SRM Institute of Science and Technology

Faculty of Engineering and Technology

SRM Nagar, Kattankulathur- 603 203
Kancheepuram District, Tamil Nadu

15ME304L - AUTOMATION LAB

OBSERVATION
 Automation Laboratory
Safety Precautions

General:
 Users must adhere to safety procedure of the laboratory.
 Unauthorized persons are not permitted in the laboratory.
 Dress Code : Uniform with shoes
Safety Precautions:
 Do not exceed the maximum permissible pressure of 2 bar, in pneumatic work
benches.
 Do not open compressed air until pneumatic connections have been completed
and secured.
 Do not disconnect tubing while under pressure.
 Danger of accident due to pneumatic tube slipping off!
– In the event that tubing slips off: Switch OFF the compressed air supply
immediately.
– Use shortest possible tubes for connections.
 Connect the devices with plastic tube with an outside diameter of 6 mm.
 Push the tube into the one touch connector firmly.
 Air supply should be given only after due verification of the circuit.
 Switch OFF the compressed air supply before dismantling the circuit.
 Do NOT use compressed air to clean parts of your body or clothing or to
perform general space cleanup.
 NEVER attempt to stop or repair a leak while that portion is still under pressure.
 Danger of injury during troubleshooting!
 Use a tool to actuate the limit switches. (For example a screwdriver).
 For electro pneumatic circuits - Use low voltage only (max. 24 V DC).
 Electrical connections should be checked for its correctness before switching
ON the supply.
 SRM Institute of Science and Technology
Faculty of Engineering and Technology
Department of Mechanical Engineering
15ME304L - AUTOMATION LAB

List of Experiments

CYCLE I

1. Speed control circuits for double acting cylinder.

2. Synchronization circuit for two cylinders.

3. Continuous reciprocation of double acting cylinder.

4. Logic operations AND, OR in pneumatic circuits.

5. Sequencing of two cylinders Circuit.

6. Cascading circuit for trapped signals – 2 Cylinder.

CYCLE II

7. Cascading circuit for trapped signal – 3 Cylinder.

8. Sequencing of two cylinders using electro pneumatic circuits

9. PLC control pneumatic / hydraulic linear actuator Circuits.

10. a) Speed control of AC servo motor.

b) Velocity calculations in hydraulic linear actuation.

11. a) Process control using virtual instrumentation.

b) Pick and place operation using ABB Robot – Demo.

12. Mini project.

 SYMBOLS
SUPPLY COMPONENTS
Variable
Compressor
compressor

Air service unit FRL

Air filter
Air filter
manual drain

Air filter
Lubricator
automatic drain

Air cooler Air dryer

PNEUMATIC ACTUATORS

Double Acting
Single Acting Cylinder With
Cylinder Two Cylinder

Double Acting
Double Acting Cylinder With
Cylinder Double Side
Rod
Double Acting Double Acting
Cylinder Cylinder
Adjustable (Rodless
Cushioning Cylinder)
Multi piston
cylinder double
acting

Semi Rotary
Air Motor
Air Motor
DIRECTION CONTROL VALVES
2 4 2

2/2 Valve 5/2 Valve

5 3
1 1

4 2
2
3/2 Valve 5/2 Single Pilot
Valve
5 3
1 3
1

4 2
4 2
4/2 Valve 5/2 Double Pilot
Valve
5 3
1 3
1

2 2

3/2 Roller 3/2 Single

Valve Solenoid Spring
1 3
1 3 Return Valve
2 5/2 Single 4 2

3/2 Idler Solenoid

Roller Valve Operated Spring
5 3
1 3 Return DCV 1

2 4 2

5/2 Double
3/2 Single Solenoid
5 3
Pilot Valve 1 3 Operated DCV 1

4 4
6 2 6 2
5/3 Double
6/2 Valve Solenoid
Operated Spring
5 3 5 3
1 Balance DCV 1

4 2
5/3 Double
Pilot Operated Propositional
Spring 5 3 Valve
Balance Valve 1

One Way
Throttle Valve Direction Flow
Control Valve
2

Nozzle 1 1
OR Valve /
Shuttle valve
2
Orifice AND Valve / 1 1
Twin pressure
valve
 2 1 Spring Loaded 2 1
Check Valve Check Valve

2
2
Pilot operated 12
Quick exhaust 1
check valve valve 3
1

2 2

Time delay
12 Time delay 10
valve with
valve with
normally
3 normally open 3
closed
1 1

2 2

Variable Variable
Pressure Relief Pressure
Valve 1 Reducing Valve
3 1

ELECTRICAL CONTROLS
0V +24V
Electrical connection Electrical connection
0 volt 24 volt

3 1

Mack Switch Break switch

4 2

3 1
Manual operated push Manual operated push
button – Mack switch button –Break switch
4 2

3 1
Manual operated push Manual operated push
button button
Mack switch- Detent 4 Break switch- Detent 2

A1

Relay Solenoid
A2

A1 A1

5 OFF Delay Timer 5

ON Delay Timer
A2 A2

A1 R1
5
Proportional valve
Counter A2 R2 solenoid
HYDRAULIC COMPONENTS

Fixed Variable
Displacement Pump Displacement Pump

Oil Filter
Accumulator

Cooler Heater

P T

Pump Unit
Filter Ts

Hydraulic Motor Hydraulic semi

rotary actuator

Tank

PRESSURE CONTROL VALVE

Pressure Relief Pressure Reduce

P

A
T

P
Valve Valve

Pressure Relief Valve

A

P
P

With Pilot Variable Pressure

T

Control Reduce Valve

Shutoff/Counteracting 3 - Way Pressure

T
P

Valve Reducing Valve

P
X
Y

Closing Pressure Variable Closing

Compensator Pressure
A

A
P

Compensator
X
X
Y

Opening Pressure Variable Opening

Compensator Pressure
A

A
P

Compensator
X

X
Department of Mechanical Engineering
Automation Lab
 CIRCUIT DIAGRAM

Meter in circuit for slow extension Meter in circuit for rapid extension
and rapid retraction and slow retraction

Department of Mechanical Engineering

Automation Lab
 SPEED CONTROL CIRCUITS FOR DOUBLE ACTING CYLINDER
AIM
To devise and simulate possible ways of speed control circuits for a
double acting cylinder.

