Lab Report Control Engineering

Submitted By:

Waqar Ahmed
BSME01183097
SEC: C

Submitted To:
Sir Abdul Raheem

The University of Lahore

Department of Mechanical Engineering

The University of Lahore
 Experiment No 1

Objective
Introduction to Programmable Logic Control (PLC) & to study the communication between
PLC and computer.

Apparatus

PLC Trainer

Trainer Diagram
History
Industrial automation began long before PLCs. In the early to mid1900s, automation was usually
done using complicated electromechanical relay circuits. However, the amount of relays, wires
and space needed to create even simple automation was problematic. Thousands of relays could
be necessary to automate a simple factory process! And if something in the logical circuit needed
to be changed? Then it became very difficult.

Theory

PLC stands for Programmable Logic Controllers. They are basically used to control automated
systems in industries. They are one of the most advanced and simplest forms of control systems
which are now replacing hard-wired logic relays at a large scale.

Three typical experiments, include:

• elevator
• traffic light and
• manipulator
Combination of PLCs are designed to work on a factory floor; thus, they can withstand harsh
environments. Nevertheless, careful installation planning can increase sys-tem productivity and
decrease maintenance problems. The best location for a programmable controller is near the
machine or process that it will control, as long as temperature, humidity, and electrical noise are
not problems.

Placing the controller near the equipment and using remote I/O where possible will minimize
wire runs and simplify start-up and maintenance.
Need of PLCs
Hard wired panels are very time consuming to wired, debug and change
Advantages of PLCs
• Easy to modify input and output devices
• Easy to programmed and maintain
• Be able to function in industrial environment
• Flexible and have faster response time

Trainer board overview

The PLC trainer board has two basic modules.

I. Main board module with PLC.

II. Add on external board module

Base Board Module
The base board module is basically a platform where PLC can be interfaced with the Input/output
module as well as with the analog module. This board is distributed into four sub-modules, digital
input/output, relay controlled AC supply, expansion connector, and the analog module.

Digital Input module

This module consists of all the inputs of PLC. The inputs are connected with the LED’s which as
well as with pins.

Digital Output module

This module consists of all the outputs of the PLC. The outputs are connected with the LED’s.
The CPU of the PLC also has LED with shows the status of the input and the output.
Relay controlled AC supply
This is used to drive equipment that requires AC supply. The relay is controlled through PLC,
which further controls the AC supply.

Expansion Connector
This expansion connector is used to connect the add-on modules to the main board. All the digital
inputs and the outputs are linked with the expansion connector along with 24V power supply and
ground.

Analog module

The analog module is connected with the analog channel of the PLC. This module helps students
to connect analog devices with the PLC. Normally the CPU-224 provides two analog input
channels and one analog output channel. Devices such as AC motor, analog valves etc. can be
connected with the analog output channel while devices such `as Thermostat, RTD can be
connected with the analog input channel of the PLC.

Input Simulator

Input Simulator section is used to provide inputs to the PLC. This section consists of Toggle
inputs as well as momentary inputs. It is up to the user to use any of these inputs.

PLC Supply

PLC supply section is available to supply power to the relay common points. This is to facilitate
the user so that the user can use any supply at the output.

The Siemens CPU-224 has three common relay points known as L1, L2 and L3. These points are
used to supply power at the output. Using the patch cords connect these common points with the
PLC supply according to the demand
Procedure
Once the I/O modules are in place and their wires have been bundled, the wiring
to the modules can begin. The following are recommended procedures for I/O
wiring:

• Remove and lock out input power from the controller and I/O before any installation and
wiring begins.
•
• Verify that all modules are in the correct slots. Check module type and model number by
inspection and on the I/O wiring diagram. Check the slot location according to the I/O
address assignment document.

• Loosen all terminal screws on each I/O module.

• Locate the wire bundle corresponding to each module and route it through the duct to the
module location. Identify each of the wires in the bundle and check that they correspond
to that particular module.
• Starting with the first module, locate the wire in the bundle that connects to the lowest
terminal. At the point where the wire is at a vertical height equal to the termination point,
bend the wire at a right angle towards the terminal.

