Sensorics - PLC Lab - Manual - MTE2243

SENSORICS & PLC LAB MANUAL
SENSORICS & PLC LABORATORY MANUAL
MTE 2243
IV Semester B.Tech Mechatronics 2024
Prepared By. Faculties

Lab Coordinator – Sensorics & PLC lab
Mrs.Spoorthi Singh
Dr. Ishwar biradi)
Approved By. Dr.D.V.Kamath

HoD - Mechatronics
Department of Mechatronics 1
IV Semester B.Tech (MTE 2243)

Mechatronics 2024
NAME: _
REG NO:
ROLL NO:
DEPARTMENT OF MECHATRONICS
VISION OF MAHE
• Global leadership in human development, excellence in education and healthcare.
MISSION OF MAHE
• Be the most preferred choice of students, faculty and industry
• Be in the top 10 in every discipline of education health sciences, engineering and management.
VISION OF MIT
Excellence in Technical Education through Innovation and Teamwork.
MISSION OF MIT
Educate students professionally to face social challenges by providing a healthy learning environment
grounded well in the principles of engineering, promoting creativity, and nurturing teamwork.
VISION OF THE MECHATRONICS ENGINEERING DEPARTMENT

Excellence in Mechatronics Education through Innovation and Team Work
MISSION OF THE MECHATRONICS ENGINEERING DEPARTMENT
Educate students professionally to face social challenges by providing a healthy learning environment
grounded well in the principles of Mechatronics engineering, promoting creativity, and nurturing
teamwork.
PROGRAM EDUCATIONAL OUTCOMES OF THE MECHATRONICS ENGINEERING
DEPARTMENT (PEOs)
1. Apply analytical skills and modelling methodologies to recognize, analyze, synthesize and
implement operational solutions to engineering problems, product design and
development, and manufacturing.
2. Work in national and international companies as engineers who can contribute to research
and development and solve technical problems by taking an initiative to develop and
execute projects and collaborate with others in a team.
3. Pursue higher education in globally reputed universities by conducting original research in
related disciplines or interdisciplinary topics, ultimately contributing to the scientific
community with novel research findings.
4. Become technology leaders by starting high – tech companies based on social demands and
national needs.
5. Maintain and expand professional competence by keeping up with evolving
technologies, research developments, and lifelong learning.
PROGRAM OUTCOMES (POs) PRESCRIBED BY NBA ACROSS ALL DEPARTMENTS

The GAs are exemplars of the attributes expected of a graduate of an accredited program.
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals,
and an engineering specialization to the solution of complex engineering problems.
2. Problem analysis: Identify, formulate, research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences,
and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and design
system components or processes that meet t h e specified needs with appropriate consideration for
the public health and safety, and the cultural, societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of the
information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modelling to complex engineering activities with
an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal, and cultural issues and the consequent responsibilities relevant to the
professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering solutions
in societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms
of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader in
diverse teams, and in multidisciplinary settings.
10.Communication: Communicate effectively on complex engineering activities with the engineering
community and with society at large, such as, being able to comprehend and write effective reports
and design documentation, make effective presentations, and give and receive clear instructions.
11.Project management and finance: Demonstrate knowledge and understanding of t h e engineering
and management principles and apply these to one’s own work, as a member and leader in a team,
to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in
independent and life-long learning in the broadest context of technological change.
PROGRAM SPECIFIC OUTCOMES OF THE MECHATRONICS ENGINEERING

DEPARTMENT (PSOs)
At the end of the course the student will be able to:
1. Apply the knowledge of sensors, drives, actuators, controls, mechanical design and modern software
tools to integrate a system for performing specified tasks.
2. Articulate designs, modelling, analysis, and testing of Mechatronics products, systems and
controllers using appropriate technology and software tools
GENERAL GUIDELINES OF PROFESSIONAL CONDUCT:

• Be in the Lab 10 min prior to the schedule. Late comers will have penalty of some marks, and an
apology letter to be written and submitted.
• Conduct yourself in a responsible manner at all times in the laboratory.
• Follow all written and verbal instructions carefully. If you do not understand a direction or part of
a procedure, ask the faculty before proceeding with the activity.
• Perform only those experiments authorized by your faculty. Carefully follow all instructions, both
written and oral. Unauthorized experiments are not allowed.
• Observe good housekeeping practices. Work areas should be kept clean and tidy at all times.
• Be alert and proceed with caution at all times in the laboratory. Notify the faculty immediately of
any unsafe conditions you observe.
• Labels and equipment instructions must be read carefully before use. Set up and use the equipment
as directed by your faculty.
• Experiments must be personally monitored at all times. Do not wander around the room, distract
other students, startle other students or interfere with the laboratory experiments of others.
• Report any accident (spill, breakage, etc.) or injury (cut, burn, etc.) to the teacher immediately, no
matter how trivial it seems. Do not panic.
SAFETY AND RISK MEASURES WITH DO’s AND DON’T’:

Sensorics Lab:
• After making the circuit connections, verify from the instructor/faculty and only then proceed further
with the experiment.
• Improper or wrong wiring of cable connections can cause harm to sensor, thus, follow the prior
instructions given by the faculty/lab attender.
• Connecting wrong power supply device without prior knowledge should be avoided, and hence,
check the power supply before switching it ON.
• The power supply used for the sensors of this lab should not exceed 24V DC.
• All the sensors must be handled with extreme care.
• Materials in the sample case must be kept in proper place and do not misplace any of them.
• After completion of the experiment, switch off the power supply, carefully dismantle the connections
and then, hand over the components to the present staff/faculty.
PROGRAMMABLE LOGIC CONTROLLER LAB:

• Check the power supplies for PLC Hardware and PC before switching ON.
• Make sure a commutation channel is established between PLC hardware and PC.
• Do not connect any component to PLC hardware until you have read the data sheet of the component.
• If any kind of noise, heat, spark, etc. is observed, switch off the power supplies and inform the lab
attender or faculty immediately.
• Switch off the PLC hardware and shutdown the PC before you leave the lab.
CLO’s :
At the end of the course the students will be able to:
CLO1 Identify the industrial sensor and draw the characteristic.
CLO2 Implement a wiring connection with different logical combination.
CLO3 Demonstrate the hardware and software components of PLC.
CLO4 Develop ladder programming for different industrial applications.
CLO5 Create an individualistic prototype model using sensors and PLC technology.
LIST OF EXPERIMENTS:
Sensorics Lab
Sr TITLE OF EXPERIMENT DATE Max FACULTY MARKS
No. Marks SIGN Obtained
1. a) Behavior of inductive, capacitive,

magnetic, Ultrasonic sensors, light
scanners 10
b) Logic operation of sensors
2. a) Switching distance, Hysteresis and

Reduction factor of Inductive sensor NJ. 10
b) Response curves of Inductive Sensor
3. a) Operating range, hysteresis and

reduction factor of direct detection
sensor OJ with and without optical
waveguide
b) Calibration of switching distances,
hysteresis and reduction factor of the 10
ultrasonic sensor
4. Response curves of the magnetic sensor

MJ (Parallel and Vertical) 10
Programmable Logic Controller Lab

5. a) Digital Logic Gates
b) Tank Filling Device Simulator System 10
6. Road Works Traffic Lights

10
7. Cleaning System
10
8. Traffic Signal
10
Project Presentation with Demo 20
TOTAL MARKS 100
1.a) Behavior of Inductive, Capacitive, Magnetic, Light Reflection

scanner, and Ultrasonic sensors
INDUCTIVE SENSOR:
Aim: Find out response of an inductive sensor for various materials and write observations in tabular
form.
Assembly Diagram:
Procedure:
1. Mount the inductive sensor NJ (8 mm) onto the elevation compensation in the middle of the
mounting plate and complete the electrical connections (see assembly diagram).
2. Move different material samples from the table one after another in front of the sensor
(manually).
3. Please observe the state of the LEDs.
4. Note down, which materials the sensor detects.
Observation Table:
1.1 Behavior of inductive sensor

Material Sample Detected
Yes No
St37
Plastic, Black
Plastic, white
Copper
Plastic, Clear
Cardboard
Aluminum
Solenoid
Aluminum, light gray
Brass
Sheet of paper
Foam
V2A (stainless steel)
CAPACITIVE SENSOR:
Aim: Find out response of a capacitive sensor for various materials and write observations in tabular
form.
Assembly Diagram:
Procedure:
1. Mount the capacitive sensor CJ (8 mm) onto the elevation compensation in the middle of the
(manually).
Observation Table:
1.2 Behavior of capacitive sensor

Yes No
St37
Plastic, Black
Plastic, white
Copper
Plastic, Clear
Cardboard
Aluminum
Solenoid
Aluminum, light gray
Brass
Sheet of paper
Foam
MAGNETIC SENSOR:
Aim: Find response of a magnetic sensor for various materials in different alignment and write
observations in tabular form.
Assembly Diagram:
Procedure:
1. Mount the magnetic field sensor MB (60 mm) onto the elevation compensation in the middle
of the mounting plate and complete the electrical connections (see assembly diagram).
(manually).
Observation Table:
1.3 Behavior of magnetic field sensor

Yes No
St37
Plastic
Copper
Cardboard
Aluminum
Solenoid vertical
Solenoid parallel
LIGHT REFLECTION SCANNER

