SR NO. List of Experiments Page No.

01 Operation of welding plant using Transformer

01

02 Modeling and simulation of DC motor

05

03 Speed Control of DC motor using PWM

10

04 Current and Speed Controller of PMDC Motor

15

05 Intelligent DC SERVO Controller

19

06 Velocity Control of AC Servo Motor

26

07 Logic Gates using PLC step7

30

08 One Way Two Direction Traffic Light and Two Way Traffic light Control using
37
PLC step-7
09 Three Way & Four Way Traffic Light Control using PLC step-7
44

10
Temperature control Fan using PLC 50

11 Stepper Motor Control

53

12 Automatic Bottle Filling System using PLC

57

0
 Lab # 01
Operation of welding plant using Transformer
Objective:
 To perform on of the welding techniques and understand important of arc welding.
 Define the problem that occurs on the arc welding.
 Recognize the type of metal, electrode, and tools that are used in arc welding.
 Recognize types of arc welding and steps to create the arc welding.
 To know safety measure when use the welding machine along the welding process.

Equipment’s required:
 AC Supply
 Welding Transformer
 Welding Piece
 Electric Holder
 Chipping Hammer
 Wire Brush
 Hand Screen
 Hand Gloves
 Electrode
 Cables, cable connectors
 Earthing clamps
 Helmet
 Safety goggles
 Aprons
 sleeves

Theory:
Welding:
Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by
using high heat to melt the parts together and allowing them to cool causing fusion. Welding is distinct from
lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal.

Welding Transformer:
Welding Transformers are used in AC machines to change alternating current from the power line into
a low-voltage, high amperage current in the secondary winding. A combination of primary and/or secondary
taps on the welding transformer are commonly used to provide a macro adjustment of the welding current, as
well as adjustment of secondary voltage. Transformer ratings for AC machines are expressed in KVA
(kilovolt-amperes) for a specified duty cycle.
This duty cycle rating is a thermal rating, and indicates the amount of energy that the transformer can
deliver for a stated percentage of a specific time period, usually one minute, without exceeding its temperature
rating. The RMS Short Circuit Secondary Current specification indicates the maximum current that can be
obtained from the transformer. Since heating is a function of the welding current, this parameter gives an
indication of the thickness of the materials that can be welded. A welding transformer is basically a step
down transformer. The reason n for this is a high current is required for the arc to be generated for the welding.

1
Diagram of Welding Transformer:

Figure 1: Diagram of welding Transformer

Requirements of a Welding Transformer:

A welding transformer should satisfy the following requirements:
1. It should have a drooping static volt-ampere characteristic.
2. To avoid spatter, the surge of the welding current during a short- circuit should be limited to the least
possible above the normal arc current.
3. The open circuit voltage should not normally exceed 80 volts and in no case 100 volts.
4. The output current should be controllable continuously over the full available range.
5. The open circuit voltage should be just sufficiently high for ready initiation of an arc and not too high to
impair the economics of welding.

Important Fact of Welding Transformer:

It should be noted that the welding transformers have a rather low power factor due to the fact that
they incorporate coils having high inductive reactance. Welding transformers, therefore, must not have power
ratings higher than is necessary for the performance of the assigned job. Nor should they be run at no-load for
a long time.

Arc Welding:
Arc welding is a welding process that is used to join metal to metal by using electricity to create enough
heat to melt metal, and the melted metals when cool result in a binding of the metals. It is a type of welding
that uses a welding power supply to create an electric arc between a metal stick ("electrode") and the base
material to melt the metals at the point-of-contact. Arc welders can use either direct (DC) or alternating (AC)
current, and consumable or non-consumable electrodes. The welding area is usually protected by some type
of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated.
In the arc welding, the arc is used to create intense heat and this heat is used to join the metals together. The
arc is brought in between two metal pieces and due to the heat generated, the metals melt and when it cools a
strong welded joint is formed.
2
Arc Welding Circuit Diagram:

Figure 2: Basic Diagram of ARC Welding

The following terminologies are related to arc welding:
Squeeze time.
It is the time that elapses between the electrode pressure first applied on the work and the initial application
of current.
Weld time.
It is the time, expressed in cycles of supply, during which the welding current flows through the parts being
welded.
Hold time.
It is the time during which the pressure is kept applied at the point of welding after the welding current has
ceased to flow.
OFF time.
After the weld is perfectly hardened, the time that elapses before the electrodes reclose, if the welding machine
is still energized, is the OFF time.

Application
It is the versatile welding process. It is most widely used welding process in the world because of its
simplicity and good welding efficiency. Almost in every manufacturing industry the arc welding is used for
producing strong joints. Today it remains an important process in fabrication of steel structures and vehicles.
It is most widely used in automotive industries, construction industries, in construction of buildings,
shipbuilding industries, and aerospace industries, for the maintenance or repair works.

Procedure:
 First of all, we applied AC supply.
 After that we used step down transformer to produce low voltage and high current.
 Set the welding current, voltage according to the type of metal to be joined.
 Clean the mild steel flats to be joined with wire brush.
 Arrange the flat pieces properly providing the gap for full penetration for joint (gap ½ thickness of
flat).
 Then we placed the pieces to be weld between the electrodes that produces arc by high electricity.

3
  Practice striking of arc, speed and arc length control.
 After that we used the welding stick that uses electric current to form an electric arc between the sticks
and metals to be joined.
 Strike the arc and make the tacks at the both ends to hold the piece of metal together during the welding
process.
 Lay beads along the joint maintain the proper speed and arc length (speed 100-150 minimum).
 We can used stick welding for repair work, manufacturing and construction.
 Clean the welded zone and submit.

Conclusion:
From this experiment we observed how to do arc welding. We also learnt about welding transformer
and working of welding transformer.

4
 Lab # 02
Modeling and simulation of DC motor
Objective:
To perform the simulation of the DC motor.

Apparatus:
 Computer
 Matlab
 Simulink
Block diagram:

Figure 3 Equivalent Model

Theory:
a) DC motor
A DC motor is any of a class of rotary electrical machines that converts direct current electrical energy
into mechanical energy. The most common types rely on the forces produced by magnetic fields. Nearly all
types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically
change the direction of current flow in part of the motor.
DC motors were the first type widely used, since they could be powered from existing direct-current
lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using either a
variable supply voltage or by changing the strength of current in its field windings. Small DC motors are used
in tools, toys, and appliances. The universal motor can operate on direct current but is a
lightweight brushed motor used for portable power tools and appliances. Larger DC motors are used in
propulsion of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of power
electronics has made replacement of DC motors with AC motors possible in many applications.
b) PMDC motor
Basic configuration of a permanent magnet DC motor is very similar to that of a normal DC motor.
The working principle of any DC motor is same, i.e. when a current carrying conductor is placed in a magnetic
field, it experiences a force. A permanent magnet DC motor also works on the same principle.

