value when the instruction RTO
goes false
Increment the count at each false–to–true transition. CTU
Decrement the count at each false-to-true transition CTD
Count high-speed pulses from a fixed
HSE
Controller High-speed input
Reset the accumulated value and status bits of a timer or
RES
counter. Do not use with TOF timers.

Timer On-Delay (TON)

Use the TON instruction to turn an output on or off after the timer
TON
has been on for a preset time interval. The TON instruction begins
to count time base intervals when rung conditions become true. As
long as rung conditions remain true, the timer adjusts its
Timer T4: 0 accumulated value (ACC) each evaluation until it reaches the preset
Timer Base 0.01 value (PRE). The accumulated value is reset when rung conditions
go false, regardless of whether the timer has timed out.
Timer Off-Delay (TOF)

Use the TOF instruction to turn an output on or off after is rung has
TOF
been off for a preset time interval. The TOF instruction begins to
TIMER OFF DELAY count time base intervals when the rung makes a true-to-false
transition. As long as rung conditions remain false, the timer
Timer T4:1
increments its accumulated value (ACC) each scan until it reaches
Time base 0.01 the preset value (PRE). The accumulated value is reset when rung
conditions go true the timer has timed out.

Retentive Timer (RTO)

RTO Use the RTO instruction to turn an output on or off after its timer
has been on for a preset time interval. The RTO instruction is a
RETENTIVE TIMER ON
retentive instruction that begins to count time base intervals when
rung conditions become true. As long as rung conditions remain
Timer T4: 2 true, the timer increments its accumulated value (ACC) until it
reaches the preset value (PRE).
Time base 0.01
Using counters
Counter instructions have three word data file elements. Word 0 is
the control word, containing the status bits of the instructions. Word
1 is the preset value; word 2 is the accumulated value.

How Counters Work: The figure below demonstrates how a

counter works. The count value must remain in the range of –
32768, a counter status overflow (OV) or underflow (UN) bit is set.
 Count Up (CTU)

CTU COUNT
The CTU is a retentive output instruction that counts false-to-true
UP rung transitions. Rung transitions can be caused by events occurring
in the program such as parts traveling past a detector or actuating a
Counter C5:0 limit switch.
Prese 120
t

Count Down (CTD)

CTD The CTD is a retentive output instruction that counts false-to-true

rung transitions Rung transitions can be caused by events occurring
COUNT DOWN in the program such as parts traveling past a detector or actuating a
limit switch.
Counter C5:1

Preset 120

High-Speed Counter (HSC)

HSC

HIGH SPEED The High-Speed Counter is a variation of the CTU counter. The
COUNTER HSC instruction is enabled when the rung logic is true and disabled
Counter
when the rung logic is false.
Departme
C5:0 n
Preset 120
 Reset (RES)

Use a RES instruction to reset a timer or counter. When the RES

instruction is enabled, it resets the retentive on-delay timer, count
up, or countdown instruction having the same address as the RES
instruction.
Math Instruction

The following output instruction allows you to perform computation and math operations on
individual words. Use these instructions with fixed. SLC 5/01, SLC 5/02, SLC 5/03, and SLC
5/04 processors, except where noted.

If you want to: Use this instruction

Add two values ADD
Subtract two values SUB
Multiply one value from another MUL
Divide one value by another DIV
Perform a double divide DDV
Change the sign of the
NEG
source value and place it in the destination
Set all bits of a world to zero CLR
Convert an integer to BCD TOD
Convert a BCD value to an integer value FRD
Multiplex data DCD
Find the square roof of a value SQR
Scale a value SCL

Add (ADD)

Use the ADD instruction to add one value (source A) to another value
ADD (source B) and place the result in the destination.
Source

Source

B Dest
Subtract (SUB)

SUB
Use the SUB instruction to subtract one value (Source B) from another
(Source A) and place the result in the destination.
Subtract

Source A

Multiply (MUL)

MUL
Use the MUL instruction to multiply one value (source A) by another (source
Multipl B) and place the result in the destination.

Source

Source
Divide (DIV)

B
DIV
Dest
Divide Use the DIV instruction to divide one value (source A) by another (source
B). The rounded quotient is then placed in the destination. If the remainder
Source is 0.5 or greater, round up occurs in the destination. The unrounded quotient
is stored in the most significant word of the math register. The remainder is
A placed in the least significant word of the math register.

