fallsem2015 16 cp1639 tb02 mechatronics lab record

Name :

Reg. No :`

Course & Branch :

Laboratory Report Fall Semester

2015 – 2016

SCHOOL OF

MECHANICAL AND

BUILDING SCIENCES

VIT - A place to learn;

A chance to grow

MEE528 FLUID POWER SYSTEMS AND FACTORY AUTOMATION

VIT University SMBS Mechatronics Laboratory Page 1

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


CONTENTS

S. No Date Experiment Page. No Faculty

1 Study of Programmable Logic Controller and PLC software

2 PLC Programming Exercises

i) On-Off Latch control

ii) NC and NO contacts

iii) Timers

iv) Counters

v) Timers – counters

3 Study of Automation Studio 6.0

4 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

5 Simulation and analysis of Electro-hydraulic / pneumatic circuits

(i) Cylinders sequencing control

(ii) PLC controlled electro-hydralic / pneumatic circuit

6 Design of electro-hydraulic circuit

7 Design of electro-pneumatic circuit

8 Design of PLC controlled hydraulic circuit

9 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


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, trouble-shoot, 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.

Ex. No: 01 Study of Programmable Logic Controller

Date:


Block diagram:

Applications:


Develop a ladder program to use momentary push buttons to turn on and turn of an output withlatching 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:

Ex. No: 02 (a)ON-OFF Latch Control

Date:


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:




Ladder Diagram: Connection diagram:

Report:

Ex. No: 02 (b)NC and NO contacts

Date:


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:




Ladder Diagram

Ex. No: 02 (c)Timers

Date:


Connection diagram:

Report:


Design a PLC program and prepare a I/O connection diagram for the following counter specifications:

i) Counts the no. of times a push button is pressed.ii) Decrement the counter value each time a second push button is pressed.iii) Turns on a light any time the counter accumulated value is less than 8.iv) Turns on a second light when the counter value is equal to or greater than 8.v) Resets the counter to zero when a selector switch is closed

Objective:




Ladder Diagram

Ex. No: 02 (d)Counters

Date:


Connection diagram:

Report:


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:




Ladder Diagram:

Ex. No: 02 (e)Timers – Counters

Date:


Connection diagram:

Report:


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.


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 user-friendly approach, shortening the learning curve and increasing productivity. With AutomationStudio, 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 includingPneumatics, 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 simulationpace 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 librarydisplays 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,

Ex. No: 03Study of Automation Studio software

Date:


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, thisallows 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 customizeand 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 anOPC 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


List of hydraulic circuit symbols:


List of pneumatic circuit symbols:


List of electrical component symbols:


a) Objective:

b) Components:

S. No. Description Specification Quantity1.2.3.4.5.6.7.8.9.10.

c) Circuit diagram:

Ex. No: 04 (i) Simulation and analysis of pneumatic cylinder control with direction control valvesDate:


d) Analysis:

e) Results and discussions:


a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 04 (ii) Simulation and analysis of Pneumatic cylinders sequence control using cascade methodDate:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 04 (iii)Simulation and analysis of hydraulic lifting system

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 04 (iv)Simulation and analysis of two hand operated safety circuit

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 04 (v)Simulation and analysis of Meter in/out speed control

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 04 (vi )Simulation and Analysis of Counter Balance Circuit

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 05 (i) Simulation and analysis of Electro-hydraulic / pneumatic circuits

Sequencing control of cylinder actuationDate:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 05 (ii) Simulation and analysis of PLC controlled Electro-hydraulic / pneumatic circuitsDate:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 06 Design of Electro-Hydraulic Circuit

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 07 Design of Electro-Pneumatic Circuit

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 08 Design of PLC Controlled Hydraulic Circuit

Date:


d) Analysis:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 09 Design of PLC Controlled Pneumatic Circuit

Date:


d) Analysis:



a) Objective:

b) Components:


c) Experimental setup:

Ex. No: 10 (i) Automation using PLC - Sensors and Actuators Interfacing

Date:


d) Ladder and connection diagrams:



a) Objective:

b) Components:


c) Circuit diagram:

Ex. No: 10 (ii) HMI / MMI interfacing with PLC

Date:


d) HMI/MMI Screen layout:


e) Analysis:

f) Results and discussions:


a) Objective:

b) Components:


c) Experimental setup:

Ex. No: 10 (iii) Modular Automation using PLC

Date:


d) Ladder and connection diagrams:


e) Analysis:

f) Results and discussions:

fallsem2015 16 cp1639 tb02 mechatronics lab record

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