ASSIGNMENT – 1

Subject- INDUSTRIAL AUTOMATION Due date-

Introduction to Industrial Automation

Q.1 What is automation? Discuss the advantages and disadvantages of automation.

Q.2 State any four needs of industrial automation.
Q.2 Explain the basic elements of an Automated System.
Q.3 What do you understand by:
a) Computer – Aided Design
b) Computer – Aided Manufacturing
c) Computer – Integrated Manufacturing
Q.4 How can expert system help in maintenance automation?
Q.5 How does fixed high – volume automation differs from flexible automation.
Q.6 Consider an automated turning operation in which a cone-shaped geometry is
generated. Assume the system is automated and the robot is used to load and unload
the work unit. The work cycle consists of the following steps
i) load starting work piece.
ii) position cutting tool prior to turning
iii) turning.
iv) reposition tool to a safe location at and of turning.
v) unload finished work piece.
Identify the activities and process parameter(s) in each step of the operation.
Q.7 Consider an automated cell consisting of a CNC machine tool, a parts storage unit and
a robot for loading and unloading the parts between the machine and the storage unit.
Possible errors that might effect the system can be divided into following categories:
i) machine and process
ii) cutting tools.
iii) work holding fixture.
iv) part storage unit.
v) load / unload robot.
Develop a list of possible errors that might be included in each of these five
categories.
Q.8 Discuss the concept of low cost automation with suitable example.

ASSIGNMENT – 2

Subject- INDUSTIAL AUTOMATION Due date-

Control Systems

Q.1 a) Define PLC.

b) Explain PLC operating cycle.

Q.2 Discuss the logic control and sequence control elements.

Q.3 What are the logic functions used for switches

a) in series
b) in parallel

Q.4 Draw the ladder rungs and write the instruction sequence to represent:
a) Two switches are normally open and both have to be closed for a motor to operate.
b) Either of two, normally open, switches have to be closed for a coil to be energized
and operate an actuator.
c) A motor is switched on by pressing a spring return push-button start switch and
motor remains on until another spring-return push button stop switch is pressed.

Q.5 Devise a timing circuit that will switch an output on for 10 sec then switch it off.

Q.6 A selection committee comprises four members including the chairman. In order for a
candidate to be selected, he or she has to have the support at least two members. The
chairman however can push any candidate through. If each member is provided with a
switch, design a logic that will ring a bell when candidate is selected.

Q.7 Develop a ladder diagram to fulfill the following conditions in a MCC:

When the start switch is ON, the motor is ON
When the stop switch is ON, the motor is OFF
When the motor is ON, the green light is ON
When the motor is OFF, the red light is ON

Q.8 Write the truth tables and the instruction sequence for following statements
a) The inverse of the out come of OR ing A and B, is the same as when the inverse of
A and B separately AND ed. i.e. A+B = A.B
b) The inverse of the out come of AND ing A and B is the same as when the inverse
of A and B are separately OR ed. i.e. A.B = A+B

Q.9 Draw ladder logic for a three motor system having the following conditions:
 Motor (M1) starts as soon as the start switch is on, after 10 seconds, M1 goes off and
M2 starts. After 5 seconds M2 goes off and M3 comes on. After 10 seconds M3 goes
off and M2 comes on; and after 5 seconds, M2 goes off and M1 comes on and the
cycle is repeated.

Q 10 Design a ladder diagram that will control a stepper motor so that it moves 10 steps
forward, waits for 20 seconds and then cause the motor to move 10 steps in reverse
direction.
Q10. Construct the ladder logic diagram and the instruction sequence for the following
Boolean logic equations.

a) Y = (X1 + X2) X 3
b) Y = (X1 + X2) (X 3 + X4)
c) Y = (X1 + X2) + X 3
d) Y = X1 X2

Q11. Draw ladder logic to start a motor and then after a delay of 100 s start a pump. When
the motor is switched off there should be a delay of 10 s before the pump is switched
off.

Q12. Draw a ladder logic diagram for a domestic washing machine to switch on pump to
pump water for 100 s into the machine, then switch off and switch on a heater for 50 s
to heat the water. The heater is then switched off and another pump is to empty the
water from the machine for 100 s.

