LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
1
Shri Vile Parle Kelvani Mandals
Dwarkadas J. Sanghvi College Of Engineering Vile Parle, Mumbai (W.)-4000 56
DEPARTMENT OF PRODUCTION ENGINEERING
Dwarkadas. J. Sanghvi College of Engineering
Department of Production Engineering
B.E. Semester VIII
Subject: Automation and Control Engineering
LABORATORY MANUAL
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
2
AUTOMATION AND CONTROL ENGINEERING
LIST OF PRACTICALS
MODULE 1. PNEUMATICS
1. Extension and Retraction of double acting cylinder with speed control in both directions.
2. Automatic return of double acting cylinder with option of single cycle and auto cycle along
with speed control and rapid return.
3. Automatic retraction of double acting cylinder after delay; with arrangement for
confirmation of complete retraction.
4. Cycle A+, B+, delay, A-, B- to be executed for double acting cylinder A and single acting
cylinder B.
MODULE 2. ELECTRO-PNEUMATICS
5. A double acting cylinder is to be controlled by a single solenoid valve, using one push
button for extension and another for retraction
6. A double acting cylinder is to be controlled by a double solenoid valve. Use sensors /
reed switches for sensing the extended and retracted position of the cylinder, with option of
single cycle and auto cycle.
7. Cycle A+, B+, A-, B- to be executed for double acting cylinder A and single acting
cylinder B.
MODULE 3. PNEUMATICS USING PROGRAMMABLE LOGIC CONTROLLER
8. A cylinder is to automatically feed 10 work pieces on pressing a push button and then stop.
There should also be an alternate provision to manually stop the cylinder using a stop push
button.
9. A cylinder must move forward on pressing a push button, after a 10 second delay. It must
stay in the forward position for 5 seconds and then retract automatically. It must be capable
of continuous cycles until stopped by another push button.
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
3
Experiment No. 1
PNEUMATICS CIRCUIT:
CONTROL OF A
DOUBLE ACTING CYLINDER
WITH SPEED CONTROL IN
BOTH DIRECTIONS
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
4
CIRCUIT DIAGRAM FOR
Experiment No. 1
60
%
40
%
4 2
5
1
3
2
1 3
2
1 3
1 .0
A
1 .1
1 .5
B
1 .4
0 .1
1 .2 1 .3
2
1 3
0 .2
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
5
A i m: -
A do ub le a c t i n g cyl i nd e r i s t o ex t en d on p r e s s i n g a pu sh bu t t on A
an d r e t r ac t w h en a p us h bu t t on B i s p re s s ed . S p eed i s t o be con t r o l l ed i n bo th d i r ec t io ns .
Equ ip ment Us ed : -
S r . No . D es i gna t ion C o mp on en t D es cr ip t i on
1 1 . 0 D o ub le A c tu a t in g C yl i nd e r
2 1 . 1 5 /2 W ay V a l v e
3 1 . 2 3 /2 W ay V a l v e
4 1 . 3 3 /2 W ay V a l v e
5 1 . 5 O n e Wa y F l o w Co n t r o l v a l ve
6 1 . 4 O n e Wa y F l o w Co n t r o l v a l ve
7 0 . 2 3 /2 W ay V a l v e
8 0 . 1 FR L U n i t
9 C om pr ess o r
W or ki ng o f t he Ci r c u i t : -
T h e pu sh b u t t on A i s p r es sed th e 5 / 2 w a y v a l v e i s a c t iva t ed an d a i r f l o ws t o t h e rea r end o f t h e d ou b l e a c t i n g cyl i n de r t h ro u gh the ch eck v a l v e . T h e a i r comi n g ou t f r om th e f ro n t end o f t h e cyl i n der f l ow s th r ou gh t h e o n e w a y f l o w co n t r o l v a l ve and t hu s t h r o t t l i n g and s p eed co n t ro l t ak es p l ace . H en ce t h e c yl i n de r ex t end s t o i t s ex t r eme p os i t i on .
Wh en t h e p us h b u t to n B i s p r e s s ed t h e 5 /2 w ay v a l v e ge t s i t s p i l o t s i gn a l and i s d eac t iv a t ed . T h e a i r t h en f lo ws to t h e f r on t en d o f t h e do ub l e a c t in g cyl i n d e r t h r o u gh t h e ch eck v a l ve . Th e a i r comi n g ou t f r om th e r ea r en d o f t h e c yl i n de r f l o ws t h ro u gh t h e o n e w ay f l o w co n t ro l v a l v e and t hu s th r o t t l i n g and s p eed con t ro l t ake s p l ace o f t he r e t r a c t s t ro k e . H ence th e c yl i nd e r r e t ra c t s t o i t s ex t r em e p os i t i on .