• Cut the wire to a length that extends 1/4 inch past the edge of the terminal screw. Strip
approximately 3/8 inch of insulation from the end of the wire. Insert the uninsulated end
of the wire under the pressure plate of the terminal and tighten the screw.

• If two or more modules share the same power source, jumper the power wiring from one
module to the next.

• If shielded cable is being used, connect only one end to ground, preferably at the rack
chassis. This connection will avoid possible ground loops. A ground loop condition
exists when two or more electrical paths are created in a ground line or when one or more
paths are created in a shield. Leave the other end cut back and unconnected, unless other-
wise specified
• Repeat the wiring procedure for each wire in the bundle until the module wiring is
complete.

• After all of the wires are terminated, check for good terminations by gently pulling on
each wire.

Conclusion
• The PLC is primarily used to control machinery. A program is written for the PLC
which turns on and off outputs based on input conditions and the internal program. In
this aspect, a PLC is similar to a computer. However, a PLC is designed to be
programmed once, and run repeatedly as needed. In fact, a crafty programmer could use
a PLC to control not only simple devices such as a garage door opener, but their whole
house, including switching lights on and off at certain times, monitoring a custom built
security system, etc. Most commonly, a PLC is found inside of a machine in an
industrial environment.

Comments:

• The application of the PLC and the new test process is an accurate example of a real-
world industrial setting and tests that might go along with implementing new procedures.
Rugged and designed to withstand vibrations, temperature, humidity, and noise.
• It have interfacing for inputs and outputs already inside the controller.
• PLCs are easily programmed and have an easily understood programming language
• The programmable logic controller's (PLC's) ability to support a range of communication
methods makes it an ideal control and data acquisition device for a wide variety of
industrial automation and facility control applications
Experiment No 1 (cont’d)

Communication between PLC and Computer:

Apparatus
Computer, PLC, FRC

Theory
Due to theirs constantly increasing performance and vast availability of PC applications for the
manufacturing process, the Personal Computer is being used more and more on the factory
shop floor in addition to the programming unit. To make PLC data available for the PC
application you will need a working and cost effective data link between PLC and PC. PC
programmers’ angle of vision, or we have some standard hardware connection to PLC and try
to analyze how we can create communication to PLC with effective using of this connection
properties.

Types of the hardware connections

Basically, without deep analyze of the different connections, we have three basic types of the
connections between PC and PLC.

Direct connection
It means connection between one PC to one PLC, all another connection via this gate is
impossible. Typical example of such connection can be straight connection via serial RS232
port.
Star connection
It means connection in network, where two or more slave nodes can be connected to one master
node, slave cannot communicate to other slaves, or connection between slaves is limited.
Typical example of such connection can be some realization of industrial networks (Prefab’s -
DP, Inter bus).

Parallel connection
It means connection between PCs and PLCs via some network so that each node can
communicate to each another in the same network. Typical example of such connection may
be (MPI, MELSEC-NET, and Ethernet).

Requirements to the communication

Simply, about requirements to the communication, we can say so we will need a working and
effective communication between PLC and PC.

• Working communication means possibility to read and to write data or group of data
(registers, memory, inputs, outputs) from/to PLC with good accuracy.
• Effective means easy programmable and fast read/write functions in Application
Program Interface (API).
If we analyze before mentioned problems, we can consider four basic requirements to the
communication:

• Access to data
• Accuracy
• Transmission speed
• Easy programmability
Procedure
Connecting Computer to the CPU

1. Set the DIP switches on the PC/PPI cable for the baud rate supported by your personal
computer. You should also select 11-bit and DCE if these options are supported by
your PC/PPI cable.

2. Connect the RS-232 end of the PC/PPI cable (labeled PC) to the communications port
of your computer, either COM1 or COM2, and tighten the connecting screws.
3. Connect the RS-485 end of the PC/PPI cable (labeled PPI) to the communications
port of the CPU, and tighten the connecting screws.

Verifying the default parameters for communications interface

You can verify the default parameters for your interface by following the steps below:

1. In the STEP 7-Micro/WIN 32 window, click the Communications icon, or select View >

Communications from the menu. The Communications Links dialog box appears.

