FALLSEM2015 16 CP1639 TB02 Mechatronics Lab Record

Laboratory Report
Fall Semester
2015 2016
MEE528 FLUID POWER

SYSTEMS AND FACTORY
AUTOMATION
SCHOOL OF
MECHANICAL AND
BUILDING SCIENCES
VIT - A place to learn;
A chance to grow
Name
Reg. No :`
Course & Branch :
SCHOOL OF MECHANICAL AND BUILDING SCIENCES

FLUID POWER SYSTEMS AND FACTORY AUTOMATION Laboratory
Certified that, this is a bonafide record of work done by

Mr. / Ms.______________________________________________
of____ semester M.Tech. ____________________________ during
Fallsemester 2015 2016.
University Registration No.
Date:
Faculty In-Charge
Submitted for the Term End Practical Examination held on ________________________.
EXAMINER
VIT University SMBS Mechatronics Laboratory
Page 1
CONTENTS
S. No
Date
Experiment
Study of Programmable Logic Controller and PLC software
PLC Programming Exercises
Page. No
i) On-Off Latch control

ii) NC and NO contacts
iii) Timers
iv) Counters
v) Timers counters
3
Study of Automation Studio 6.0
Simulation and analysis of pneumatic and hydraulic circuits

(i) Pneumatic cylinder reciprocation with direction
control valves.
(ii) Pneumatic cylinders sequence control using cascade
method
(iii) Hydraulic Lifting circuit
(iv) Two hand operated safety circuit
(v) Meter in/out speed control circuit
(vi) Counter balance circuit
Simulation and analysis of Electro-hydraulic / pneumatic

circuits
(i) Cylinders sequencing control
(ii) PLC controlled electro-hydralic / pneumatic circuit
Design of electro-hydraulic circuit
Design of electro-pneumatic circuit
Design of PLC controlled hydraulic circuit
Design of PLC controlled pneumatic circuit
10
Automation using PLC interfacing field devices with PLC

systems.
(i) Sensors and actuators interfacing with PLC
(ii) HMI / MMI interfacing with PLC
(iii) Modular automation using PLC control
Page 2
Faculty
Ex. No: 01
Date:
Study of Programmable Logic Controller
Introduction
The PLCs are designed to be relatively "user-friendly" so that electricians can easily make the
transition from all-relay control to electronic systems. They give users the capability of displaying
and trouble-shooting ladder logic on a cathode ray tube (CRT) that showed the logic in real time. The
logic can be "rewired" (programmed) on the CRT screen, and tested, without the need to assemble
and rewire banks of relays.
The existing push-buttons, limit switches, and other command components continue to be
used, and become input devices to the PLC. In like manner, the contactors, auxiliary relays,
solenoids, indicating lamps, etc., become output devices controlled by the PLC. The ladder logic is
contained as software (memory) in the PLC, replacing the inter-wiring previously required between
the banks of relays. If one understands the interface between the hardware and the software, the
transition to PLCs is relatively easy to accomplish. This approach to control allows "laymen" to use
the control without necessarily being expert computer programmers.
Plc Hardware
Programmable controllers have a modular construction. They require a power supply,
control processor unit (CPU), input /output rack (I/O), and assorted input and output modules.
Systems range in size from a compact design with limited memory and I/O points to systems that can
handle thousands of I/O, and multiple, inter-connected CPUs. A separate programming device is
required, which is usually an industrial computer terminal, a personal computer, or a dedicated hand
held programmer.
CPU contains microprocessor. The basic instruction set is a high level program, installed in
Read Only Memory (ROM). The programmed logic is usually stored in Electrically Erasable
Permanent Read Only Memory (EEPROM). The CPU will save everything in memory, even after a
power loss. Since it is "electrically erasable',' the logic can be edited or changed as the need arises.
The programming device is connected to the CPU whenever the operator needs to monitor, troubleshoot, edit, or program the system, but is not required during the normal running operations.
I/O module assembly contains slots to receive various input and output modules. The rack
can be local, combined with the CPU and power supply, or remote. Each rack is given a unique
address so that the CPU can recognize it. Within each rack, the slots have unique addresses. Power
and communication cables are required for remote installations. The replaceable I/O modules plug
into a back-plane that communicates directly with the CPU or through the cable assembly. Field
wiring terminates on "swing arms" that plug into the face of the I/O modules. This allows a quick
change of I/O modules without disconnecting the field wiring. Every module terminal also has a
unique address.
PLC Operation (PLC SCAN)
When running, the CPU scans the memory continuously from top to bottom, and left to
right, checking every input, output, and instruction in sequence. The scan time depends upon the
size and complexity of the program, and the number and type of I/O. The scan is in few milliseconds.
This short time makes the operation appear as instantaneous, but one must consider the scan
sequence when handling critically timed operations and sealing circuits. Complex systems may use
interlocked multiple CPUs to minimize total scan time. As the scan reads the input image table, it
notes the condition of every input, and then scans the logic diagram, updating all references to the
inputs. After the logic is updated, the scanner resets the output image table, to activate the required
outputs.
Page 3
Block diagram:
Applications:
Page 4
Ex. No: 02 (a)