Q13. Devise a system using PLC, which can be used to control the movement of a piston in
a cylinder so that when a switch is momentarily pressed, the piston moves in one
direction and when a second switch is momentarily pressed the piston moves in the
other direction.

Q14. Devise a system using PLC, which can be used to control the movement of a piston in
a cylinder using a 4/2 solenoid operated pilot valve. The piston is to move in one
direction when a proximity sensor at one end of the stroke closes contacts and in the
other direction when a proximity sensor at the other end of the stroke indicates its
arrival there.

Q15. Draw a ladder logic diagram using counters C1 and C2 for a machine which is
required to direct 6 items along one path for packaging in a box and then 12 items
along another path for packaging in another box. Write the instruction sequence also.
 ASSIGNMENT – 3

Subject-INDUSTIALAUTOMATION Submission date-

19/4/2017

Fluid Control Components

Q1 Draw the symbols for (a) a pressure relief valve (b) a3/2 valve which has actuators of
a push button and a spring (c) a 4/2 valve (d) flow valve with adjustable flow control
(e) shuttle valve.

Q2 Explain with neat sketch the construction and working of servo control valve.

Q3 Parts to be clamped for a drilling operation. The technician needs to activate and
deactivate a pneumatic clamp and holds the part in a fixture on the drilling machine.
The clamp must be activated before the drilling cycle begins and deactivated at the
end of the drilling cycle.

Q4 Parts are accumulating on a conveyor belt and waiting to be released and transferred
to the next phase of assembly. Technicians at multiple stations need to control the
gate release mechanism to have parts sent to their assembly station.

Q5 Draw a signal inversion circuit.

Q6 Draw a pneumatic circuit with memory function.

Q7 Draw a pneumatic/hydraulic system that can be used to operate the vehicle assuming
that the opening and closing of the doors are controlled by two button switches ON
and OFF.

Q8 A plastic thermo-forming machine is capable of heating and forming parts of various

thicknesses. The parts must be held in their molded positions while the plastic is
curing in its final form. The length of time needed to cure the plastic will vary
depending on the thickness. This in turn will require a forming operation that has a
variable time delay before the part is automatically released.

Q9 A large stamping press must have a part in place, the clamps engaged and the safety
guard closed before the press can operate. The pneumatic circuit needed for this type
of machine is designed to minimize potential safety hazards.

Q10 A gravel yard has a single conveyor that can transport gravel to two different loading
docks. In order to shift the out feed of the conveyor to the alternate loading dock the
operator must push a button. As a safety precaution, the conveyor will always be held
in the last shifted position.
Q11 Boxes are being filled with packing material that is dispensed in a time-released
quantity. The exact amount of packing material needed is dispensed in one cycle. The
operator must not be able to double pack the boxes, which would create an overflow
situation. The operator will push a button to activate the dispensing gate. Once the
button is pushed the cycle will continue until completed. A new cycle cannot be
started until the first cycle is completed and the push button released. Even if the push
button is held down continuously, a new cycle cannot be started.

Q12 The machine head of a precision grinder needs to continuously reciprocate over a
cylinder head surface being finished. The speed of the stroke must be controlled in
both directions.

Q13 A pallet of parts has to be lifted and then transferred onto an Automatic Guided
Vehicle (AGV) to be transported to a loading dock. The machine operator needs to
make this happen automatically by pushing and releasing a button one time.

Q14 A power door opening system must be controlled with a timed cycle. Operators need
to activate the door cycle from both inside and outside by pushing a button. The door
needs to remain open for an adjustable time period before it automatically closes. The
operators must also have a means to keep the door open continuously when needed.

Q15 Consider two cylinders A and B and require when the start button id pressed the
piston of cylinder A extends and then when it is fully extended piston of cylinder B
extends. When this has happened and both are extended we might need the piston of
cylinder A to retract and when it is fully retracted we might then have the piston of B
retract. Draw the pneumatic circuit using a) two actuator sequential control b) cascade
control