2. In the Communications Links dialog box, double-click on the icon for the PC/PPI cable.
The Set the PG/PC Interface dialog box appears.
3. Select the "Properties" button. The Properties dialog box for the interface appears. Check
the properties to ensure that they are correct. The default transmission rate is 9,600 bauds (9.6
kbps).

Note: If the hardware that you are using does not appear on the list shown in "Set the PG/PC
Interface" dialog box, then you must install the correct hardware.

Completing the Communication Connection

Once you have installed STEP 7 –Micro/WIN 32 software on your PC and set up your PC
for communications with the PC/PPI cable, you are ready to complete the logical connection
to the S7-200 CPU. (If you are using a programming device (PG), STEP 7-Micro/WIN 32
is already installed.

Follow the steps below to communicate with the S7-200 CPU.

1. In the STEP 7 –Micro/WIN 32 screen, click the Communications icon, or select View

> Communications from the menu. The Communications Links dialog box appears and

shows that there are no CPUs connected.

2. Double click the refresh icon in the Communications links dialog box. STEP 7-
Micro/WIN 32 checks for any S7-200 CPUs (stations) that are connected, up to the highest
station address in the specified communication parameters. A CPU icon appears on the
Communications Links dialog box for each connected station.
3. Double click the CPU station icon that you want to communicate with. You will notice that
the communication parameters on the Setup Communications dialog box reflect the
parametersfor the selected station.

4. You are now communicating with the S7-200 CPU.

Conclusion
The PLC is primarily used to control machinery. A program is written for the PLC which
turns on and off outputs based on input conditions and the internal program. In this aspect, a
PLC is similar to a computer. However, a PLC is designed to be programmed once, and run
repeatedly as needed.In fact, a crafty programmer could use a PLC to control not only simple
devices such as a garage door opener, but their whole house, including switching lights on
and off at certain times, monitoring a custom built security system, etc. Most commonly, a
PLC is found inside of a machine in an industrial environment.

Comments
In order to program a PLC, communications must take place because the Programming
device(computer) must communicate with the PLC CPU in order to transfer the
configuration and control logic before the PLC can even begin to run.
The programmable logic controller's (PLC's) ability to support a range of communication
methods makes it an ideal control and data acquisition device for a wide variety of industrial
automation and facility control applications.
 EXPRIMENT No 2
Objective
To implement Flash Light using PLC Trainer

Apparatus
PLC Trainer, Computer, Siemens Micro Win Software, Connecting Wires.

Theory
PLC trainer is used to acquire practical knowledge of PLC interfacing with different
applications or modules. PLC trainer has two basic modules

• Main board module with PLC

• Add-on external board module

Main Board Module

Main board consists of a base board which is basically a platform where PLC can be
interfaced with I/O module as well as with the analog module. This board is further
distributed into four sub-modules, digital I/O, relay controlled AC supply, expansion
connector and the analog module.

DEPARTMENT OF MECHANICAL 16
ENGINEERING
Digital Input Module

This module consists of all the inputs of PLC. The inputs are connected with the LED’s
which as well as with pins.

Digital Output Module

This module consists of all the outputs of the PLC. The outputs are connected with the
LED’s. The CPU of the PLC also has LED which shows the status of the input and the
output.

Relay Controlled AC Supply

This is used to drive equipment that requires AC supply. The relay is controlled through
PLC, which further controls the AC supply.

Expansion Connector

This expansion connector is used to connect the add-on modules to the main board. All the
digital inputs and the outputs are linked with the expansion connector along with power
supply and ground.

DEPARTMENT OF MECHANICAL 17
ENGINEERING
Analog Module

The analog module is connected with the analog channel of the PLC. This module helps
students to connect analog devices with the PLC. Devices such as AC motor, analog valves
etc. can be connected with the analog output channel while devices such as thermostat,
RTD etc. can be connected with the analog input channel of the PLC.

Task
In this experiment you have to glow each output LED one at a time using timers. This
sequence should start with a pulse at I0.0 and should stop with a pulse at I0.1. Use the
following steps to implement this operation.

