E.G.S. PILLAY ENGINEERING COLLEGE...

E.G.S. PILLAY ENGINEERING COLLEGE

(Autonomous)

Approved by AICTE, New Delhi | Affiliated to Anna University, Chennai

Accredited by NAAC with “A‟ Grade | Accredited by NBA (CSE, EEE, MECH)

NAGAPATTINAM – 611 002.

DEPARTMENT OF MECHANICAL ENGINEERING

M.E. - MANUFACTURING ENGINEERING

FIRST SEMESTER

2017 - 2018

1704MF107 - INDUSTRIAL AUTOMATION AND MECHATRONICS LABORATORY

LAB RECORD

NAME : ----------------------------------

REG. NO. : ----------------------------------

E.G.S. PILLAY ENGINEERING COLLEGE

(Autonomous)

Approved by AICTE, New Delhi | Affiliated to Anna University, Chennai

Accredited by NAAC with “A‟ Grade | Accredited by NBA (CSE, EEE, MECH)

NAGAPATTINAM – 611 002.

BONAFIDE CERTIFICATE

REGISTER NO.: -----------------------------

Certified to be the bonafide record of work done by-----------------------------------,

M.E. - Manufacturing Engineering / I Semester, during the year of 2017-2018.

Head of the Department Staff-in-charge

Submitted for practical examination held in ------------------ at E.G.S. Pillay Engineering

College, Nagapattinam – 611 002.

INTERNAL EXAMINER EXTERNAL EXAMINER

TABLE OF CONTENTS

SL.

NO. DATE NAME OF THE EXPERIMENT

PAGE

NO. MARKS SIGN.

1

Introduction to Mechatronics System

2 Simulation of Single Acting Cylinder

Circuit

3 Simulation of Double Acting Cylinder

Circuit

4 Simulation of Simple Hydraulic Circuit

using Autosim Software

5 Simulation of Simple Pneumatic Circuit

using Autosim Software

6

Simulation of Electro Hydraulic Circuit

7

Simulation of Electro Pneumatic Circuit

8

PLC Control of Single Acting Cylinders

ON And OFF Delay Timer

9

Automatic Actuation of Double Acting

Cylinder Using PLC

10

PLC Control of Sequencing Circuit Using

PLC Ladder Diagram

11

Running a stepper motor at different

speed in two directions using 8051

Microcontroller

12

Running a stepper motor for required

angle within 360°, which is equivalent to

256 steps.

13

Running a stepper motor into two parts

14 To run Stepper Motor in both Forward

and Reverse directions with delay.

EX.NO: 01 INTRODUCTION TO MECHATRONICS SYSTEM

DATE:

AIM:

To study about the important features, about Mechatronics system.

INTRODUCTION TO MECHATRONICS SYSTEM:

Mechatronics is one of the new and existing fields on the engineering landscape,

subsuming parts of traditional engineering fields and requiring a broader approach to the design

of system that we can formally call as Mechatronics system. Many industries improving their

works through automation which is based on the inter connection between the electronic control

systems and mechanical engineering. Such control systems generally use microprocessors as

controllers and have electrical sensors extracting information from mechanical inputs through

electrical actuators to mechanical systems.

This can be considered to be application of computer based digital control techniques

through electronic and electric interfaces to mechanical engineering problems. Successful design

of Mechatronics can lead to products that are extremely attractive to customer in quality cost-

effectiveness.

MECHATRONICS DEFINITION:

Mechatronics may be defined as a multi-disciplinary field of study that implies the

synergistic integration of electronic engineering, electric engineering, control engineering and

computer technology with mechanical engineering for the design, manufacture, analysis and

maintenance of a wide range of engineering products and processes.

“Mechatronics brings together areas of technology involving sensors and measurement systems,

drive and actuation systems, analysis of the behavior of systems microprocessor systems”.

The integration across the traditional boundaries of mechanical engineering, electrical

engineering, electronics and control engineering has to occur at the earliest stages of the design

process if cheaper, more reliable; more flexible systems are to be developed.

APPLICATIONS OF MECHATRONICS ENGINEERING:

Mechatronics engineering finds application in the following fields.

