M Tech Fluid Power Manual

SCHOOL OF MECHANICAL AND BUILDING SCIENCES
2008-2009
SMBS-MECHATRONICS DIVISION
FLUID POWER SYSTEM AND FACTORY AUTOMATION
Part - A
Development of ladder logic and simulate by using

Picosoft 3.0
Part - B
Design and simulation of hydraulic and pneumatic circuit using Automation

studio software
Part - C
Electro pneumatic and hydraulic circuit
SCHOOL OF MECHANICAL AND BUILDING SCIENCES
FLUID POWER SYSTEM AND FACTORY AUTOMATION

M.Tech - Mechatronics
Fall Semester 2014
NAME
REGISTER NO.
MEE 528 : FLUID POWER SYSTEM AND FACTORY AUTOMATION
Certified that, this is a bonafide record of work done by Mr. / Ms. _________________________________________
M.Tech. (Mechatronics) during the year Fall semester 2014.
University Registration No.
Date:
Faculty In-Charge
Submitted for the Term End Practical Examination held on ________________________.
INTERNAL EXAMINER
EXTERNAL EXAMINER
1.
STUDY OF PROGRAMMABLE LOGIC CONTROLLER

& PLC PROGRAMMING EXERCISES
Programmable Logic Controller- An overview

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 interwiring 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 the "brains" of the PLC. It is often referred to as a microprocessor or sequencer. 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 may be as short as 15 milliseconds or less. 15 milliseconds per scan would produce
67 scans per second. 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.
Part A
Development of ladder logic and simulate by using Picosoft 3.0
Ex. No: 1
PLC CONTROL PROBLEM - 1
Date:
When an ON PUSH button is pressed motor A and Motor B should go ON immediately and after a time delay of
10seconds motor C should go ON. When an OFF push button is pressed all the 3 motors should go off.
-----------------------------------------------------------------------------------------------------------------------------Objective:
To develop the PLC ladder logic diagram for given control problem and to simulate the program accordingly to the
stated conditions using PLC software.
Components Required:
PLC Module
PLC software (PICO Soft / MicroWin STEP 7)
Computer system
PLC-PC Interface Data Cable
Patch cords
Procedure :
Create Ladder Logic Program

Simulate and Test Ladder Logic Program
Transfer Ladder Logic Program
Printout a circuit diagram.
Ladder Diagram:
REPORT:
Ex. No: 2
Date:
Motor A should go ON when an ON push button 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:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
10
Ex. No: 3
PLC CONTROL PROBLEM 3
Date:
A motor is to be switched ON from three places by any one ON push buttons. Likewise the motor can be switched OFF
from any three places by any of the off buttons. A master reset switch should reset the motor any time if it is pressed.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
11
Ex. No:4
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
12
Ex. No: 5
Date:
Design a PLC program and prepare a I/O connection diagram for the following counter specifications:
a)
Counts the no. of times a push button is pressed.
b)
Decrement the counter value each time a second push button is pressed.
c)
Turns on a light any time the counter accumulated value is less than 8.
d)
Turns on a second light when the counter value is equal to or greater than 8.
e)
Resets the counter to zero when a selector switch is closed
----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
13
Ex. No: 6
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
14
Ex. No: 7
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
15
REPORT:
Ex. No: 8
Date:
Develop the ladder logic that will turn on an output light, 15 seconds after switch A has been turned ON
----------------------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
16
17
Ex. No: 9
Date:
Write PLC program to operate a light according to the following sequence:
a)
A momentary push button is pressed to start the sequence.
b)
The light is switched on and remains on for 2 s.
c)
The light is then switched off and remains off for 2 s.
d)
A counter is incremented by 1 after this sequence.
e)
The sequence then repeats for a total of 4 counts.
f)
After the 4th count, the sequence will stop and the counter will be reset to zero.
------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Report:-
18
Ex. No: 10
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

REPORT:
19
Ex. No: 11
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Printout a circuit diagrams.
REPORT:
20
Ex. No: 12
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

REPORT:
21
Ex. No: 13
Date:
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.
-----------------------------------------------------------------------------------------------------------------------------Objective:
PLC Module
Computer system
Patch cords
Procedure :

Ladder Diagram:
REPORT:
22
Part B
Design and simulation of hydraulic and pneumatic circuit using

Automation studio software
23
Automation Studio An 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.
Dynamic and Realistic Simulation in Full Color.
Thousands of Symbols in Modular Libraries
BOM, Parts Catalog and Database Link Interfaces to Programmable Logic Controllers (PLCs) and
Equipment
A New Generation of Tools for the Automation and Fluid Power Industries
Automation Studio will play a useful role in both design and training in the following array of interrelated fields of
activities:
Industrial hydraulic systems
Industrial pneumatic systems
Mobile hydraulic systems
Electrical controls systems
PLC controls applications
Automated controls applications
Technical publications
Service and troubleshooting
24
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 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, 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.
25
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.
26
Ex. No: B1
Date:
PNEUMATIC CYLINDER RECIPROCATION USING LEVER / PUSH BUTTON OPERATED DIRECTION CONTROL
VALVE
Aim:
To design a pneumatic control circuit for the given sequence of operation and to simulate in Automation studio
software.
Sequence of operated:
A+ A- : Lever operated / Push Button.
Requisites:
Component selection from Automation Studio Software
1.
Double acting actuator
2.
FRL unit.
3.
5/2 valve with lever operated.
Procedure:
1.
The circuit is designed as per the control problem given.
2.
The components are selected from Automation Studio library and proper connections are made.
3.
The designed circuit is simulated and studied for different parameters.
Inference:
The connected circuit is error free and the required sequence of motion is obtained.
27

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SCHOOL OF MECHANICAL AND BUILDING SCIENCES

FLUID POWER SYSTEM AND FACTORY AUTOMATION

Development of ladder logic and simulate by using

Design and simulation of hydraulic and pneumatic circuit using Automation

Electro pneumatic and hydraulic circuit

SCHOOL OF MECHANICAL AND BUILDING SCIENCES

FLUID POWER SYSTEM AND FACTORY AUTOMATION

Fall Semester 2014

MEE 528 : FLUID POWER SYSTEM AND FACTORY AUTOMATION

University Registration No.

Submitted for the Term End Practical Examination held on ________________________.

STUDY OF PROGRAMMABLE LOGIC CONTROLLER

Programmable Logic Controller- An overview

PLC CONTROL PROBLEM - 1

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 2

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM 3

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 4

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM 5

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

Resets the counter to zero when a selector switch is closed

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 6

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 7

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 1

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 9

A momentary push button is pressed to start the sequence.

The light is switched on and remains on for 2 s.

The light is then switched off and remains off for 2 s.

A counter is incremented by 1 after this sequence.

The sequence then repeats for a total of 4 counts.

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 10

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagram.

PLC CONTROL PROBLEM - 11

Create Ladder Logic Program

Transfer Ladder Logic Program

Printout a circuit diagrams.