1. When a pulse comes at I0.0 latch a memory element M0.0.

2. Use M0.0 as an input a start a timer T37.
3. Use the timers (T37) value to glow Q0.0, Q0.1, and Q0.2 up to Q1.1.
4. At any point in time the operation should stop when a pulse comes at I0.1.

Flash light control Ladder Logic Program

DEPARTMENT OF MECHANICAL 18
ENGINEERING
DEPARTMENT OF MECHANICAL 19
ENGINEERING
DEPARTMENT OF MECHANICAL 20
ENGINEERING
Connections
1. Connect A.0 with I0.0
2. Connect A.1 with I0.0
3. Connect 24V with L1, L2 and L3.

Precautions
The following precaution should be adopted during practical:

1. Wires should be connected properly.

2. Program file should be relevant.

3. Hand should be dried during performance.

Conclusion
This experiment concludes that the PLC trainer works with different programs. Different
combinations of inputs and outputs can be had using different configurations.

Comments

In this experiment, we use PLC Trainer to implement the flash light by using Siemens Micro Win

Software. PLC is attached with computer and software is working in it and by using PLC

Trainer we implement flash light easily. And after this experiment we have to glow each output

LED one’s at a time using timer.

DEPARTMENT OF MECHANICAL 21
ENGINEERING
 Experiment No 3
Objective

To implement Logic Gates using PLC Trainer.

Apparatus
PLC Trainer, Integrated Circuit (IC), Connecting Wires

DEPARTMENT OF MECHANICAL 22
ENGINEERING
Theory

OR Gate

The OR gate performs logical addition commonly known as OR function. The output is
high when any one of the inputs is high. The output is low level when both the inputs are
low.

Symbol Truth Table

I0.0 I0.1 Q0.0

0 0 0

0 1 1

1 0 1

1 1 1

DEPARTMENT OF MECHANICAL 23
ENGINEERING
 Or Gate Ladder Logic Program

AND Gate

The AND gate performs a logical multiplication commonly known as AND function
.The output is high when both the inputs are high.

Symbol Truth Table

I0.0 I0.1 Q0.0

0 0 0

0 1 0

1 0 0

1 1 1

DEPARTMENT OF MECHANICAL 24
ENGINEERING
 And Gate Ladder Logic Program

NOR Gate

The NOR gate is a contraction of OR-NOT. The output is high when both inputs are low.
The output is low when one or both inputs are high.

Symbol Truth Table

DEPARTMENT OF MECHANICAL 25
ENGINEERING
 NOR Gate Ladder Logic program

XOR Gate

The output is high when any one of the inputs is high. The output is low when both the
inputs are low and both the inputs are high.

Symbol Truth Table

DEPARTMENT OF MECHANICAL 26
ENGINEERING
 Xor Gate Ladder Logic Program

NOT Gate

The NOT gate is called an inverter. The output is high when the input is low. The output is
low when the input is high.

Symbol Table

DEPARTMENT OF MECHANICAL 27
ENGINEERING
 Inverter Gate Ladder Logic Program

Connections

Connect B.0 with I0.0

Connect B.1 with I0.0
Connect 24V with L1, L2 and L3.

Procedure
• Place gate on PLC Trainer board.
• Connect input and output according to the truth table.
• Switch on the circuit.
• Observe the output and verify the truth table.

DEPARTMENT OF MECHANICAL 28
ENGINEERING
Conclusion

There are many control situations requiring actions to be initiated when a certain combination of logic
functions conditions is realized in a PLC. Say, for an automatic drilling machine, there might be the
condition that the drill motor is to be activated when the limit switches are activated that indicate the
presence of the workpiece and the drill position as being at the surface of the workpiece. Such a situation
involves the AND logic function, condition A AND condition B having both to be realized for an output
to occur. This activity is a consideration of such logic functions.

Comments

Logic Gates act as switches in a circuit that performs logical operation. In this experiment, we study the
different logic gates and draw truth tables and implementation of logic gates by using PLC Trainer and
verify the truth table. Logic gates are used in microprocessors, microcontrollers, embedded
system applications, and in electronic and electrical project circuits.