Source

Dest
Scale Data (SCL)

SCL
When this instruction is true, the value at the source address is multiplied
Scale by the rate value. The rounded result is added to the offset value and
Rate placed in the destination. Use this instruction with SLC 5/02, SLC 5/03,
and SLC 5/04 processors.
[/10000]
Offset

Comparison Instructions

Following input instructions allow you to compare values of data, Use these instructions with
fixed, SLC 5/01, SLC 5/02, SLC 5/03, and SLC 5/04 processors.

If you want to: this instruction:

Test whether two value is not equal EQU

Test whether one value is not equal to EQ

Test whether one value is less than a second value LES

Test whether one value is less than or equal to a second value LEQ

Test whether one equal to second value is greater than another GRT

Test whether one value is greater than or equal to a second GEQ

value
Test portions of two values to see whether they are equal MEQ

Test whether one value is within the limit range of two other LIM
values
Equal (EQU)

EQU

EQUAL Use the EQU instruction to test whether two values are equal. If source
A and source B are equal, the instruction is logically true. If these values
Source A
are not equal, the instruction is logically false.
Source B

Not Equal (NEQ)

NEQ

NOT EQUAL Use the NEQ instruction to test whether two values are not equal. If
source A and source B are not equal, the instruction is logically true. If
Source A the two values are equal, the instruction is logically false.
Source B

Less Than (LES)

LES
Use the LES instruction to test whether one value (source A) is less than
LESS THAN another (source B). If source A is less than the value at source B the
instruction is logically true. If the value at source A is greater than or
Source A
equal to the value at source B, the instruction is logically false.
Source B

Less Than or Equal (LEQ)

LEQ

LESS THAN OR Use the LEQ instruction to test whether one value (source A) is less
EQUAL than or equal to another (source B). If the value at source A is less
than or equal to the value at source B, the instruction is logically
Source A
Depar

Source B
 true. If the value at source A is greater than the value at source B, the
instruction is logically false.

Greater Than (GRT)

GRT
Use the GRT instruction to test whether one value (source A) is
GREATER THAN
greater than another (source B). If the value at source A is greater than
Source A the value at source B. The instruction is logically true. If the value
at source A is less than or equal to the value at source B, the
Source B instruction is logically false.

Greater Than or Equal (GEQ)

GEQ
Use the GEQ instruction to test whether one value (source A) is
greater than or equal to another (source B). If the value at source A is
GREATER THAN greater than or equal to the value at source B, the instruction is
OR EQUAL logically true. If the value at source A is less than the value at source
Source A B, the instruction is logically false.

Source B
Masked Comparison for Equal MEQ)

MEQ

MASKED EQUAL Use the MEQ instruction to compare data at a source address with
data at a reference address. Use of this instruction allows portions of
Source the data to be masked by a separate word.

Mask

Limit Test (LIM)

LIM

LIMIT TEST Use the LIM instruction to test for value within or outside a specified
range, depending on how you set the limits. Use this instruction with
Test 5/02 and 5/03 processors.
High Lim
Depar

11
 Move and Logical Instructions

The following output instructions allow you to perform move and logical operations on
individual words. Use these instructions with fixed. SLC 5/01, SLC 5/02, SLC 5/03, and
SLC 5/04 processors.

If you want to: Use this instruction:

Move the source value to the destination MOV

MVM
Move data from a source location to a
selected portion of the destination
Perform an AND operation AND
Perform an inclusive OR operation OR
Perform an Exclusive Or operation XOR
Perform a NOT operation NOT
Move (MOV)

MOV

MOVE This output instruction moves the source value to the destination
location.
Source

Masked Move (MVM)

MVM
The masked move instruction is a word instruction that moves
MASKED MOVE data from a source location to a destination, and allows portions
of the destination data to be masked by a separate word.
Source

RESULT:
Thus the important feature Programmable Logic Controller was studied.

11
EX.NO:3 DATE:

SIMULATION OF SINGLE ACTING CYLINDER BY USING

AUTOMATION SOFTWARE
Aim

To construct a circuit to trigger the forward and return stock by single acting cylinder using a leaver
operated dcv( direct method ).