APPARATUS REQUIRED:
Hardware Required
1. Flow Control Valve,
2. FRL Unit,
3. 5/2 or 5/3 or 4/3 Direction Control Valve (DCV),
4. Double acting Cylinder,
5. Connectors
6. Hose
SOFTWARE REQUIRED
Festo Fluid SIM

THEORY:
In a meter in circuits, a flow control valve is connected to the forward
stroke of the cylinder. This way the forward stroke can be controlled for the meter in
circuit. In a meter out circuits the flow control valve is connected the reverse stroke
of the cylinder and hence control the forward stock.
When the flow control valve is connected and part of the air is exposed to the
atmosphere and hence speed can be control. This circuit is known as bleed off
circuit. Then circuit can be used to forward stroke of the cylinder piston.
PRE-LAB QUESTIONS
1. Define fluid power.
2. Draw the block diagram of a basic pneumatic system.
3. What are different types of valves used in Pneumatic circuit?
4. What is FRL?
5. What are the different valves used for speed control?
6. Name the three speed control circuits.
7. What is the use of compressor?
8. Draw the symbol for check valve
9. Draw the symbol for flow control valve
10. Draw the symbol for 5/2 DCV.

Department of Mechanical Engineering

Automation Lab
 12

CIRCUIT DIAGRAM

Meter out circuit for slow extension Meter out circuit for rapid extension
and rapid retraction and slow retraction

Department of Mechanical Engineering

Automation Lab
PROCEDURE:
1. The main supply is connected to the input of FRL Unit.
2. The FRL Unit connected to the 5/2 DCV and to a flow control valve.
3. Valve using a “T” joint in case of bleed of circuit.
4. From the DCV, a pipe is connected to the cylinder head end with a flow control
valve in between in the case of a meter in circuit.
5. From the other end of cylinder, a pipe line is connected back to the exhaust fort
of DCV with flow control valve in between in the case of a meter out circuit.
6. Air supply was supplied to the circuits and the connection of the operation of the
three circuits was checked.
7. Similarly by using festo fluid SIM software three circuits were constructed and
simulated.
POST LAB QUESTIONS:
1. What is the difference between Meter - in and Meter- out circuit?
2. What is the use of check valve?
3. In double acting cylinder
a) Extension stroke is faster than retraction stroke
b) Retraction stroke is faster than extension stroke
c) Both are same
d) depends on the type of pump used
4. What is advantage of meter– out control over meter- in control?

Department of Mechanical Engineering

Automation Lab
 CIRCUIT DIAGRAM

Bleed of circuit

Department of Mechanical Engineering

Automation Lab
Application problem
Draw a suitable speed control circuit for controlling the load
on a down-acting vertical cylinder. Justify your answer.

INFERENCE:

RESULT:
Thus the possible ways of speed control circuits namely meter in, Meter out and
bleed of circuit were devised and simulated.

Department of Mechanical Engineering

Automation Lab
 Synchronization circuit –parallel

Department of Mechanical Engineering

Automation Lab
 SYNCHRONIZATION CIRCUIT FOR TWO CYLINDERS

AIM
To devise and simulate the synchronization circuits in parallel and series for
two cylinders.

APPARATUS REQUIRED:
Software Required
Festo Fluid SIM - Hydraulic

THEORY
Two identical cylinders can be synchronized by piping them in series or
parallel. However, it is necessary for the load on the cylinders to be identical in order for
them to extend in exact synchronization. When loads differ, the cylinder with the lower
load would extend first since it moves at a lower pressure when this cylinder has
completed its stroke, the system pressure increases and then the cylinder with the
greater load will extend. No two cylinders are completely identical as differences in
passing function will vary from cylinder to cylinder. This would prevent exact cylinder
synchronization in any circuit.

PRE-LAB QUESTIONS
1. State the design considerations followed for a pneumatic circuit.
2. What are the applications of fluid power?
3. What are the different compressors used to compress the air?
4. When the air cushion is required?
5. What are the different valves used in pneumatics?
6. What is pneumatic direction control valve?
7. Differentiate between hydraulic and pneumatic systems?

Department of Mechanical Engineering

Automation Lab
 Synchronization circuit – series

Department of Mechanical Engineering

Automation Lab
PROCEDURE
1. The pipe lines are taken and first a pipe line is connected from the input line to the
FRL unit.
2. Then another pipe line is connected from the FRL unit to closed path end of DCV.
3. For series connection, a pipe line is connected from one end of DCV to the cylinder
head of first cylinder.
4. For parallel connection a “T” – joint is used to connect from the DCV to the input
ends of the both cylinders.
5. Similarly, the other ends of the cylinders are connected back to the exhaust port of
the DCV using “T” joint.
6. After completing the connection the operation can be obtained by the air supply and
the synchronization was verified.
7. Similarly by using Festo fluid SIM software the synchronization circuits in parallel and
series were constructed and simulated.

POST LAB QUESTIONS

1. What is the importance and applications of this circuit?
2. What do you mean by synchronization of multiple cylinders?
3. In the above two circuits which one is found to be best synchronized circuit?
4. What is the purpose of quick exhaust valve?
Application problem
Devise a suitable circuit and justify your answer

INFERENCE

RESULT
Thus the synchronization circuits parallel and series were devised and
simulated.

Department of Mechanical Engineering

Automation Lab
Continuous Reciprocating Using Limit Switch

Cylinder A

A- A+

Department of Mechanical Engineering

Automation Lab
 CONTINUOUS RECIPROCATING OF DOUBLE ACTING CYLINDER

AIM
To obtain continuous reciprocating motion of pneumatic cylinder

APPARATUS REQUIRED
HARDWARE REQUIRED
1. Flow Control Valve,
2. FRL Unit,
3. 5/2 or 5/3 or 4/3 Direction Control Valve (DCV),
4. DA Cylinder,
5. Connectors
6. Hose
SOFTWARE REQUIRED
Festo Fluid SIM
THEORY
The automatic reciprocating action is obtained with help of two limit switches. When air
supply is given air goes through DCV to obtain the extension of cylinder. At the full extension the
piston rod end touches the limit switch L1 and produces a pilot air which actuates the DCV from
opposite end and hence produce retraction stroke of the cylinder. At the full retraction piston rod
touches the limit switch L2 it actuates the DCV and return to its original position and the cycle
continues.