DEPARTMENT OF MECHANICAL 28
ENGINEERING
 Experiment No 4

Objective
To control temperature by using temperature control module through PLC.

Apparatus
PLC, Computer System, Temperature control trainer, FRL cable.

Theory
In general there are 2 types of modules utilized in the temperature control. (1)
Voltage; It provides a value ranging from 0-10V DC signal to PLC with respect
to the temperature and (2) Current; It works on the same principle but it just displays
the output in amperes with respect to the temperature.

Input pin voltage: Analog input when particular input is activated.

Output pin voltage: 12V DC when particular O/P is activated from PLC.
Power supply: From PLC trainer
Interface: 40 pin FRC cable needed with PLC
S/N MODULE PLCTRAINER

1 Heater of Voltage Section Q0.0

2 Fan of Voltage Section Q0.1

3 Analog output of Voltage Section A+

4 Heater of Current Section Q0.3

5 Fan of Current Section Q0.4

6 Analog output of Current Section NON

Procedure

First of all make sure that the PLC trainer is switched off and make sure CPU relay toggle switch
is at the stop position. First connect the computer with the PLC trainer by the aid of the VGA
cable. Then by the help of 3 wires connect the +24V PLC supply to relay output 1L, 2L, 3L. Once
the connections are made, use the FRC cables to connect the PLC trainer to the temperature control
unit. Now using the set of wires we connect the heater with the PLC input/output control at Q0.0
terminal and the voltage from the sensor to the analog input to PLC. Turn on the PLC trainer power
button and then by the help of the SIEMENS step 7 program, download the data block and by the
aid of the VGA cable transfer the data to the PLC trainer. Turn the CPU relay toggle switch to run
and we can see the results, that the heater shows the output value in form of voltages with
temperature being the input. The fan starts to spin at a certain value of voltage and it further rotates
faster as the voltage goes up. We can repeat this experiment for current as well.
 Conclusion
As a conclusion we can state that temperature control is a method in which we don’t really need to
Procedure
directly measure the temperature of a certain body as we can also measure it by various other
methods. The current and the voltage produced has a direct relation with the temperature as was
seen in the experiment that the value of voltage was greater for the greater values of temperatures
and vice versa.

Comments

Initially the PLC trainer shows no activity when the power is provided. It remains the same between
the values 0-0.46. At 0.47 bulb indicating heating starts to blink, and at 0.49 the fan starts to spin
slowly and then comes to a stop at 0.5, and after a brief interval it starts to spin at a much faster rate
starting at 0.51 gradually going onto 0.52 and so on. All of these mentioned results indicate that
voltage with temperature are in fact directly proportional.
 EXPERIMENT No 05
Objective
Procedure
To control Traffic Signal Module by using PLC Trainer

Apparatus
PLC Trainer, Traffic Light Control Trainer, FRC cable, Connecting Wires

Theory
About the Module

There is a need for engineers and technicians to be familiar with PLCs and to be able to
program. The need to be connected to a physical system and be programmed correctly if
they are to provide the quality of monitoring and control required.

Trainer diagram

Traffic lights, which may also be known as stoplights, traffic lamps, traffic signals, stop-
and-go lights, robots or semaphore, are signaling devices positioned at road intersections,
pedestrian crossings and other locations to control competing flows of traffic. Traffic lights
have been installed in most cities around the world. They assign the right of way to road
users by the use of lights in standard colors (red - yellow - green), using a universal color
code (and a precise sequence to enable comprehension by those who are color blind). In
China, there were unsuccessful attempts to change the meaning of "red" to "go" during the
Cultural Revolution.

DEPARTMENT OF MECHANICAL 34
ENGINEERING
 Types of Traffic Light

• Single aspects
Procedure
• Dual aspects
• Three or more aspects

Pedestrian and cyclist crossing lights

• Pelican crossing
• Puffin Crossings
• Toucan Crossings
• Facilities for blind or partially sighted pedestrians
• Zebra Crossing
• Pedestrian Refuges
• Reducing pedestrian delays

Standards around the world

European Standard

The European approach to a signalized crossing is use dual or more rarely, a triple aspect.
With a blackened out lens of a pictogram pedestrian. For cyclist, the same approach is used
with the lens blackened out for a bicycle frame. It is not uncommon to see lenses with both
symbols on them.