R esu l t : -
T h e c i rcu i t a f t e r b e i n g con n ec t ed as sh o wn i n t h e c i rcu i t d i ag r am
s ho u l d wo rk a s ex p ec t ed . Th e c yl i nd e r s ho u l d ex t en d on p r e s s in g
b u t to n A and r e t r ac t on p r es s in g bu t t on B . S p eed C on t r o l du r i n g f o r w a rd an d r ev e rse s t r ok e sh ou ld be p os s i b l e b y ad j us t i n g th e s c r ews
o n th e f lo w con t ro l v a l v es o n ro d and cap en d , r e sp ec t iv e l y.
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
6
Experiment No. 2
PNEUMATICS CIRCUIT:
CONTROL OF A DOUBLE ACTING
CYLINDER : WITH AUTOMATIC
RAPID RETURN
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
7
CIRCUIT DIAGRAM FOR
Experiment No. 2
50
%
4 2
5
1
3
1
2
3
LS2LS1
2
1 3
2
1 3
2
1 3
LS1
1 1
2
2
1 3
LS2
1 .0
1 .0
1 .8
1 .31 .61 .4
1 .2
1 .1
1. 101 .5
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
8
A i m: -
A u t om a t i c r e t u rn o f d ou b l e a c t i n g cyl i n d e r wi th t h e op t io n o f
s in g l e and au t o c yc l e a lo n g wi t h sp eed con t r o l a n d r ap id re t u r n .
Equ ip ment Us ed : -
S r .N o D es i gna t ion C o mp on en t D es cr ip t i on
1 1 . 0 D o ub le A c tu a t in g C yl i nd e r
2 1 . 1 5 /3 W ay V a l v e
3 1 . 2 S hu t t l e V a l v e
4 1 . 3 3 /2 W ay V a l v e
5 1 . 4 3 /2 W ay V a l v e
6 1 . 10 O n e Wa y F l o w Co n t r o l V a l v e
7 1 . 5 Q u ick Ex h au s t V a lv e
8 1 . 6 3 /2 W ay V a l v e
9 1 . 8 3 /2 W ay V a l v e
1 0 0 . 1 FR L U n i t
1 1 C om pr ess o r
W o rkin g o f th e C ircu i t : -
3 /2 W ay V a l v e num b er ed 1 . 8 i s a l r e ad y ac t i v a t ed a t t h e s t a r t o f t he c yc l e . W h en t h e pu sh b u t t on "1 . 4 " i s p r es s ed , a i r f l ow s and
g i v e s an ac t iv a t in g p i lo t in g s i gn a l t o 5 /3 w ay v a l v e 1 .1 . T h e a i r t h en f l ow s th r ou gh t h e Q u i ck Ex h aus t Va l v e b yp as s and p r e s su r i z es t he
r e a r end o f t h e Dou b l e A c t i n g C yl i nde r w h i ch th en ex t en ds to ex t r em e
p os i t i on " LS 2 " . Th r o t t l i n g i s do n e th r ou gh a o n e w ay f l o w co n t ro l
v a lv e . "LS2 when ac t iva ted t r ips 3 /2 wa y v a l v e 1 .3 wh i ch g iv es d eac t iv a t in g p i l o t s i gn a l t o 1 .1 . A i r no w en t e r s t h e f ro n t en d o f t h e c yl i n d e r t h r ou gh th e check v a l v e and th e a i r f r om t he r ea r en d i s
r e l e as ed qu i ck l y t h r o u gh a Q u i ck Ex hau s t v a l v e . H en ce R ap id R e t u rn t ak es p l ace . I f t h e 3 /2 w a y v a l v e 1 . 6 i s s wi t ch ed o n th en mu l t i c yc l i n g wi l l o ccu r an d th e p ro ce ss w i l l r ep ea t i t s e l f .