In hydraulic system automatic reciprocating action can also be obtained by using two
sequencing valves. When hydraulic supply is given oil goes through DCV to obtain the extension of
cylinder. After the full extension of the cylinder pressure gets buildup in the circuit and if the
pressure exceeds the predetermined pressure in sequencing valve the sequencing valve 1 gets
operated and a pilot signal which actuates the DCV from opposite end and hence produce
retraction stroke of the cylinder. Again after the full retraction of the cylinder pressure gets buildup
in the circuit and if the pressure exceeds the predetermined pressure in sequencing valve the
sequencing valve 2 gets operated and a pilot signal which actuates the DCV and return to its original
position and the cycle continues.

PRE-LAB QUESTIONS
1. What is the use of mechanically actuated limit switches? Draw the symbol.
2. What is need for push button DCV switches in circuit?
3. How double acting cylinders differ from single acting cylinder?
4. Can proximity switches used as limit switch in pneumatic circuit
5. When the air cushion is required?
6. How does a limit switch differ from a push button switch?

Department of Mechanical Engineering

Automation Lab
Continuous Reciprocating Using Sequencing Valves

Department of Mechanical Engineering

Automation Lab
PROCEDURE
1. Input Supply Line is given to FRL Unit.
2. Then a T – joint is taken and pipe lines are connected such that one pipe line goes to push
button valve, which another goes to other limit switches L1 and L2.
3. New, two pipe lines are taken and one is connected from DCV to blank end of the cylinder
and other from DCV to rod end of cylinder.
4. The two alternate ends of DCV are connected two ends of L1 and L2 respectively and
connecting other pipe line between push button and DCV.
5. Now the supply is given and push button valve is pressed which results is actuation of air
pilot controlled DCV and to cylinder.
6. By using Festo Fluid SIM construct the hydraulic circuit by using two sequencing valves.
7. Simulate the circuit and verify continues reciprocating of cylinder.

POST LAB QUESTIONS

1. How the DCV is actuated in the reciprocation circuit?
2. Where the continuous reciprocation circuit is used?
3. What is the action of pilot valve?
4. What is the difference between reciprocating and synchronizing circuit?
5. Name the component which changes the direction to the required direction.

APPLICATION PROBLEM
The machine head of a precision grinder needs to continuously reciprocate
over cylinder head surface being finished. The speed of the stroke must be
controlled in both directions.

INFERENCE

RESULT
Thus the connections circuits using limit switch and pressure sequencing valve were devised
and simulated

Department of Mechanical Engineering

Automation Lab
 AND Logic

Application circuit for AND logic

Two push buttons has to be pressed for extension and for retraction both the push
button has to be released. This circuit is used for safety applications in heavy duty press.
The operator has to press/release two DCV for the extension and retraction of cylinder it
is pool proof system.

Department of Mechanical Engineering

Automation Lab
 LOGIC OPERATIONS AND, OR IN PNEUMATIC CIRCUITS

AIM
To devise and simulate the circuits for AND, OR logic operations.
APPARATUS REQUIRED
Hardware Required
1. FRL Unit,
2. Connectors
3. Hose
4. DA Cylinders
AND logic OR logic
5. 5/3 double pilot operated DCV - 5. 5/2 double pilot operated DCV -
1nos, 1 nos,
6. 5/2 push button 2- nos, 6. 3/2 push button 3 –nos,
7. Check valve- 1nos 7. Shuttle valve

Software Required
Festo Fluid SIM

THEORY
AND logic
The AND logic is used in industries mainly to actuate a output based on
triggering the inputs connected in series. One such example is two handed safety
circuit in a pressing environment.
A two handed safety circuit consists of two push button valves that must be
actuated to cause the cylinder to extend. Retracted of the cylinder will not occur
unless both the push buttons are released. When both push button valves are not
operated together, the pilot air to this position valve is vented. Both the hand is used to
operated the circuit and hence the name safety circuit.
OR Logic
The OR logic is used to get output by either any one of the input that are
connected parallel to each other.
A OR logic circuit consists of two push button valves with a shuttle valve. Either
any one of valve must be actuated to cause the cylinder to extend. These type of
circuits used in industries like hazardous environment, remotely located and during
maintenance activities.

PRE-LAB QUESTIONS

1. How many push buttons are required construct a two handed safety circuit?

2. Draw the symbol for shuttle valve and quick exhaust valve.

3. Draw the symbol for twin pressure valve.

4. How do you install a pneumatic cylinder?

Department of Mechanical Engineering

Automation Lab
 OR Logic

Department of Mechanical Engineering

Automation Lab
PROCEDURE
1. Connection is given from the main supply to FRL Unit.
2. Using “T” joint, the FRL Unit is connected to the push button valve followed by
check valve for AND logic / push button valve followed by shuttle valve for OR
Logic.
3. From the logic valves the pilot signal is given to the 5/3 or 5/2 double pilot
operated DCV.
4. From the 5/3 or 5/2 pilot operated DCV, one connection is given to the blank end
of the cylinder and another to the rod end of cylinder.
5. In AND logic simulation when the push buttons are pressed, the desired
extension is achieved and retraction of cylinder is achieved by releasing both the
push buttons.
6. In OR logic either one of the push button is pressed, the desired extension of the
cylinder is achieved.
POST LAB QUESTIONS:
1. When the cylinder will retract in a two handed safety circuit?
2. State the advantage of two handed safety circuit?
3. State the advantage of two step speed control circuit?
4. What is the function of shuttle valve?
5. What is meant by MPL.

Department of Mechanical Engineering

Automation Lab
 Cylinder A
a- a+

0 mm 175 mm 300 mm

Limit switch
located between a+ and a-
where the 2nd speed is required

Speed 2 Speed 1

Two step speed control circuit

Application circuit for OR logic

The total stroke length of cylinder A is 300 mm. At the time of extension from
0 to 175 the velocity should be 2.5m/s and from then 176 mm to 300 mm the
velocity should 0.8 m/s and retraction faster than the two.

Department of Mechanical Engineering

Automation Lab
APPLICATION PROBLEM

Design a AND Logic circuit for extending double acting cylinder using twin pressure
valve.

INFERENCE

RESULT
Thus AND, OR logic circuit were devised and simulated.

