LAB MANUAL

MIT - SIEMENS
CENTRE OF EXCELLENCE
FOR
MECHATRONICS

G.S. MANDAL’S
MAHARASHTRA INSTITUTE OF TECHNOLOGY,
AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

INDEX

Serial
Practical Title Page No.
No.
1 Vision & Mission 01

2 Program Educational Objectives 01

3 Program Outcomes 01

4 Program Specific Outcomes 03

5 Course Objectives & Course Outcomes 03

6 Lab Instructions 04

7 Study and Demonstration of Mechatronics System Components 05

8 Study and Demonstration of Sensors 09

9 Study and Demonstration of Actuators 14

10 Study and Demonstration of PLC Hardware and Software 20

11 PLC Programing Exercises – NO NC. 28

12 PLC Programing Exercises – SR RS Blocks. 28

13 PLC Programing Exercises – Latching circuit. 28

14 Mechatronics System Case Study 28

PREPARED BY: Prof. P. J. PALKAR (Lab i/c) APPROVED BY: Dr. A. J. Keche (HMED)
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Vision and mission of the department

Vision: To be a center of excellence in the field of Mechanical Engineering where the best of
teaching, learning and research synergize and serve the society through innovation and
excellence in teaching.
Mission: To provide world-class under-graduate and graduate education in Mechanical
Engineering by imparting quality techno-managerial education and training to meet current and
emerging needs of the industry and society at large.
Program Education Objectives
PEO-I Graduates will apply the tools and skills acquired during their undergraduate studies
either in advanced studies or as employees in engineering industries
PEO-2 Graduates of the program will have successful technical and professional career.
PEO-3 Graduates of the program will continue to learn to adopt constantly evolving technology.
PEO-4 Graduates will demonstrate sensitivity towards societal issues.
Program Outcomes
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, review 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 the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and
environmental considerations.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

4. Conduct investigations of complex problems: Use research-based knowledge and

search 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 teamwork: 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 the
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.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

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

PSO-I: Ability to design & analyse components & systems for mechanical performance
PSO-II: Ability to apply and solve the problems of heat power and thermal systems.
PSO-III: Ability to solve real life problems with the exposure to manufacturing industries

Course Outcomes
MED: Automation system design (Honor/Minor)
CO No. Code Statement
CO 1 MED 903.1 List out the different sensors and their working principles.

CO 2 MED 903.2 Explain the uses and working of different actuators in the industrial
automation.
CO 3 MED 903.3 Describe role of different mechanical components and their working in the
automation system.
CO 4 MED 903.4 Relate the controllers used for automation with the PLC, for industrial
applications.
CO 5 MED 903.5 Compare different sensors and actuators and select proper one for a typical
industry application.
CO 6 MED 903.6 Apply the knowledge of sensors, actuators and PLC for the automation of
given application/system.
Course Objectives
1. To give an idea about various sectors of manufacturing where automation can be
implemented.
2. To aware students about different technologies practiced in different sections of
manufacturing.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Lab Instructions
1. Respect the test equipment and be gentle with it.
2. If you don’t know something about a circuit or electronics hardware, ask before
rushing ahead.
3. Perform only those experiments authorized by your teacher.
4. Carefully follow all instructions, both written and oral.
5. Ensure that safety devices are adequate, appropriate and in good working condition.
6. You must not open the PC cases or install additional hardware or software on the Lab
computers.
7. Please report any problem, including damage to equipment, as soon as it occurs.
8. It is your responsibility to keep the Lab neat and tidy.
9. Turn off all PC monitors and instruments when not in use.
10. Turn off the ceiling fans and lights if you are last person leaving the lab.

For EMERGENCY

In the case of an electrical emergency, such as electrocution or fire, all 240V

and 415V, general purpose power outlets in the lab can be isolated/turned off.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Practical No. 01
Aim: - Study and demonstration of mechatronics system and its components.
Introduction to Mechatronics:
Mechatronics is the synergistic integration of sensors, actuators, signal conditioning, power
electronics, decision and control algorithms, and computer hardware and software to manage
complexity, uncertainty, and communication in engineered systems.
Typical knowledgebase for optimal design and operation of mechatronic systems comprises of:
– Dynamic system modeling and analysis
-- Thermo-fluid, structural, hydraulic, electrical, chemical, biological, etc.
– Decision and control theory
– Sensors and signal conditioning
– Actuators and power electronics
– Data acquisition
-- A2D, D2A, digital I/O, counters, timers, etc.
– Hardware interfacing
– Rapid control prototyping
– Embedded computing

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Fig.: - Disciplinary Foundations of Mechatronics

Fig.: - Elements of Mechatronics System

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Elements of Mechatronics System

Mechatronics system comprise of various elements of Mechanical, Electrical, Electronics
domains.
Mechanical elements refer to
• Mechanical structure, mechanism, thermo-fluid, and hydraulic aspects of a mechatronics
system.
• Mechanical elements require physical power to produce motion, force, heat, etc.
Electromechanical elements refer to:
Sensors
A variety of physical variables can be measured using sensors, e.g., light using photo-resistor,
level and displacement using potentiometer, direction/tilt using magnetic sensor, sound using
microphone, stress and pressure using strain gauge, touch using micro-switch, temperature using
thermistor, and humidity using conductivity sensor.
Actuators
DC servomotor, stepper motor, relay, solenoid, speaker, light emitting diode (LED), shape
memory alloy, electromagnet, and pump apply commanded action on the physical process.
Electrical elements refer to:
Electrical components (e.g., resistor (R), capacitor (C), inductor (L), transformer, etc.), circuits,
and analog signals.
• Electronic elements refer to:
analog/digital electronics, transistors, thyristors, opto-isolators, operational amplifiers, power
electronics, and signal conditioning

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

• The electrical/electronic elements are used to interface electromechanical sensors and actuators
to the control interface/computing hardware elements.
Control interface/computing hardware elements refer to:
Analog-to-digital (A2D) converter, digital-to-analog (D2A) converter, digital input/output (I/O),
counters, timers, microprocessor, microcontroller, data acquisition and control (DAC) board, and
digital signal processing (DSP) board.
• Control interface hardware allows analog/digital interfacing
– communication of sensor signal to the control computer and communication of control signal
from the control computer to the actuator.
• Control computing hardware implements a control algorithm, which uses sensor
measurements, to compute control actions to be applied by the actuator.
Mechatronics Applications
• Smart consumer products: home security, camera, microwave oven, toaster, dish washer,
laundry washer-dryer, climate control units, etc.
• Medical: implant-devices, assisted surgery, haptic, etc.
• Defense: unmanned air, ground, and underwater vehicles, smart munitions, jet engines, etc.
• Manufacturing: robotics, machines, processes, etc.
• Automotive: climate control, antilock brake, active suspension, cruise control, air bags, engine
management, safety, etc.
Conclusion:
Thus, we have studied the Mechatronics system, its components and applications.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Practical No. 02
Aim: - Study and Demonstration of Sensors.
Introduction to Sensors
A sensor is a device that receives a stimulus and responds with an electrical signal.
Sensors are almost always transducers, but transducers are not necessarily sensors.
A transducer is a device which converts signals from one form to another. This can include
loudspeakers and linear positioners are well as physical quantity to electrical signal devices.
Sensor is a device that when exposed to a physical phenomenon (temperature, displacement,
force, etc.) produces a proportional output signal (electrical, mechanical, magnetic, etc.).
The term transducer is often used synonymously with sensors. However, ideally, a sensor is a
device that responds to a change in the physical phenomenon. On the other hand, a transducer is
a device that converts one form of energy into another form of energy. Sensors are transducers
when they sense one form of energy input and output in a different form of energy. For example,
a thermocouple responds to a temperature change (thermal energy) and outputs a proportional
change in electromotive force (electrical energy). Therefore, a thermocouple can be called a
sensor and or transducer.
Normally, the output from a sensor requires post processing of the signals before they can be fed
to the controller. The sensor output may have to be demodulated, amplified, filtered, linearized,
range quantized, and isolated so that the signal can be accepted by a typical analog-to-digital
converter of the controller. Some sensors are available with integrated signal conditioners, such
as the microsensors. All the electronics are integrated into one microcircuit and can be directly
interfaced with the controllers.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Classification of Sensor:
Sensors are classified as passive or active. In passive sensors, the power required to produce the
output is provided by the sensed physical phenomenon itself (such as a thermometer) whereas
the active sensors require external power source (such as a strain gage).
Furthermore, sensors are classified as analog or digital based on the type of output signal.
Analog sensors produce continuous signals that are proportional to the sensed parameter and
typically require analog-to-digital conversion before feeding to the digital controller.
Digital sensors on the other hand produce digital outputs that can be directly interfaced with the
digital controller. If many sensors are required, it is more economical to choose simple analog
sensors and interface them to the digital controller equipped with a multi-channel analog-to-

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

digital converter.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Conclusion:
Thus, we have studied various sensors, their types and their applications.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Practical No. 03
Aim: - Study and Demonstration of Actuators.
Introduction to Actuators:
Actuators are basically the muscle behind a mechatronics system that accepts a control
command (mostly in the form of an electrical signal) and produces a change in the physical
system by generating force, motion, heat, flow, etc. Normally, the actuators are used in
conjunction with the power supply and a coupling mechanism as shown in Fig. below. The
power unit provides either AC or DC power at the rated voltage and current. The coupling
mechanism acts as the interface between the actuator and the physical system. Typical
mechanisms include rack and pinion, gear drive, belt drive, lead screw and nut, piston, and
linkages.

Fig.: - Typical Actuating unit

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Classification Actuators can be classified based on the type of energy. They are essentially of
electrical, electromechanical, electromagnetic, hydraulic, or pneumatic type. The new
generations of actuators include smart material actuators, microactuators, and Nanoactuators.
Actuators can also be classified as binary and continuous based on the number of stable-state
outputs. A relay with two stable states is a good example of a binary actuator. Similarly, a
stepper motor is a good example of continuous actuator. When used for a position control, the
stepper motor can provide stable outputs with very small incremental motion.
Principle of Operation
Electrical Actuators
Electrical switches are the choice of actuators for most of the on-off type control action.
Switching devices such as diodes, transistors, triacs, MOSFET, and relays accept a low energy
level command signal from the controller and switch on or off electrical devices such as motors,
valves, and heating elements. The gate terminal receives the low energy control signal from the
controller that makes or breaks the connection between the power supply and the actuator load.
When switches are used, the designer must make sure that switch bounce problem is eliminated
either by hardware or software.
Electromechanical Actuators
The most common electromechanical actuator is a motor that converts electrical energy to
mechanical motion. Motors are the principal means of converting electrical energy into
mechanical energy in industry. Broadly they can be classified as DC motors, AC motors, and
stepper motors. DC motors operate on DC
Electromagnetic Actuators

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

The solenoid is the most common electromagnetic actuator. A DC solenoid actuator consists of a
soft iron core enclosed within a current carrying coil. When the coil is energized, a magnetic
field is established that provides the force to push or pull the iron core. AC solenoid devices are
also encountered, such as AC excitation relay. A solenoid operated directional control valve is
shown in Fig. Normally, due to the spring force, the soft iron core is pushed to the extreme left
position as shown. When the solenoid is excited, the soft iron core will move to the right
extreme position thus providing the electromagnetic actuation. Another important type is the
electromagnet. The electromagnets are used extensively in applications that require large forces.

Fig.: Solenoid Operated Direction Control Valve

Hydraulic and Pneumatic Actuators

Hydraulic and pneumatic actuators are normally either rotary motors or linear piston/cylinder or
control valves. They are ideally suited for generating very large forces coupled with large
motion. Pneumatic actuators use air under pressure that is most suitable for low to medium

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

force, short stroke, and high speed applications. Hydraulic actuators use pressurized oil that is
incompressible.
They can produce very large forces coupled with large motion in a cost-effective manner. The
disadvantage with the hydraulic actuators is that they are more complex and need more
maintenance. The rotary motors are usually used in applications where low speed and high
torque are required. The cylinder/piston actuators are suited for application of linear motion such
as aircraft flap control. Control valves in the form of directional control valves are used in
conjunction with rotary motors and cylinders to control the fluid flow direction as shown in Fig.
above. In this solenoid operated directional control valve, the valve position dictates the
direction motion of the cylinder/piston arrangement.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
P a g e | 18
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Conclusion:
Thus, we have studied the actuators, their types and applications.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
P a g e | 19
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Practical No. 04
Aim: - Study and Demonstration of PLC Hardware and Software.
Introduction to PLC
A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used
for automation of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or light fixtures.
The word “Programmable” differs it from the conventional hard-wired relay logic control. PLC
can be easily Programmed or changed as per the application’s requirement.

What are PLC Capabilities? Advantages of PLC

-Logic Control Reduced Space
-Timer Energy Saving
-Counter Ease of Maintenance
-Arithmetic Function Economical
-PID Control Greater Life & Reliability
-Analog Signal Tremendous Flexibility
-Communication Shorter Project Time
-Signals & Listing Archiving & Documentation
-Real time function
-HMI Panels
Advantages of PLC

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

• Reduced space – Compact construction compared to Hard wired controller, Less wiring

• Energy saving – 1/10th of power consumed by equivalent Relay logic control

• Ease of Maintenance – Modular replacement / Easy troubleshooting / Error diagnostic by

Software

• Economical – Low payback period

• Greater Life & Reliability – Lesser moving parts, Reduced wear & tear

• Tremendous flexibility – Control logic can be changed without rewiring / Supports Complex
functions like Time delays, Counting, Comparing, Arithmetic operations

• Online / Offline programming possible

• High processing speed & great flexibility in processing both Analog & Digital signal

Components of PLC
There are 5 basic components in a PLC system

• PLC processor or controller cpu

• Input / Output module

• Chassis or Backplane

• Power supply

• Programming Software that runs in a PC

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

PLC CPU
Stores the control program and data in its memory. Performs logic operation with the data.
Performs calculations. CPU has 3 types of Memories.

1) System Memory – OS, PII, PIQ, Timers, Counters etc.

2) Load Memory – Used to store the user program. e.g. Memory Card
3) Work Memory – Used to store the parts of user program required for program processing.

Fig.: PLC Block Diagram

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Fig.: Digital Input Module

Purpose of Digital Input/output Module
The digital input module is used for signal conversion to 5V DC, which is required for working
of the controller.
Also, it is used for the signal isolation and for serial communication with CPU. Input module
acts as Interface between field control Inputs and CPU. The voltage/ current signals generated by
Sensors, Transducers, Limit switches, Push buttons etc. are applied to the terminals of Input
module.
Input module converts the field signal into standard control signal for processing by PLC.
receives 24 V DC or 230 V AC & delivers 5V DC. Sends one signal at a time to CPU by
multiplexing action. Analog input module or digital input module are there for input and output

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

of PLC. Analog Current Input module – 4 to ± 20mA or 0 to ± 20 mA. Analog Voltage Input
module – 0 to ± 50mV or 0 to ± 500 mV or 0 to ± 10 V. Digital Input module – 24 V DC, 230 V
AC.
PLC Programing
PLC Scan Cycle

• Sense the Input

• Process the Logic

• Give Output

Fig.: PLC Program Scan Cycle

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Programming Languages
A program loaded into PLC systems in machine code, a sequence of binary code numbers to
represent the program instructions. Assembly language based on the use of mnemonics can be
used, and a computer program called an assembler is used to translate the mnemonics into
machine code. High level Languages (C, BASIC, etc.) can be used.

Programming Devices
PLC can be reprogrammed through an appropriate programming device:
Programming Console, Computer, Hand Programmer etc.

Introduction to Ladder Logic

Ladder logic uses graphic symbols like relay schematic circuit diagrams.
Ladder diagram consists of two vertical lines representing the power rails. Circuits are connected
as horizontal lines between these two verticals.

Ladder diagram features

Power flows from left to right.
Output on right side cannot be connected directly with left side.
Contact cannot be placed on the right of output.
Each rung contains one output at least.
Each output can be used only once in the program.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
P a g e | 25
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

A particular input a/o output can appear in more than one rung of a ladder.
The inputs a/o outputs are all identified by their addresses, the notation used depending on the
PLC manufacturer.

Introduction to Statement list

Statement list is a programming language using mnemonic abbreviations of Boolean
logic operations. Boolean operations work on combination
of variables that are true or false.
A statement is an instruction or directive for the PLC.
Statement List Operations
* Load (LD) instruction.
* And (A) instruction.
* Or (O) instruction.
* Output (=) instruction.

Function Block Diagrams

Function block is represented as a box with the function name written in.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Fig.: PLC Programming Languages

Conclusion:
Thus, we have studied the PLC construction working and basics of PLC programming.

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
P a g e | 27
 G.S. Mandal’s
MAHARASHTRA INSTITUTE OF TECHNOLOGY, AURANGABAD
DEPARTMENT OF MECHANICAL ENGINEERING

Name of laboratory: Centre of Excellence Mechatronics

LABORATORY MANUAL
Class: Third year Part: I/II Course code: MED 903
Name of course: Automation System Design

Practical No. 05
Title: - PLC Programing Exercises – NO NC.
(Students have to develop and test the PLC ladder program for at least two basic examples)

Practical No. 06
Title: - PLC Programing Exercises – SR RS Block.
(Students have to develop and test the PLC ladder program for at least two basic examples)

Practical No. 07
Title: - PLC Programing Exercises – Latching circuit.
(Students have to develop and test the PLC ladder program for at least two basic examples)

Practical No. 08
Title: - Mechatronics System Case Study.
(Student have to prepare report on case study of at least one mechatronics system application)

PREPARED BY: Prof. P. J. PALKAR (Lab I/C) APPROVED BY: Dr. A. J. Keche (HMED)
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