R esu l t : -
T h e c i r cu i t i s t o b e co n n ec t ed a s s ho wn i n t h e c i r cu i t d i ag r am and
t e s t ed w i th p h ys i ca l com po n en t s . S in g l e C yc l e / M u l t i C yc l e
a r r an gement i s t o b e p ro v id ed i n t h e c i r cu i t . Rap i d re tu r n o f C yl i nd er
w i l l b e mad e pos s ib l e d u e t o t h e u se o f t h e Q u i ck Ex h aus t Va lv e . F l ow
o u t o f t h e c yl i n de r i s me t e r ed , t hu s f l o w co n t ro l d u r in g f o r w a rd s t r ok e
i s m ad e p os s ib l e . T h e c i r cu i t i s t h us fu n c t i on a l and ach i ev e s t he
o b j ec t iv es .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
9
Experiment No. 3
PNEUMATICS CIRCUIT:
CONTROL OF A DOUBLE ACTING
CYLINDER : AUTOMATIC
RETRACTION AFTER DELAY
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
10
CIRCUIT DIAGRAM FOR
Experiment No. 3
50%
2
1
12
3
4 2
5
1
3
2
1 3
2
1 3
LS12
1 3
LS2
LS1 LS2
2
1 3
1 .0
1 .3
0 .1
0 .2
1 .4
1 .21 .5
1 .1
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
11
A i m: -
A d o ub l e a c t i n g c yl in de r s ho u ld ex t end o n p r es s in g a p u sh b u t ton
A an d r e t r a c t au to m at i ca l l y a f t e r a d e l ay. A n a r r an gem ent t o co n f i rm co mpl e t e r e t r a c t i on sh ou ld b e in c lu ded in t he c i r cu i t .
W o rkin g o f th e C ircu i t : -
A t t h e s t a r t o f t h e c yc l e t h e c yl i nd e r i s i n r e t r a c t ed pos i t i o n and
h en ce 3 /2 Wa y V a l v e A i s a c t i v a t ed . W h en th e pu sh b u t to n A i s p r e s s ed , a c t i v a t i n g p i l o t s i gn a l i s g iven to t h e Do ub l e Ac t i n g C yl i n d e r 1 .0 . Th e cyl i n d er ex t end s t o i t s o u t e r m os t p os i t i on .
Wh en th e c yl i n d e r ex t en ds , LS 2 i s p r e s s ed , a i r f l o ws th r ou gh a t im e d e l a y c i r cu i t . Wh en t h e d e l a y i s co mp le t ed t h e d eac t i v a t i n g p i lo t s i gn a l i s s en t t o t he 5 /2 W ay v a l v e 1 . 1 , an d t he c yl i nd e r r e t u r ns t o t h e r e t r a c t ed p os i t i o n LS 1 . Th us the c i r cu i t s com pl e t e d .
S r . No . D es i gn a t io n C om po nen t D es cr ip t io n
1 1 . 0 D o ub le A c t i n g C yl i n d e r
2 1 . 1 5 /2 W ay V a l v e
3 1 . 2 3 /2 W ay V a l v e
4 1 . 3 3 /2 W ay V a l v e
5 1 . 4 3 /2 W ay V a l v e
6 1 . 5 T im e D el a y v a l ve
7 0 . 2 3 /2 W ay V a l v e
8 0 . 1 FR L U n i t
9 C om pr ess o r
R esu l t : -
T h e c i r cu i t w as con n ec t ed a s s ho wn i n t he c i rcu i t d i ag r am and
t e s t ed wi t h ph ys i ca l com po n en t s . Bo th ex tens io n and r e t r ac t io n a r e
p us h bu t to n con t ro l l ed . D u e t o t h e r o l l e r l im i t s wi t ch a t LS 1 co mpl e t e r e t r a c t i on i s con f i r m ed an d c yc l e w i l l no t s t a r t aga i n u n les s
t h e cyl i n de r i s i n r e t r a c t ed con d i t i o n . T im e D el ay v a l v e i s u sed whi ch
co n t ro l s t h e d e l a y b e tw een th e ro l l e r l imi t sw i t ch LS 2 an d r e t r ac t o f c yl i n d e r . T h e c i r cu i t w as th us fu n c t i on a l and ex p e r i m en t i s com pl e t ed .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
12
Experiment No. 4
PNEUMATICS CIRCUIT:
CONTROL OF A DOUBLE ACTING
CYLINDER A AND SINGLE ACTING CYLINER B TO EFFECT THE SEQUENCE:
A+ B
+ DELAY A
- B
-
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
13
4 2
5
1
3
2
1 3
A0 A1 B1B0
2
1 3
2
1 3
B0
50%
2
1
12
3
2
1 3
B1
2
1 3
A1
2
1 3
A0
2
1 3
1 .0
0 .1
0 .2
2 .3
2 .1
2 .2
1 .3
1 .5
1 .4
1 .2
1 .1
2.0
CIRCUIT DIAGRAM FOR
Experiment No. 4
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
14
A i m: -
Do ub le a c t i ng c yl i n d e r A and a s in g l e a c t in g c yl i nd e r B sh ou ld
ex ecu t e t h e c yc l e A+ , B+ , D e l a y, A - , B -
W o rkin g o f th e C ircu i t
A t th e s t a r t o f t h e c yc l e t h e c yl in d e rs A a nd B a r e i n r e t r a c t ed po s i t i o n an d hen ce v a l v e 2 .3 i s a c t i v a t ed . Wh en p ush b u t to n 1 .2 i s p r es s ed a c t iv a t in g p i lo t s i gna l i s s en t t o 5 /2 w a y v a l v e 1 .1 and h en ce C yl in de r "A " s t a r t s t o ex t en d . At f u l l ex t en s i on i t t r i p s 3 /2 w ay v a l v e 2 .2 du e t o sw i t ch A 2 . 2 . 2 g i v es ac t i v a t i n g p i lo t s i gn a l t o 2 .1 w h i ch i n t u r n c au s es S in g l e a c t i n g c yl i nd e r "2 . 0 " t o ex t en d .