Department of Mechanical Engineering

Automation Lab
Sequencing of A+ B+ A- B- using limit valve

Department of Mechanical Engineering

Automation Lab
 SEQUENCING OF TWO CYLINDERS CIRCUIT
AIM
To devise and simulate fluid power circuit for the given sequence A + B+ A- B-.
APPARATUS REQUIRED
Hardware Required
1. FRL Unit,
2. Flow Control Valve,
3. 5/2 Direction Control Valve (DCV),
4. DA Cylinders,
5. 3/2 roller operated limit valves
6. Connectors
7. Hose
Software Required
Festo Fluid SIM
THEORY
Clamp and work circuits use at least two cylinders, air or hydraulic. One cylinder
advances first and clamps the workpiece in a fixture. Then the other cylinder(s) moves in with
tools for cutting, drilling, pressing, forming, or other operations on the workpiece. The
sequencing circuits are used to achieve the desired functions in a sequential order using
sequence valves or by limit valves/ limit switches
PRE-LAB QUESTIONS
1. What is a sequencing circuit?
2. What is the use of time delay valve?
3. Draw the symbol for 5/3 pilot actuated ,spring centered DCV
4. Draw the symbol for 4/3 DCV
5. What are the different types of pneumatic cylinders?
PROCEDURE
1. First the input supply line is given to FRL Unit.
2. FRL Unit is connected to one end of push button valve.
3. From the other end of the push button valve, another pipe line is taken and connects
to DCV.

Department of Mechanical Engineering

Automation Lab
Sequencing of A+ B+ A- B- using sequencing valve

Department of Mechanical Engineering

Automation Lab
 4. The circuit is completed by taking pipe lines and connecting from limit switches to the
pilot ends of the direction control valves as per the circuit diagram.
5. Now checking the connection, the supply is given and push button is pressed to initiate
the sequence, which actuates the cylinders in a desired sequence.
6. By using Festo Fluid SIM construct the hydraulic circuit by using two sequencing valves.
7. Simulate the circuit and verify the Sequence.
POST LAB QUESTIONS
1. State the applications of sequencing circuits.
2. What are the factors to be considered for designing a sequencing circuit?
3. What is displacement – event diagram?
4. How do you give the reference letter to the cylinders and their extension or
retraction?
5. What is the purpose of spring centered DCV?
APPLICATION PROBLEM

INFERENCE

RESULT
Thus the sequencing circuit for the sequence A+ B+ A- B- using limit switch and
sequencing valve were devised and simulated.

Department of Mechanical Engineering

Automation Lab
Cascading two Cylinders Sequence A+B+B+A-

Department of Mechanical Engineering

Automation Lab
 CASCADING CIRCUIT FOR TRAPPED SIGNALS – 2 CYLINDERs

AIM
To devise and simulate fluid power circuit for the given sequence A+ B+ B- A-
using cascading method.

APPARATUS REQUIRED
Hardware Required
1. FRL Unit,
2. 5/2 double pilot operated DCV -3 nos ,
3. DA Cylinders -2 nos,
4. 3/2 roller operated limit valves -4 nos,
5. Connectors
6. Hose
Software Required
Festo Fluid SIM

THEORY
Sequences like A+ B+ B- A- / clamping, punching, retracting punching cylinder
and de clamping cannot be obtained in normal sequencing method due to trapped
signal. Cascade control is a technique used to give sequential circuits by switching
on and off the air supply to valves in groups. It avoids the problem of trapped
signals and used to obtain the correct sequence.

PRE-LAB QUESTIONS
1. What is cascading circuit?
2. What are the steps involved in designing a cascading circuit?
3. Group the sequence A+, B+ B-, A-
4. What are the different methods to designing a pneumatic circuit with more than
two cylinders?
5. State the principle of Pascal’s law

PROCEDURE
1. The A+ B+ B- A- circuit is solved by the two group cascade method.
2. The sequence is divided into groups at the point where the trapped signals
(Fighting signals) occurred Eg. B+ B-.
3. For the given sequence A+ B+ B- A- the minimum possible grouping is
A+ B+ / B- A-
Group I / Group II
4. Draw the group change over valve at the bottom of the circuit.
5. Draw the group pressure lines above the group valve (Cascade valve).
6. The first function A+ in group I is signaled directly from by that group supply.
7. The last function B+ in group I will be used to select the group II.
8. Then first function B- in group II is signaled directly from by that group supply.

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
 9. The last function A- in group II will be used to select the group I.
10. The circuit is completed by taking pipe lines and connecting from limit switches
to the pilot ends of the direction control valves and group changing valve as per
the circuit diagram.
11. Now checking the connection, the supply is given and push button is pressed to
initiate the sequence, which actuates the cylinders in a desired sequence.
12. By using Festo Fluid SIM construct the circuit by two groups.
13. Simulate the circuit and verify the Sequence.

Rules for Constructing Cascade Circuits

1. Obtain the correct sequence and divide the sequence in to minimum possible
groups. while dividing into groups no cylinder letter repeat once in a group
e.g. A+ B+ / B- C+ / C- A-
Group I / Group II / Group III
2. For continuous cycle, a cycle should be required as part of a continuous program
and thus a cascade group may continue into the next cycle.
Thus we have the cycle sequence A+ B+ C+ B- A- C- we could have, with a
continuous program, the groups.
A+ B+ C+ / B- A- C- (or) A+ B+ /C+ B- A- /C- the aim should be to
minimum the no of group.
3. A start/stop valve is needed. If the cycle is to be continuous, use the last operation
to supply signal to start the sequence over again. The start/ start valve should be in
the link that selects group I
4. Draw the pilot change over valve for the group at the bottom of the circuit and draw
the group pressure lines above the cascade valve with initially the pilot air on group
I the lines are termed as “bus bars”.
5. Each group is actuated in turn.
6. Input signal to select group I results in pressure applied to group I level and no
pressure to the other groups (group II and group III). Similarly selection of group II
results in pressure to group II and no pressure to the other groups (group I and
group III).
7. The first function of each group is signalled directly by the group supply. The last
trip valve to be operated in each group will be supplied with main air and causes
the next group to be selected. The other trip valves in each group will be operated
with air from their respective groups and initiate the next function.
8. Each group limit valves input pressure connected with respective group lines.

