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Programming Industrial Automation Laboratory

Manual
2021-22
Do’s
▪ Be punctual.
▪ Maintain discipline & silence.
▪ Keep the Laboratory clean and tidy.
▪ Enter Laboratory without shoes.
▪ Handle instruments with utmost care.
▪ Come prepared with Programs and learning materials.
▪ Follow the procedure that has been instructed.
▪ Return all the issued equipment’s properly.
▪ Get the signature on experiment result sheet daily.
▪ For any clarification contact faculty/staff in charge only.
▪ Shut down the power supply after the experiment.

Don’ts
▪ Avoid unnecessary chat or walk.
▪ Playing mischief in the laboratory is forbidden.
▪ Disfiguring of furniture is prohibited.
▪ Do not start the experiment without instructions.
▪ Avoid using cell phones unless absolutely necessary.
▪ Avoid late submission of laboratory reports.
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INTRODUCTION
A programmable Logic Controller (PLC) is a specialized computer used for the control and operation
of manufacturing process and machinery. It uses a programmable memory to store instructions and
execute functions including on/off control, timing, counting, sequencing, arithmetic, and data
handling. Programmable Logic Controllers (PLC) are used in almost every aspect of industry to
expand and enhance production. Where older automated systems would use hundreds or thousands of
electromechanical relays, a single PLC can be programmed as an efficient replacement. The
functionality of the PLCs has evolved over the years to include capabilities beyond typical relay
control. Sophisticated motion control, process control, distributive control systems, and complex
networking have now been added to the PLC’s functions. Therefore, PLCs provide many advantages
over conventional relay type of control, including increased reliability, more flexibility, lower cost,
communication capability, faster response time and convenience to troubleshoot.

The main objectives of the laboratory course are:


• Identify and explain the purpose of the parts of a programmable logic controller
• Use basic PLC relay instructions to write, debug and troubleshoot ladder logic programs
• Develop and demonstrate programs using timer and counter functions that are integrated to a
PLC
• Properly use program control instructions
• Properly use math and data manipulation instructions
• Describe and use immediate input and output instructions
• Interface digital and analog devices to PLCs
• Explain the need and process for troubleshooting PLC controlled systems
• Prepare students for challenging industrial jobs in the engineering technology areas

Major advantages of using PLC are as follows:


• The PLC is a hardened industrial computer designed to withstand the harsh factory
environment.
• PLCs are reusable they contain a changeable program that eliminators extensive and
component changes and that makes them cost effective
• PLCs offer easy troubleshooting
• PLCs feature easy installation and small size.
• Increase productivity.
• Ease of programming.
• Ability to communicate with computer.
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ARCHITECHTURE OF PLC

IEC 1131 programming standard :

A standardized set of PLC programming guidelines, set forth by the International Electro
technical Commission, that includes general PLC information, equipment and test requirements,
programming languages, user guidelines, and communication standards. IEC 61131-3 not only
describes the PLC programming languages themselves, but also offers comprehensive concepts and
guidelines for creating PLC projects.
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Structure of the building blocks


POUs correspond to the blocks in previous (conventional) programming systems. POUs can call each
other with or without parameters. As the name implies, POUs are the smallest independent software
units of a user program. There are three types of POUs: Function (FUN), Function block (FB) and
Program (PROG), in ascending order of functionality. The main difference between functions and
function blocks is that functions always produce the same result (function value) when called with the
same input parameters, i.e. they have no “memory”. Function blocks have their own data record and
can therefore “remember” status information (instantiation). Programs (PROG) represent the “top” of
a PLC user program and have the ability to access the I/Os of the PLC and to make them accessible to
other POUs. IEC 61131-3 predefines the calling interface and the behaviour of frequently needed
standard functions (std. FUN) such as arithmetic or comparison functions, as well as standard function
blocks (std. FB), such as timers or counters.

Declaration of variables
The IEC 61131-3 standard uses variables to store and process information. Variables correspond to
(global) flags or bit memories in conventional PLC systems. However, their storage locations no
longer need to be defined manually by the user (as absolute or global addresses), but they are managed
automatically by the programming system and each possess a fixed data type. IEC 61131-3 specifies
several data types (Bool, Byte, Integer). These differ, for example, in the number of bits or the use of
signs. It is also possible for the user to define new data types: user-defined data types such as
structures and arrays. Variables can also be assigned to a certain I/O address and can be battery backed
against power failure. Variables have different forms. They can be defined (declared) outside a POU
and used program-wide, they can be declared as interface parameters of a POU, or they can have a
local meaning for a POU. For declaration purposes they are therefore divided into different variable
types. All variables used by a POU have to be declared in the declaration part of the POU. The
declaration part of a POU can be written in textual form independently of the programming language
used. Parts of the declaration (input and output parameters of the POU) can also be represented
graphically.
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Some of the used Instructions


Bit Instructions
The following instructions are used with fixed, SLC 5/01, SLC 5/02, SLC 5/03, and SLC 5/04
processors.

If you want to: Use this Instruction:


Examine a bit for an On conditions XIC
Examine a bit for an Off conditions XIO
Turn a bit On or Off OTE
Turn a bit On OLT
Turn a bit Off OUT

Trigger a one time event OSR

Timer and Counter Instructions


Timers and counters are output instructions. Use the following instructions with fixed, SLC 5/01,
SLC 5/02, SLC 5/02, SLC 5/03, and SLC 5/04 processors.

If you want to: Use this instruction:

Count time base intervals when the instruction is true TON

Count time base intervals when the Instruction is false TOF


Count time base intervals when the instruction is true and
retain the accumulated value when the instruction RTO
goes false
Increment the count at each false–to–true transition. CTU
Decrement the count at each false-to-true transition CTD
Count high-speed pulses from a fixed
HSE
Controller High-speed input
Reset the accumulated value and status bits of a timer or
RES
counter. Do not use with TOF timers.
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Installation & Wiring


Safety Guidelines
Providing a safe operating environment for personnel and equipment is our responsibility and should
be our primary goal during system planning and installation. Automation systems can fail and may
result in situations that can cause serious injury to personnel or damage to equipment. Do not rely on
the automation system alone to provide a safe operating environment. We should use external
electromechanical devices, such as relays or limit switches that are independent of the PLC
application to provide protection for any part of the system that may cause personal injury or damage.

Plan for Safety:


The best way to provide a safe operating environment is to make personnel and equipment safety part
of the planning process. We should examine every aspect of the system to determine which areas are
critical to operator or machine safety. If we are not familiar with PLC system installation practices
then we can refer to installation guidelines provided with the system or we should obtain additional
information from sources like NEMA, NEC, etc.

Three levels of protection:


We should use the following techniques, which provide three levels of system control.
1. Orderly system shutdown sequence in the PLC control program
2. Mechanical disconnect for output module power
3. Emergency stop switch for disconnecting system power

Emergency Stops:
It is recommended that emergency stop circuits be incorporated into the system for every machine
controlled by a PLC. For maximum safety in a PLC system, these circuits must not be wired into the
controller, but should be hardwired external to the PLC. The emergency stop switches should be
easily accessed by the operator and are generally wired into a master control relay (MCR) or a safety
control relay (SCR) that will remove power from the PLC I/O system in an emergency. MCRs and
SCRs provide a convenient means for removing power from the I/O system during an emergency
situation by de-energizing an MCR (or SCR) coil, power to the input (optional) and output devices is
removed. This event occurs when any emergency stop switch opens. However, the PLC continues to
receive power and operate even though all its inputs and outputs are disabled. The MCR circuit could
be extended by placing a PLC fault relay (closed during normal PLC operation) in series with any
other emergency stop conditions. This would cause the MCR circuit to drop the PLC I/O power in
case of a PLC failure (memory error, I/O communications error. etc.).
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Emergency Power disconnect:


A properly rated emergency power disconnect should be used to power the PLC controlled system as
a means of removing the power from the entire control system. It may be necessary to install a
capacitor across the disconnect to protect against a condition known as “outrush“. This condition
occurs when the output triacs are turned off by powering off the disconnect, thus causing the energy
stored in the inductive loads to seek the shortest distance to ground, which is often through the triacs.
After an emergency shutdown or any other type of power interruption, there may be requirements that
must be met before the PLC control program can be restarted. For example, there may be specific
register values that must be established (or maintained from the state prior to the shutdown) before
operations can resume. In this case, we may want to use retentive memory locations, or include
constants in the control program to ensure a known starting point.

Orderly System Shutdown:


Ideally, the first level of protection can be provided with the PLC control program by identifying
machine problems. Analyze our application and identify any shutdown sequences that must be
performed. Typical problems such as jammed or missing parts, empty bins, etc., create a risk of
personal injury or equipment damage.
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Wiring Guidelines:
Power Input Wiring

Fuse Protection for Input Power


There are no internal fuses for the input power circuits, so external circuit protection is needed to
ensure the safety of service personnel and the safe operation of the equipment itself. To meet
UL/CSA specifications, the input power must be fused.

Planning the Wiring Routes:


The following guidelines provide general information on how to wire the I/O connections to PLCs.
1. Each terminal connection of the PLC can accept one 14 AWG wire or two 16 AWG size wires. Do
not exceed this recommended capacity.
2. Always use a continuous length of wire. Do not splice wires to attain a needed length.
3. Use the shortest possible wire length.
4. Use wire trays for routing whereever possible.
5. Avoid running wires near high energy wiring.
6. Avoid running input wiring close to output wiring where possible.
7. To minimize voltage drops when wires must run a long distance , consider using multiple wires for
the return line.
8. Avoid running DC wiring in close proximity to AC wiring where possible.
9. Avoid creating sharp bends in the wires
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Name of the student: USN: 0 1 F E B A R

Lab: Demo Type

Problem Description
Develop a program that will cause output D to go true when switch A and switch B are closed or when switch
C is closed.
Equipment used: Panasonic PLC & FPWinPro software

Truth Table:

Steps involved:

• To detect and monitor the switch A, B and, C continuously and change the output D accordingly.

Equivalent ladder diagram:


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Name of the student: USN: 0 1 F E B A R

Lab: Demo Type


Problem Description
Develop a program that will cause output D to be on when push button A is on, or either B or C are on.

Equipment used: Panasonic PLC & FPWinPro software

Truth Table:

Steps involved:

• To detect and monitor button A, B, and C continuously and change the status of output D.

Equivalent ladder diagram:

Conclusion:
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Name of the student: USN: 0 1 F E B A R

Lab: Demo Type

Problem Description
Design a motor controller that has a forward and a reverse button. The motor forward and reverse outputs will
only be on when one of the buttons are pushed. When both buttons get pushed the motor will not work.

Equipment: Indralogic software

Assignment of input/output variables:

Truth Table:

Steps involved:

• To monitor forward and reverse buttons, and rotate the motor according the switch status.

Equivalent ladder diagram:


Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Demo Type

Problem Description

Sequential control of 2 double-acting cylinders with impulse valves


Objective : This exercise demonstrates a displacement- dependent sequential control with double- acting
cylinder without signal overlapping. Signaling elements are electric cylinder Switches with proximity
switching (magnetic field sensors), electrically controlled 5/2 directional control impulse valves are used as
actuators.

Procedure:
Pneumatic circuit diagram
• Both double-acting cylinders are controlled by 5/2 directional control impulse valves.
• The valves are equipped with visual display and manual override.
• Valve 1 has the solenoid coils designated Y1 and Y2, valve 2 those with Y3 and Y4.
• When signal voltage is applied to the solenoid coils Y1 and Y3, the cylinders extend, when voltage is
applied to Y2 and Y4 the cylinders retract.
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• Both cylinders have cylinder switches with visual displays mounted in their end positions, these are
designated B1 to B4.
• The extension speed of both cylinders can be infinitely adjusted with a one-way flow control valve.

Equivalent ladder diagram:


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Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description

Consider the design of a burglar alarm for a house. When activated an alarm and lights will be activated to
encourage the unwanted guest to leave. This alarm be activated if an unauthorized intruder is detected by
window sensor and a motion detector. The window sensor is effectively a loop of wire that is a piece of thin
metal foil that encircles the window. If the window is broken, the foil breaks breaking the conductor. This
behaves like a normally closed switch. The motion sensor is designed so that when a person is detected the
output will go on. As with any alarm an activate/deactivate switch is also needed. The basic operation of the
alarm system, and the inputs and outputs of the controller are itemized here

Aim: To design PLC logic to implement burglar alarm

Equipment: Rexroth PLC & IndraWorks software

Assignment of input/output variables:

A = Alarm and lights switch (1 = on) W = Window/Door sensor (1 = OK)


M = Motion Sensor (0 = OK) S = Alarm Active switch (1 = on)
The basic operation of the alarm can be described with rules.
1. If alarm is on, check sensors.
2. If window/door sensor is broken (turns off), sound alarm and turn on lights button

The next step is to define the controller equation. In this case the controller has 3 different inputs, and a single
output, so a truth table is a reasonable approach to formalizing the system. A Boolean equation can then be
written using the truth table .Of the eight possible combinations of alarm inputs, only three lead to alarm
conditions.

Truth Table & Boolean Logic Expression:


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Equivalent PLC logic:

Conclusion :
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Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description

One open tank is installed in the plant of which liquid level is to be controlled. When level reaches
the Level Low, Outlet flow is blocked and inlet flow is allowed until high level is achieved. And
when Level High is detected, outlet flow is allowed and inlet flow is blocked.

Problem Diagram

Steps involved:

• To detect high and low level of liquid in the tank, two level switches are used which gives output
in digital terms, that is when corresponding levels are detected, it gives output high otherwise
remain low.
• To control level of this system, Single Acting piston valve can be used which has two states, either
fully open or fully close.
• Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the side
upper most position.
• When inputs are detected, output to Control Valve has to be latched in order to continuously fill or
empty the system.
• Master start/stop is also provided to shut down or start the entire process.
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Ladder diagram
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Components required

▪ Rexroth training Kit -1 (L10 or L20)


▪ Indralogic software

Scope/Applications

Following are the major applications it can be used for

→Water level indication

→Dam water indication system

→Home water supply system.

Circuit Diagram

] Marks
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Flow Chart

[ ] Marks
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Working Principle [ ] Marks


This is a ladder logic for PLC automated tank filling and draining. When the
water level in the tank reaches the low point, the outlet is closed and the inlet is
opened for filling the tank. This continues till the time the high point sensor is
not triggered. Once that is done the inlet is blocked and the outlet is opened.
During the filling of the tank the outlet is not opened as soon as the low point
sensor is switched off.'

Code and connections [ ] Marks


ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty


Name
&Signature
Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description
When a part is placed on the conveyor at position 1, and when a start button is pressed it moves to
position 2. Upon reaching position 2, it stops for the stamping operation to take place. After stamping
it automatically moves to position 3. It stops at position 3, where the part is removed manually from
the conveyor. Assume only one part is on the conveyor at a time. Add limit switches, interlocks, push
buttons, etc. as required.
Problem Diagram

Problem Solution

• Assuming all the contacts available are of Normally Open type.


• Push Buttons to Start and Stop the process in case of malfunctioning.
• Use of Level Switches to detect the positions 1, 2 and 3 as shown as LS1, LS2 and LS3
respectively.
• Reversible motor with UP_MOTOR coil for reverse direction and DN_MOTOR coil for forward
direction control.
• Conveyor Motor to move the part from position 1 to 2 and after stamping, 2 to 3.
• LSDN and LSUP are two other limit switches which detect the lower most and upper most
position of the stamper arm.
• Additional use of relay contacts in the software during programming to store the various bits in
order to run Motor continuously.
• Interlocking by using XIC contacts in the software in order to prevent from Malfunctioning.

Logic Diagram:
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Ladder diagram

Components required
▪ Rexroth training Kit -1 (L10 or L20)
Indralogic software
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Scope/Applications
Following are the major applications it can be used for

→Postal system

→Banking

→Barcode stamping

Circuit Diagram

[ ] Marks
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Flow Chart
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Working Principle
This ladder logic is for PLC automation of material stamping using conveyor belt. When an object is placed on
conveyor belt on position 1 the belt moves forward. this happens till the belt reaches position 2 where its
stopped. The stamping then takes place which is controlled by sensors to control motion of stamper. Once the
stamping is done the belt is moved to position 3 automatically where the part is removed manually. [ ]
Marks
Code and connections [ ] Marks
ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name &Signature


Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description
Develop a PLC program that will control a miniature set of traffic lights. These lights will go through a normal
sequence, but will have pedestrian cross walk buttons that will activate a cross walk signal when pressed.
When done the student should understand the design and implementation of time dependent control circuits.

Process Description:
We want to develop a controller for a set of traffic lights that is at the cross of Main St. and a less used Cross
Rd. The lights under two possible sequences as shown below. In the normal sequence the green for cross is
shorter with no cross walk light. If a cross walk button is pushed while the Main light is green or yellow the
Cross green light will be on longer with a walk sign.

▪ Equipment Rexroth training Kit -1 (L10 or L20)

Assignment of input/output variables:


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Procedure:
1. Draw a state transition diagram for the traffic lights given the process description below.
2. Write the ladder logic model for the state transition diagrams.
3. Develop an exhaustive test table that will test all of the possible transition states for the traffic lights.

Ladder diagram
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Department of Automation and Robotics

▪ Components required
▪ Rexroth training Kit -1 (L10 or L20)
▪ Indralogic software

Scope/Applications

Following are the major applications it can be used for

→Traffic control system

→industry security systems

→emergency systems
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Circuit Diagram
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Flow Chart
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Working Principle
The ladder logic is for automating signal transition from green to yellow for vehicles and pedestrians. The signal
starts of with cross green which is for 10s after which cross yellow signal is on for 4s. After this the main green
signal goes high for 20s which is then followed by main yellow which of 4s. During the main green or main yellow
signal if anyone presses the cross-walk button, in the next cycle the cross green is for 20s instead of 10. [ ]
Marks

Code and connections [ ] Marks


ShownCompleted
ErrorsExecuted
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Assessment for 5 marks (please tick one)


o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name &Signature


Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description

Objects are moving on a conveyor belt 1. When an empty box is detected, conveyor belt starts and 5pcs are
packed in a box. When box is filled, it is carried to the storage area via conveyor belt 2. Implement
automation of this process in PLC using Ladder Diagram programming language.

Problem Diagram

Problem Solution

• Use proximity switches to detect moving objects on the conveyor belt 1 and to detect an empty box
on conveyor belt 2.

• Use counter to count number of objects to be packed.

• Use timer such that when 5pcs are detected, conveyor runs for a while and stops when 5th object is
finally collected in the box. Assume time by calculating conveyor belt speed.

• When number of parts to be packed are detected timer is activated. When timer is over, it stops the
conveyor until next empty box is detected.

• Assuming time taken by the last 5th object is 2secs to be collected.


Department of Automation and Robotics
Department of Automation and Robotics

▪ Components required
▪ Rexroth training Kit -1 (L10 or L20)
▪ Indralogic software

Scope/Applications

Following are the major applications it can be used for

→Product Shipping

→Food industries

→Healthcare

Circuit Diagram
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Flow Chart

[ ] Marks
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Working Principle [ ] Marks


M2 is on at first. When the sensor S2 detects an empty box motor 2 stops and
motor 1 is turned on. On conveyor belt 1 there are objects which is detected
by sensor S1 when they pass by it. When the sensor detects 5 objects(i.e goes
high-low 5 times) M1 is stopped and 2s later M2 is again started where the
box is now full. This cycle keeps on repeating.

Code and connections [ ] Marks


ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name


&Signature
Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description
Whenever a part is placed on the drilling table, pneumatic clamper clamps the part and drilling process is
done. When drilling is done, clamper releases the part by releasing pressure. When another part is
detected, the process is repeated. Implement this in PLC using Ladder Diagram programming language.

Problem Diagram

Problem Solution
• Set lower and upper limit of a motor to stop and start the drilling process. This is done for precise
drilling and to obtain uniformity.
• Pressure operated clamping device is used to hold the objects firmly. This is operated by 20psig
air supply which is provided when an object is detected.
• Limit detection object is placed on the motor to detect upper and lower limit by the switches.
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Ladder diagram
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▪ Components required Rexroth training Kit -1 (L10 or L20)

Scope/Applications

Following are the major applications it can be used for

Circuit Diagram

[ ] Marks
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Flow Chart

[ ] Marks
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Working Principle [ ] Marks


When an object is placed on the drilling platform the part detector goes high.
Once the part detector is in high state the part is clamped by clamper. The
drilling process in then initiated by switching on motor which comes down
and performs drilling. Once the motor reaches the lower limit switch L1 the
motor start moving upward. This happens till the time the upper limit switch
is not triggered. Once the upper limit switch is triggered the motor stops, the
drill is turned off and the part is released from the clamper.

Code and connections [ ] Marks


ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name


&Signature
Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type

Problem Description
One open tank is installed in the plant of which liquid level is to be controlled. When level reaches the
Level Low, Outlet flow is blocked and inlet flow is allowed until high level is achieved. And when Level
High is detected, outlet flow is allowed and inlet flow is blocked.

Problem Diagram

Diagram of a single tank level controlplc-program-control-level-single-tank-01

Problem Solution
• To detect high and low level of liquid in the tank, two level switches are used which gives output
in digital terms, that is when corresponding levels are detected, it gives output high otherwise
remain low.
• To control level of this system, Single Acting piston valve can be used which has two states, either
fully open or fully close.
• Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the
side upper most position.
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• When this inputs are detected, output to Control Valve has to be latched in order to continuously
fill or empty the system.
• Master start/stop is also provided to shut down or start the entire process.

Logic Diagram:
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▪ Components required
▪ Rexroth training Kit -1 (L10 or L20)
▪ Indralogic software

Scope/Applications

Following are the major applications it can be used for

→ Water level indication


→ Dam water indication system
→Home water supply system.
Department of Automation and Robotics

Circuit Diagram [ ] Marks

Flow Chart [ ] Marks

Working Principle [ ] Marks


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Code and connections [ ] Marks
ShownCompleted
ErrorsExecuted

Assessment for 5 marks (please tick one)


o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name &Signature


Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: Exercise Type


Title: Vehicle control system

Problem Description

A vehicle shown in Figure below carries two different objects with different sizes. Initially, the vehicle waits at
the mid-point of the system.
• When a large-sized object is placed on the vehicle, it moves backward up to the 1st drop point. After
reaching to the point, vehicle waits until the object on is removed. Then, vehicle returns back to the mid-
point.
• When a small-sized object is placed on the vehicle, it moves forward up to the 2nd drop point. After
reaching to the point, vehicle waits until the object on is removed. Then, vehicle returns back to the mid-
point.
• During the movement, if an object comes in front of the vehicle stops with the help of a photo sensor, then a
buzzer is turned on to indicate the situation. When the object is removed, the vehicle continues its
movement.
• Red LED is on when the object is detected in front of the vehicle. The green LED indicates that the
vehicle reached 1st drop point, and yellow LED indicates that the vehicle reached to the 2nd drop point.
Construct a PLC logic for this system.

Equipment used: Rexroth PLC & Indralogic software

Assignment of input/output variables:

Truth Table & Boolean expression:


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Ladder Diagram:
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Department of Automation and Robotics

▪ Components required Rexroth training Kit -1 (L10 or L20)

Scope/Applications

Following are the major applications it can be used for

→Transport

→Vehicle shipment

→Vehicle manufacturing plants

Circuit Diagram [ ] Marks


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Flow Chart

[ ] Marks
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Working Principle [ ] Marks


The vehicle first needs to come to the middle point for the process to begin.
When the vehicle is at the mid-point the sensor LS5 goes high and the process
can start. When a heavy object is places on the vehicle both sensors LS3 and
LS4 go high and the vehicle will move backwards till LS1 goes high and the
green LED goes high. Once LS1 goes high the object will be removed from the
vehicle and the vehicle returns to the mid-point. When a light object is placed
on the vehicle only one of the sensors LS3 or LS4 goes high and the vehicle
moves forward till LS2 goes high. Once LS2 goes high the yellow LED also is
turned on and the object will be removed. Once the object is removed the
vehicle returns to mid-point. The vehicle stops in between if any obstacle is
there on the path which turns on the red LED. Once the object is removed the
vehicle moves starts moving again.
Code and connections [ ] Marks
ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name


&Signature
Department of Automation and Robotics

Name of the student: USN: 0 1 F E B A R

Lab: structured enquiry

Problem Description
( Station1 / Station2 / Station3)

Problem Diagram

Problem Solution
Department of Automation and Robotics

Logic Diagram:
Department of Automation and Robotics

Components required

Scope/Applications

Following are the major applications it can be used for

Circuit Diagram [ ] Marks

Flow Chart [ ] Marks


Department of Automation and Robotics

Working Principle [ ] Marks

Code and connections [ ] Marks


ShownCompleted
ErrorsExecuted
Assessment for 5 marks (please tick one)
o Poor → 0 ~ 2 marks
o Good → 3 ~ 4 marks
o Excellent → 5 marks
Note: Refer to rubrics for more details!

Conclusion and Remarks Faculty Name &Signature


Department of Automation and Robotics

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