Light Sequence

Green: Cross with caution

Amber (if used): Same value as a flashing green Flashing Green: Continue to cross if
already in the intersection. Do not start to cross.

Red: Do not cross

North American Standard

Green or White (Walking Person or WALK); Cross with caution Flashing Red/Orange
(Stop hand or DON'T WALK); Continue to cross if already in the intersection. Do not start
to cross Red/Orange; do not cross.

DEPARTMENT OF MECHANICAL 35
ENGINEERING
 Asia
Green: Cross
Procedure
Yellow: Cross if already in intersection, otherwise do not (however by law, you are
allowed to cross)
Red: Do not cross
Green (sometimes blue) Arrow: Turn only the direction the arrow points

Pedestrians
Green man: Walk
Flashing Green Man: Cross if already in intersection, otherwise do not
Red Man: Do not cross

Procedure
Specifications
Interface: 40 pin FRC cable needed with PLC.
Input pin voltage: 24VDC when particular I/P is activated from PLC.
Output pin voltage: 24VDC when particular O/P is activated from PLC.
Power supply: From PLC trainer.

Pin Connections

S/ N MODULE PLC O/P

TRAINER

1 North RED/GREEN Q0.0

2 North YELLOW Q0.1

3 South RED/GREEN Q0.2

4 South YELLOW Q0.3

5 East RED/GREEN Q0.4

DEPARTMENT OF MECHANICAL 36
ENGINEERING
 6 East YELLOW Q0.5
Procedure 7 West RED/GREEN Q0.6

8 West YELLOW Q0.7

The ladder program given with this has to be first downloaded in the PLC and then run; the
apparatus is connected with inputs and outputs of PLC through 40 pin FRC cable. The red
and green light of every signal is connected to the same output i.e. if output is low green
light will glow and if output is high then red light will glow.

Traffic light control Ladder Logic Program

DEPARTMENT OF MECHANICAL 37
ENGINEERING
Procedure

DEPARTMENT OF MECHANICAL 38
ENGINEERING
Conclusion
This experiment is about controlling a traffic light using PLC, and ladder logic language chose to
program the PLC. The PLC used is from Siemens Company.
From this experiment, we controlled the Traffic Light Module by using PLC Trainer. The system is a
four-way junction traffic light, need to be controlled using Siemens. The system has four main
functions. The program controlling the junction and providing these four junctions was written by ladder
logic language. All these functions achieved by using the developed program with the PLC.

Comments

At the end, the aims of this experiment is to program a PLC to control a traffic light and allowed the
pedestrian to pass the junction safely, and provide an algorism to control the junction in case of high
vehicles density, and program a priority function allowed authorized emergencies to pass the junction in
fast way.

DEPARTMENT OF MECHANICAL 28
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

Experiment No 06

Objective

To control water level by using PLC.

Apparatus

PLC, Water Level Control Trainer, Computer System, FRL Cable

Trainer diagram

DEPARTMENT OF MECHANICAL 40
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

Theory
There is a need for engineers and technicians to be familiar with PLCs and to be able to
program. The need to be connected to a physical system and be programmed correctly if they
are to provide the quality of monitoring and control required. The experience and skill to be
able to achieve this can best be obtained through practical hands-on use of a PLC connected
to a real system. The object is to connect and program an external programmable logic
controller to monitor and control the level of water in a tank system. Water level
management using PLC is design to control the level of water and avoid wastage of water
in the tank. The system has an automatic pumping system attach to it. We are controlling the
water level by using PLC, Sensors and motor. PLCs communicate, monitor and control
automated processes like assembly lines, machine functions, or robotic devices. PLC's act
as the physical interfaces between devices on the plant or manufacturing floor and a
SCADA or HMI system.