Apparatus required
1.Automation software
2.Computer
Procedure

1. Open the file automation software and open a new file.

2. Then the select the required circuit using the library tool bar.

3. Then pick the required cylinder and valves required.

4. Then drag it and place it is the file.

5. Then give the connections as given in the circuit.

6. Then save the circuit and then select the simulation option.

11
 Diagram:

Result:
Thus the simulation operation of a single acting cylinder was done.

11
EX.NO:4 DATE:

SIMULATION OF DOUBLE ACTING CYLINDER BY USING

AUTOMATION SOFTWARE

Aim

To perform the simulation of double acting cylinder with use of automation software.

Apparatus required
1.Automation software
2.Computer
Procedure

1. Open the file automation software and open a new file.

2. Then the select the required circuit using the library tool bar.

3. Then pick the required cylinder and valves required.

4. Then drag it and place it is the file.

5. Then give the connections as given in the circuit.

6. Then save the circuit and then select the simulation option.

11
 Diagram:

Result:
Thus the simulation operation of a double acting cylinder was done.

11
EX.NO:5 DATE:

DESIGN OF CIRCUITS WITH LOGICAL SEQUENCE (AND GATE ) USING ELECTRO

PNEUMATIC TRAINER KITS
Aim
To construct a pneumatic circuit to control the single acting cylinder control by Two-way pressure
valve using electro pneumatic trainer kits.

Apparatus Required

 Compressor air
 FRL
 Two-way pressure valve
 Single acting cylinder

Figure. 1. Circuit Diagram of the AND Logic in the Single Acting Cylinder
Procedure
1. Draw the circuit diagram.

2. Connect the compressor air supply to FRL unit.

3. Any two of the outputs of FRL unit directly connected to 3/2 push button valve inlet first and
second.

4. Both 3/2 push button valves outputs to give AND Gate input.

5. Check the all circuit.

6. Open the hand slide valve. The air passes in both 3/2 pushbutton valves input port.
11
7. When both push buttons is press the cylinder should be activated.
Truth table
Input 1 Input 2 Output

ON ON ON

OFF OFF OFF

OFF ON OFF

ON OFF OFF

Result

The pneumatic circuit of two way pressure valve was simulated.

11
EX.NO:6 DATE:

DESIGN OF CIRCUITS WITH LOGICAL SEQUENCE (OR GATE ) USING ELECTRO

PNEUMATIC TRAINER KITS

Aim

To construct a pneumatic circuit to control the single acting cylinder using electro pneumatic trainer
kits.

Apparatus Required

 Compressor air
 Tube
 3/2 push button valve
 Shuttle valve
 Single acting cylinder

Figure. 2. Circuit Diagram of the 11

OR Logic in the Single Acting Cylinder.
Procedure

1. Draw the circuit diagram ( Refer Fig. 2)

2. Connect the compressor air supply to FRL unit.
3. Any two of the output of FRL unit to first 3/2 push button valve inlet and second 3/2 push
button valve inlet.
4. Both 3/2 push button valves outputs to give shut the valve inlet ports.
5. Check the all circuits.
6. Open the hand slide valve. The air passes in both 3/2 push button valve inlets.
7. Press any one push button valve. The cylinder will be activated.

Truth table
Input 1 Input 2 Output

OFF OFF OFF

ON OFF ON

OFF ON ON

ON ON ON

Result

Thus the single acting cylinder controlled by OR Gate.

11
EX.NO:7 DATE:

AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+B+B-A-) USING PLC

Aim:

To perform sequencing of two pneumatic cylinders (A and B) in the order of A+B+ B-A- using
PLC.

Apparatus Required:

1. FRL Unit
2. Flow Control valve
3. 5/3 solenoid operated directional control Valve
4. 5/2 solenoid directional control Valve
5. PLC pneumatic trainer
6. Double Acting Pneumatic Cylinder
7. Polyurethane Tubes and Electrical wires

ACTUATED POSITION

Figure. 3

11
Procedure:

1. Connect the FRL unit, Control valves, directional control valves and cylinders as shown in the
circuit.
2. Draw the functional block diagram using PLC software and save it in the computer.
3. Give connections between PLC and PC using USB port and download the program to the PLC.
4. Give connections from the reed switches to the PLC input and from the PLC output to the
respective solenoid valves.
5. Adjust the FRL and set the pressure as 6 bars.
6. Switch on the electric supply.
7. Execute the program from the PLC and observe the sequencing of cylinders being carried out
automatically.