3 /2 w a y v a l ve 1 .3 i s t r i p ped d u e t o ro l l e r l im i t s w i t ch B1 . A i r n ow f l o ws t h r o u gh a t im e d e l a y c i r cu i t . Wh en t h e d e l a y i s
co mpl e t ed d eac t i va t i n g p i l o t s i gn a l i s g iv e t o 1 . 1 C yl i n d e r A r e t r a c t s an d to u ches ro l l e r l imi t s wi t ch A 1 . T h i s i n t u rn c aus e s r e t r a c t o f B .
H en ce th e c yc l e i s comp l e t ed i n t he g i v en s eq uen ce A + , B+ ,
D e l ay, A - , an d B -
Equ ip ment Us ed : -
S r . No . D es i gna t ion C o mp on en t D es cr ip t i on
1 1 . 0 D o ub le A c t i n g C yl i n d e r A
2 1 . 1 5 /2 W ay V a l v e
3 1 . 2 3 /2 W ay V a l v e
4 1 . 3 3 /2 W ay V a l v e
5 1 . 5 T im e D el a y v a l ve
6 2 . 0 S i n g l e A c t i n g C yl in d e r B
7 2 . 1 3 /2 W ay V a l v e
8 2 . 2 3 /2 W ay V a l v e
9 2 . 3 3 /2 W ay V a l v e
1 0 0 . 2 3 /2 W ay V a l v e
1 1 0 . 1 FR L U n i t
1 2 C om pr ess o r
R esu l t : -
T h e c i r cu i t w as con n ec t ed a s sh ow n in t h e c i r cu i t and t es t ed wi th
p h ys i ca l co mp on en t s . Do ub le A c t i n g an d S i n g le A c t i n g Cyl i n d e rs hav e
b een us ed t o p e r f o r m th e g i v en s eq uen ce o f op e r a t i on s . A s r equ i r ed
ex t ens io n o f B s t a r t s o n l y a f t e r co n f i rm a t io n o f ex t ens i on o f A b y
r o l l e r l i mi t s wi t ch . S imi l a r l y B r e t r ac t s a f t e r t he co nf i rm at io n o f f u l l
r e t r a c t i on o f A . Th e c i r cu i t w as th us f u nc t io n a l and ex p e r im en t i s
co mpl e t e .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
15
Experiment No. 5
ELECTRO-PNEUMATIC CIRCUIT:
CONTROL OF DOUBLE ACTING
CYLINDER USING SINGLE
SOLENOID SPRING RETURN
VALVE
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
16
4 2
5
1
3
Y1
+24V
PB1
K1
K1
Y1
0V
1 .0
1 .1
1 2
2
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
17
A i m: -
A D ou b l e A c t in g cyl i n d e r i s t o b e con t ro l l ed b y a 5 /2 wa y s i n g le
s o l eno i d , s p r in g r e tu r n v a l ve .