Electronic home appliances

Electronic entertainment products

Engine systems (cars)

Large scale application

BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Schematic Layout of Hydraulic System

Reservoir (or air tank):

A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid (usually oil).

Pump:

The pump is used to force the liquid into the system.

Prime mover:

A Prime mover, usually an electric motor, is used to drive the pump.

Valves:

Valves are refitted in the system to control liquid direction, pressure, and flow rate.

Actuator:

An actuator is provided to convert the liquid energy into mechanical force or torque to do useful

work. The actuator is the actual working element of the system. The actuators can be either

cylinders (to provide linear motion) or hydro motors (to provide rotary motion).

Fluid-transfer piping:

The hydraulic Piping is provided to carry the compressed liquid from one place to another.

BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

Schematic Layout of Pneumatic System

Reservoir (or air tank):

An air tank is provided to store the compressed air required for the operations.

Compressor:

The compressor is used to compress the atmospheric air so as to increase the pressure of the air.

Prime mover:

A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:

Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:

An actuator is provided to convert the air energy into mechanical force or torque to do useful

work.

Fluid-transfer piping:

Piping is provided to carry the compressed air from one place to another.

BASIC SYMBOLS USED IN HYDRAULIS AND PNEUMATIC SYSTEM:

Symbols Description

LINES

-continuous line - flow line

-dashed line - pilot, drain

-envelope - long and short dashes around two or more

component symbols

CIRCULAR

-large circle - pump, motor

-small circle - Measuring devices

-semi-circle - rotary actuator

SQUARE

-one square - pressure control function

-two or three adjacent squares - directional control

DIAMOND

-diamond - Fluid conditioner (filter, separator, lubricator, heat

exchanger)

MISCELLANEOUS SYMBOLS

-Spring

-Flow Restriction

TRIANGLE

-solid - Direction of Hydraulic Fluid Flow

-open - Direction of Pneumatic flow

PUMPS AND COMPRESSORS

Fixed Displacement Hydraulic Pump

-unidirectional

-bidirectional

Variable Displacement Hydraulic Pump

-unidirectional

Compressor

-Compressor

Symbols Description

DIRECTIONAL CONTROL VALVES

Directional Control Valve (2 Ports / 2 Positions)

-Normally closed directional control valve with 2 ports and 2

finite positions.

-Normally open directional control valve with 2 ports and 2

finite positions.


-Normally closed directional control valve with 3 ports and 2

finite positions.

-Normally open directional control valve with 3 ports and 2

finite positions.


-directional control valve with 4 ports and 2 finite positions



*-(center position can have various flow paths)

Directional Control Valve (5 Ports / 2 Positions) Normally A Pneumatic Valve


Directional Control Valve (5 Ports / 3 Positions) Normally A Pneumatic Valve


CONTROL METHODS

Manual Control

-general symbol (without showing the control type)

-pushbutton

-lever

-foot pedal

Mechanical Control

-plunger or tracer

-spring

Symbols Description

-roller

-roller(one direction only)

Electrical Control

-Solenoid (the one winding)

Pilot Operation

-pneumatic

-hydraulic

Pilot Operated Two-Stage Valve

-Hydraulic: Hyd pilot second stage

CHECK VALVES, SHUTTLE VALVES, RAPID EXHAUST VALVES

-check valve -free flow one direction, blocked flow in other

direction

-pilot operated check valve, pilot to close

-pilot operated check valve, pilot to open

Shuttle Valve

-to isolate one part of a system from an alternate part of circuit

Rapid Exhaust Valve/Pneumatic

-installed close to an actuator for rapid movement of the

actuator

PRESSURE CONTROL VALVES

Pressure Relief Valve(Safety Valve) Normally Closed

- Line pressure is limited to the setting of the valve, secondary

part is directed to tank

PROPORTIONAL PRESSURE RELIEF

- line pressure is limited to and proportional to an electronic signal

SEQUENCE VALVE

- When the line pressure reaches the setting of the valve, valve

opens permitting flow to the secondary port. The pilot must be

externally drained to tank.

PRESSURE REDUCING VALVE

- pressure downstream of valve is limited to the setting of the valve

FLOW CONTROL VALVES

Throttle valve

-adjustable output flow

FLOW CONTROL VALVE

-with fixed output (variations in inlet pressure do not affect rate of

flow)

-with fixed output and relief port to reservoir with relief for excess

flow (variations in inlet pressure do not affect rate of flow)

-with variable output

-fixed orifice

-metered flow toward right free flow to left

-pressure compensated flow control fixed output flow regardless of

load

-pressure and temperature compensated

-with variable output and relief port to reservoir

FLOW DIVIDING VALVE

-flow is divided equally to two outputs

SHUT-OFF VALVE

-Simplified symbol

Symbols Description

FILTERS, WATER TRAPS, LUBRICATORS AND MISCELLANEOUS APPARATUS

Filter or Strainer

-filter

Water Trap

-with manual drain

-with automatic drained

Filter With Water Trap

-with manual drain

-automatic drain

Air Dryer

- refrigerant, or chemical removal of water from compressed air

line

Lubricator

-oil vapor is inducted into air line

Conditioning unit

-compound symbol of filter, regulator, lubricator unit

-Simplified Symbol

RESULT:

Thus the important feature Mechatronics system was studied.

EX.NO: 02 SIMULATION OF SINGLE ACTING CYLINDER CIRCUIT

DATE:

AIM:

To simulate the single acting cylinder circuit by using AUTOSIM 200 software.

APPARATUS REQUIRED:

1. CPU, Monitor

2. Keyboard and Mouse

3. AUTOSIM 200 Software

PROCEDURE:

1. Autosim software icon is available is the desktop by double clicking the icon.

2. The software home page will open, click new for creating the blank page.

3. Side of the wizard tool is available by using tool use drown the circuit.

4. In the tool symbols, just trag the symbol to the sheet which are the element are necessary

such as (pneumatic –supply element actuator values) compressor, 3/2 mechanically

operated spring controlled direction controlled valve and single acting cylinder.

5. Then correct the ports according to the circuit.

6. Finally simulate by using the simulation tool.

RESULT:

Thus the simulation of the single acting cylinder circuit is simulated by using AUTOSIM

200 software.

EX.NO: 03 SIMULATION OF DOUBLE ACTING CYLINDER CIRCUIT

DATE:

AIM:

To simulate the double acting cylinder circuit by using AUTOSIM 200 software.

APPARATUS REQUIRED:

1. CPU and Monitor



PROCEDURE:









RESULT:

Thus the simulation of the double acting cylinder circuit is simulated by using

AUTOSIM 200 software.

EX.NO: 04 SIMULATION OF SIMPLE HYDRAULIC CIRCUIT

DATE:

AIM:

To simulate the simple hydraulic circuit by using AUTOSIM 200 software.

APPARATUS REQUIRED:

1. CPU and Monitor



PROCEDURE:





such as (simple hydraulic circuit –supply element actuator values) compressor, 3/2

mechanically operated spring controlled direction controlled valve and single acting

cylinder.



RESULT:

Thus the simulation of the simple hydraulic circuit is simulated by using AUTOSIM 200

software.

EX.NO: 05 SIMULATION OF SIMPLE PNEUMATIC CIRCUIT

DATE:

AIM:

To simulate the simple pneumatic circuit by using AUTOSIM 200 software.

APPARATUS REQUIRED:

1. CPU and Monitor



PROCEDURE:

1. Fluidsim software icon is available is the desktop by double clicking the icon.








RESULT:

Thus the simulation of the simple pneumatic circuit is simulated by using AUTOSIM 200

software.

EX.NO: 06 SIMULATION OF ELECTRO HYDRAULIC CIRCUIT

DATE:

AIM:

To simulate the electro hydraulic circuit by using AUTOSIM 200 software.

APPARATUS REQUIRED:

1. CPU and Monitor



PROCEDURE:





such as (hydraulic –supply element actuator values) compressor, 3/2 mechanically




RESULT:

Thus the simulation of the electro hydraulic circuit is simulated by using AUTOSIM 200

software.

EX.NO: 07 SIMULATION OF ELECTRO PNEUMATIC CIRCUIT

DATE:

AIM:

To simulate the electro pneumatic circuit by using AUTOSIM 200 software.

APPARATUS REQUIRED:

1. CPU and Monitor



PROCEDURE:









RESULT:

Thus the simulation of the electro pneumatic circuit is simulated by using AUTOSIM 200

software.


DATE:

AIM:

To design a circuit to extend and retract the single acting cylinder with the help of delay

timer controlled by PLC.

APPARATUS REQUIRED:

1. Single acting cylinder

2. RS 232 cable

3. Versa pro software

4. 3/2 single solenoid valve

5. FRL unit

6. PLC

7. Connecting wires and tube

PROCEDURE:

ON DELAY TIMER:

1. Draw the circuit diagram

2. Provide +24V and –24V from PLC trainer to panel.

3. Open the versa pro software in desktop

4. Interface PLC with PC using RS 232 cable.

5. Write a ladder diagram.

6. Output of PLC (q1) is directly connected to input of solenoid coil.

7. Following the opening procedure of versa pro software.

8. Check the ladder diagram.

9. Connect the air supply to FRL unit.

10. Run the PLC. After some delay the cylinder will be activated.

CIRCUIT DIAGRAM: ON DELAY TIMER

PROCEDURE:

OFF DELAY TIMER






6. Output of PLC (q1) is directly connected to input of solenoid coil.




10. Run the PLC and observe the working of single acting cylinder.

CIRCUIT DIAGRAM-OFF DELAY TIMER

RESULT:

Thus the actuation of single acting cylinder with ON and OFF delay timer was done using PLC.


DATE:

AIM:

To simulate the automatic sequence of double acting cylinder using PLC

APPARATUS REQUIRED

1. Double acting cylinder

2. RS 232 cable


4. 5/2 double solenoid valve

5. FRL unit

6. PLC

7. Connecting wires and tube.

PROCEDURE:






6. Both outputs of PLC (q1 and q2) are directly connected to inputs of solenoid coils.


8. Check the ladder diagram and connect the air supply to FRL unit

9. Run the PLC and observe the working of double acting cylinder.

CIRCUIT DIAGRAM

RESULT:

Thus the ladder diagram for the automatic running of double acting cylinder is drawn and

executed.


DATE:

AIM:

To design a circuit for the sequence A+B+A-B using PLC.

APPARATUS REQUIRED:

1. Single and double acting cylinder

2. RS 232 cable


4. 3/2 single solenoid valve, 5/2 double solenoid valve

5. FRL unit

6. PLC

7. Connecting wires and tube

PROCEDURE:






6. Outputs of PLC (q1, q2, q3 and q4) are directly connected to the inputs of solenoid coil.




10. Run the PLC and observe the working of double acting cylinder.

CIRCUIT DIAGRAM:

RESULT:

Thus the ladder diagram for the automatic running of double acting cylinders is designed and

executed.

EX.NO: 11 RUNNING A STEPPER MOTOR AT DIFFERENT SPEED IN

TWO DIRECTIONS USING 8051 MICROCONTROLLER

DATE:

AIM:

To run a stepper motor at different speed in two directions.

PROGRAM:

4100 21 1A 41 START: LXI H,LOOK UP

4103 06 04 MVI B, 04

4105 7E REPT: MOV A,M

4106 D3 C0 OUT 0C0H

4108 11 03 03 LXI D, 0303H

410B 00 DELAY NOP

410C 1B DCX D

410D 7B MOV A,E

410E B2 ORA D

410F C2 0B 41 JNZ DELAY

4112 23 INX H

4113 05 DCR B

4114 CZ 05 41 JNZ REPT

4117 C3 00 41 JMP START

411A 09 03 06 0C LOOK UP: DB 09 05 06 0A

RESULT:

Enter the above program starting from location 4100. Execute the same. The stepper

motor rotates. Speed can be varied by varying the count at DE pair. Direction can be varied by

entering the data in the look-up table in the reverse order.

EX.NO: 12 RUNNING A STEPPER MOTOR FOR REQUIRED ANGLE

WITHIN 360°, WHICH IS EQUIVALENT TO 256 STEPS

DATE:

AIM:

To run a stepper motor for required angle within 360°, which is equivalent to 256 steps.

PROGRAM:

4101 OE HEX DATA MVI C, HEX DATA

4102 21 20 41 START: LXI H, LOOK UP

4105 06 04 MVI B, 04

4107 7E REPT: MOV A,M

4108 D3 C0 OUT C0

410A OD DCR C

410B CA 24 41 JZ END

410E 11 03 03 LXI D, COUNT

4111 00 DELAY: NOP

4112 1B DCX D

4113 7B MOV A,E

4114 B2 ORA D

4115 C2 11 41 JNZ DELAY

4118 23 INX H

4119 05 DCR B

411A C2 07 41 JNZ REPT

411D C3 02 41 JMP START

4120 09 05 06 0A LOOK UP: DB 09 05 06 0A

4124 76 END: HLT

RESULT:

Enter the above program and execute it. By converting the required step in decimal to hex and

entering the hex data at 4101 the motor rotates for so much steps and then stops.

EX.NO: 13 RUNNING A STEPPER MOTOR INTO TWO PARTS

DATE:

AIM:

Enter the program starting from 5000H onwards. Connect the stepper motors in the two

ports. Execute the program.

PROGRAM:

5000 ORG 5000H

5000 21 1B 50 START: LXI H, LOOKUP

5003 06 04 MVI B, 04

5005 7E REPT: MOV A, M

5006 D3 C0 OUT 0C0H

5008 D3 C8 OUT 0C8H

500A 11 03 03 LXI D, 0303H

500D 1B DELAY: DCX D

500E 7B MOV A, E

500F B2 ORA D

5010 C2 0D 50 JNZ DELAY

5013 23 INX H

5014 05 DCR B

5015 C2 05 50 JNZ REPT

5018 C3 00 50 JMP START

501B 09 05 06 0A LOOKUP: DB 09H, 05H, 06H, 0AH

501F END

RESULT:

Now it can be seen that the two stepper motors runs in the forward direction

simultaneously.

EX.NO: 14 RUNNING A STEPPER MOTOR IN BOTH FORWARD AND

REVERSE DIRECTIONS WITH DELAY

DATE:

AIM:

To run Stepper Motor in both forward and reverse directions with delay.

PROGRAM:

4100 ORG 4100H

4100 0E 20 START: MVI C, 20H

4102 21 3F 41 FORWD: LXI H, FORLOOK

4105 CD 21 41 CALL ROTATE

4108 0D DCR C

4109 C2 02 41 JNZ FORWD

410C CD 35 41 CALL STOP

410F 0E 20 MVI C, 20H

4111 21 43 41 REVES: LXI H, REVLOOK

4114 CD 21 41 CALL ROTATE

4117 0D DCR C

4118 C2 11 41 JNZ REVES

411B CD 35 41 CALL STOP

411E C3 00 41 JMP START

4121 06 04 ROTATE: MVI B, 04H

4123 7E REPT: MOV A, M

4124 D3 C0 OUT 0C0H

4126 11 03 03 LXI D, 0303H

4129 1B LOOP1: DCX D

412A 7B MOV A, E

412B B2 ORA D

412C C2 29 41 JNZ LOOP1

412F 23 INX H

4130 05 DCR B

4131 C2 23 41 JNZ REPT

4134 C9 RET

4135 11 FF FF STOP: LXI D, FFFFH

4138 1B LOOP2: DCX D

4139 7B MOV A, E

413A B2 ORA D

413B C2 38 41 JNZ LOOP2

413E C9 RET

413F 09 05 06 0A FORLOOK DB 09H, 05H, 06H, 0AH

4143 0A 06 05 09 REVLOOK DB 0AH, 06H, 05H, 09H

4147 END

RESULT:

Enter the program starting from 4100H location and connect the stepper motor in port 1.

Execute the program. Now you can see that the stepper motor runs in forward direction and

reverse direction continuously with a delay.

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