Find response of direct detection sensor and through beam sensor for various materials.
Assembly Diagram:
Procedure:
1. Mount the light reflection sensor OJ onto the elevation compensation in the middle of the
(manually).
Observation Table:
1.4 Behavior of reflection light scanner OJ

Material Reflection light scanner One way Light barrier
Sample Detected Sample detected
Yes No Yes No
St37
Plastic, Black
Plastic, white
Copper
Plastic, Clear
Cardboard
Mirror Vertical
Solenoid
Aluminum, light
gray
Brass
Sheet of paper
Mirror rotated by 45
Reflective foil
ULTRASONIC SENSOR
Aim: Find response of an ultrasonic sensor for different materials.
Assembly Diagram:
Procedure:
1. Mount the ultrasonic sensor onto the elevation compensation in the middle of the mounting
plate and complete the electrical connections (see assembly diagram).
(manually).
Observation table:
1.5 Behavior of an ultrasonic sensor
Yes No
Metal
Plastic, Black
Plastic, white
Solenoid
Foam
Cardboard
1. b) Logic operation of sensors
Aim: To realize logical AND and OR operations using various sensors.
The exercise shows the possibility of logic operations of switch outputs of proximity switches. Such
simple logical operations are useful, whenever long leads to the control unit are necessary or whenever
additional sensors are integrated into the system. OR-Logic-Operations by parallel operation of the
outputs and And-operations by a series switching are possible.
In the exercise the inductive proximity switch NJ, the capacitive sensor CJ, the reflection light scanner
OJ with mounted fiber optics TLG and the ultrasonic sensor have to be operated logically.
Assembly Diagram:
OR Circuit
AND Circuit
Procedure:
1. Connect all sensors in the given manner for respective logic operation.
Observation:
Exercise Question 1: Connect all five proximity (inductive, capacitive, light reflection, Magnetic and ultrasonic)
sensors in parallel and list out its behavior of detecting any 5 materials with the maximum range of distance in
mm at which it detects the objects.
Exercise Question 2: Connect the combination of inductive, capacitive , Magnetic and ultrasonic sensors in
NOR & XOR logical operation pattern and list out its behavior of detecting any 5 materials.
2. a) Switching Distance, Switching Hysteresis and

Reduction Factor of the Inductive sensor NJ
Aim: Measure the operating distance of the inductive sensor NJ (8 mm) by means of the standard
measuring plate of St37 (steel).
• Displacement [mm]= (current difference w.r.t. reference [mA]) x 18.75

• Switching point difference (mm)= Switching distance_ON – Switching distance_OFF
• Switching hysteresis= [(switching point difference)/Switching distance_ON] x 100
Assembly Diagram:
Procedure:
1. Turn the mounting plate transversely.
2. Mount the guide carriage with sample carrier and the device for distance measurement in the
middle of the mounting plate.
3. The tapered measuring flag (18mm) made of St37 is used as standard measuring plate.
4. Place the devices from the device list on the matrix base according to the assembly diagram
and fix the standard measuring plate at the sample carrier with graduation.
5. Reposition the inductive sensor on the elevation compensation, such that its active surface
aims at the center of the material sample.
6. The sensor must reach over the distance sensor towards the material sample, to such a degree
that it can touch it.
7. Switch on the power supply unit.
8. If the material sample touches the sensor the measuring instrument will display a value > 4
mA. Note down this value as the reference value.
9. Move sample and note down readings.
Observation Table:
Switching distance and hysteresis of inductive sensor
Reference value:
Switching Switching Difference to Switching Switching Switching
status point reference distance point hysteresis
mA value mm difference %
mA mm
ON
OFF
For checking the reduction factor of the Inductive sensor NJ (8 mm) for
different metals:
The reduction factor is defined as the ratio of the determined ON switch point / switch ON point for
Steel sample St 37
• Displacement [mm]= (switch ON current [mA] – reference current [mA]) x 18.75
• Reduction Factor= Switching distance_ON/ Switching distance_ON_St37
• R%= R x 100%
Assembly Diagram:
Procedure:
3. The tapered measuring flag (18mm) made of St37 is used as standard measuring plate.
5. Reposition the inductive sensor on the elevation compensation, such that its active surface
aims at the center of the material sample.
10. Change materials and note down the readings.
11. Calculate reduction factor based on the findings.
Observation Table:
Inductive sensor: reduction factor
Reference Value:
Material Current/ Switch on point Reduction factor
mA mm %
Steel St37
Copper
Aluminum
Small Solenoid
Brass
Stainless steel
V2A
2. b) Response curves of Inductive sensor
Aim: Determine the response curve of the inductive sensor NJ (8 mm) with the standard measuring
plate.
This curve shows the relationship of operating range and lateral displacement of the material sample.
• Difference [mm]= (current difference w.r.t. reference [mA]) x 18.75