RESULT:
Thus the single cycle automation of multiple cylinders is operated in sequence
(A+B+B-A-) using PLC.

11
EX.NO:8 DATE:

ACTUATION OF HYDRAULIC CYLINDER TO FIND OUT SPEED VS. DISCHARGE

Aim

To actuate the double acting hydraulic cylinder to find out speed vs. discharge

Apparatus required

Oil tank, single-phase motor, gear pump, pressure relief valve, 4/3 double solenoid valve, flow control
valve, double acting cylinder, load cell, and data actuation card than lab view software.

Procedure

1. Switch on the electrical power supply with motor.

2. Switch on the power supply to the control unit.

3. Open the lab view software in the system.

4. Inter face hydraulic trainer with system using RS-232.

5. Open the speed. Go to operate, click the run then power on (below).

6. Now extend the system by pressing the up button.

11
 7. Now regulate the flow control valve, contract the system by pressing down position after seen
monitor in velocity cm/sec.

8. Now adjust the flow control valves and set the maximum flow, to find the up and velocity.

9. Repeat the velocity values for different flows

HYDRAULIC LINEAR ACTUATION TRAINER

Tabulation
S. No Velocity in UP ( Velocity in DOWN Discharge in UP Discharge in
cm/sec) ( cm/sec) FLOW ( L/sec) DOWN FLOW
( L/sec)

Calculation

W. K. T.

 Velocity Speed  Flow

Area
SPEED in ‘cm/sec’
FLOW( DISCHARGE) in ‘L/sec’
AREA in ‘m2 ’

π 2
 Area  D
4
 Flow = velocity × Area

MODEL CALCULATION:

D Diameter of Cylinder cm
Cylinder diameter = 50mm
Cylinder rod diameter = 30mm
Cylinder stroke length = 150mm
11
GRAPH:
Speed VS Discharge

MODEL GRAPH:

Result

The actuation of hydraulic cylinder was carried out.

11
EX.NO:9 DATE:

WATER LEVEL CONTROLLER USING PROGRAMMABLE LOGIC CONTROLLER

AIM:
To control the water level of a tank using programmable logic controller.

APPARATUS REQUIRED:

1. Level control trainer kit

2. PLC (Allen Bradley Micrologix 1500 LRP series C)
3. PC with RS Logix Software
4. RS232 cable
5. Patch chords

PROCEDURE:

1. Load the RS logix software to the PC

2. Open the RS logix software
3. Switch On the PLC trainer
4. Connect PLC with level control kit.
5. Open the New folder and draw the ladder logic program
6. Select the correct hardware configuration.
7. Store the Program to PLC
8. Run the program
9. Verify the performance of the water level control using PLC.

PROCESS DESCRIPTION:
Liquid level control is a basic and necessary process for all the process industry. Here the level
of liquid is to be maintained inside the tank to a specific height.Here there is a water
reservoir from which the water needs to be pumped out to the process tank.
In the process tank there are two sensors connected around the edges of the tank according to
the required heights i.e., one sensor is connected at the near bottom end of the tank called as
lower level sensor and another one on the near top edge of the tank called as higher level
tank. To let the water out of the tank there is a pipe connected at the bottom of the tank with a
valve. This valve is to be used by user for the process application

The level sensor is a magnetic sensor and when the liquid level is above the high level
sensor a HL (high level) signal is send to the PLC. When the liquid level goes down the
low level sensor LL (low level) signal is send to the PLC. The PLC checks the signals
send by these sensors through its input port and give the proper signals through its output
port as per the ladder logic program.
11
Sequence of process control actions done by the PLC:

1. When the water level in the tank is less than the lower level then the lower level sensor
senses and turns the motor on to fill the tank.
2. Then the tank is filled up until it reaches the higher level where the higher level
sensor senses and makes the motor off and filling of water stops.