W o rkin g o f th e C ircu i t
O n keep i n g t h e Pu sh bu t to n p r es s ed . R e l a y K ge t s en e r g i zed
w h ich caus es m ake S w i t ch K 1 to c l ose an d ac t i v a t es So len o i d Y I . D u e
t o t h i s a c t i v a t i n g p i l o t i n g s i gn a l i s g i v en t o so l eno id an d po r t 1 i s
co nn ec t ed to po r t 4 . Th i s r esu l t s i n t h e ex t ens i on o f 1 . 0 . Fo r f u l l
ex t ens io n th e pu sh b u t to n ha s t o b e k ep t p re s s ed .
Wh en t h e pu sh b u t to n i s r e l e as ed t he e l e c t r i c s i gna l i s cu t - o f f
an d du e to s p r in g r e t u rn ac t i on , t h e 5 / 2 w a y S i n g l e So l en o id V a lv e
s h i f t s t o co nn ec t po r t 1 t o p o r t 2 . Ai r n o w f l ow s i n t o t he an nu lu s o f t h e
c yl i n d e r , t h us c au s i n g i t t o r e t r a c t t o i t s o r i g in a l p os i t i on .
Equ ip ment Us ed : -
S r .N o . D es i gna t ion C o mp on en t D es cr ip t i on
1 1 . 0 D o ub le A c t i n g cyl i n d e r
2 1 . 1 5 /2 W ay S i n gl e So len o i d V a l ve
3 K 1 R e l a y
4 Y 1 S o l en o i d
5 P B1 P us h Bu t t on
6 2 4 V E l ec t r i c con nec t i on
7 C om pr ess o r
R esu l t : -
T h e c i r cu i t w as as sem bl ed a s sh ov . l l 1 i n t h e c i r cu i t wi t h p h ys i ca l
co mp on en t s . Th e c yl i n d e r ex t end ed w h i l e t h e p us h b u t to n was kep t
p r e s s ed and r e t r ac t ed as s oo n as i t w as r e l e as ed . H en ce a Do ub le
A c t i n g C yl i n d er was con t r o l l ed b y a 5 /2 W a y S i n g l e So l eno i d , Sp r i n g
R e t u rn V al v e . T hu s t h e c i r cu i t was f un c t io n a l and ach i ev ed i t s
o b j ec t iv es .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
18
Experiment No. 6
ELECTRO-PNEUMATIC CIRCUIT:
CONTROL OF DOUBLE ACTING
CYLINDER USING DOUBLE
SOLENOID VALUE, TO EFFECT
AUTOMATIC EXTENTION AND
RETRACTION USING PROXIMITY
SENSORS
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
19
A0 A1
4 2
5
1
3
Y1 Y2
+24V
PB1
A0
K1
K1
Y1
A1
K2
K2
Y2
0V
1 3 4 6
3 6
1.0
1.1
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
20
A i m: -
A do ub l e a c t i n g cyl in de r i s t o b e con t r o l l ed b y a 5 / 2 w ay d o u b l e s o l eno i d v a lv e . An i n du c t i v e p r ox imi t y s en s o r i s t o b e u s ed to s en s e
t h e r e t r a c t ed po s i t i o n an d a c ap ac i t i ve s en so r t o b e u s ed to s ens e the
ex t en ded po s i t i o n o f t h e ac tu a t o r .
W o rkin g o f th e C ircu i t
C yl i nd e r 1 .0 i s i n i t i a l l y i n i t s i n i t i a l l y p o s i t i o n a s s how n i n t h e
c i r cu i t d i ag r am . At p os i t i o n A1 In d u c t iv e P rox imi t y S wi t ch i s ON. H en ce on p r es s in g t h e p us h bu t to n . Re l a y, K l ge t s a c t iv a t ed w hi ch in
t u rn en e r g i z es So len o i d Y I . T h i s cau s es C yl i nd e r 1 .0 t o ex t end to
p os i t i on A2 .
A t A 2 C ap ac i t i v e P r ox im i t y S w i t ch i s t u rn ed O N an d h ence R e l a y K 2 ge t s a c t i v a t ed w h ich in t u r n en er g i z e s S o l en o i d Y2 . Th i s c aus es
C yl i nd e r 1 . 0 t o r e t r a c t t o po s i t i o n A 1 T h e c yc l e c an be r ep ea t ed b y
p r e s s i n g t h e pus h bu t t on aga i n .