Procedure
• First the ladder program given with this has to be first downloaded in the PLC.
• For downloading procedure of ladder program please refer operating manual of
PLC trainer
• After this run the apparatus is connected with inputs and outputs of PLC through 40
pin FRC cable.
• The level of tank will rise as the analog voltage will increase; this means that the
analog voltage will be controlled by the PLC.
• There are two pumps and two valves which mean that the speed of rise and fall will
vary in accordance with the situation.
• The level of tank should be maintained at half or ¾ of the total.

Specification:

Interface: 40 pin FRC cable needed with PLC.

Digital Input pin voltage: 24VDC, particular I/P is activated from PLC

Digital Output pin voltage: 24VDC, particular O/P is activated from PLC
Level Indicator: Analog voltage from PLC

Power supply: From PLC trainer

DEPARTMENT OF MECHANICAL 41
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

Pin Connections

DEPARTMENT OF MECHANICAL 42
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

DEPARTMENT OF MECHANICAL 43
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

Water level control Ladder Logic Program

DEPARTMENT OF MECHANICAL 44
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

DEPARTMENT OF MECHANICAL 45
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

DEPARTMENT OF MECHANICAL 46
ENGINEERING
 LAB MANUAL
CONTROL ENGINEERING

Conclusion
In this activity, aim of automating the level control process was readily achieved. No human
supervision was necessary. The system did not use float sensors yet denoted the accurate
level. Hence the short coming of the float sensors that is unwanted vibrations and high cost
can easily overcome through PLC.

Comments
After performing this experiment we came to know the working of water level control apparatus
by using PLC. As we connect the wires and runs the apparatus by using computer software
SIMENS then the PLC is in run state and then water level in the water tank drops as we open
the output valve 1 and close the output valve 2 when water level reaches its lower level and we
close the output valve 1 as well as output valve 2 the input pump 2 in on and again the water
level is rises in the water tank and we can control this cycle.

DEPARTMENT OF MECHANICAL 47
ENGINEERING
 EXPRIMENT NO 07
Objective
To study and operate the Elevator Control by PLC Trainer

Apparatus
PLC Trainer, Elevator Control Trainer, Computer System, FRL Cable

Trainer Diagram

Theory

An elevator (or lift in British English) is vertical transport equipment that efficiently moves
people or goods between floors (levels, decks) of a building, vessel or other structure. In the
17th century the prototypes of elevators were located in the palace buildings of England and
France. In the middle 1800s, there were many types of crude elevators that carried freight.
Most of them ran hydraulically.
The first hydraulic elevators used a plunger below the car to raise or lower the elevator. In
1882, when hydraulic power was a well-established technology, a company later named
the London Hydraulic Power Company was formed. It constructed a network of high
pressure mains on both sides of the Thames which, ultimately, extended to 184 miles and
powered some 8,000 machines, predominantly lifts (elevators) and cranes.

Different types of elevator are Freight elevators, stage lifts, Vehicle elevators, Aircraft
elevators, Residential elevator.

DEPARTMENT OF MECHANICAL 48
ENGINEERING
 About the module

There is a need for engineers and technicians to be familiar with PLCs and to be able to
program. The need to be connected to a physical system and be programmed correctly if
they are to provide the quality of monitoring and control required.

The experience and skill to be able to achieve this can best be obtained through practical
hands-on use of a PLC connected to a real system.

Elevator control (ST-2422) enables students and practicing engineers to gain invaluable
practical experience of the principles and application of programmable logic controllers.

The object is to connect and program an external programmable logic controller to monitor
and control the Elevator system. Elevator doors are shown with dot-matrix and the floor
indicator is seven-segment display. Call switches and floor switches are used as inputs.

Role of PLC Trainer in Motion Control

PLCs Used for Motion Control. They are capable of handling large amounts of I/O for
tasks like timing and counting, and other sequential machine logic.

PLCs are computer, they can be programmed to interface directly with the drives to control
motion axes. The degree of sophistication involves involved depends on the processing
capabilities of the PLC. Low-end, commodity PLCs are best suited to simpler
motion¾start, stop, simple motion profiles.