Date:
ON-OFF Latch Control
Develop a ladder program to use momentary push buttons to turn on and turn of an output with
latching circuit.
Objective:
To develop the PLC ladder logic diagram for given control sequences and to simulate the program to
the stated conditions using PLC software.
Components Required: PLC software (PICO Soft / MicroWin STEP 7)
Procedure:
Create ladder logic program using PLC software with comments.

Simulate and run ladder logic program
Test ladder logic program with inputs.
Document Ladder logic program and PLC connection diagram.
Ladder Diagram:
Connection diagram
Report:
Page 5
Ex. No: 02 (b)

Date:
NC and NO contacts
A motor has on-off controls from three locations. It is to be turned on from any one location by a
push button. Also the motor can be turned off from any one of the three locations. A master reset
switch should be used reset the motor any time.
Objective:
Procedure:

Ladder Diagram:
Connection diagram:
Report:
Page 6
Ex. No: 02 (c)

Date:
Timers
Motor A should turn on when a Push Button 1 is pressed. It should go off when an OFF button is
pressed. As soon as motor A is switched off, motor B should go ON and it should run for 10
seconds and switched off.
Objective:
Procedure:

Ladder Diagram
Page 7
Connection diagram:
Report:
Page 8
Ex. No: 02 (d)

Date:
Counters
Design a PLC program and prepare a I/O connection diagram for the following counter
specifications:
i)
ii)
iii)
iv)
v)
Counts the no. of times a push button is pressed.

Decrement the counter value each time a second push button is pressed.
Turns on a light any time the counter accumulated value is less than 8.
Turns on a second light when the counter value is equal to or greater than 8.
Resets the counter to zero when a selector switch is closed
Objective:
Procedure:

Ladder Diagram
Page 9
Connection diagram:
Report:
Page 10
Ex. No: 02 (e)

Date:
Timers Counters
Write PLC program to operate a light according to the following sequence:

i) A momentary push button is pressed to start the sequence.
ii) The light is switched on and remains on for 2 s and turned off for 3 s.
iii) A counter is incremented by 1 after this sequence.
iv) The sequence then repeats for 4 counts and the sequence will stop and resets.
Objective:
Procedure:

Ladder Diagram:
Page 11
Connection diagram:
Report:
Page 12
Problems for practice:

1. When an ON PUSH button is pressed motor A and Motor B should go ON immediately and after a
time delay of 10 seconds motor C should go ON. When an OFF push button is pressed all the 3
motors should go off.
2. Turn ON light L1 when push button PB1 is pressed. Turn ON light L2 when push button PB2 is
pressed. Interlock the pushbutton so that L1 and L2 cannot be turned ON at the same time.
3. Write a program that will turn a light on when a count reaches 5. The light is then go off when a
count 8 is reached.
4. Develop the ladder logic that will turn on a light, after switch A has been closed 10 times. Push
button B will reset the counters.
5. Develop the ladder logic that will turn on an output light, 15 seconds after switch A has been
turned ON.
6. In a conveyor system when a Start button is pressed, conveyor 1 motor begins running. After 15
plates have been stacked motor 1 stops and conveyor 2 motor begins running. After 5 seconds,
motor 2 stops and the sequence is repeated automatically. A reset button is used to reset the
counter and timer.
7. Develop a program that will latch on an output B 20 seconds after input A has been turned on.
After A is pushed, there will be a 10 second delay until A can have any effect again. After A has been
pushed 3 times, B will be turned off.
8. A motor will be controlled by two switches. The Go switch will start the motor and the Stop switch
will stop it. If the Stop switch was used to stop the motor, the Go switch must be thrown twice to
start the motor. When the motor is active a light should be turned on. The Stop switch will be wired
as normally closed.
9. Develop the ladder logic that will turn on a green light and a red light alternatively with a delay of
3 seconds continuously, after pushbutton switch has been pressed.
Page 13
Ex. No: 03
Date:
Study of Automation Studio software
Introduction
Automation Studio is a unique circuit design, simulation, and project documentation
software package that meets the needs of engineers for Automation, Controls, and Fluid Power
applications.
Automation Studio is an innovative schematic capture, simulation and project
documentation software package for automation and fluid power systems design. A New Generation
of tools for the automation and fluid power industries.
Features
The Ideal Standalone Package for Easy and Integrated Circuit Design Multi-Document Projects.
i) Dynamic and Realistic Simulation in Full Color.
ii) Thousands of Symbols in Modular Libraries
iii) BOM, Parts Catalog and Database Link Interfaces to Programmable Logic Controllers
(PLCs) and Equipment
iv) A New Generation of Tools for the Automation and Fluid Power Industries
Automation Studio is intuitive and is the affordable application-oriented tool for integrators,
OEMs, engineers. All the expected features of a schematic design package are available in a userfriendly approach, shortening the learning curve and increasing productivity. With Automation
Studio, there is no need for additional editing software. It provides component libraries, drawing
tools, basic shapes and elements that allow you to create special symbols of any complexity and to
customize diagrams and project templates. Automation Studio can be equally useful for sales people
as well as for engineers.
Automation Studio is a completely integrated software that allows users to Design,
Document, simulate, and animate circuits consisting of various automation technologies including
Pneumatics, Hydraulics, PLCs, Sequential Function Charts (SFC), Electrical Controls, and many more.
Multi-Document Projects Automation Studio allows the creation of multi- document projects. This is
helpful when separating diagrams by functions and categories. During simulation, all diagrams
interact with each other. Users can also include other types of documents such as Word, Excel, or
any Windows-based application. This is useful when adding notes and instructions to a project.
Automation Studio is perfect for preparing designs and quotes. Projects can be presented to
customers dynamically through simulation, proving concepts and limiting risks during
implementation and start-up.
Troubleshooting with Simulation With intrinsic simulation features like pace control,
component color-coding and animation, designers can monitor the actual circuit Operation and find
faults that may occur. This helps functionally validate designs, a capability that no other CAD system
can even approach. Dynamic and Realistic Simulation in Full Color Automation Studio includes
simulation capabilities that meet the requirements of all the supported technologies. During
simulation, components become animated and lines are color-coded according to their states. Users
can also precisely monitor variable values, pressures, flows, and displacement values at any point in
a circuit simply by inserting measuring instruments or using the plotting functions. The simulation
pace can also be adjusted with functions such as Normal, Step by Step, Slow Motion, and Pause.
Thousands of Symbols in Modular Libraries Automation Studio's libraries incorporate
internationally recognized graphics standards, including ISO, DIN, IEC, and JIC standards. Each library
displays component categories in a comprehensive fashion. Simply browse through the list, select
then drag and drop the component onto the schematic. Make your Own Symbols, Components,
Page 14
Templates, and Libraries By using the standard components, the flexible drawing tools, and the
grouping function, you can create and customize your own libraries and templates. For training,
instructors can create libraries specific to their application, thereby limiting the number of
components to what is needed.
Customize Libraries for Increased Productivity By customizing symbols and libraries, this
allows designers and engineers to quickly implement projects that meet corporate specifications.
BOM, Parts Catalog and Database Link This feature makes it possible for you to generate
project documentation. Users can assign specific catalog data to each component; enter part
numbers, prices, descriptions, and all the technical data quickly and easily. They can also customize
and create reports. Furthermore, users can print or export information to another application such
as a spreadsheet, a word processor, or an inventory system.
The software allows printing to standard engineering sizes including ANSI A-E and ISO A4-A0.
Users can define title block contents, borders, map locators, bills of materials, and schematic scaling
factors. More information Communication to Controllers and Equipment via OPC and CANBUS.
To connect Automation Studio to the outside world, users can choose one of two options:
the I/O Interface kit or the OPC Client module. The Automation Studio I/O Interface kit is a
hardware solution that allows the user to connect 8 inputs and 8 outputs directly into a PLC I/O or
to real equipment such as relays, contacts, valves, sensors, etc. The OPC Client is a standard
software interface that allows Automation Studio to exchange data with any device for which an
OPC server software is up lied by its manufacturer. OPC turns automation Studio into a versatile I/O
simulator or a oft-PLC. For mobile applications, the use of an OPC - CAN bus server can allow an
interface between controllers and Automation Studio. I/O Interface Kit, OPC Client Module.
Application
Automation Studio will play a useful role in design in the following array of interrelated fields:
Industrial hydraulic systems

Industrial pneumatic systems
Mobile hydraulic systems
Electrical controls systems
PLC controls applications
Automated controls applications
Technical publications
Service and troubleshooting
Page 15
List of hydraulic circuit symbols:
Page 16
List of pneumatic circuit symbols:
Page 17
List of electrical component symbols:
Page 18
Ex. No: 04 (i)

Date:
Simulation and analysis of pneumatic cylinder control with direction

control valves
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 19
d) Analysis:
e) Results and discussions:
Page 20
Ex. No: 04 (ii)

Date:
Simulation and analysis of Pneumatic cylinders sequence control using

cascade method
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 21
d) Analysis:
Page 22
Ex. No: 04 (iii)