Equ ip ment Us ed : -
S r . No . D es i gn a t io n C om po nen t D es cr ip t io n
1 1 . 0 D o ub le A c t i n g C yl i n d e r
2 1 . 1 5 /2 W ay D o u b l e So l eno i d V a l v e
3 K 1 R e l a y
4 K 2 R e l a y
5 Y 1 S o l en o i d
6 Y 2 S o l en o i d
7 In d u c t iv e P rox imi ty S w i t ch
8 C apac i t i v e P r ox imi t y S wi t ch
9 P us h Bu t t on
1 0 2 4 V E l ec t r i c con nec t i on
1 1 C om pr ess o r
R esu l t : -
T h e c i r cu i t w as a s sem bl ed as s ho wn i n t h e c i r cu i t wi t h phys i ca l
co mp on en t s . Th e cyl i n d e r wi l l ex t en d o n l y w h en r e t r ac t ed pos i t i on i s
co n f i rm ed b y an In d u c t i v e P r ox imi t y S wi t ch and t he p ush bu t to n i s p r e s s ed . O n fu l l ex t ens i on C ap ac i t i v e P rox i mi t y S wi t ch ge t s a c t i v a t ed
w h ich au t om at i ca l ly c au s e s c yl i nd e r 1 . 0 t o re t ra c t H en ce a D ou b l e
A c t i n g C yl i n d e r w as co n t ro l l ed b y a 5 /2 W ay D o u b l e So l en o i d V a l v e
an d ex t r em e po s i t i o ns w er e s ens ed b y C ap ac i t i v e an d i ndu c t iv e p r ox imi t y S w i t ch es . Th us th e c i r cu i t w as f un c t io n a l and ach iev ed i t s
o b j ec t iv
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
21
Experiment No. 7
ELECTRO-PNEUMATIC CIRCUIT:
CONTROL OF A DOUBLE ACTING
CYLINDER A AND SINGLE ACTING CYLINER B TO EFFECT THE SEQUENCE:
A+ B+ DELAY A- B- ;
USING REED SWITCHES AND
SENSORS
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
22
4 2
5
1
3
Y1 Y2
2
1 3
Y3
B0 B1 S0 S1
+24V
0V
PB1
S0
Y1
B1
K2
K1
K1
S1
Y2
B0
K2
K1
Y3
1 .0
2 .1
2 .0
1 .1
1 3 4 5 7 8
4
8
3
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
23
A i m: -
D o ub le ac t in g c yl i n d e r A & a s in g le a c t i n g c yl i nd e r B s h ou ld
ex ecu t e t he c yc l e A + , B+ , A - , B - . Ex t ens i on o f B i s t o s t a r t on l y a f t e r a
s e t o f p r es su r e i s r e ach ed in A , as s ens ed b y a p r e s su r e s wi t ch .
Ex t end ed & r e t r ac t ed p os i t i o ns o f A a r e t o b e s ens ed b y r eed s wi t ch es & t h a t o f B a r e t o be s en sed b y p r ox i mi t y s en s o rs .
W o rkin g o f th e C ircu i t : -
In i t i a l l y C yl i n d e rs A and B a r c i n r e t ra c t ed s t a t e an d h ence R eed
S wi t ch B l an d In d u c t iv e P r ox imi t y S w i t ch S 1 a r c a c t i va t ed r e s pec t iv e l y
o n p r e s s i n g th e pus h b u t to n So leno id Y 1 i s ene r g i z ed . A i r f l o w s f r om
p o r t 1 t o p o r t 4 o f t h e 5 / 2 W ay d o ub l e S o l en o i d V a l ve . T h i s c au ses
C yl i nd e r A to ex t en d . A P r es su r e s wi t ch "P 1 " i s con n ec t ed to t h e cap
en d o f 1 .0 w h i ch sen s es t h e in c r eas e i n p r es su r e t o t h e r eq u i r ed p r e se t
an d t h en "c lo s es " . A s r eed s wi t ch B2 i s a l s o O N . Re l a y K I ge t s
a c t i v a t ed and en e r g i z es s o l en o id Y 3 , A i r f l ow s f r om po r t 1 t o p o r t 2 o f
3 /2 W ay S i n g l e So l eno i d Va lv e . H ence c yl i n d er 8 ex t en ds to p os i t i on
S 2 .