5
 Figure 4:- PMDC motor

i. Equivalent circuit of PMDC motor

The schematic diagram for a DC motor is shown below. A DC motor has two distinct circuits: Field circuit and
armature circuit. The input is electrical power and the output is mechanical power. In this equivalent circuit,
the field winding is supplied from a separate DC voltage source of voltage Vf. As in PMDC motor the field is
produced by permanent magnet, there is no need of drawing field coils in the equivalent circuit of permanent
magnet DC motor. The supply voltage to the armature will have armature resistance drop and rest of the supply
voltage is countered by back emf of the motor. Hence voltage equation of the motor is given

Where, I is armature current and R is armature resistance of the motor.

Eb is the back emf and V is the supply voltage.

ii. Mathematical model of PMDC motor

The mathematical model of DC motor or PMDC motor is

Figure 5:- Mathematical model

Working principle:
As we said earlier the working principle of PMDC motor is just similar to the general working principle
of DC motor. That is when a carrying conductor comes inside a magnetic field, a mechanical force will be
experienced by the conductor and the direction of this force is governed by Fleming’s left hand rule. As in a
permanent magnet DC motor, the armature is placed inside the magnetic field of permanent magnet; the
armature rotates in the direction of the generated force. Here each conductor of the armature experiences the
mechanical force F = B.I.L Newton where, B is the magnetic field strength in Tesla (weber / m 2), I is the
current in Ampere flowing through that conductor and L is length of the conductor in meter comes under the
magnetic field. Each conductor of the armature experiences a force and the compilation of those forces
produces a torque, which tends to rotate the armature.

Simulink Block Diagram:

6
 Figure 6:- Simulink Model

Figure 7:- Inside the motor or sub-block

Procedure:
 Open the Mat-lab
 Open the Simulink and draw the model of DC motor according to the equations.
 Put all the components on the editor model
 Connect all the components with the each other and then putting the given values
 Run the simulation and note the outputs
 And note the value in table by changing the Torque and the voltage
 As shown in the figure.
 Observation and Calculations:
 By changing Voltage:
Sr. Number Voltage (V) Speed (r/sec) Current (A) Torque (Nm)
1 150 660.3 16.74 30
2 180 802.4 17.09 30
3 195 873.3 17.3 30
4 200 897 17.34 30
5 210 944.4 17.46 30
6 225 1015 17.67 30
7 230 1039 17.71 30
8 250 1134 17.98 30

 Graphs:
 Speed at 250V:

7
  Current at 250V:

By changing torque:
Sr. Number Voltage (V) Speed (r/sec) Current (A) Torque (Nm)
1 250 1172 6.58 7
2 250 1160 10.05 14
3 250 1148 13.52 21
4 250 1144 15.01 24
5 250 1139 16.49 27
6 250 1134 17.98 30

8
Graphs:

Speed at 30 Nm:

Current at 30 Nm:

Conclusion:
In this experiment we learnt about the model of DC motor on MATLAB and make its model and
observe the changing in the graphs of voltage, current, torque etc by changing the values of the voltage and
the value of torque. We observe that by increasing the torque speed goes on decreasing. And by increasing the
voltage speed increases.

9
 Lab # 03
Speed Control of DC motor using PWM
Objective:
To perform the simulation for Speed Control of DC motor using PWM.
Apparatus:
 Computer
 Mat-lab
 Simulink
Block diagram:
Block diagram is

Figure 8:- Block Diagram

Theory:
a) Pulse Width Modulation
Pulse-width modulation (PWM), or pulse-duration modulation (PDM), is a way of describing a digital
(binary/discrete) signal that was created through a modulation technique, which involves encoding
a message into a pulsing signal. Although this modulation technique can be used to encode information for
transmission, its main use is to allow the control of the power supplied to electrical devices, especially
to inertial loads such as motors. In addition, PWM is one of the two principal algorithms used
in photovoltaic solar battery chargers, the other being maximum power point tracking.
The average value of voltage (and current) fed to the load is controlled by turning the switch between
supply and load on and off at a fast rate. The longer the switch is on compared to the off periods, the higher
the total power supplied to the load.
The PWM switching frequency has to be much higher than what would affect the load (the device that uses
the power), which is to say that the resultant waveform perceived by the load must be as smooth as possible.
The rate (or frequency) at which the power supply must switch can vary greatly depending on load and
application, for example
Switching has to be done several times a minute in an electric stove; 120 Hz in a lamp dimmer; between
a few kilohertz (kHz) and tens of kHz for a motor drive; and well into the tens or hundreds of kHz in audio
amplifiers and computer power supplies.

10
 Figure 9:- PWM

b) Duty Cycle
The term duty cycle describes the proportion of 'on' time to the regular interval or 'period' of time; a
low duty cycle corresponds to low power, because the power is off for most of the time. Duty cycle is
expressed in percent, 100% being fully on. When a digital signal is on half of the time and off the other half
of the time, the digital signal has a duty cycle of 50% and resembles a "square" wave. When a digital signal
spends more time in the on state than the off state, it has a duty cycle of >50%. When a digital signal spends
more time in the off state than the on state, it has a duty cycle of <50%.
The main advantage of PWM is that power loss in the switching devices is very low. When a switch
is off there is practically no current, and when it is on and power is being transferred to the load, there is almost
no voltage drop across the switch. Power loss, being the product of voltage and current, is thus in both cases
close to zero. PWM also works well with digital controls, which, because of their on/off nature, can easily set
the needed duty cycle.
Simulink Block Diagram:

Figure 10:- Simulink Block diagram

Figure11:- Inside motor

11
 Figure 12:- Inside Voltage block

Figure 13:-Inside current block

Procedure:
 First, we open the Mat-lab software by double clicking on the icon of Mat-lab present on the desktop.
 Open the Simulink and draw the model of DC motor according to the equations.
 Put all the components on the editor model
 Connect all the components with the each other and then putting the given values
 Run the simulation and note the outputs
 And note the value in table by changing the Torque and the voltage
 As shown in the figure.
Calculations and observations:
Keeping torque constant Tl=30, Voltage=240
Table 1:
Sr. Number Duty Cycle (%) Average Average Speed (rpm)
Vdc (V) Idc (A)
1 0.2 48 15.45 177.5
2 0.4 96 16.05 404.7
3 0.6 144 16.64 632
4 0.8 192 17.24 859.2
5 1 240 17.83 1086
Graphs:
At duty cycle 60 % and torque 30Nm

Figure 2:- AVG voltage or DC Voltage

12
 Figure 3:- Voltage

Figure 4:- AVG Current

Figure 5:- Speed

Keeping duty cycle constant =60%, Voltage=240

Table 2:
Sr. Number Torque (Nm) Average Average Speed (rpm)
Vdc (V) Idc (A)
1 5 144 4.25 673.4
2 10 144 6.30 665.1
3 15 144 9.20 656.8
4 20 144 11.6 648.5
5 25 144 14.16 640.2

Graphs:
At duty cycle 60% and torque 20Nm
13
 Figure 6:- Vdc

Figure 7:- Voltage

Figure 8:- AVG Current

Figure 9:- Speed

Conclusion:
In this experiment we learnt that how to control the speed of DC motor using PWM in MATLAB and
make its model and observe the changing in the graphs of voltage, current, torque etc by changing the values
of the duty cycle and the value of torque. We observe that by increasing the torque speed goes on decreasing.
Current goes on increasing.
14
 Lab # 04
Current and Speed Controller of PMDC Motor
Objective:
To study about current and speed controller of PMDC motor.

Apparatus:
 MATLAB & Simulink

Block Diagram:

Theory:
Speed and Current Control:
The motor speed depends on the amplitude of the applied voltage. The amplitude of the applied voltage is
adjusted using the PWM technique. The required speed is controlled by a speed controller, which is
implemented as a conventional proportional-integral (PI) controller. The difference between the actual and
required speeds is input to the PI controller which then, based on this difference, controllers the required DC-
bus current.
The required DC-bus current is controlled by a current controller, which is also implemented as a conventional
proportional integral (PI) controller. The difference between the actual and required DC-bus current is input
to the PI controller which then, based on this difference, controls the duty cycle of the PWM pulses, which
correspond to the voltage amplitude required to maintain the desired speed. The current controller, which is
the inner-loop controller, is updated more frequently, for example every PWM period, compared to the speed
controller, which is the outer-loop controller.
Mathematical modeling:
Dc Motor and Load:
The de machine contains an inner loop due to the induced emf. It is not physically seen; it is magnetically
coupled. The inner current loop will cross this back-emf loop.

𝑇𝑙 = 𝐵𝑙 𝑤𝑚
𝑤𝑚 (𝑠) 𝑘𝑏
=
𝐼𝑎 (𝑠) 𝑏𝑡 (1 + 𝑠𝑇𝑚 )
15
 𝐼𝑎 (𝑠) 𝑘1 (1 + 𝑠𝑇𝑚 )
=
𝑉𝑎 (𝑠) (1 + 𝑠𝑇1 )(1 + 𝑠𝑇2 )
𝐽
𝑇𝑚 =
𝐵𝑡
𝐵𝑡 = 𝐵𝑙 + 𝐵1

Given data:
Voltage  V  220V
Current  I  8.3 A
Speed    1470rpm
Ra  4
J  0.0607
La  0.072 H
Bt  0.0869
K b  1.26
Vmax  10V
I max  20 A
Converter parameters are
Kr 31.05
G 
1  Tr S 1  0.00138S
Current Transducer Gain
HC=0.3545
Motor Transfer Function
K1 (1  Tm S )
T .F 
(1  T1S )(1  T2 S )
1 1 1 B R 1 Bt Ra 2 K b 2  Ra Bt
 ,   [ t  a ] (  ) ( )
T1 T2 2 J La 4 J La JLa
T1  0.107
T2  0.02096
0.0449  0.0314S
T .F 
0.002S 2  0.128S  1
Load Transfer Function
 14.5
 T .F 
Ia 1  0.7 S
Design of Current Controller
TC  T2  0.02096
LTC
KC 
K1 K r H CTm
KC  2.35

16
Current Loop Approximation
Ia Ki


I a 1  Ti S
K fi 1
 Ki  
HC 1  K fi
KC K r K1Tm H C
 K fi 
TC
Ia 2.75


I a 1  0.0027S
Speed Controller Design
K S (1  TS S )
GS ( S ) 
TS S
1
 KS 
2 K 2T4
T4  Ti  T
TS  4T4
28.73  0.5S
GS ( S ) 
0.0188S

Simulink Model:

Simulink results after PI Controller:

Speed:

17
Current:

Conclusion:
From this experiment we learnt about speed and current controller of PMDC Motor by using PI
Controller. And also the graphical results of speed and current.

18
 Lab # 5
Intelligent DC SERVO Controller
Objective:
Familiar with the basic principle and how to use intelligent servo controller; master the basic motor
control principle, and the adjustment methods of current loop, velocity loop and position loop.
Apparatus:
 Computer
 Easy Motion Studio software
 DC servo control trainer IT-4421
What is a servo drive?
Servo systems consist of four main components: a motor, a drive, a controller, and a feedback device,
which is typically an encoder. The controller and drive work together to determine what the motor needs to
do (the controller) and send the necessary electrical energy to the motor to make it happen (the drive).

Figure

The controller is responsible for calculating the path or trajectory required and sending low-voltage
command signals to the drive. The drive then sends the necessary voltage and current to the motor to achieve
the required motion. The drive can control torque, velocity, or position, although in servo systems, the most
common parameter to be controlled is torque.
A servo drive can also be referred to as an amplifier, because it takes the control signal from the
controller and amplifies it to deliver a specific amount of voltage and current to the motor. Of servo drives,
with a common one being the torque-mode amplifier. It converts the command signal from the controller into
a specific amount of current to the motor. Since current is directly proportional to torque, the drive is
controlling the amount of torque that the motor produces. (In a linear motor, where current is proportional to
force, the drive is directly controlling the force output of the motor.)
Remember that servo motor torque is directly related to current, as shown by the equation:
T = KT * I
Where:
T = Torque
KT = Motor constant
I = Current
One of the most important tools for sizing a servo motor is its torque-speed curve. But often, the torque-
speed curve is specific to a certain motor-drive combination. This is because the continuous and peak torque
capabilities of the motor are affected by the thermal properties of both the motor and of the drive. Inefficiencies
in the motor cause it to produce heat, which can degrade bearing lubrication and insulation around the
windings. Excessive heat—typically caused by running a motor above its peak torque—can demagnetize the
motor’s magnets. Although the drive has no moving parts, heat can damage its power transistors.

19
ISM4803 intelligent controller:
ISM4803 is a high-performance intelligent servo module that combines motion controller, drive and PLC
functionality in a single compact unit. The ISM4803 module is a flexible, cost-effective solution particularly
adapted to the distributed and coordinated control of brushless, DC or step motors of powers up to 150 W,
with voltages up to 48 V. Programmable with the high-level Techno soft Motion Language (TML), ISM4803
embeds, on a single board, advanced motion control and basic PLC specific functionality.
Typical applications include distributed motor control with the possibility of electronic gearing or CAM
functions, optionally in a CAN network.

Figure
DC Servo Control Trainer:
Servo motors plays a very important role in industry process. These servo motor can be DC or AC
depending on the requirement. The DC servo trainer IT-4421 is a closed loop DC servo system designed in
modular construction. The key concept behind this trainer system is to provide practical working knowledge
of a closed loop DC servo systems to the users by integrating basic theories and step-by-step experiments into
one subject. To maximize the educational effectiveness, each section ends with a brief experiment to conclude
what the user has learned in the experiment.

Figure

Advantages of Servo Motor:

 Low Cost
 Smooth rotation at low speeds
 Low cost drive
 No power used at standstill
 High peak torque available
 Flat speed-torque curve
 Wide variety of types available
20
  High speed attainable
Procedure:
 Install easy motion software
 After installation icon of software will created on desktop
 Then double click on the icon to open the software
 A window will open as shown in the figure
 Click on the point to open the new project. A window will open and press o
 After pressing ok

 select setup as shown below a new window will open

Figure
21
 Now select edit so following drive setup will open like shown

Figure

 Now click on detect and following window will open and press yes

Figure

 After detection select the current controller as shown below

22
 Figure

 Then click on test as following will open

Figure

 Click on start so following window or graph will open after the completion of the test
23
 Figure

 We also see the changes in the graphs of current and speed by changing the current and speed values

Figure

 Now select the position controller test as following tab will open

24
 Figure

 The graph of position is shown below also we can change the position of the motor by changing the
position.

Figure

Conclusion:
In this experiment we learnt about how to control the speed, current and position of the DC servo motor
by using the easy motion software with the help of the intelligent servo controller, installed in the trainer of
ISM4803 controller. And the required graphs are shown. We also observe the changes after changing the
values.
25
 Lab # 06
Velocity Control of AC Servo Motor
Objective:
Be familiar with the measure method of AC servo motor parameters and the velocity control of AC
servo motor.
Apparatus:
 Computer
 PANATERM software
 AC servo control trainer IT-4420
Theory:
INTRODUCTION:
AC Servo Motors have been traditionally used for position/speed control applications especially in
light weight, precision instrumentation area in airborne systems. These motors, though more expensive than
industry standard split-phase induction motors and ac driven stepper motors, have a much better torque speed
characteristics
AC servo motors incorporate encoders are used with controllers for providing feedback and closed-
loop control. These motors can be positioned to high accuracy, meaning that they can be controlled exactly as
required for the application. Often servo motors have better bearings or higher tolerance designs, and some
smaller designs also use higher voltages in order to achieve greater torque. This AC servomotor can be placed
to high accuracy and also controlled precisely as compulsory for the applications. Frequently these motors
have high performance bearings it helps the motor to control the accurate torque of AC Servo motor.
Block diagram:

Figur#6.1(Block Diagram)
Construction of AC servo motor:
The AC servomotor is basically a two phase induction motor with some special design features. The stator
consists of two pole-pairs (A-B and C-D) mounted on the inner periphery of the stator, such that their axes are
at an angle of 90° in space. Each pole-pair carries a winding. One winding is called reference winding and the
other is called a control winding. The exciting current in the winding should have a phase displacement of
90°. The supply used to drive the motor is single phase and so a phase advancing capacitor is connected to
one of the phase to produce a phase difference of 90°. The stator constructional features of AC Servo motor are
shown in figure.

Figure#6.2 (Stator Construction of AC servomotor)

26
 The rotor construction is usually squirrel cage or drag-cut type. Rotor Construction of AC Servo motor is
shown in figure the squirrel cage rotor is made of laminations. The rotor bars are placed on the slots and short
circuited at both ends by end rings. The diameter of the rotor is kept small in order to reduce inertia and to
obtain good accelerating characteristics.
The Drag-cup construction is employed for very low inertia applications. In this type of construction
the rotor will be in the form of hollow cylinder made of aluminum. The aluminum cylinder itself acts as short
circuited rotor conductors. (Electrically both the types of rotor are identical).
Trainer Overview:
The AC servomotor trainer is composed of a
 Mechanical Assembly and Load
 AC Servo motor (MSMF042L1U2M)
 Ac Servo Driver (Panasonic MADLN05SE)
 PC-based control software.
Mechanical Assembly:
The mechanical Assembly consists of a main Shaft, belt pulley and Load Assembly.
AC Servo motor:
There are several advantages to choosing AC servo motors over DC servo motors. They offer more
torque per weight, efficiency, reliability and reduced radio frequency noise. And in the absence of a
commentator, they require less maintenance and have a longer life expectancy. AC servo motors are used in
a wide variety of applications where position control is critical and are frequently used in robotics,
semiconductor equipment, machine tools, and aircrafts. The motor is outfitted with an optical encoder which
provides the current actual position as feedback data.
Panasonic MADLN05SE Controller:
Panasonic MADLN05SE is a high performance servo controller, integrated motion controller, drive
and other functions. It allows to drive AC servo motors in clockwise or counter clockwise, Positioning,
Velocity and torque of AC servo motors. Users can program in PANATERM software to control the speed,
torque and positioning of AC servomotors, User can change and set the parameters for different experiments
like control the rotation per minute, time of destination and force from controller etc. It combined the advanced
motion control technology with specific features.
PC-based Control Software:
The PANATERM software assists users in setting parameters (parameter is defined on the screen, it
will be sent to the driver immediately. Once you register parameters you frequently use, they can be easily set
up on the screen), monitoring control conditions, setup support, and analyzing mechanical operation data on
the PC screen, when installed in a commercially available personal computer, and connected to the MINAS
series through the USB interface.
Features:
AC servo motor has the advantage of small volume, fast dynamic performance, high overload and
large range of velocity adjustment. So it is widely used in the servo systems for precious velocity adjustment
or position tracking. High-performance AC motors and servo motors use discrete analog components as part
of the control loop to reduce energy consumption and maximize performance. Measuring the current of a
three-phase AC motor provides input to control the motor. These can each be measured independently if two
phases are measured simultaneously, their phase relationship is known and the current in the third phase can
be calculated.

Figure#6.3(Servo Drive)

27
Function:
Velocity control by analog speed command:
The analog speed command input voltage is converted to equivalent digital speed command. You can set
the filter to eliminate noise or adjust the offset.
Relevant Parameters:

Figure#6.4(Relevant Parameter)
Connections:

Figure#6.5(Connection)
Procedure:
 Connect the connector X4 on the Panasonic controller.
 Confirm the default values of velocity parameters.
 Connect the SRV-ON input GND.
 Connect ZEROSPD input to GND.
 Connect + 10V DC output pin to SPR/TRQR/SPL input pin.
 Gradually increase from 0V to confirm the motor runs.
 Confirm the motor rotational speed in monitor mode.
 If the motor does rotate at a micro speed with command voltage of 0.
 When you want to change the rotational speed and direction, setup the following parameters again.
 Pr3.00: Speed setup, internal/external switching
 Pr3.01: Speed command rotational direction selection
 Pr3.03: Reversal of speed command input
Parameter:

28
 Figure#6.6(Parameter)

Input signal status:

Figure#6.7(Input signal)

Conclusion:
In this experiment, we learnt about the basic features of the AC servo trainer IT-4420 and how to
control the velocity and speed of the AC servo motor and observe the change in the speed by changing velocity.

29
 Lab # 07
Logic Gates using PLC step7
Objective:
Implementation of Logic Gates using PLC step7
Apparatus:
 Computer
 Industrial control Lab
 PLC step7 software
 PLC trainer
Theory:
Ladder logic Functions:
There are many control situations requiring actions to be initiated when a certain combination of
conditions is realized. Thus, for an automatic drilling machine, there might be the condition that the drill motor
is to be activated when the limit switches are activated that indicate the presence of the work piece and the
drill position as being at the surface of the work piece. Such a situation involves the AND logic function,
condition A and condition B having both to be realized for an output to occur. This section is a consideration
of such logic functions.
I. AND logic function
Figure 1a shows a situation where an output is not energized unless two, normally open, switches are
both closed. Switch A and switch B have both to be closed, which thus gives an AND logic situation. We can
think of this as representing a control system with two inputs A and B (Figure 1b). Only when A and B are
both on is there an output.
Thus if we use 1 to indicate an on signal and 0 to represent an off signal, then for there to be a 1 output
we must have A and B both 1.

Figure 1: AND logic gate

Truth Table:
Inputs Output
A B
0 0 0

0 1 0
1 0 0
1 1 1

An example of an AND gate is an interlock control system for a machine tool so that it can only be operated
when the safety guard is in position and the power switched on.
The ladder diagram starts with | |, a normally open set of contacts labeled input A, to represent switch A and
in series with it | |, another normally open set of contacts labeled input B, to represent switch B. The line then

30
terminates with O to represent the output. For there to be an output, both input A and input B have to occur,
i.e., input A and input B contacts have to be closed.
In general // On a ladder diagram contacts in a horizontal rung, i.e., contacts in series, represent the
logical AND operations.

Figure 2: AND gate with a ladder diagram rung

II. OR logic function
Figure 3a shows an electrical circuit where an output is energized when switch A or B, both normally
open, are closed. This describes an OR logic gate (Figure 3b) in that input A or input B must be on for there
to be an output.

Figure 7.4: OR logic gate

Truth Table:
Inputs Output
A B
0 0 0
0 1 1
1 0 1
1 1 1

Figure 3: (a) OR electrical circuit (b) OR logic gate

The ladder diagram starts with | |, normally open contacts labeled input A, to represent switch A and
in parallel with it | |, normally open contacts labeled input B, to represent switch B. either input A or input
B have to be closed for the output to be energized (Figure 4c). The line then terminates with O to represent
the output.
In general // Alternative paths provided by vertical paths from the main rung of a ladder diagram,
i.e., paths in parallel represent logical OR operations.
An example of an OR gate control system is a conveyor belt transporting bottled products to
packaging where a deflector plate is activated to deflect bottles into a reject bin if either the weight is not
within certain tolerances or there is no cap on the bottle.

31
 Figure 4: OR gate
NOT logic function
Figure 5a shows an electrical circuit controlled by a switch that is normally closed. When there is an
input to the switch, it opens and there is then no current in the circuit. This illustrates a NOT gate in that
there is an output when there is no input and no output when there is an input (Figure 5c). The gate is
sometimes referred to as an inverter.

Figure 5: NOT gate

Truth Table:
Input A Output
0 1
1 0
The input A contacts are shown as being normally closed. This is in series with the output ( ). With no input
to input A, the contacts are closed and so there is an output. When there is an input to input A, it opens and
there is then no output.
An example of a NOT gate control system is a light that comes on when it becomes dark, i.e., when
there is no light input to the light sensor there is an output.

Figure 6: (a) NOT circuit (b) NOT logic with a ladder rung (c) high output when no input to A
III. NAND Logic Function
Suppose we follow an AND gate with a NOT gate (Figure 6a). The consequence of having the NOT
gate is to invert all the outputs from the AND gate. An alternative, which gives exactly the same results, is
to put a NOT gate on each input and then follow that with OR (Figure 6b).
The same truth table occurs, namely
Inputs Output
A B
0 0 1
0 1 1
1 0 1
1 1 0

32
 Figure 7: NAND gate
Both the inputs A and B have to be 0 for there to be a 1 output. There is an output when input A and
input B are not 1. The combination of these gates is termed a NAND gate (Figure 7).

Figure 8: A NAND gate program and graph

An example of a NAND gate control system is a warning light that comes on if, with a machine tool,
the safety guard switch has not been activated and the limit switch signaling the presence of the work piece
has not been activated.
NOR logic function
Suppose we follow an OR gate by a NOT gate (Figure 8a). The consequence of having the NOT gate
is to invert the outputs of the OR gate. An alternative, which gives exactly the same results, is to put a NOT
gate on each input and then an AND gate for the resulting inverted inputs (Figure 8b).
The following is the resulting truth table
Inputs Output
A B
0 0 1
0 1 0
1 0 0
1 1 0
The combination of OR and NOT gates is termed a NOR gate. There is an output when neither input
A nor input B is 1. Figure 9 shows a ladder diagram of a NOR system. When input A and input B are both
not activated, there is a 1 output. When either X400 or X401 are 1 there is a 0 output.

33
 Figure 9: NOR gate

Figure 10: NOR gate

IV. Exclusive OR (XOR) logic function
The OR gate gives an output when either or both of the inputs are 1. Sometimes there is, however, a
need for a gate that gives an output when either of the inputs is 1 but not when both are 1, i.e., has the truth
table:

Inputs Output
A B
0 0 0
0 1 1
1 0 1
1 1 0
When input A and input B are not activated then there is 0 output. When just input A is activated,
then the upper branch results in the output being 1. When just input B is activated, then the lower branch
results in the output being 1. When both input A and input B are activated, there is no output. In this example
of a logic gate, input A and input B have two sets of contacts in the circuits, one set being normally open
and the other normally closed. With PLC programming, each input may have as many sets of contacts as
necessary.

Figure 11: XOR gate

Procedure:
 First we turn on the pc inn which the PLC software was installed.
 Then we double click on the icon of step-7 V-13.
 After some time a window will open then after adding the device 1215DC/DC/DC.
 Then we define the PLC tags
 After this we make the programs of all the logic gates one by one and check the operation using the
PLC trainer.
 In this we learnt about the logic gates.
PLC Programs:
Task 1:
The ladder logic of NOT gate is shown below: -

34
 Figure 12: NOT Gate
Task 2:
The ladder logic of AND gate is shown below: -

Figure 13: AND Gate

Task 3:
The ladder logic of NAND gate is shown below: -

Figure 14: NAND Gate

Task 4:
The ladder logic of OR gate is shown below: -

Figure 15: OR Gate

Task 5:
The ladder logic of NOR gate is shown below: -

Figure 16: NOR Gate

Task 6:
The ladder logic of XOR gate is shown below:-

35
 Figure 17: XOR Gate
Task 7:
The ladder logic of XNOR gate is shown below: -

Figure 18: XNOR Gate

Conclusion:
In this experiment we learnt about the use of Logic Gates using PLC and we make the programs of the
logic gates on the step-7 software. We also use the PLC trainer to check the programs of the logic Gates.

36
 Lab # 08
One Way Two Direction Traffic Light and Two Way Traffic light Control using PLC
step-7
a) One Way two direction Traffic light Control using PLC
Objective:
Implementation of One Way two direction Traffic light Control using PLC step7
Apparatus:
 Computer
 Industrial control Lab
 PLC step7 software
 PLC trainer
Theory:
PLC timers are instructions that provide the same functions as on-delay and off-delay mechanical and
electronic timing relays. A PLC timer provides a preset delay to the control actions. In general, there are three
types of PLC timer delays, ON-delay timer, OFF-delay timer and retentive timer on. The terms represented in
the timer block in the PLC are a Preset value which means the delay period of the timer, an Accumulated
value which is the current delay of the timer. A timer begins the counting on time-based intervals and continues
until the accumulated value equals the preset value. When the accumulated value equals the preset time the
output will be energized. Then the timer sets the output.
I. TON timer or ON delay timer
An ON delay timer is used where we need a time delay before the time delay before an instruction
becomes true.

Figure 1: Timer on Delay

Figure 2: Timer on Delay graph

 The timer starts operating when the rung condition becomes true. The timer delay starts counting when
the rung condition starts to accumulate.
 When the Preset value becomes equal to the accumulated value, the output is made true.
 The timed output becomes true sometime after the timer rung becomes true; hence, the timer is said to
have an on-delay.
 The length of the delay can be adjusted by setting the preset value.
II. TOFF timer or OFF delay timer:
A TOFF timer will keep the output energized for a preset time after the rung signal has gone false.
37
 Figure 3: Timer off Delay
The TOFF timer will have all the contents as in the TON timer, with the similar function.

Figure 4: Timer off Delay graph

 When the rung timer is true, the output will be true without any delay. When the rung signal becomes
false the timer starts operating.
 The timer starts accumulating times when the rung condition becomes true, until the accumulated value
becomes equal to the Preset value.
 The output turns off when the output will turn false when the accumulated value equals the preset value.
Traffic lights:
Traffic lights, also known as traffic signals, traffic lamps, traffic semaphore, signal lights, stop
lights, robots (in South Africa and most of Africa), and traffic control signals (in technical parlance), are
signaling devices positioned at road intersections, pedestrian crossings, and other locations to control flows of
traffic.

Procedure:
 First of all we turn on the PC present in the industrial lab
 Then we double click on the icon of the step-7 software to open it
 A new window will open
 We add the new device and after adding a new device a new window will open
 In this window we define the PLC tags or Table of the inputs and outputs simultaneously like the
trainer inputs and outputs.
 Then we make the program of the one way traffic lights to control the lights
 We set the different time for the different lights to glow
 Then we turn on the trainer
 Then we load the program to check or control the lights
 After this we run the program and see the control of the lights
 After this we save the program of one way traffic lights
 The ladder logic of the program is given below.

PLC Ladder Logic:

Ladder Logic for One way

The ladder logic for this is given as:
In the one way traffic control we can control the lights by following program
38
 Figure 5: Ladder logic for one way
Conclusion:
In this experiment we learn about the control of the one way two direction traffic lights control using
PLC. After running the program we see that how the traffic lights glow with the difference of the time which
is given or define.

b) Two Way Traffic light Control using PLC

Objective:
Implementation of Two Way Traffic light Control using PLC step7
Apparatus:
 Computer
 Industrial control Lab
 PLC step7 software
 PLC trainer
 Traffic lights Trainer
Theory:
PLC timers are instructions that provide the same functions as on-delay and off-delay mechanical and
electronic timing relays. A PLC timer provides a preset delay to the control actions. In general, there are three
types of PLC timer delays, ON-delay timer, OFF-delay timer and retentive timer on. The terms represented in
the timer block in the PLC are a Preset value which means the delay period of the timer, an Accumulated
value which is the current delay of the timer. A timer begins the counting on time-based intervals and continues
until the accumulated value equals the preset value. When the accumulated value equals the preset time the
output will be energized. Then the timer sets the output.
TON timer or ON delay timer
An ON delay timer is used where we need a time delay before the time delay before an instruction
becomes true.

39
 Figure 1: Timer on Delay

Figure 2: Timer on Delay graph

 The timer starts operating when the rung condition becomes true. The timer delay starts counting when
the rung condition starts to accumulate.
 When the Preset value becomes equal to the accumulated value, the output is made true.
 The timed output becomes true sometime after the timer rung becomes true; hence, the timer is said to
have an on-delay.
 The length of the delay can be adjusted by setting the preset value.
TOFF timer or OFF delay timer:
A TOFF timer will keep the output energized for a preset time after the rung signal has gone false.

Figure 3: Timer off Delay

The TOFF timer will have all the contents as in the TON timer, with the similar function.

Figure 4: Timer off Delay graph

 When the rung timer is true, the output will be true without any delay. When the rung signal becomes
false the timer starts operating.
 The timer starts accumulating times when the rung condition becomes true, until the accumulated value
becomes equal to the Preset value.
 The output turns off when the output will turn false when the accumulated value equals the preset value.
Retentive timer
40
 A retentive timer is used when you want to retain accumulated time value through the power loss or
the change in the rung state. A retentive timer accumulates time whenever the device receives power, and it
maintains the current time should power be removed from the device. Loss of power to the timer after reaching
its preset value does not affect the state of the contacts. The retentive timer must be intentionally reset with a
separate signal for the accumulated time to be reset

Figure 5: Retentive Timer (RTO)

An example logic is shown above.
 When the push bottom PB1 is pressed, the timer starts working and the reading starts accumulating.
 When we push the PB1 button then rung become false and the timer stops working. Consider we are
switching ON the push after a time, the timer starts counting from the previous value before the timer
is stopped.
 We have to add another switch PB2 to reset the values in the timer
Traffic lights:
Traffic lights, also known as traffic signals, traffic lamps, traffic semaphore, signal lights, stop
lights, robots (in South Africa and most of Africa), and traffic control signals (in technical parlance), are
signaling devices positioned at road intersections, pedestrian crossings, and other locations to control flows of
traffic.