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
POST LAB QUESTIONS
1. What do you mean by group valve and group line?
2. What is the important rule in the cascading circuit design?
3. Where the cascade circuits are used?
4. What is the purpose of displacement – event diagram?
5. How many valves are used for each cylinder in a cascading circuit?
6. For a cascading circuit containing three groups, how many cascade valves are
required?

APPLICATION PROBLEM

INFERENCE

RESULT
Thus the sequence A+ B+ B- A- using cascading technique were devised and simulated.

Department of Mechanical Engineering

Automation Lab
Cascading three Cylinders Sequence A+ B+ B- C+ C- A-

Department of Mechanical Engineering

Automation Lab
 CASCADING CIRCUIT FOR TRAPPED SIGNALS – 3 CYLINDERs

AIM
To devise and simulate fluid power circuit for the given sequence A+ B+ B- C+ C-
A- and A+ B+ C+ C- B- A- using cascading method.
APPARATUS REQUIRED
Hardware Required
1. FRL Unit,
2. 5/2 double pilot operated DCV
3. DA Cylinders
4. 3/2 roller operated limit valves
5. Connectors
6. Hose
Software Required
Festo Fluid SIM

THEORY
Sequences like A+ B+ B- C+ C- A- (clamping, Punching, Labeling of operations)
cannot be obtained in normal sequencing method due to trapped signal. Cascade
control is a technique used to give sequential circuits by switching on and off the air
supply to valves in groups. It avoids the problem of trapped signals and used to obtain
the correct sequence.

PRE-LAB QUESTIONS
1. What do you mean by cascade valve?
2. What are the steps involved in designing a cascading circuit?
3. Group the sequence A+, B+, B-, A-, C+, D+, C-, D-
4. What are the different methods to designing a pneumatic circuit with trapped
signals?
5. In a four groups of operations how many group valves and group lines
required?

PROCEDURE
1. The A+ B+ B- C+ C- A- sequencing is solved by the cascade method.
2. The sequence is divided into groups at the point where the trapped signals
(Fighting signals) occurred Eg. B+ B-.
3. For the given sequence A+ B+ B- C+ C- A- the minimum possible grouping is
A+ B+ / B- C+ / C- A-
Group I / Group II / Group III
4. Draw the group change over valve at the bottom of the circuit.
5. Draw the group pressure lines above the group valve (Cascade valve).
6. The Last function in sequence A- will be used to select the group I / Start the
cycle.

Department of Mechanical Engineering

Automation Lab
Cascading three Cylinders Sequence A+ B+ C+ C- B- A-

Department of Mechanical Engineering

Automation Lab
7. The first function A+ in group I is signaled directly from by that group supply.
8. The last function B+ in group I will be used to select the group II
9. Like the other groups are obtained.
10. The circuit is completed by taking pipe lines and connecting from limit switches to the
pilot ends of the direction control valves and group changing valve as per the circuit
diagram.
11. Now checking the connection, the supply is given and push button is pressed to initiate
the sequence, which actuates the cylinders in a desired sequence.
12. By using Festo Fluid SIM construct the circuit by two groups.
13. Simulate the circuit and verify the Sequence.

Post Lab Questions:

1. What do you mean by group valve and group line?

2. What is the important rule in the cascading circuit design?
3. When the cascading circuits are used?
4. What is the purpose of displacement – event diagram?
5. How many group lines are required for five groups?
6. Justify your answer and group sequence for the following application.

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
APPLICATION PROBLEM

INFERENCE

RESULT
Thus the connections were given and the cascading circuit was designed operated
successfully in a given sequence.

Department of Mechanical Engineering

Automation Lab
Sequencing of double acting cylinders (A+ B+ A- B-)

Department of Mechanical Engineering

Automation Lab
 SEQUENCING OF TWO CYLINDERS USING ELECTRO PNEUMATIC CIRCUITS

AIM
To devise and simulate electro pneumatic circuits for sequencing of two double
acting cylinders A+B+A-B-.

APPARATUS REQUIRED
HARDWARE REQUIRED
1. FRL Unit,
2. Connectors
3. Hose
4. DA Cylinders with magnetic strip
5. Read switch
6. 5/2 solenoid operated DCV
7. Timer module
8. Connecting wires

SOFTWARE REQUIRED
Festo Fluid SIM

PRE-LAB QUESTIONS

1. What is mean by limit switch?

2. What is mean by read switch?

3. Draw the symbol for solenoid valve and relay.

4. Draw the symbol of NO and NC switch.

5. What is mean by dedentant switch.

PROCEDURE
1. Connection is given from the main supply to FRL Unit.

2. From FRL to the solenoid operated DCV to double acting cylinder.

3. +ve 24 V DC supply is given to limit / read switch’s

4. –ve 24 V DC supply is given to the solenoid operated DCV and relay.

5. From limit / read switch’s connections are given to the respective relays and from

relays the relay output to the respective solenoid operated DCV

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
 6. Now pneumatic supply and 24 V DC supply is turned ON which results in
actuation of electro pneumatic circuit.
7. Similarly by using festo fluid SIM software electro pneumatic circuits were
constructed and simulated.
POST LAB QUESTIONS:
1. Draw the symbol of double acting cylinder with magnetic strip.
2. How relay is deferent from solenoid?
3. What is mean by memory function in DCV?
4. Compare NO and NC switches with an example.

APPLICATION PROBLEM
When the push button is pressed the components are continuously removed from
the feeder magazine as shown in below figure and stops went the push button is released.
Design electro pneumatic circuit.

NFERENCE

RESULT
Thus the electro pneumatic circuits for continuous reciprocation / timer
module / counter module / sequencing of two double acting cylinders is devise and
simulate.

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
 PLC CONTROL PNEUMATIC / HYDRAULIC LINEAR ACTUATOR CIRCUITS

AIM

To device and simulate a ladder logic for continuous reciprocation of pneumatic/ hydraulic linear
actuator with timer and counter using PLC.