C apac i t i v e P rox imi t y S w i t ch S2 ac t i v a t es so l en o id Y2 d u e t
w h ich C yl i nd e r A re t r ac t s t o i t s o r i g i na l po s i t i o n as po r t I i s co nn ec t ed
t o p o r t 2 o f 1 . 1 . R eed Sw i t ch 81 i s n ow in c los ed co nd i t i on and
ac t i v a t es r e l a y K 2 w hi ch caus e s N o rm al l y C l o sed (N C) s wi t ch K2 to
o p en ; hen ce deac t iv a t in g r e l a y K 1 w h i ch in - t u rn d c - en er g i z e s so l eno id
Y 3 . Va lv e 2 . 1 s h i f t s d u e t o s p r in g r e t u r n and po r t 2 i s con n ec t ed to
d r a i n . Th i s c aus es C yl i nd e r B r e t r ac t s d ue t o i t s s p r in g re t u r n ac t io n .
Equ ip ment u sed: -
S r . No . D es i gn a t io n C om po nen t D es cr ip t io n
1 1 . 0 D o ub le A c t i n g C yl i n d e r
2 2 . 0 S i n g l e A c t i n g C yl in d e r
3 1 . 1 5 /2 W ay D o u b l e So l eno i d V a l v e
4 2 . 1 3 /2 W ay D o u b l e So l eno i d V a l v e
5 K 1 R e l a y
6 K 2 R e l a y
7 Y 1 S o l en o i d
8 Y 2 S o l en o i d
9 Y 3 S o l en o i d
1 0 B 0 R eed S wi t ch
1 1 B 1 R eed S wi t ch
1 2 S 0 In d u c t iv e P rox imi ty S w i t ch
1 3 S 1 C apac i t i v e P r ox imi t y S wi t ch
1 5 P B 1 P us h Bu t t on
1 6 2 4 V E l ec t r i c a l conn ec t io n
1 7 C om pr ess o r
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
24
R esu l t : -
T h e c i r cu i t w as a s s embl ed as s ho wn I t h e c i r cu i t d i ag ram us i n g
p h ys i ca l com po n en t s . C yl i n d e r A ex t en ds & a f t e r s u f f i c i en t p r e s s u r e i s
b u i l t up , on l y t h en d o es Ex tens io n o f B t ak e s p l ace . O N co n f o r m at i on
o f fu l l ex t en s i on o f B as s e ns ed b y c ap ac i t i ve p r ox imi ty s w i t ch r e t r a c t
o f cyl i n d e r A t ake s p l ace whi ch i s con f i r med b y R eed S wi t ch B1 .
f i na l l y C yl i n d e r B r eac t s t o S 1 . T he C yc l e c an b e repea t ed aga i n b y
p r e s s i n g t h e Pu sh Bu t t on . T hu s , t h e c i r cu i t i s f un c t io n a l & ach iev es i t s
o b j ec t iv es .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
25
Experiment No. 8
ELECTRO-PNEUMATICS CIRCUIT USING PLC:
A cylinder is to automatically feed 10
work pieces on pressing a push button
and then stop. There should also be an
alternate provision to manually stop the
cylinder using a stop push button.
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
26
C IR C U IT D IA G R AM FOR
Ex pe r im en t No . 8
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
27
A i m: -
A c yl i n d e r i s t o au t om at i ca l l y f e ed 10 w o rk p i eces on p r e s s in g a p u sh
b u t to n and t h en s to p . Th e r e s ho u ld a l so b e an a l t e r n a t e p ro v i s io n to
m anu a l l y s t op t h e cy l i n d e r us i n g a s t op pus h bu t t on .
Equ ip ment Us ed : -
S r . No . D es i gna t ion C o mp on en t D es cr ip t i on
1 1 . 0 D o ub le A c tu a t in g C yl i nd e r
2 1 . 1 5 /2 W ay V a l v e
3 0 . 1 FR L U n i t
4 C om pr ess o r
W o rkin g o f th e C ircu i t : -
Wh en P us h Bu t to nP B1 i s p r es sed , t h e f l ag i s en e r g i z ed an d th e Co un te r
s t a r t s i t s o p er a t io n . S i n ce th e f l ag and t he co un t e r a r e en e r g i z ed , t he
s ub s eq u en t r un gs wi l l s eq u en t i a l l y ge t en e r g i z ed u n t i l t h e se t cou n t i s
r e ach ed o r t h e f l ag i s r es e t b y t h e S t o p Bu t to n S B .
A s lo n g as t he f l ag i s s e t , i f C yl i n de r A i s i n t h e r e t ra c t ed p os i t i on ,
Li m i t S wi t ch A 0 i s s wi t ch ed on and th us a s s een f ro m t h e l ad d er
d i ag r am , S o l en o i d Y 1 w i l l en e r g i s e and cau s e t h e c yl i nd er t o ex t end .