Procedure:
 First of all we turn on the PC present in the industrial lab
 Then we double click on the icon of the step-7 software to open it
 A new window will open
 We add the new device and after adding a new device a new window will open
 In this window we define the PLC tags or Table of the inputs and outputs simultaneously like the
trainer inputs and outputs.
 Then we make the program of the two way traffic lights to control the lights
 We set the different time for the different lights to glow

41
  Then we turn on the trainer
 Then we load the program to check or control the lights
 After this we run the program and see the control of the lights
 After this we save the program of two way traffic lights
 The ladder logic of the program is given below.

PLC Ladder Logic:

Ladder Logic for Two way

42
Conclusion:
In this experiment we learn about the control of the two way traffic lights control using PLC. After
running the program we see that how the traffic lights glow with the difference of the time which is given or
define.

43
 Lab # 9
Three Way & Four Way Traffic Light Control using PLC step-7
Objective:
Implementation of Three Way (T-Chowk) Traffic light Control using PLC step7
Apparatus:
 Computer
 Industrial control Lab
 PLC step7 software
 PLC trainer
 Traffic lights Trainer
Theory:
PLC timers are instructions that provide the same functions as on-delay and off-delay mechanical and
electronic timing relays. A PLC timer provides a preset delay to the control actions. In general, there are three
types of PLC timer delays, ON-delay timer, OFF-delay timer and retentive timer on. The terms represented in
the timer block in the PLC are a Preset value which means the delay period of the timer, an Accumulated
value which is the current delay of the timer. A timer begins the counting on time-based intervals and continues
until the accumulated value equals the preset value. When the accumulated value equals the preset time the
output will be energized. Then the timer sets the output.
Traffic Lights Rules:
Traffic Signals

Traffic control signals are devices placed along, beside, or above a roadway to guide, warn, and
regulate the flow of traffic, which includes motor vehicles, motorcycles, bicycles, pedestrians, and other road
users.

RED—A red signal light means STOP.

A right turn can be made against a red light ONLY after you stop and yield to pedestrians and vehicles
in your path. DO NOT turn if there is a sign posted for NO TURN ON RED.

44
 RED ARROW—A red arrow means STOP until the green signal or green arrow appears. A turn may
not be made against a red arrow.

FLASHING RED—A flashing red signal light means exactly the same as a stop sign: STOP! After
stopping, proceed when safe and observe the right-of-way rules.

YELLOW—A yellow signal light warns you that the red signal is about to appear. When you see the
yellow light, you should stop, if you can do so safely. If you can't stop, look out for vehicles that may enter
the intersection when the light changes.

YELLOW ARROW—A lighted red arrow is about to appear. Stop if you are not already in the
intersection.
GREEN—A green light means GO, but you must first let any vehicles, bicycles, or pedestrians
remaining in the intersection get through before you move ahead.

You can turn left ONLY if you have enough space to complete the turn before any oncoming vehicle,
bicycle, or pedestrian becomes a hazard. Vehicles turning left must always yield to those going straight from
the opposite direction.
Do not enter an intersection, even when the light is green, unless there is enough space to cross
completely before the light turns red. If heavy traffic causes you to block traffic, you can be cited.

45
 GREEN ARROW—A green arrow means GO, but first you must yield to any vehicle, bicycle, or
pedestrian still in the intersection.
Procedure:
 First of all, we turn on the PC present in the industrial lab
 Then we double click on the icon of the step-7 software to open it
 A new window will open
 We add the new device and after adding a new device a new window will open
 In this window we define the PLC tags or Table for the inputs and outputs of the three-way direction
traffic lights simultaneously like the trainer inputs and outputs.
 Then we make the program of the three-way (T-Chowk) and Four-way traffic lights to control the
lights
 We set the different time for the different lights to glow
 Then we turn on the trainer
 We connect the trainer of the traffic lights with PLC
 Then we load the program to check or control the lights
 After this we run the program and see the control of the lights
 After this we save the program of three-way and Four-way traffic lights
 The ladder logic of the program is given below.
PLC Ladder Logic:
Ladder Logic for three way (T-Chowk)

46
47
 Figure 10.1: Program for the three-way traffic lights
PLC Ladder Logic:
Ladder Logic for Four way four direction

48
 Figure 11.2: PLC Program of Four Direction
Conclusion:
In this experiment we learn about the control of the three way traffic lights control using PLC. After
running the program we see that how the traffic lights glow with the difference of the time which is given or
define.

49
 Lab # 10
Temperature control Fan using PLC
Objective:
Implementation of Temperature control Fan using PLC
Apparatus:
 Computer
 PLC step7 software
 PLC trainer
Theory:
Temperature sensor:
A temperature sensor is a device that detects and measures hotness and coolness and converts it into
an electrical signal.
A temperature sensor is a device, typically, a thermocouple or RTD, that provides
for temperature measurement through an electrical signal. A thermocouple (T/C) is made from two dissimilar
metals that generate electrical voltage in direct proportion to changes in temperature.
Temperature control is a process in which change of temperature of a space (and objects collectively
there within), or of a substance, is measured or otherwise detected, and the passage of heat energy into or out
of the space or substance is adjusted to achieve a desired temperature.

Figure No 11.1: Block Diagram

1.4 Procedure:
 First of all, we turned on our PC and open the software step seven.
 We construct the ladder logic of temperature control by using PLC in the software
 Check the results and verify by running it on the hardware by using temperature control module.
 After turn off the PC/ Lap top
 In this window we define the PLC tags or Table for the inputs and outputs of the temperature sensor
like the trainer inputs and outputs.
 Then we make the program of temperature sensor.
 We set the different temperature for the different lights to glow
 Then we turn on the trainer
 We connect the trainer of the temperature sensor with PLC
 Then we load the program to check the temperature sensor
 After this we run the program
 After this we save the program.
50
 The ladder logic of the program is given below.

51
 Figure No 11.2: Temperature control

Conclusion:
In this experiment we learn about the Implementation of Temperature control using PLC. After running
the program we observed the fan volt, current and the heater volt, current. The system has a good stability and
a good reliability.