[BLOCK DIAGRAM OF LIQUID LEVEL SET UP]

11
RESULT:

The liquid level trainer kit was set up and liquid level was controlled by using
PLC ladder logic program.
11
 Exp No:10 Date:

LIFT CONTROL SYSTEM using PLC

Aim:

To control the lift plant model using programmable logic controller.

Apparatus required:
1. Lift control system
2. PLC (Allen Bradley micrologix 1500 LRP series C)
3. PC with RXlogix Software
4. RS232 cable
5. Patch chords
Procedure:
1. Load the RXlogix software to the PC
2. Open the RXlogix software
3. Switch on the PLC trainer and lift controls system
4. Connect PLC with Lift control system kit.
5. Open the New folder and draw the ladder logic program
6. Select the correct hardware configuration.
7. Store the Program to PLC
8. Run the program
9. Verify the performance to the lift control system

Program description:
I1, I2, I3 - Requisition switch.
I4, I5, I6 - Sensor Inputs.
Q2, Q3, Q4, Q5 - Output for stepper motor.

1. I1, I2, I3 are requisition switches I4, I5, I6 are the sensor placed in each floor. The other coils
used in the program are the set coil, reset coil, positive transition coil, negative transition coil are in
memory location.
2. The timer functions are used to produce the required time delay.
3. Bit sequence functions used to drive the stepper motor.
4. Whenever the requirement switch I1, is pressed the set coil M1 is energized and bit sequence
outputs are enabled then the stepper motor rotates.
5. When the motor reaches the respective floor, the switch I4 gets closed and energizes both
positive transition coil & negative transition coil.
6. The positive transition coil energizes one more set coil, which is used to enable the timer.
7. This is used to give time delay for the lift in each floor.

11
 8. The negative transition coil, which was energized, is used to reset the requisition.
9. The above functions are repeated in each floor.

Conditions for rotation of Motor:

1. Consider the lift is in ground floor, when the requisition is given from first floor or second floor
the motor has to move forward.
2. If the lift is in top floor then it has to move in the reverse direction.
3. If the lift is in middle floor then according to the requisition, lift will move in forward
orreverse direction.
Program

11
11
11
Result:

It is observed that lift is controlled smoothly by using programmable logic controller.

48
 VIVA - VOCE
1. What is meant by sensor?
2. What are the various types of control system?
3. Distinguish between closed loop system and open loop system.
4. What are the types of strain gauges?
5. Define - LVDT
6. What is meant by fluid power?
7. What is a check valve?
8. What is a solenoid valve?
9. Define – FRL unit
10. Define – DCV
11. Differentiate between meter-in and meter-out controls.
12. What is the function of an unloading valve?
13. What is the function of a sequence valve?
14. What is the function of a shuttle valve?
15. What is the function of a spool valve?
16. What is the function of a process control valve?
17. What is the function of a 2-way pressure valve?
18. Why hydraulic power is especially used in heavy works?
19. Where are pneumatic systems preferred?
20. Name the basic components of a hydraulic system.
21. What is the function of a relief valve in a hydraulic system?
22. Draw the symbols for a pressure relief valve and a pressure reducing valve.
23. What is meant by NC and NO contacts?
24. What is meant by an actuator?
25. What are the types of actuators?
26. What is a control valve?
27. What are the types of control valves?
28. What is a circuit control valve?
29. What is the function of flow control valve?

49
30. Distinguish between flow control and needle valve.
31. What is the function of time delay valve?
32. What is the function of pilot operated valve?
33. What is a quick exhaust valve?
34. What is the difference between a strainer and a filter?
35. Distinguish between hydraulics and pneumatics?
36. What is the purpose of a pressure regulator?
37. Why lubricator is used in pneumatic systems?
38. What are the advantages of hydro- pneumatics?
39. What is meant by logic control?
40. Name the different pneumatic position sensors.
41. How do you rate a compressor?

42. What is a programmable logic controller?

43. What are the basic elements of a PLC?
44. What are the various approaches for entering the program for PLC?
45. What is a ladder diagram?
46. What is the purpose of an electrical timer?
47. Draw the general ladder rungs to represent a latch circuit.
48. How does a PLC differ from relay logic?
49. What are the features of a PLC?
50. What is the function of proximity switch?

HOD

50