A s th e cyl i n d er fu l l y ex t en ds , l imi t sw i t ch A1 wi l l be sw i t ch ed o n and
f r om t h e ru n g , w e can s ee th a t So l en o i d Y2 w i l l ge t en e rg i z ed , t h e reb y
cau s in g th e cyl i n d er t o r e t r a c t .
E ach t im e th e So len o i d Y2 i s en e r g i z ed , t h e cou n t e r i n c r em en t s b y a
co un t o f 1 . O n ce th e cou n t e r r e ach es t he s e t v a l u e , wh ich i s 1 0 in t h i s
c a s e , i t d e - en e r g i s es an d t he en t i r e c i rcu i t i s r es e t u n t i l t h e s t a r t b u t t on
i s p re s s ed aga in .
R esu l t : -
T h e c i r cu i t a f t e r b e in g con n ec t ed a s sh ow n i n t h e c i r cu i t d i ag r am
s ho u l d wo rk a s ex p ec ted . T h e cyl i n d e r sh ou ld ex t en d o n p re s s in g the
b u t to n on th e s wi t ch bo a r d an d ex ecu t e 1 0 s t ro kes . A t t h e en d o f t he
1 0t h
s t ro k e i t sh ou ld s to p au to m at i ca l ly .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
28
A l l o ca t i on l i s t and Ladd er d i ag ra m f o r E xp er i ment 8 :
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
29
Experiment No. 9
ELECTRO-PNEUMATICS CIRCUIT USING PLC:
A cylinder must move forward on
pressing a push button, after a 10
second delay. It must stay in the
forward position for 5 seconds and then
retract automatically. It must be capable
of continuous cycles until stopped by
another push button.
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
30
C IR C U IT D IA G R AM FOR
Ex pe r im en t No . 9
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
31
A i m: -
A c yl i nd e r mu s t mo v e f o rw a rd on p re s s i n g a pus h b u t to n , a f t e r a 10
s econ d d e l a y. I t mu s t s t ay i n t h e f o rw a r d p os i t i on fo r 5 s eco nd s and
t h en r e t r a c t au to ma t i ca l l y . I t m u s t b e cap ab l e o f co n t in uo us cyc l es
u n t i l s t op ped b y an o th e r p ush b u t to n .
Equ ip ment Us ed : -
S r . No . D es i gna t ion C o mp on en t D es cr ip t i on
1 1 . 0 D o ub le A c tu a t in g C yl i nd e r
2 1 . 1 5 /2 W ay V a l v e
3 0 . 1 FR L U n i t
4 C om pr ess o r
W o rkin g o f th e C ircu i t : -
Wh en Pu sh Bu t t onP B1 i s p r e s s ed , t he f l ag i s en e r g i z ed an d th e T im er
s t a r t s i t s o pe r a t io n . S in ce th e f l ag and th e t im e r TO N0 a r e en er g i z ed ,
t h e su bs equ en t ru ng w i l l ge t en er g i z ed on l y a f t e r t he s e t t im e h as
e l aps ed . A s th e o pen co n t ac t o f T im er c lo se s , s o l eno i d Y 1 i s en er g i zed
an d t h e cyl i n d er ex t en ds . A f t e r t h e c yl i n d e r h a s f u l l y ex t en d ed , t h e
t im e r T O N1 i s en er g i z ed an d i t s co n tac t i n t h e s ub seq uen t rn g c lo s es ,
a f t e r wh i ch s o l en o id Y2 i s en e r g i z ed cau s i n g th e cyl i n d er t o r e t ra c t .
A s l on g a s t h e f l ag i s s e t , t h i s s equ ence w i l l con t in ue , un l es s t h e s top
b u t to n i s p r es s ed .
R esu l t : -
T h e c i r cu i t a f t e r b e in g co nn ec t ed as s ho wn in t he l ad d e r d i ag r am
s ho u l d w o rk a s ex pec t ed . Th e cyl i n d er s ho u l d ex t end 10 s econ ds a f t e r
p r e s s i n g th e bu t ton o n th e sw i t ch bo a r d an d s t a y i n t h e ex t end ed
p os i t i on f o r 5 s econ ds . Th i s s equ en ce s h ou l d con t in u e t i l l s t o p b u t t on
i s p re s s ed .
LABORATORY MANUAL : AUTOMATION AND CONTROL ENGINEERING
32
A l l o ca t i on l i s t and Ladd er d i ag ra m f o r E xp er i m ent 9 :
Recommended