52
 Lab # 11
Stepper Motor Control
Objective:
Stepper Motor Control using PLC.
Apparatus:
 Computer
 Industrial control Lab
 PLC step7 software
 PLC trainer
Theory:
PLC timers are instructions that provide the same functions as on-delay and off-delay mechanical and
electronic timing relays. A PLC timer provides a preset delay to the control actions. In general, there are three
types of PLC timer delays, ON-delay timer, OFF-delay timer and retentive timer on. The terms represented in
the timer block in the PLC are a Preset value which means the delay period of the timer, an Accumulated
value which is the current delay of the timer. A timer begins the counting on time-based intervals and continues
until the accumulated value equals the preset value. When the accumulated value equals the preset time the
output will be energized. Then the timer sets the output.
Stepper Motor:
Stepper motors are DC motors that move in discrete steps. They have multiple coils that are
organized in groups called "phases". By energizing each phase in sequence, the motor will ro tate, one
step at a time. With a computer controlled stepping you can achieve very precise positioning and/or speed
control. For this reason, stepper motors are the motor of choice for many precision motion control
applications.
Stepper motors come in many different sizes and styles and electrical characteristics.

Working Principle:
Working of Permanent Magnet Stepper Motor. The operation of this motor works on the principle that
unlike poles attract each other and like poles repel each other. When the stator windings are excited with a DC
supply, it produces magnetic flux and establishes the North and South poles.
PLC Trainer:
It is a module or an integrated circuit used to control different types of motors that are fixed on it. Ladder logic
programming is used for performing different tasks on it which is shown in diagram.

53
Procedure:
 First of all we turn on the PC present in the industrial lab
 Then we double click on the icon of the step-7 software to open it
 A new window will open
 We add the new device and after adding a new device a new window will open
PLC Ladder Logic:
Ladder Logic for Stepper motor Control:

54
a

55
Conclusion:
In this experiment we learn about the control of the stepper motor control using PLC. After
running the program we see that how the motor rotates with the difference of the time which is given or define.
In this experiment we learn about the operation of the stepper motor control.

56
 Lab # 12
Automatic Bottle Filling System using PLC
Objective:
Implementation of Automatic Bottle Filling System using PLC
Apparatus:
 Computer
 Industrial control Lab
 PLC step7 software
 PLC trainer
Theory:
Introduction:
An Automation is the utilization of different control techniques for operating equipment’s such as
operations in factories, aircraft and other applications with reduced human power. The filling process is a
mission performed by a machine that fills liquid products such as water or cold drinks. Traditional bottling
methods include placing bottles on a conveyor belt and filling only one bottle at a time. In this paper, it has
been designed and implement water filling machine system for different sized bottles by using PLC. Where
the water filling machine system includes design and implement prototype of a flat belt conveyor and
automatic process for water filling machine using the solenoid valve and sensors which gives the appropriate
information to control unit then design the controller using PLC. The PLC plays important role to implement
automatic filling process by using PLC programing software and ladder diagram language. It was found that
the water filling machine using PLC is less operational cost and less power consumption than the traditional
control systems, in addition more flexible and time saving.
Level Sensor:
A float switch is a type of level sensor, a device used to detect the level of liquid within a tank. The switch
may be used to control a pump, as an indicator, an alarm, or to control other devices.

Figure 1 Level Sensor

Water Pump:
It is used to fill the water Tank from the main reservoir. It is DC pump which operates with 12 V DC Supply.

Figure 2: DC Pump
57
Inductive Proximity Sensors:
Inductive proximity sensors are used for non-contact detection of metallic objects. Their operating principle
is based on a coil and oscillator that creates an electromagnetic field in the close surroundings of the sensing
surface.

Figure 3: Proximity Sensor

DC motor:
DC motor is type of rotary electrical machines that convert electrical current into mechanical motion. In this
apparatus a DC motor is used to rotate the conveyor belt to move the bottle first under the valve and after it
filled move it away from valve. This DC motor operate 12 DC supply with gear box which is used to increase
the torque and reduce the speed as required as shown in Figure

Figure 3: DC motor with gear box

Water solenoid valve:

A solenoid valve is an electromagnetic controlled device utilized to control the flow of liquid or gas by
opening and closing a gate by a certain value of current as shown in Figure. When a current applied to the coil
of the solenoid it will become like magnetic which exerts a force on a piece of iron to close the gate and pulled
it toward the center of the coil so it opens the gate and allow liquid to flow. A tank used to provide the liquid
to the solenoid.

Figure 4:Water solenoid valve.

58
Relay:
Relays are switches that open and close circuits electromechanically or electronically. Relays control one
electrical circuit by opening and closing contacts in another circuit. As relay diagrams show, when a
relay contact is normally open (NO), there is an open contact when the relay is not energized. The low voltage
that the relay will accept to control the switch is 5 V. The laser and the sensor worked are on 5V but the input
to PLC is on 24 V DC so the relay is used to connect the laser and sensor to the input of the PLC. In the output
side, the relay is connected from the output of the PLC to each of the DC motor and the solenoid valve for
the purpose of protection.

Figure 6:- Relay

Conveyor System:
Nowadays with many industrial applications, a conveyor system is used to move object from one location to
another in effective way to reduce losing time and effort and it is very useful in packaging process. A conveyor
system has several forms but, in this paper, a Flat belt type is used to move the bottles as shown in Figure.
Conveyors are especially useful in applications which including the transportation of heavy or large materials.
A Flat belt conveyer has the belt is made from elastic material. Six pulleys a distributed along the belt, the
first one rotates with the rotation of motor shaft and it usually called drive pulley and the other five pulley
called idler pulley. The Flat belt is fitted with aluminum plate between the pulleys to support the belt.

Figure 5: Flat belt conveyor

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System Working:
When the Level of the Water in the Tank is Low it is detected by Low Level Sensor which switch On the
pump and start filling the water in the tank. When the level of the water reach at higher-Level high-Level
switch detects it and Switch off the Pump and stop filling. The water filling machine starts when the push
button switch is pressed and this caused working the DC motor hence the conveyor belt is moving. The bottles
move on the conveyor belt until the first bottle reaches under the solenoid valve where the proximity detects
the bottle, hence the proximity sensor is sensing the bottle and gives a control signal to the PLC through the
relay(24v). This leads to stopping the DC motor and hence the conveyer belt stops and the solenoid valve
operates and the bottle starts filling the water (using timer in PLC to time this process).when the bottle is fully
filled with water, the solenoid valve is closed and the motor is working to move the conveyor belt again to
carry the bottle away from the solenoid valve. If another bottle is detected under the valve, the process
will be repeated and when the stop button is pressed, the whole process will be stopped.
Uses:
 Material Handling
 Elevators and escalators
 packaging
 water treatment plants
 Parts Detection
 Cold Drinks Filling Industry
Ladder Logic:

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Conclusion:
An automatic water filling machine system for different sized bottles by using PLC has been developed and
implemented. The PLC is used in this system to get more productivity with less time high reliability for and
flexible in work. The system is designed to working with different sized bottles by simply change the program.

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