APPARATUS REQUIRED
HARDWARE REQUIRED
1. PLC
2. Pneumatic/ hydraulic Linear actuator
3. 5/2 (or) 4/3 solenoid operated DCV
4. RS – 232 cables
5. Patch chords.
SOFTWARE REQUIRED
 Versa pro software

Theory
The double acting cylinder is continuously reciprocated with ladder logic program. In
pneumatic trainer kit read switch is used as a feedback device for identifying the position of the
cylinder. In hydraulic trainer kit electrical operated limit switch is used as a feedback device for
identifying the position of the cylinder.
In pneumatic trainer kit continues reciprocation is obtained by ladder logic for continues
remove the material from the feeder magazine. In some application we need a delay time before
extension of cylinder in continues reciprocation so that the material will be removed from the
magazine after the pre determined time. This can be obtained by ON delay timer in ladder logic. In
another application the actuator has to continuously reciprocate for some pre determined counts
so that the determined no’s of materials can be removed from the feeder. This can be obtained by
counter in ladder logic.
In hydraulic trainer kit continues reciprocation is obtained by ladder logic. In this kit 4/3
spring center double solenoid operated DCV is used. When the solenoid gets de-energized the
spring makes the spool to moves to neutral position and the fluid will not flow on either side. In this
case the cylinder will extend/retract until the limit switch is in contact after that solenoid gets de-
energized and extension/retraction will not be there. In such kind of application the input (limit
switch) has to be latched with the output so that the actuator will continuously extend/retract (OR)
Set and reset coil can be used in ladder logic program.

Pre-Lab Questions

1. What do you mean by PLC? List its application of PLC.

2. What do you mean by memory in 5/2 DCV?
3. What is mean by read switch?
4. Draw the symbol of NC and NO switch used in ladder logic.
5. Draw the symbol and compare 5/2 and 4/3 double solenoid DCV.

Department of Mechanical Engineering

Automation Lab
 PLC controlled electro pneumatic ladder diagram for continuous reciprocation
%I00001 %Q00001

%I00002 %Q00002

PLC controlled electro pneumatic ladder diagram for continuous reciprocation with
delay timer before extension.

%M00001 %Q00001

%I00002 %Q00002

%I00001 %M00001
ONDTR
TENTHS
%R00001
%I00002
R

100 PV

Where

%I0001 → Read switch retracted position

%I0002 → Read switch extended position
%Q0001 → Solenoid valve (extension)
%Q0002 → Solenoid valve (retraction)
%M0001 → Marker (Internal Relay)

Department of Mechanical Engineering

Automation Lab
PROCEDURE
Pneumatic material feeder
1. Turn on the Verso pro software.
2. Interface the PLC with the computer buy using connect option in the software.
3. Now connect the retraction limit switch to I1 in PLC and extension limit switch to I2.
4. Similarly extension solenoid is connected to Q1 and retraction solenoid is connected to Q2.
5. Now built the ladder logic as per the requirement.
6. Case I : build a ladder logic in such a way that the components are continuously removed from the
magazine.
7. Case II : build a ladder logic in such a way that the components are continuously removed from the
magazine with a time delay before the extension of cylinder with ON delay timer.
8. Case III : build a ladder logic in such a way a fixed quantity of components are continuously removed
from the magazine with UP counter.
9. Now clear the all the programs stored in the PLC.
10. Store the existing ladder logic in PLC and load the program.
11. Run the ladder logic to simulate the program.
Hydraulic trainer kit
12. Interface the PLC with hydraulic trained kit by using patch card.
13. I1 of PLC is connected with retraction side limit switch and I2 is connected with extension
side of the PLC.
14. Similarly Q1 of the PLC is connected with solenoid extension and Q2 is connected with
solenoid retraction.
15. Create a ladder logic for continues reciprocation of double acting cylinder.
16. Store the existing ladder logic in PLC and load the program.
17. Run the ladder logic to simulate the program.

Department of Mechanical Engineering

Automation Lab
PLC controlled electro pneumatic ladder diagram for continuous reciprocation for 10
counts

%I00001 %M00001 %Q00001

%I00002 %Q00002

%Q00001 %M00001
DNCTR

%R00001
%I00003
R

10 PV

Where

%I0001 → Read switch retracted position

%I0002 → Read switch extended position
%I0003 → Counter Reset
%Q0001 → Solenoid valve (extension)
%Q0002 → Solenoid valve (retraction)
%M0001 → Marker (internal relay)

Department of Mechanical Engineering

Automation Lab
Post-Lab Questions

1. Compare ON delay and OFF delay timer.

2. Compare up counter and down counter.
3. What so you mean by latching?
4. What is mean by set and reset coil in ladder logic?
5. What is mean by marker in ladder logic?
6. Draw the symbol of ON delay timer and UP Counter.

Department of Mechanical Engineering

Automation Lab
 PROGRAMMABLE LOGIC CONTROLLER ( VPLCT-02)
DIGITAL INPUTS
Power
+ 24V DC

ON

S1 S2 S3 S4 S5 S6 S7 S8 OFF

L1 L2 L3 L4 L5 L6 L7 L8

I1 I2 I3 I4 I5 I6 I7 I8

I1 I2 I3 I4 I5 I6 I7 I8

INPUTS OUTPUTS DIGITAL OUTPUTS

24V DC 24V DC HSC I/P ( CH 1 )

+ - + - Q1 Q2 Q3 Q4 Q5 Q6

+ -
+VE Q1 Q2 Q3 Q4 Q5 Q6
LOGIC
LAMP
+VE C1 V1 C1 LOAD
24V DC 24V DC
+ - + -
PWM O/P ( CH 2 )
L1 L2 L3 L4 L5 L6
-VE
LOGIC + -

-VE C2 C2 -VE F1 F2 F3 F4 F5 F6

L2
HYDRAULIC SYSTEM LINEAR ACTUATION
( VPAT-12)
Power
FORWARD LS2
ON

L1 + -
OFF
REVERSE LS1

+ -

MOTOR
PISTON
+ -

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
 Ladder Diagram For Hydraulic Continues Reciprocating With Set and
Reset

%I 00001 %Q 00001
S
%Q 00002
R

%I 00002 %Q 00002
S
%Q 00001
R

Ladder Diagram For Hydraulic Continues Reciprocating With Latching

.
%I 00001 %I 00002 %Q 00001

%Q 00001

%I 00002 %I 00001 %Q 00002

%Q 00002

Where

%I00001 → Limit switch retracted position

%I00002 → Limit switch extended position

%Q00001 → Solenoid valve (extension)

%Q00002 → Solenoid valve (retraction)

Department of Mechanical Engineering

Automation Lab
Inference

Result:
Thus the ladder logic for continuous reciprocation with timer and counter for pneumatic
and hydraulic trainer kit were built and executed with PLC.

Department of Mechanical Engineering

Automation Lab
Control Voltage = Rated Voltage (11.4V)

S.No. Speed (N) Load Torque

rpm (Kg) (N m)

Department of Mechanical Engineering

Automation Lab
 SPEED CONTROL OF AC SERVO MOTOR
A. Determination of Motor Constant K2:
Aim :
To determine the motor constant K2.
Equipment Required :

1. Two phase A.C servo motor speed control and transfer function study trainer (PEC-00A).
2. Patch chords.
3. Volt meter (0-20 V) MC
Procedure:

1. Connect G1K1 of pulse isolation output to G1K1 of SCR1.

2. Connect G2K2 of pulse isolation output to G2K2 of SRC1.
3. To operate open loop control mode using switch S1.
4. 9 Pin D – Connector is connected from motor setup to backside of the trainer (PEC –
00A).
5. Keep Speed indicator switch is in PV mode.
6. Connect AC voltmeter (0 – 20V) or multimeter across the control phase winding (C1, C2).
Experimental Procedure:

1. Switch ON the 230V AC supply to the reference winding.

2. Switch ON the 230V AC supply to the motor setup.
3. Switch ON the pulse ON / OFF switch S2.
4. Vary the control voltage pot (C.V) and set the rated voltage (11.4V) to control phase
winding.
5. Apply the load on the motor step by step up to motor will run at 0 rpm.
6. For each step note the reading (Load, Speed) as shown in the table 1.
7. To calculate the torque value.
8. Plot the graph Speed Vs Torque.
9. The slope of speed – torque curve given the motor constant K2.
Formula
Torque (T) = 9.81 × r × s
Where:
r = Radius of shaft in m.
s = Applied Load in kg.

Department of Mechanical Engineering

Automation Lab
Model Graph:

Department of Mechanical Engineering

Automation Lab
Result

Thus the motor constant K2 ___________ was obtained.

Department of Mechanical Engineering

Automation Lab
Open loop PI controller

S.No. Set Speed Process Speed

Department of Mechanical Engineering

Automation Lab
B. Speed Control of AC Servomotor With Open Loop PI Controller
Aim :

To control the speed of A.C servo motor using open loop PI controller.

Equipment Required :

1. Two phase A.C servo motor speed control and transfer function study trainer (PEC – 00A).
2. Patch chords.

Procedure :

1. Connect G1K1 of pulse isolation output to G1K1 of SCR1.

2. Connect G2K2 of pulse isolation output to G2K2 of SRC1.
3. To operate open loop control mode using switch S1.
4. 9 Pin D – Connector is connected from motor setup to backside of the trainer (PEC – 00A).
5. Speed indicator switch is in CV mode.

Experimental Procedure :

1. Switch ON the 230V AC supply to the reference winding.

2. Switch ON the 230V AC supply to the motor setup.
3. Switch ON the pulse ON / OFF switch S2.
4. To set the motor speed using control voltage pot (C.V) take the set speed as shown in the
table – 3.
5. To switch on the speed indication to PV mode , note the process speed (To see the front
panel seven segment display).
6. Repeat the same procedure again and again using control voltage pot (C.V) and note the
reading set speed and process speed, as shown in the table.

Result :

Thus the speed of the AC servomotor was controlled using open loop PI controller.

Department of Mechanical Engineering

Automation Lab
Closed loop PI controller

S.No. Set Speed Process Speed

Department of Mechanical Engineering

Automation Lab
C. Speed Control of AC Servomotor with closed Loop PI Controller
Aim :

To control the speed of A.C servo motor using closed loop PI controller

Equipment Required :

1. Two phase A.C servo motor speed control and transfer function study trainer (PEC – 00A).
2. Patch chords.

Procedure :

1. Connect G1K1 of pulse isolation output to G1K1 of SCR1.

2. Connect G2K2 of pulse isolation output to G2K2 of SRC1.
3. To operate open loop control mode using switch S1.
4. 9 Pin D – Connector is connected from motor setup to backside of the trainer (PEC – 00A).
5. Speed indicator switch is in CV mode.

Experimental Procedure :

1. Switch ON the 230V AC supply to the reference winding.

2. Switch ON the 230V AC supply to the motor setup.
3. Switch ON the pulse ON / OFF switch S2.
4. To set the motor speed using control voltage pot (C.V) take the set speed as shown in the
table.
5. To switch ON the speed indication to PV mode , note the process speed in the table
6. Repeat the same procedure again and again using control voltage pot (C.V) take the readings.
Set speed and process speed as shown in table.

Result :

Thus the speed of the AC servomotor was controlled using closed loop PI controller.

Department of Mechanical Engineering

Automation Lab
 Tabulation

Velocity Velocity Discharge Discharge

Sl. No Extension Retraction Extension Retraction
(cm/sec) (cm/sec) (Lit/sec) (Lit/sec)

Flow Calculation

Velocity (speed) = Flow / Area (cm/sec)

Flow = Discharge (Q) in (Lit/sec) (1 liter = 1000 cm3)

Area = π / 4 X D2 (cm2)

D = Diameter of cylinder (40 mm)

Department of Mechanical Engineering

Automation Lab
 VELOCITY CALCULATIONS IN HYDRAULIC LINEAR ACTUATION.

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

Apparatus Required
 Hydraulic power pack
 4/3 Double solenoid valve
 Flow control valve
 Double acting cylinder
 Data actuation card
 Lab view software

Procedure
1. Switch on the electrical power supply for motor and control unit.
2. Open the lab view software in the system.
3. Inter face hydraulic trainer with system using RS-232.
4. Go to speed option → Select Run. Then Power on.
5. Now extend the system by pressing the up button.
6. Now regulate the flow control valve, contract the system by pressing down position. Note
down the velocity cm/sec which is displayed in the monitor.
7. Now adjust the flow control valve and set the maximum flow, to find the extension velocity.
8. Repeat the procedure for different flow.

Result
The actuation of hydraulic cylinder was carried out

Department of Mechanical Engineering

Automation Lab
 NI cDAQ – 9174

NI 9219 Universal AI Module

Department of Mechanical Engineering

Automation Lab
 PROCESS CONTROL USING VIRTUAL INSTRUMENTATION
AIM:
To develop a Virtual instrument (VI) using LabVIEW software for temperature
measurement using thermocouple , NI cDAQ – 9174, and NI 9219 Universal AI Module

Apparatus Required:
1. NI cDAQ - 9174
2. NI 9219 Universal AI Module
3. USB cable for connecting cDAQ to the PC
4. 15Amps power card with charging cable
5. PC with NI LabVIEW 2015 software
6. Thermocouple
7. Thermometer
8. Water bath
Tools Used In Labview Sofware:
Controls Pallette:
1. Thermometer
2. Round LED
FUNCTIONS PALETTE:
1. DAQ Assistant
2. Greater or equal
3. Wait (ms)
4. Case structure
5. While loop

Theory:

NI cDAQ – 9174

NI CompactDAQ USB chassis provide the plug-and-play simplicity of USB to sensor and
electrical measurements on the benchtop, in the field, and on the production line.
Bycombining more than 60 sensor-specific NI C Series I/O modules with patented NI Signal
Streaming technology, the NI CompactDAQ platform delivers high-speed data and ease of use
in a flexible, mixed-measurement system. Modules are available for a variety of sensor
measurements including thermocouples, RTDs, strain gages, load and pressure transducers,
torque cells, accelerometers, flow meters, and microphones.

Department of Mechanical Engineering

Automation Lab
Front Panel:

On True Condition:

On False Condition:

Block Diagram:

Department of Mechanical Engineering

Automation Lab
NI 9219 Universal AI Module

The NI 9219 is a four-channel universal C Series module designed for multipurpose

testing in any NI CompactDAQ or CompactRIO chassis. With the NI 9219, you can measure
several signals from sensors such as strain gages, RTDs, thermocouples, load cells, and other
powered sensors. The channels are individually selectable, so you can perform a different
measurement type on each of the four channels. Measurement ranges differ for each type of
measurement and include up to ±60 V for voltage and ±25 mA for current.

NI Compact DAQ supports the following modules

1. Analog input
2. Analog output
3. Digital input
4. Digital output

All the above mentioned four modules can be connected and data can be obtained
instantaneously.
Procedure :

1. Open the LabVIEW 2015

2. Front panel>>Controls palette>>Numeric>>Thermometer
3. Front panel>>Controls palette>>Boolean>>Round LED
4. Block diagram>>Functions palette>>Measurement I/O>>NI-DAQmx>>DAQ Asst
5. Block diagram>>Functions palette>>Comparison>>Greater or equal
6. Block diagram>>Functions palette>>Numeric>>Numeric constant
7. Block diagram>>Functions palette>>Structures>>Case structure
8. Block diagram>>Functions palette>>Structures>>While Loop
9. Block diagram>>Functions palette>>Boolean>>True constant
10. Block diagram>>Functions palette>>Boolean>>False constant
11. Wire them all as shown in the figure -03, rectify if any error (broken line) exist .
12. Connect the thermocouple with the analog input module NI 9219 Universal AI
Module.
13. Plug in the NI 9219 Universal AI Module in to any slot of the C DAQ
14. Connect the power supply to the C DAQ and connect the usb to the pc.
15. Wait for the system to recognize the module, and run the program through the
front panel.
16. Ensure that before plugin stop the program and then switch off the power supply.

Results :

Virtual instrument (VI) is developed for temperature measurement using LabVIEW

software for using thermocouple , NI cDAQ – 9174, and NI 9219 Universal AI Module

Department of Mechanical Engineering

Automation Lab
 6 axis robot – ABB IRB 1410

Department of Mechanical Engineering

Automation Lab
 PICK AND PLACE OPERATION USING ABB ROBOT – DEMO
AIM
To pick and place the wooden peg from one location to other by using ABB robot
manual mode.

APPARATUS REQUIRED
 ABB Robot
 Flex Pendent
 Pneumatic air supply

INDUSTRIAL ROBOT
Specification
 ABB : (ASEA Brown Boveri)
 IRC5 : Industrial Robot Controller
 Robot Supplier : ABB, China
 Robot Version : IRB 1410
 Robot Controller : IRC5
 Handing Capacity : 5 kg
 Reach : 1.45 m
 Manipulator Weight : 225 kg
 Number of Axis : 6
Types of motion
 Axis 1 - Rotation Motion
 Axis 2 - Arm Motion
 Axis 3 - Arm Motion
 Axis 4 - Wrist Motion
 Axis 5 - Bend Motion
 Axis 6 - Turn Motion
PROCEDURE
 The electrical supply to the robot is turned ON.
 Once the supply is turned ON, a white light in the controller panel display will start
blinking.
 Grip the flex pendant in left hand and press the pad so the white light is blowing.
These enables the all the keys in the flex pendant.
 For jogging the robot the select jogging mode from main menu.
 In jogging there are 3 modes, namely axes mode, linear mode and reorient mode.
 In axis mode, axis 1-3 or axis 4-6 can be jogged.
 In linear mode the TCP moves in a straight line.
 In Reorientation mode, TCP remains at a fixed position but the orientation of the tool
about the point changes.
 By necessary combination of the three modes bring the gripper closer to the
wooden peg.
 Once the gripper reached near to the wooden peg the speed of the motion has to be
decrease.
 For changing the speed of the arm, go to increment in main menu and select medium.

Department of Mechanical Engineering

Automation Lab
Department of Mechanical Engineering
Automation Lab
  The robot arm is slowly moved to the exact position for gripping the wooden peg.
 Form the main menu select Input / Output.
 For griping the wooden peg d01 is made set and d03 is made reset. Now the gripper
gets actuated and wooden peg is hold.
 Slowly lift the wooden peg from the location. The speed of the robot ram can be
increased so that the destination can be reached quickly.
 When the robot arm reaches nearer to the destination, speed of the arm to be
reduced.
 Once the destination is reached the wooden peg is un-grip by reset d01 and set d03 in
Input / Output.
 Now the wooden peg is placed in the required location and the arm can be moved
away from that position.

RESULT
Thus the pick and place operation of wooden peg from one location to other location
was performed by ABB robot manual mode.

Department of Mechanical Engineering

Automation Lab