• Lateral Displacement [mm]= (difference [mm] – material width [mm]) / 2
Assembly Diagram:
Procedure:
2. Mount the guide carriage with sample carrier and the device for distance measurement
somewhat above in the middle of the mounting plate.
3. The tapered measuring flag (18mm) made of St37 is used as standard measuring plate (steel).
4. Fix it at the non-rotatable sample carrier, it has to be parallel to the rail of the guide carriage.
5. The elevation compensation is fixed in parallel to the rail in a distance of approx. 2 ... 3 cm to
the carriage.
6. Fix the sensor at the elevation compensation.
7. The active sensor face must touch the material sample that has been moved in front of the
sensor.
9. The switch output of the sensor is active (LED lights up).
10. Now move the sample material left and right to the sensor and note down the readings.
11. Repeat the experiment for the capacitive sensor.
Observation Tables:
Inductive sensor response curve
Switching Switch on points Difference Lateral
distance mA left mA right mA mm displacement
mm X
Mm
8
7
6
4
2
0
Observations
Response curve:
Exercise Question1: Measure the Switching Distance, Switching Hysteresis and Reduction
Factor of the inductive sensor NJ (8 mm) for the brass and aluminum measuringplates to find out
the minimum and maximum switching point ranges.
Exercise Question2: Determine the response curve of the inductive sensor NJ (8 mm) for the
brass and aluminum measuringplates.
3. a) Switching Distance, Switching Hysteresis and Reduction Factor

of the direct detection sensor OJ without and with Optical Waveguide
Aim: Determine the Switching distance of the direct detection sensor OJ with the standard measuring
plate made of white plastic. Examine the dependence between selected sensitivity and operating range
or hysteresis.

Assembly Diagram:
Procedure:
3. The white plastic is used as standard measuring plate.
5. Reposition the light sensor on the elevation compensation, such that its active surface aims at
the center of the material sample.
10. Now fix optical waveguide to the light sensor and repeat the procedure.
Observation table:
Switching distance and hysteresis of direct detection sensor (without optical waveguide)
Reference Value:
Material/ Switch on /off point Difference to Switch on/ off point Hysteresis
Distance reference value %
mm mA ON mA OFF mA ON mA OFF mm ON mm OFF
White
plastic
250mm
White
plastic
200mm
Aim: Determine the reduction factor of the direct detection light sensor with and without optical
waveguide for different materials.
• R%= R x 100%
Assembly Diagram:
Procedure:
12. Now fix optical waveguide to the sensor and repeat the procedure.
Observation Table:
OJ reflection sensor: reduction factor
Reference Value:
mA mm %
Plastic, white
Plastic gray
Plastic red
Plastic green
Plastic black
Plastic clear
Plastic tinted
Steel St37
Aluminum
V2A Steel
Copper
Brass
Switching Distance, hysteresis and reduction factor of the direct detection sensor
OJ with optical waveguide
Aim: Determine the operating range of the direct detection sensor OJ with the standard measuring
plate made of white plastic. Examine the dependence between selected sensitivity and operating range
or hysteresis.

Assembly Diagram:
Procedure:
20. Now fix optical waveguide to the light sensor and repeat the procedure.
Observation table:
Switching distance and hysteresis of reflection light sensor with optical waveguide
Reference Value:
Material/ Switch on /off point Difference to Switch on/ off point Hysteresis
Distance reference value %
mm mA ON mA OFF mA ON mA OFF mm ON mm OFF
White
plastic
150mm
Reduction factor of direct detection sensor with optical waveguide
Aim: Determine the reduction factor of the direct detection light sensor with and without optical
waveguide for different materials.
• R%= R x 100%
Assembly Diagram:
Procedure:
24. Now fix optical waveguide to the sensor and repeat the procedure.
Observation Table:
Reduction factor with optical waveguide
Reference Value:
mA mm %
Plastic, white
Plastic gray
Plastic red
Plastic green
Plastic black
Plastic clear
Plastic tinted
Steel St37
Aluminum
V2A Steel
Copper
Brass
Exercise Problem1: Find out Operating range, hysteresis and reduction factor of direct detection
sensor OJ with and without optical waveguide.
Exercise Problem 2: Calibrate the switching distances, hysteresis and reduction factor of the
ultrasonic sensor.
3. b) Calibration of Switching Distances and Hysteresis and Reduction

factor of the Ultrasonic sensor
Aim: To teach-in-sensing ranges and find hysteresis of the ultrasonic sensor.

The maximum detection range of the used ultrasonic sensor is 500 mm. As the mounting plate and the
device for distance measurement is limited, we only use two selected sensing ranges: 100 mm and 200
mm. On this occasion we exercise once again the teaching-in of these switch points.
The ultrasonic sensor has a teach-in input. By means of this input the switch output for 5 different
functions can be programmed for two teach-in- sensing ranges. For programming the connected
programming Unit UB-Prog is used.
Assembly Diagram:
Procedure:
1. A white plastic plate (80 x 80 mm) serves as standard measuring plate.
2. Place the devices on the mounting plate according to the assembly diagram.
3. Mount the ultrasonic sensor onto the elevation compensation in a way that its active sensor
face (white transducer) aims at the material sample.
4. By repositioning the sensor on the elevation compensation it aims at the center of the sample.
6. Move the measuring flag towards the sensor, to such a degree that it touches the transducer.
7. Note down the indicated value as reference value.
8. Teach-in of the switch point close to the sensor (100 mm). Move the target 100 mm away
from the sensor. Press button A1 at the UB-Prog and touch the white transducer at the sensor
simultaneously with the finger.
9. Is the sample still positioned at 100 mm? Then press button A2.
10. After taking readings repeat steps 8 and 9 for 200mm.
11. Note down the readings in observation table and find hysteresis.
Observation table:
Calibration and hysteresis of ultrasonic sensor
Reference Value:
Taught Switching point Hysteresis
Switching ON mA ON mm OFF mA OFF mm mA mm %
distance
mm
100
200
For Reduction Factor:

1. Use the setup for previous experiment.
2. Set teach in value to 200mm with standard material i.e. plastic 80x80mm.
3. Take readings and change material.
4. Note down readings for other materials and find reduction factor
Observation table:
Reduction factor of ultrasonic sensor
Reference Value:
Material with Current/ switch on point Reduction factor
switching mA mm %
distance
200mm
Plastic 80x80
Plastic 40x80
Cardboard
Foam
Metal, any
4) Response curves of the magnetic sensor MJ
Aim: Determine the response curve of the magnetic sensor MJ (60 mm).
These curves show the relationship between operating range and lateral displacement of the material
sample, in this case a cylindrical permanent magnet. For magnetic sensors shape and size of the
response range is dependent on the size (strength) of the approached magnet and of the geometry of
its magnetic field.
• Difference [mm]= (current difference w.r.t. reference [mA]) x 18.75
• Lateral Displacement [mm]= (difference [mm] – material width [mm]) / 2
Take following observations and plot graph for respective observation
• Magnetic sensor, response curve for vertical approach, large solenoid.
• Magnetic sensor, response curve for parallel approach, large solenoid.
• Magnetic sensor, response curve for vertical approach, small solenoid.
• Magnetic sensor, response curve for parallel approach, small solenoid.
Assembly Diagram:
Procedure:
2. Mount the guide carriage with sample carrier and the device for distance measurement
somewhat above in the middle of the mounting plate.
3. The large and small solenoids are used as standard measuring plates.
4. Fix it at the non-rotatable sample carrier, it has to be parallel to the rail of the guide carriage.
5. The elevation compensation is fixed in parallel to the rail in a distance of approx. 2 ... 3 cm to
the carriage.
6. Fix the sensor at the elevation compensation.
7. The active sensor face must touch the material sample that has been moved in front of the
sensor.
9. The switch output of the sensor is active (LED lights up).
10. Now move the sample material left and right to the sensor and note down the readings.
11. Repeat the experiment for different arrangements as mentioned in the aim of the experiment.
Observation tables:
Large solenoid vertical left to right
Reference value:
Switching Switching point Difference to reference Lateral displacement
distance mA ON mA OFF mA ON mA OFF mm ON mm OFF
mm
0
2
4
6
8
10
Large solenoid vertical right to left

Reference value:
mm
0
2
4
6
8
10
Main curve
Reference value:
Switching Main curve Switching Difference to reference Lateral displacement
distance points
mm mA left mA right mA mm mm
75
70
65
60
55
50
35
20
10
8
6
4
0
Large solenoid parallel left to right

Reference value:
mm
0
2
4
6
8
10
Large solenoid parallel right to left

Reference value:
mm
0
2
4
6
8
10
Exercise Problem 1: Develop Response curves of the magnetic sensorMJ with Parallel arrangement.
Exercise Problem 2: Develop Response curves of the magnetic sensorMJ with Vertical arrangement.
Programmable Logic Controller Lab:
The knowledge of material regarding the manufacturing automation using programmable logic
controller, is important for industrial engineer. Factory automation mainly covers; Machine level
automation, Production line or work cell automation, Shop floor automation, and Plant level
automation. The present manual focus on the 1st level of factory automation e.g. machine automation
level. It provides an introduction and application of programmable logic controller (PLC) with
illustrated example in automating the manufacturing processes. It also focuses on some problems and
applications of PLC in sequential and logic automations. Furthermore, it introduces different types of
logic sensors/actuators. Hence, this manual is intended as a reference manual on Manufacturing
Automation using PLCs, for both undergraduate engineering students as well as practicing engineers.
Description of Indra Control L20
The Indra Control L20 is a modular and scalable control. It combines the benefits of a compact small
control with a standardized I/O system on the basis of terminal technology. It is a hardware platform
that can be used for PLC applications. It provides onboard interfaces, e. g. high-speed inputs and
outputs (8 each) and communication interfaces, such as Ethernet, PROFIBUS and RS232. The locally
available I/O units can be extended by the Rexroth Inline I/O system, just by simply mounting the
components side by side. Application programs, incl. runtime, are completely stored to an easily
accessible standardized Compact Flash medium.
Indra Control L20
Mid-range compact controller.

• Communication: Ethernet TCP/IP, PROFIBUS, RS232
• On board I/O: 8 fast inputs, 8 fast outputs
• I/O extension: up to 63 Inline I/O modules
Functional overview:
Indra Logic L20 –Technical data
The PLC training system
The PLC training system is used to learn/consolidate knowledge of the programming languages specified in accordance
with IEC 61131-3, such as Ladder Diagram (LD), Function Block Diagram (FBD), Instruction List (IL) and Sequential
Function Chart (SFC) .To provide input sensors and voltage levels that are required for the programming exercises and the
available example PLC projects. To visualize digital output signals (through LED displays). For practical editing and
solving of additional PLC project exercises that are available.
The PLC training system can be used in all training and further development areas to learn and consolidate knowledge of
"PLC programming" either as a standalone or a networked solution. Each system is a separate learning island from the
"student's perspective", but it can also be addressed by the trainer's PLC programming device.
Operating elements of the PLC training system:
1: PLC IndraLogic L20

2: Ethernet connection
3: 19" rack of profiled aluminum
4: Power supply unit
5: Digital input field
6: Digital output field
7: Analogue I/O range
8: System connections to optional universal simulator
Introduction- Universal simulator

The PLC universal simulator consists of the basic board, 24 exercise templates and 2 connection cables. Place the basic
board on a table, together with your PLC training device. Note! The training device must be equipped with interfaces in
form of 37-pole sub-D plugs. The plug assignment is shown on the following page. We recommend a PLC training system
by Bosch Rexroth. Here, the interfaces are readily configured. Connect the two 37-pole sub-D lines with the PLC universal
simulator according to the figure. The device is now ready for operation.
Universal simulator for the PLC training system with working PLC projects:
• 24 ready-programmed example PLC projects on data media: for illustrative demonstration of different PLC programming
types/techniques. All projects can be downloaded, started, tested and directly monitored in the PLC training system.
• Suitably labeled templates: for clear visualization and operation of the example PLC projects.
• Universal board incl. cable kit for connection to the PLC training system: for ergonomic display and operation as well as
for inclusion of the templates.
Universal simulator
Software requirements:
• Microsoft operating system Windows 2000 professional or higher
• Internet protocol (TCP/IP) installed on the operating system side
• Correct installation of the "IndraWorks" programming environment supplied (for project planning and configuration of
the PLC)
• Correct installation of the "IndraLogic" PLC programming software provided (for creating and testing PLC programs)
The following figure shows a completely configured and program IndraLogic L20 project example
(1) IndraWorks project

(2) Device name
(3) Logic object node (PLC project)
(4) PLC blocks (POU)
(5) PLC task management
(6) Local I/O area of the IndraLogic L40 (Onboard I/O)
(7) Local Inline area of the IndraLogic L40
(8) Rexroth Inline module
(9) Internal Profibus DP master of the IndraLogic L40 DPM
(10) DP slave at the internal Profibus DP master
(11) Module of the DP slave
(12) PLC addresses of the slave module, here outputs
Ex: 5.a) Digital Logic Gates
AND, OR, NOR, XOR, XNOR
Ex: 5.b) Tank Filling Device Simulator System
Exercise definition:
A tank filling device simulator consists of 3 tanks that are equipped with signal
encoders. The tank filling device simulator system can be switched on using the S1
pushbutton called “Start”. For switching off the device simulator system, S2 pushbutton
“Stop” can be used. For the "Max" notifications of tank, the signal encoders S3, S5 and
S7 are used. For the "Min" notifications, signal encoders S4, S6 and S8 are used. The
storage tanks can be arbitrarily filled and emptied by hand manually.
Conditions:
1. For filling the tanks 1, 2 & 3, the valves Y1, Y2 and Y3 are used. Filling of the tanks
must happen in series i.e H1, H2, & H3.
2. A control is to secure that after an “empty” (Ex: for tank 1, S3 & S4 both must be
OFF) notification occurs, only 1 tank can be filled at a time in the specified order.
3. The filling of the next tank continues until the corresponding “full” notification has
occurred.
(i.e for Ex : if S3 & S4 both are ON , then only H1 should stop filling & next H2 should
start for filling)
4. Once all the tank fills, its water should start to drain out one after the other from H4,
H5 & H6.
Exercise Question1: Write the LD program for A tank filling device simulator exercise, where all three
tanks must be filled parallelly. When s3, s5 & s7 sensors are ON, the inlet valves of all 3 tanks should
get close and outlet valves of all 3 tanks should open to drain.
Exercise Question2: the LD program for A tank filling device simulator exercise by applying AND
/OR logic gates for 3 Tanks, i.e ex: while any two tanks are in filling state, the 3rd tank shouldn’t be able
to fill.
Ex: 6) Road Works Traffic Lights