Date:
Simulation and analysis of hydraulic lifting system
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 23
d) Analysis:
Page 24
Ex. No: 04 (iv)

Date:
Simulation and analysis of two hand operated safety circuit
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 25
d) Analysis:
Page 26
Ex. No: 04 (v)

Date:
Simulation and analysis of Meter in/out speed control
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 27
d) Analysis:
Page 28
Ex. No: 04 (vi )

Date:
Simulation and Analysis of Counter Balance Circuit
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 29
d) Analysis:
Page 30
Ex. No: 05 (i)
Simulation and analysis of Electro-hydraulic / pneumatic circuits

Sequencing control of cylinder actuation
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 31
d) Analysis:
Page 32
Ex. No: 05 (ii)

Date:
Simulation and analysis of PLC controlled Electro-hydraulic / pneumatic

circuits
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 33
d) Analysis:
Page 34
Ex. No: 06
Design of Electro-Hydraulic Circuit
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 35
d) Analysis:
Page 36
Ex. No: 07
Design of Electro-Pneumatic Circuit
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 37
d) Analysis:
Page 38
Ex. No: 08
Design of PLC Controlled Hydraulic Circuit
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 39
d) Analysis:
Page 40
Ex. No: 09
Date:
Design of PLC Controlled Pneumatic Circuit
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 41
d) Analysis:
Page 42
Ex. No: 10 (i)
Automation using PLC - Sensors and Actuators Interfacing
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Experimental setup:
Page 43
d) Ladder and connection diagrams:
Page 44
Ex. No: 10 (ii)
HMI / MMI interfacing with PLC
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Circuit diagram:
Page 45
d) HMI/MMI Screen layout:
Page 46
e) Analysis:
f) Results and discussions:
Page 47
Ex. No: 10 (iii)
Modular Automation using PLC
Date:
a) Objective:
b) Components:
S. No.
Description
Specification
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
c) Experimental setup:
Page 48
d) Ladder and connection diagrams:
Page 49
e) Analysis:
f) Results and discussions:
Page 50

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Laboratory Report

MEE528 FLUID POWER

SCHOOL OF MECHANICAL AND BUILDING SCIENCES

Certified that, this is a bonafide record of work done by

University Registration No.

Submitted for the Term End Practical Examination held on ________________________.

VIT University SMBS Mechatronics Laboratory

Study of Programmable Logic Controller and PLC software

PLC Programming Exercises

i) On-Off Latch control

Study of Automation Studio 6.0

Simulation and analysis of pneumatic and hydraulic circuits

Simulation and analysis of Electro-hydraulic / pneumatic

Design of electro-hydraulic circuit

Design of electro-pneumatic circuit

Design of PLC controlled hydraulic circuit

Design of PLC controlled pneumatic circuit

Automation using PLC interfacing field devices with PLC

VIT University SMBS Mechatronics Laboratory

Study of Programmable Logic Controller

VIT University SMBS Mechatronics Laboratory

VIT University SMBS Mechatronics Laboratory

Ex. No: 02 (a)

ON-OFF Latch Control

Create ladder logic program using PLC software with comments.

VIT University SMBS Mechatronics Laboratory

Ex. No: 02 (b)

Create ladder logic program using PLC software with comments.

VIT University SMBS Mechatronics Laboratory

Ex. No: 02 (c)

Create ladder logic program using PLC software with comments.

VIT University SMBS Mechatronics Laboratory

VIT University SMBS Mechatronics Laboratory

Ex. No: 02 (d)

Counts the no. of times a push button is pressed.

Create ladder logic program using PLC software with comments.

VIT University SMBS Mechatronics Laboratory

VIT University SMBS Mechatronics Laboratory

Ex. No: 02 (e)

Write PLC program to operate a light according to the following sequence:

Create ladder logic program using PLC software with comments.

VIT University SMBS Mechatronics Laboratory

VIT University SMBS Mechatronics Laboratory

Problems for practice:

VIT University SMBS Mechatronics Laboratory

Study of Automation Studio software

VIT University SMBS Mechatronics Laboratory

Industrial hydraulic systems

VIT University SMBS Mechatronics Laboratory

List of hydraulic circuit symbols:

VIT University SMBS Mechatronics Laboratory

List of pneumatic circuit symbols:

VIT University SMBS Mechatronics Laboratory

List of electrical component symbols:

VIT University SMBS Mechatronics Laboratory

Ex. No: 04 (i)

Simulation and analysis of pneumatic cylinder control with direction

VIT University SMBS Mechatronics Laboratory

e) Results and discussions:

VIT University SMBS Mechatronics Laboratory

Ex. No: 04 (ii)

Simulation and analysis of Pneumatic cylinders sequence control using

VIT University SMBS Mechatronics Laboratory

e) Results and discussions: