Name: Payal Patil

Reg No: 23MAC0002

VELLORE INSTITUTE OF TECHNOLOGY

(Deemed To Be University Under Section 3 Of UGC Act, 1956)
VELLORE - 632 014

ACADEMIC YEAR : 2023-2024

SUBJECT CODE & NAME : MCOA507P & INDUSTRIAL AUTOMATION

LABORATORY

Name : PAYAL PATIL

Reg. No: 23MAC0002

Course : M.tech Branch : Control And Automation Semester: II

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DEPARTMENT OF CONTROL AND AUTOMATION ENGINEERING

BONAFIDE CERTIFICATE

This is a certified that the bonafide observation book of Ms. Payal Patil
Register No. 23MAC0002 submitted for the Practical Sessions in Winter
semester 2023-2024.

Signature of the Lab-in-charge

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VELLORE INSTITUTE OF TECHNOLOGY

(Deemed To Be University Under Section 3 Of UGC Act, 1956)
VELLORE – 632 014.

CONTENTS

SOFTWARE EXPERIMENTS :

Exp Name of the Date Page Staff

No. Experiment No. Sign

Study of Basic Logic

1(a),(b) Operations in PLC 12/1/24 4 - 10

Study of Timer and Counter

2(a),(b) Operations using PLC 19/1/24 11 - 16

Control of Sequential process

3(a),(b) using PLC 9/2/24 17 - 20

Implementation of continuous
4(a),(b) actuator control using 23/2/24 21 - 25
PLC

5 Control of a sequencer process

using PLC 9/3/24 26 - 27

HARDWARE EXPERIMENTS:

Exp Name of the Date Page Staff

No. Experiment No. Sign
1 Pick and Place Robot 9/3/24 28 -32

2 Conveyor 29/3/24 33 - 37

3 3 Axis Control 5/4/24 38 - 41

4 DCS 12/4/24 42 - 44

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SW Expt. No:1(a)

Date: 12/1/24 STUDY OF BASIC LOGIC OPERATIONS IN PLC

Aim:
To verify the truth table of given logic gates using PLC.

Requirements:

1. Allen Bradely (Micro logixAnalogseries1000 )PLC

2. Programmable Peripheral Interfacing cable
3. PC
4. RSlinx500software.

Problem Definition:

AND gate:
Two limit switches connected in series and used to control a solenoid valve.

OR gate:
Two limit switches connected in parallel and used to control a solenoid valve.

NOT gate:
One limit switch is connected as an inverter.

NOR gate:
Two normally closed limit switches connected in series and used to control a solenoid
valve.

Exclusive-OR gate:
The output lamp of this circuit is ON only when push button A or B is pressed, but not
both. This circuit has been programmed using only the normally open A and B
pushbutton contacts as the inputs to the program.

Exclusive-NOR gate:
The output lamp of this circuit is ON only when both pushbutton A and B is pressed,
otherwise OFF. This circuit has been programmed using only the normally open A and
B pushbutton contacts as the inputs to the program.

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Procedure:

1. Open RSLogix 500prosoftware.

2. Create a new project by selecting appropriate processor type (here Micrologix
1000analog series).
3. Create a program and data table file.
4. Enter a ladder program, save and compile it.

a. To emulate the program:

5. Launch the RSLinx classic gateway software.
6. Enable the EMU500-1 in running mode and close it.
7. Configure the controller (PLC) communication as EMU500-1.
8. Download the program in PLC and go online. The RSlinx Emulate software
window will be opened by default.
9. Select the appropriate project by browsing open file tab.
10. Give inputs to the PLC and verify the program logic.

Ladder Program:

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Simulation:

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Inferences:

Basic logic operations like AND, OR, NOT, NOR, XOR, and XNOR are use in this
experiment. If any input is true, "OR" uses parallel routes to allow current to flow. . When
using "AND," current flow is allowed only when all inputs are true, as parallel branches
come to a single rung. "NOT" reverses a signal by using a normally closed (NC) or normally
open (NO) contact. When parallel branches and normally open contacts are combined, the
"NOR" function outputs false only when all inputs are true. When an odd number of inputs
are true, "EXOR" uses exclusive OR conditions to permit current flow.In end, if an even
number of inputs are true, "EXNOR" returns true.

Result:

Thus the ladder program is developed to verify the truth table of given logic gates.

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SW Expt. No: 1(b)

Date: 12/1/24 STUDY OF BASIC LOGIC OPERATIONS IN PLC

Aim:

To design an alarm system using logic gates in PLC.

Requirements:

1. Allen Bradely (Micro logixAnalogseries1000 )PLC

2. Programmable Peripheral Interfacing cable
3. PC
4. RSlinx 500software.

LLP

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Procedure:

1. Open RSLogix 500 pro software.

2. Create a new project by selecting appropriate processor type (here Micrologix

1000analog series).

3. Create a program and data table file.

4. Enter a ladder program, save and compile it.

a. To emulate the program:

5. Launch the RSLinx classic gateway software.

6. Enable the EMU500-1in running mode and close it.

7. Configure the controller (PLC) communication as EMU500-1.

8. Download the program in PLC and go online. The RSlinx Emulate software window
will be opened by default.
9. Select the appropriate project by browsing open file tab.

10. Give inputs to the PLC and verify the program logic.

Ladder Program:

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Simulation:

Inferences:

In this experiment, RSLogix software is used to create a ladder diagram. The first rung of the ladder
diagram representes the closure of the start button being closed, which intiaties conveyor M1 operation.
With each plate piled, a counter is introduced on the second rung. When the counter hits 15, M1 stops and
conveyor M2 begins. A timer integrated into the third rung allows M2 to operate for five seconds before
shutting off automatically. The timer's done bit resets the counter and the timer on the fourth rung, creating
a brief pulse that restarts conveyor M1. The automatic repetition of this cycle guarantees a controlled and
effective material handling procedure

Result:

Thus the ladder program is developed to implement an alarm system.

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SW Expt. No: 2(a)

Date: 19/1/24 STUDY OF TIMER AND COUNTER FUNCTIONS IN PLC

Aim:
To develop LLP for the implementation of an oscillator for the given sequence of operations.

Requirements:

1. Allen Bradely (Micro logix Analog series 1000 )PLC

2. Programmable Peripheral Interfacing cable

3. PC

4. RSlinx 500 software

Problem Definition:

DUTY CYCLE = 50% NUMBER

OF CYCLE =5

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Procedure:

1. Open RSLogix 500 pro software.

2. Create a new project by selecting appropriate processor type (here Micrologix 1000analog
series).
3. Create a program and data table file.

4. Enter a ladder program, save and compile it.

a. To emulate the program:

5. Launch the RSLinx classic gateway software.

6. Enable the EMU500-1in running mode and close it.

7. Configure the controller (PLC) communication as EMU500-1.

8. Download the program in PLC and go online. The RSlinx Emulate software window will be
opened by default.

9. Select the appropriate project by browsing open file tab.

10. Give inputs to the PLC and verify the program logic.

Ladder Diagram:

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Simulation:

Inferences:

In this experiment, a ladder diagram with specific operations is built to generate an oscillator. To get started,
toggle the output between two states using a set/reset (S/R) latch. Attach a normally open (NO) contact to
the output and a timer to the first rung. The timer closes an open contact connected to the latch's reset input
when it reaches a predefined value. The second rung has a second timer as well as a normally closed (NC)
contact from the latch output. When the second timer reaches the preset value, it opens the latch's reset
input. This cyclic process provides an oscillating output, which achieves its intended functionality.

Result:

Thus the ladder program is developed to implement an oscillator.

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SW Expt. No: 2(b)

Date: 19/1/24 STUDY OF TIMER AND COUNTER FUNCTIONS IN PLC

Aim:
To develop LLP to implement the given sequence of operations in an automatic
stacking system.

Requirements:

1. Allen Bradely (Micro logix Analog series 1000 )PLC

2. Programmable Peripheral Interfacing cable

3. PC

4. RSlinx 500 software

Problem Description:

The sequence of operation is given below:

Figure 1. Process Diagram

1. When the start button is pressed, conveyor M1 begins running.

2. After 15 plates have been stacked, conveyor M1 stops and conveyor M2 beginsrunning.
3. After conveyor M2 has been operated for 5 seconds, it stops and the sequence isrepeated
automatically.
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4. The done bit of the timer resets the timer and the counter and provides a momentarypulse to
automatically restart conveyor M1.

Procedure:

1. Open RSLogix 500 pro software.

2. Create a new project by selecting appropriate processor type (here Micrologix 1000analog
series).

3. Create a program and data table file.

4. Enter a ladder program, save and compile it.

a. To emulate the program:

5. Launch the RSLinx classic gateway software.

6. Enable the EMU500-1in running mode and close it.

7. Configure the controller (PLC) communication as EMU500-1.

8. Download the program in PLC and go online. The RSlinx Emulate software window will be
opened by default.

9. Select the appropriate project by browsing open file tab.

10. Give inputs to the PLC and verify the program logic.

Ladder Diagram:

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Simulation:

Inferences:

In this experiment, RSLogix software is used to create a ladder diagram. The first rung of the ladder
diagram representes the closure of the start button being closed, which intiaties conveyor M1 operation.
With each plate piled, a counter is introduced on the second rung. When the counter hits 15, M1 stops and
conveyor M2 begins. A timer integrated into the third rung allows M2 to operate for five seconds before
shutting off automatically. The timer's done bit resets the counter and the timer on the fourth rung, creating

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a brief pulse that restarts conveyor M1. The automatic repetition of this cycle guarantees a controlled and
effective material handling procedure.

Results:

Thus the ladder program is developed to implement an automatic stacking system.

SW Expt. No: 3(a)

CONTROLOF A SEQUENTIAL PROCESS USING PLC

Date: 9/2/24

Aim:
To control the given sequential process using PLC.

Requirements:

1. Allen Bradely (Micro logix Analog series1000 )PLC

2. Programmable Peripheral Interfacing cable
3. Personal Computer(PC)
4. RSlinx 500 software.

a) Problem Statement:

Heat the process fluid to a temperature of 80°C and stir it for 5 minutes. Allow the fluid to settle

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for another 20 minutes before it gets dried up. When heater is ON, the level isto be maintained at L2
position. The drain valve gets closed if level goes below L1 position. Make necessary Interlocking.

Fig1.Process Diagram

1. START switch along with latching is provided to switch ON the process.

2. STOP switch is provided to switch OFF the process.
3. If the process switch is ON and the outlet valve is closed , then the inlet valve is opened till the
upper limit sensor (LS2) is OFF.
4. Now the heater is switched ON till the temperature sensor senses 80°C.
5. After the heater is turned OFF ,the fluid is stirred for 5 minutes.
6. After the settling time of 20 minutes ,outlet valve is opened till the liquid level reaches its lower
limit.
7. Limit switch LS1 is provided to ensure the continuity of the process.

Ladder Program:

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Inferences:

In this experiment, with the help of RSLogix software ,ladder diagram is created to control a process using
START and STOP switches.After activation of the process switch and closing the outlet valve, the inlet
valve opens until the upper limit sensor (LS2) is deactivated. Then, the heater turns on until the temperature
sensor detects 80°C. After heater is deactivated, stirring occurs for 5 minutes. Following a settling period of
20 minutes, the outlet valve opens until the liquid level reaches the lower limit, which is monitored by limit
switch LS1, guaranteeing that the process runs continuously.

Result:

Thus the given sequential process is controlled using PLC.

SW Expt. No: 3(b)

CONTROLOF A SEQUENTIAL PROCESS USING PLC

Date: 9/2/24

Aim:
To control the given sequential process using PLC.

Requirements:
1. Allen Bradely (Micro logix Analog series1000 )PLC
2. Programmable Peripheral Interfacing cable
3. Personal Computer(PC)
4. RSlinx 500 software.

b) Problem Statement:

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Fig1.Process Diagram
The sequence of operation for the continuous filling operation is as follows:
a) Start the conveyor when the start button is momentarily pressed.
b) Stop the conveyor when the stop button is momentarily pressed.
c) Energize the run status light when the process is operating.
d) Energize the stand by status light when the process is stopped.
e) Stop the conveyor when the right edge of the box is first sensed by the photo sensor.
f) With the box in position and the conveyor stopped, open the solenoid valve and allow the box
to fill. Filling should stop when the level sensor goes true.
g) Energize the full light when the box is full.The full light should remain energized until the box
is moved clear of the photo sensor

Ladder Program:

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Inferences:

In this experiment , a ladder diagram is designed to execute a continuous filling process. Pressing
the start button initiates conveyor movement, activating the run status light. Conveyor motion halts
upon pressing the stop button or when the photo sensor detects the right edge of the box. Once the
box aligns and the conveyor stops, the solenoid valve opens to fill the box until the level sensor
detects full capacity. The full light stays lit until the box moves beyond the photo sensor's range.

Result:

Thus the given sequential process is controlled using PLC.

SW Expt. No: 4(a)

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Date: 23/2/24 Implementation of continuous actuator control using PLC

Aim:
To develop LLP to implement an Oven Temperature Control using a PLC.

Requirements:
1. Allen Bradely (Micro logix Analog series 1000 )PLC
2. Programmable Peripheral Interfacing cable
3. PC
4. RS linx 500 software.

a) Problem Statement:

The sequence of operation is given below:

1. The PLC calculates the upper and lower deadband, or off/on limits, about the set-point.
2. Upper and lower temperature limits are set automatically at 1 percent regardless of the set- point
value.
3. Set-point temperature is adjusted by means of the thumbwheel switch.
4. The analog thermocouple interface module is used to monitor the current temperature of the oven.
5. Let the set-point temperature is 400°F.
6. The electric heaters will be turned on when the temperature of the oven drops to less than 396°F and
stay on until the temperature rises above 404°F.
7. If the set-point is changed to 100°F, the dead band remains at 1 percent, with the lower limit being
99°F and the upper limit being 101°F.

Procedure:
1. Open RS Logix 500 pro software.
2. Create a new project by selecting appropriate processor type (here Micrologix 1000 analog series).
3. Create a program and data table file.
4. Enter a ladder program, save and compile it.

Ladder Program:

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Inferences:

In this experiment, a ladder logic program is developed to regulate oven temperature according to a
specified sequence. Initially, analog input and output modules are set up to communicate with the
thermocouple and control the heaters. The ladder logic program comprises rungs to compute upper and
lower deadbands, automatically adjusting temperature limits based on set-point alterations. A rung is
dedicated to setting the temperature using a thumbwheel switch. The core control logic entails comparing
the current temperature from the thermocouple with the set-point and activating heaters within the deadband
thresholds. The program ensures heaters activate when temperature falls below the lower limit and
deactivate when it surpasses the upper limit. These operations are achieved through comparison, arithmetic,
and output control instructions within the ladder logic.

Result:

Thus the ladder program is developed to implement an Owen Temperature control using PLC.

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SW Expt. No:4(b)

Date: 23/2/24 Implementation of continuous actuator control using PLC

Aim:
To develop LLP to implement an Conveyor system using a PLC.

Requirements:
1. Allen Bradely (Micro logix Analog series 1000 )PLC
2. Programmable Peripheral Interfacing cable
3. PC
4. RS linx 500 software.

b) Problem Statement:
Figure 9-11 shows a materials conveyor system with a flashing pilot light as a subroutine. The operation of
the program can be summarized as follows:
 If the weight on the conveyor exceeds a preset value, the solenoid is de-energized and pilot light
PL1will begin flashing.
 When the weight sensor switch closes, the JSR is activated and directs the processor scan to jump to
the subroutine U:3.
 The subroutine program is scanned and pilot light PL1 begins flashing.
 When the weight sensor switch opens, the processor will no longer scan the subroutine area and
pilot light PL1 will return to its normal on state.

Figure 9-11

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Procedure:
1. Open RS Logix 500 pro software.
2. Create a new project by selecting appropriate processor type (here Micrologix 1000 analog series).
3. Create a program and data table file.
4. Enter a ladder program, save and compile it.

Ladder Program:

Subroutine:

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Inferences:

In this experiment, a material in a conveyor system is monitored by a ladder logic software. Pilot light PL1
begins to blink and the solenoid is disengaged when the weight on the conveyor above a certain limit. When
the weight sensor switch closes, this is accomplished by moving to subroutine U:3. PL1 begins to flash in
the subroutine. PL1 resumes its regular on state and the subroutine is no longer scanned when the weight
sensor switch opens. This program guarantees accurate weight monitoring of the conveyor system and
notifies operators when the limit is reached.

Result:

Thus the ladder program is developed to implement an Conveyor System using PLC.

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SW Expt. No: 5

CONTROLOF A SEQUENCER PROCESS USING PLC

Date: 9/3/24

Aim:
To control the given sequencer process using PLC.

Requirements:
1. Allen Bradely (Micro logix Analog series1000 )PLC
2. Programmable Peripheral Interfacing cable
3. Personal Computer(PC)
4. RSlinx 500 software.

c) Problem Statement:

Fig1. Timing chart for two-directional control of traffic lights

In Figure 7-37 shows the original traffic light program modified to include three more lights that control
traffic flow in two directions. The sequence of operation for Traffic light Control is as follows:
a) The input to timer T4:0 is controlled by the T4:2 done bit.
b) The input to timer T4:1 is controlled by the T4:0 done bit.
c) The input rung to timer T4:2 is controlled by the T4:1 done bit.
d) The timed sequence of the lights is:
Red—30 s on
Green—25 s on
Amber—5 s on
e) The sequence then repeats itself

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Ladder Program:

Inferences:

In this experiment, The traffic light program controls the traffic light sequence by means of a
sequencer logic. The sequencer begins by using the T4:2 done bit to control the input to timer T4:0,
which turns on the red light for 30 seconds. After T4:0 is finished, T4:1 is triggered, which causes
the green light to stay on for 25 seconds. T4:1 completed bit activates T4:2, which turns on the
Amber light for five seconds after Green. After finishing, the sequencer resets and the process is
repeated. This logic efficiently manages the light sequence by maintaining a constant and
synchronized flow of traffic in both directions.

Result:

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Thus the given sequencer process is controlled using PLC.

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HW Expt. No: 1

PICK AND PLACE ROBOT

Date: 9/3/24

Aim:
To control an S7-1200 Pick and Place Robot using SIEMENS programmable logic controllers
(PLCs).

Requirements:

1. S7-1200PickandPlaceRobot.
2. Personal Computer(PC)
3. TIA Portal software.

Theory:
Designing a Pick and Place operation based on the Siemens S7-1200 PLC involves integrating several
components and functionalities to meet specific requirements. Firstly, to power the system and ensure
proper voltage regulation, DC to DC converters are employed. These converters play a crucial role in
converting the input voltage to the required levels for various components within the system, ensuring
stable and reliable operation. Secondly, Ethernet communication is utilized for seamless connectivity and
data exchange between different components of the system. Ethernet communication enables real-time
monitoring, control, and coordination of the Pick and Place Robot, facilitating efficient operation and
integration with other systems or devices within the manufacturing environment. Furthermore, Inline I/O
modules are essential for interfacing with the external environment and acquiring sensor data or
controlling actuators. These modules provide both analog and digital inputs and outputs, allowing the
system to interact with sensors to detect objects, position, or other relevant parameters, as well as control
actuators such as motors or pneumatic valves. The integration of analog inputs enables the system to
process continuous signals, such as position feedback from encoders or pressure readings from sensors,
providing precise control and feedback for the Pick and Place Robot. Digital inputs and outputs, on the
other hand, allow for the handling of discrete signals, such as limit switches or binary signals from
proximity sensors, enabling the system to detect events or trigger specific actions. Moreover, the use of
pneumatic valves is crucial for the actuation of pneumatic cylinders or grippers in the Pick and Place
Robot system. Pneumatic valves control the flow of compressed air to the actuators, enabling precise and
rapid movement of the robot armor gripper to pick up and place objects with accuracy and efficiency.

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Experiment Setup:

InputSwitches

Pneumatic
valves

DC-DC

PickandPlac Converter
eRobot

Ethernet
InlineI/OMo
Comm
dules

Gripper

Timing Diagram:

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Problem Statement:

When a switch is on pick an object from point A. place it in point B and come back to point A. The
sequence is given below.
Grip->move the arm up->move the arm left->move the arm down->place the object->move the arm up ->
move the arm right -> move the arm down.

One way pneumatic cylinders connected to PLC in the following way

Grip: Q0.4.
vertical arm1: Q0.2.
vertical arm2: Q0.5.
Horizontalarm:Q0.3
Grippingtakes2sec.
vertical arm takes 4 sec to complete the movement and the horizontal arm takes 6 sec to complete the
movement.

Procedure:

 Open TIA Portal and create a new project for the S7-1200PLC.
 Configure your hardware setup in the TIA Portal by adding the S7-1200 PLC and the necessary
digital outputs for controlling the pneumatic cylinders. Assign the given outputs to the
corresponding pneumatic cylinders (Grip, Vertical Arm 1, Vertical Arm 2, Horizontal Arm).
 Create a new program within your project to control the pick and place sequence. This program
will consist of ladder logic instructions to control the outputs based on the sequence.
 Write a ladder logic program to implement the pick and place sequence.
 Compile your program and download it to the PLC.
 Test your program by activating the switch (input) that triggers the pick and place sequence.
Ensure that the pneumatic cylinders move according to the specified sequence and timings.
 Debuganyissuesthatariseduringtestingandoptimizetheprogramforefficiencyandreliability.

Ladder Program (using SIEMENS PLC) :

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Inferences:

This experiment shows how ladder logic programming can be used to implement the provided
sequence for the S7-1200 pick and place robot. Using timers to control the duration of each
movement, the sequence can be executed step by step, activating the associated pneumatic cylinders
(Q0.2, Q0.3, Q0.4, Q0.5) to move the arm and hold the object. Each step is timed based on the given
duration for vertical and horizontal arm motions, ensuring that the pick and place operation is
completed precisely and within the time range.

Result:

Thus the ladder program is developed to implement a Pick and place robot using SIEMENS.

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HW Expt. No: 2

CONVEYOR
Date: 29/3/24

Aim:
To control an S7-1200 conveyor system using SIEMENS programmable logic controllers
(PLCs).

Requirements:

5. S7-1200 conveyor.
6. Personal Computer (PC)
7. TIA Portal software.

Theory:
Designing a conveyor system based on the Siemens S7-1200 PLC involves integrating several components
and functionalities to meet specific requirements. Firstly, the system will incorporate DC to DC converters
to regulate and convert power efficiently, ensuring optimal performance and reliability of the conveyor.
These converters play a crucial role in managing power distribution across the system, converting incoming
DC power to levels suitable for various components. Secondly, Ethernet communication is utilized for
seamless data exchange and networking capabilities within the system. The S7-1200 PLC supports Ethernet
connectivity, enabling efficient communication between the PLC, peripherals, and other devices. This
facilitates real-time monitoring, control, and data sharing, enhancing overall system efficiency and
flexibility. The integration of Inline I/O modules allows for the expansion of input and output capabilities,
including both analog and digital signals. Analog inputs and outputs enable the system to interface with
sensors and actuators that require continuous or variable signals, such as speed control or position sensing.
Digital inputs and outputs handle discrete signals, enabling the PLC to monitor and control various aspects
of the conveyor system, such as start/stop commands or sensor feedback. Furthermore, the system
incorporates metal sensors to detect the presence or absence of metallic objects on the conveyor belt. These
sensors play a critical role in automated processes, enabling the system to detect, sort, or divert items based
on their metal content. By integrating metal sensors with the PLC, the conveyor system can accurately
respond to detected objects, optimizing throughput and minimizing errors.

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Experiment Setup:

Metal
Sensor Conveyor - 1
Inline I/O
Conveyor - 2 Input modules
switches
DC-DC
Converter
Metal
Object

Ethernet
Comm port

Conveyor
Motor

Wiring Diagram:

240V AC UPS Supply Wiring:

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24V DC Distributed Wiring:

A01-CPU Digital Input Module Wiring:

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Problem Statement:

When a switch is on start conveyor 1 and delivers metal objects. After delivering 10 Objects start conveyor
2. After delivering another 10 objects stop conveyor 1 first and after a delay of 10 sec stop conveyor 2.

I/O Allocation:
 I1.0 - Input Switch
 I1.1 - Metal Object sensor
 Q0.0 - Conveyor 1
 Q0.1 - Conveyor 2

Procedure:

 Ensure the S7-1200 PLC, conveyor system, power supply, and necessary sensors (such as
proximity sensors for detecting objects on the conveyor) are properly connected and
powered.

 Launch the TIA Portal software on your computer and create a new project for the S7-1200
PLC.

 Configure the hardware setup by adding the S7-1200 PLC to your project and configuring
the input and output modules for the conveyor system, including any additional modules for
sensors.

 Write a PLC program in TIA Portal using ladder logic or any other supported programming
language. The program should control the conveyor's operation based on inputs from
sensors and other conditions.

 Download the PLC program to the S7-1200 PLC and test its functionality. Verify that the
program operates the conveyor system correctly according to the specified logic.

 If any issues arise during testing, debug the program in TIA Portal by analyzing the
program logic, checking input/output statuses, and making necessary adjustments to the
program code.

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Ladder Program ( using SIEMENS PLC) :

Inferences:

In this experiment, we used TIA Portal software to design a sequential conveyor system powered by a S7-
1200 PLC. Conveyor 1 starts up and counts the metal objects as soon as the switch is thrown. Conveyor 2
repeats the same counting procedure until it encounters two objects. Ten seconds later, Conveyor 2 also
comes to a stop. Conveyor 1 stops next. This presentation demonstrates how the PLC's independent
management of sequential tasks makes it a potentially useful tool for industrial automation jobs requiring
precise control and scheduling.

Result:

Thus the ladder program is developed to implement a conveyor system using SIEMENS PLC.

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HW Expt. No: 3
3Axis Control
Date: 5/04/24

Aim:
The aim is to automate the control of a system with three axes, including a drilling
operation, for precise motion and task execution.

Apparatus:

1. 3-axiscontrolmachine,
2. Personal Computer(PC).
3. TIA portal software

Problem Statement:

When a switch is activated, move the drilling head to the left for5seconds, then move it backward for10
seconds, and subsequently move it downward for 5 seconds. Upon the drilling head initiating the
downward movement, commence the operation of the drilling motor after a delayof2 seconds, and cease
the drilling motor 2 seconds after the drilling head commences its upward movement. Finally, return the
drilling head to its initial position.

Theory:

PLCs, or Programmable Logic Controllers, serve as the backbone of automated systems in

various industries, offering robust control over machinery and processes. The program
segment is designed to coordinate the operation of a system with three axes, likely for tasks
such as positioning, material handling, or assembly. By utilizing inputs from sensors or
switches and processing them through logical instructions, the PLC governs the behavior of
the system's actuators, including motors and valves, to achieve precise motion and task
execution. The inclusion of a drilling operation further highlights the versatility of PLC-based
control, allowing for the integration of specialized processes within a single system. Safety
features, such as emergency stop functionality, are essential components of PLC
programming, ensuring the protection of personnel and equipment in industrial environments.
Moreover, timed operations, facilitated by timers within the program, enable synchronization
of actions and adherence to predetermined schedules.

Procedure:
 Open TIA Portal and create a new project for the S7-1200 PLC.
 Configure your hardware setup in the TIA Portal by adding the S7-1200PLC and the
necessary digital outputs for controlling the motors. Assign the given outputs to the
corresponding motor.
 Create a new program within your project to control the 3 axes. This program will
consist of ladder logic instructions to control the outputs based on the sequence.
 Writealadderlogicprogramtoimplement3axiscontrolsequence.
 Compile your program and download it to the PLC.
 Test your program by activating the switch (input) that triggers the pick and place
sequence.Ensurethatthemotorsmoveaccordingtothespecifiedsequenceandtimings.
 Debug any issues that arise during testing and optimize the program for efficiency
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and reliability.

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Ladder Diagram:

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Output:

2) Left

3) Back

4) Down

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5) up

6) front

7) Right

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Inferences:

In this experiment, a predetermined set of actions is performed using the S7-1200 3-axis system via ladder
logic programming. The drilling head goes left (Q0.2) for 5 seconds, then rearward (Q0.5) for 10 seconds,
and finally downward (Q0.6) for 5 seconds once a switch (I0.1) is flipped. Then, for five seconds, it climbs
(Q0.7). The drilling operation starts two seconds into the downhill motion (Q1.0) and lasts for an extra two
seconds after the ascending motion starts. Afterwards, the head rises for 10 seconds (Q0.4), advances for 5
seconds (Q0.3), and then shifts to the right for 5 seconds.

Result:

Thus the ladder program is developed to implement a 3 axis control using SIEMENS PLC.

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 Name: Payal Patil
Reg no: 23MAC0002
HWExpt.No:4
DCS
Date:12/04/24

Aim:

The aim is to design and implement a distributed control system using Industrial Communication Protocol
Trainer (ACE 205) with ComTestPro software.

Apparatus:

1. Industrial Communication Protocol trainer(ACE205)

2. Personal Computer(PC).
3. ComTestPro software.

Problem Statement:

Design and implement a Distributed Control System(DCS) utilizing Industrial Communication Protocols
(e.g., Modbus, Profibus). The system should monitor and control industrial processes, demonstrating
proficiency in protocol configuration, data exchange, and fault tolerance within a limited lab
environment.

Theory:

A Distributed Control System (DCS) employs Industrial Communication Protocols (ICPs) to facilitate
data exchange among interconnected devices across a network. These protocols ensure seamless
communication between sensors, actuators, and controllers in industrial environments. By standardizing
data formats and transmission methods, ICPs enable real-time monitoring, control, and coordination of
processes, enhancing efficiency and reliability. Examples include Modbus, Profibus, and Foundation
Field bus. DCS with ICPs streamline operations, improve decision-making, and optimize resource
utilization in complex industrial processes.

Procedure:

 ConnectpatchchordsaccordingtoinstructionstolinktemperaturetransmittertoDelta DTB9696
PID controller.
 Determine COM port number from device manager.
 Identify memory addresses for relevant variables of Delta DTB9696: PV, SP, CO,PB, IT,
DT, A/M, Action, and Bias.
 Open 'ComTestPro' software.

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 Follow software instructions, click Start for operation (Read/Write).

 Observe data frame in Raw Data.
 Develop data frame based on Modbus theory:
i. Device ID:1
ii. RegisterAddress:4097(Setpoint Address)
iii. Command: Write Single Holding Register
iv. WriteValue:600
 Interpret raw data provided for reference.
 Reading from memory address 4096:
i. Send message:[001d][003d][016d][000d][000d] [001d][128d][202d]
ii. Received message:[001d][003d][002d][000d][236d][185d][201d]
iii. Interpret received value as 23.6(with1digit resolution) for PV.

Software Simulation:
Write:

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Read:

Inferences:

In this experiment, we saw a structured data frame that was in line with Modbus theory when
we interpreted raw data from memory address 4096. Vital characteristics including Process
Value (PV), Setpoint (SP), Control Output (CO), Proportional Band (PB), Integral Time (IT),
Derivative Time (DT), Auto/Manual mode (A/M), Action (direct or reverse), and Bias are
probably included in the data. The temperature transmitter and Delta DTB9696 PID
controller can communicate and control more effectively thanks to this well-organized data
frame, which improves industrial process management.

Result:

Thus the implementation of distributed control system using Industrial Communication

Protocol Trainer(ACE 205) achieved seamless communication via ComTestPro software.

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