Exercise Definition:
Due to construction works, the traffic on a street must be led via one lane. The traffic is to be controlled
by means of traffic lights. Upon switching on of the traffic lights (Switch on S3), both traffic lights
mustsignal red (H2 and H3). The green phase must last for at least 20 seconds before, by activating the
other initiator both signal lamps show red again. After 10 seconds, the other lane is shown green. If
there is no initiator message, the traffic lights remain in their respective condition. Switch-off of the
system may only be possible after the green phase for one lane. Optionally, a night mode can be
programmed and activated using S4.
Exercise Question1: for the above same exercise design layout use s5 as start & s6 as stop buttons.
when s4 is ON with s1 , it indicates road work at second lane and hence only first lane can be used for
one way for 5 sec by indicating H1 , H2, H4 as ON & H3 OFF. After 5 seconds it should change to H3
, H2, H4 as ON & H1 OFF for opposite direction of vehicles to travel in one way in same lane. If s2 is
switched on all H1 , H2, H3 & H4 should get off.
Exercise Question2: for the above same exercise design layout use s5 as start & s6 as stop buttons.
Allow only 5 vehicles pass in one direction at a time as counter indication at s1. After 5 it has to change
to the opposite direction by letting vehicles to travel from s2 direction where count will be considered
from s2. When s2 reach 5 counts again it has to switch it s1 direction.
Ex: 7) Cleaning System

Exercise definition:
The tank of a cleaning system is to be lowered and lifted pneumatically. After the lowering- lifting
cycle has been completed 3 times, the basket is to remain at the double-acting work cylinder in its
retracted position. During the cleaning process, the basket is to remain in the cleaning system for a
period of 5 seconds. The system is switched on using the S1 pushbutton “Start” and switched off using
the S2 pushbutton “Stop”. Using the mode S3, manual operation is possible, using S4, automatic
operation can be selected. If by accident, both buttons are activated, manual operation will take
priority. During automatic operation, the process proceeds automatically via the S1 pushbutton. In
manual operation, the cylinder is extended using the pushbutton S7 and retracted using S8. In manual
operation, it must be guaranteed that the immersion process does not take longer than 5 seconds and
is automatically switched off after 3 cycles. The immersion cycle is to be displayed by means of the
LED H3. The automatic operation must be re-started after each sequence (3 cycles) using the
pushbutton S1.
Exercise Question1: The above cleaning system is switched on using the S1 pushbutton “Start” and switched
off usingthe S2 pushbutton “Stop”. Using the mode S3, manual operation is possible, using S4, automatic
operation can be selected. The tank of a cleaning system is to be cleaned by lowered and lifted of the basket of
sponge for 5 times with the delay at lowered state as 2 sec.
Exercise Question2: The above cleaning system is switched on using the S1 pushbutton “Start” and switched
off usingthe S2 pushbutton “Stop”. Using the mode S3, manual operation is possible, using S4, automatic
operation can be selected. The tank of a cleaning system is to be cleaned by lowered and lifted of the basket of
sponge for 6 times with the delay at each lowered state as 2 sec for first 3 times and the delay at each lowered
state as 5 sec for next 3 times .
Ex: 8) Control of Traffic Signal

Exercise Definition: study the operation of traffic signal system and develop PLC logic for the same.
Description:
The objective is to control the operation of a traffic signal. The working is as follows:
1. There are four roads connected as shown in fig. Each road consists of 3 signals green, yellow and
red.
2. Initially green signal of road 1 is ON. After 60 seconds Green signal of road 1 goes off and Yellow
signal of road 1 is ON. After 5 seconds Yellow signal of road 1 goes off and red signal is ON. During
this operation of road 1other roads show red signal.
3. After road 1 shows red signal, cycle repeats for road 2. During this operation other roads show red
signal.
4. After road 2 shows red signal, cycle repeats for road 3. During this operation other roads show red
signal.
5. After road 3 shows red signal, cycle repeats for road 1.
Exercise Question1: The objective is to control the operation of a traffic signal for single road at a
time. The working is as follows:
• There are four roads connected as shown in fig. Each road consists of 3 signals red, yellow and
green.
• Initially the yellow signal of road 1 is ON (indicating vehicles to be ready), with red & green as
off. Also the remaining 3 roads with yellow & green signals should be off and red signal as ON.
• After 2 seconds Green signal of road 1 gets ON, where yellow goes off.
• After 5 seconds green signal of road 1 goes off, by making red signal ON.
• As road 1 red signal gets ON , the next road 2 red signal must go off by making yellow signal of
road 2 signal ON.
• Above process should repeat for all 4 roads one after the other for 3 times.
Exercise Question2: The objective is to control the operation of a traffic signal for double road at a
time. The working is as follows:
• There are four roads connected as shown in fig. Each road consists of 3 signals red, yellow and
green.
• Initially the yellow signal of road 1 & 2 is ON (indicating vehicles to be ready), with red & green
as off. Also the remaining 2 roads with yellow & green signals should be off and red signal as
ON.
• After 3 seconds Green signal of road 1&2 gets ON, where yellow goes off.
• After 10 seconds green signal of road 1&2 goes off, by making red signal ON.
• As road 1&2 red signal gets ON , the next roads 3&4 red signal must go off by making yellow
signal of road 3&4 signal ON.
• Above process should repeat for all 4 roads , where at a time two roads signals must work one
after the other for 4 times.

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SENSORICS & PLC LAB MANUAL

SENSORICS & PLC LABORATORY MANUAL

Prepared By. Faculties

Dr. Ishwar biradi)

Approved By. Dr.D.V.Kamath

IV Semester B.Tech (MTE 2243)

VISION OF THE MECHATRONICS ENGINEERING DEPARTMENT

PROGRAM OUTCOMES (POs) PRESCRIBED BY NBA ACROSS ALL DEPARTMENTS

PROGRAM SPECIFIC OUTCOMES OF THE MECHATRONICS ENGINEERING

GENERAL GUIDELINES OF PROFESSIONAL CONDUCT:

SAFETY AND RISK MEASURES WITH DO’s AND DON’T’:

PROGRAMMABLE LOGIC CONTROLLER LAB:

1. a) Behavior of inductive, capacitive,

2. a) Switching distance, Hysteresis and

3. a) Operating range, hysteresis and

4. Response curves of the magnetic sensor

Programmable Logic Controller Lab

6. Road Works Traffic Lights

Project Presentation with Demo 20

TOTAL MARKS 100

1.a) Behavior of Inductive, Capacitive, Magnetic, Light Reflection

1.1 Behavior of inductive sensor

1.2 Behavior of capacitive sensor

Material Sample Detected

LIGHT REFLECTION SCANNER

1.4 Behavior of reflection light scanner OJ

1. b) Logic operation of sensors

Aim: To realize logical AND and OR operations using various sensors.

2. a) Switching Distance, Switching Hysteresis and

• Displacement [mm]= (current difference w.r.t. reference [mA]) x 18.75

11. Calculate reduction factor based on the findings.

2. b) Response curves of Inductive sensor

• Difference [mm]= (current difference w.r.t. reference [mA]) x 18.75

3. a) Switching Distance, Switching Hysteresis and Reduction Factor

• Displacement [mm]= (current difference w.r.t. reference [mA]) x 18.75

• Displacement [mm]= (current difference w.r.t. reference [mA]) x 18.75

Reduction factor of direct detection sensor with optical waveguide

3. b) Calibration of Switching Distances and Hysteresis and Reduction

Aim: To teach-in-sensing ranges and find hysteresis of the ultrasonic sensor.

For Reduction Factor:

4) Response curves of the magnetic sensor MJ

Large solenoid vertical right to left

Large solenoid parallel left to right

Large solenoid parallel right to left

Programmable Logic Controller Lab:

Indra Control L20

Mid-range compact controller.

Indra Logic L20 –Technical data

The PLC training system

Operating elements of the PLC training system:

1: PLC IndraLogic L20

Introduction- Universal simulator

(1) IndraWorks project

Ex: 5.a) Digital Logic Gates

AND, OR, NOR, XOR, XNOR

Ex: 5.b) Tank Filling Device Simulator System

Ex: 6) Road Works Traffic Lights

Ex: 7) Cleaning System

Ex: 8) Control of Traffic Signal

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