In contrast, the latest generation of high-end PLCs can perform tasks that used to be the
province of standalone motion controllers, like linear interpolation and some types of
coordinated motion
DEPARTMENT OF MECHANICAL 49
ENGINEERING
Diagram

Specifications

Interface: 40 pin FRC cable needed with PLC.

Input pin voltage: 24VDC when particular I/P is activated from PLC.

Output pin voltage: 24VDC when particular O/P is activated from PLC.

Power supply : From PLC trainer

DEPARTMENT OF MECHANICAL 50
ENGINEERING
 Pin Connections

S/N Module PLC Trainer

1 Seven-Segment Output 1 Q 0.0

2 Seven-Segment Output 2 Q 0.1

3 Ground Floor Door Q 0.2

4 First Floor Door Q 0.3

5 Second Floor Door Q 0.4

6 First Floor Indicator Q 0.5

7 Second Floor Indicator Q 0.6

8 Third Floor Indicator Q 0.7

9 Elevator Up Indicator Q 1.0

10 Elevator Down Indicator Q 1.1

11 First Floor Call Switch 10.0

12 Second Floor Call Switch 10.1

13 Third Floor Call Switch 10.2

14 First Floor Destination Switch 10.3

15 Second Floor Destination Switch 10.4

16 Third Floor Destination Switch 10.5

Procedure
The ladder program given with this has to be first downloaded in the PLC and then run;
the apparatus is connected with inputs and outputs of PLC through 40 pin FRC cable.

DEPARTMENT OF MECHANICAL 51
ENGINEERING
 Elevator control Ladder Logic Program

DEPARTMENT OF MECHANICAL 52
ENGINEERING
DEPARTMENT OF MECHANICAL 53
ENGINEERING
DEPARTMENT OF MECHANICAL 54
ENGINEERING
DEPARTMENT OF MECHANICAL 55
ENGINEERING
DEPARTMENT OF MECHANICAL 56
ENGINEERING
DEPARTMENT OF MECHANICAL 57
ENGINEERING
DEPARTMENT OF MECHANICAL 58
ENGINEERING
DEPARTMENT OF MECHANICAL 59
ENGINEERING
Advantages of PLC Trainer
• Small in size, with light weight, it could be connected to other training bench for the
expansion.
• It provides a simulation to help students understand the working principle of the
elevator.
• Safety guarantee: all power line of components and signal lines are based on safety
sockets on board with insulating sheath.

Practical Applications

• Time based Motor Control

• Motor Control using Sensors

• Logic “AND” Motor Control

• Traffic Light with Timers / Sequencer

Precautions
• Check the connections accordingly.
• Hands should not be wet.
• Operate the PLC systematically.

Comments

• Elevator is a complex machine-electronic transportation system. It covers a wide

range of subjects to improve the move speed, landing accuracy, comfort and
safety and provides convenience for people.

• This elevator illustrates the principles of PLC interfacing & control based on a
real-life and easily identified application.

• The internal motor speed controller has both logic and analogue interfaces such
that a basic PLC with minimal digital I/O can be used to implement control.

• PLCs are easily programmed and have an easy understood programming

language.
 LAB MANUAL

CONTROL ENGINEERING

EXPERIMENT 12

OBJECTIVE:

b). To demonstrate the relation between temperature and electric potential using given
temperature sensor.

APPARATUS:

•
Type K thermocouple.

• Multi-meter
• Heater (for hot water)
 LAB MANUAL

CONTROL ENGINEERING

TRAINER DIAGRAM:
 LAB MANUAL

CONTROL ENGINEERING

THEORY

The principle of operation is on the See beck effect. A temperature gradient along a
conductor creates an EMF. If two conductors of different materials are joined at one point,
an EMF is created between the open ends which are dependent upon the temperature of the
junction. As T1 increases, so does V. The EMF also depends on the temperature of the open
ends T2.

The junction is placed in the process; the other end is in iced water at 0C. This is called the
reference junction.

Chromel Alumel: (Type K, color coded yellow and red) generates about 40 µV/°C (22 µV/°F).
The Alumel wire is magnetic. Junctions can be made by welding or soldering, but high
temperature silver-solders and special fluxes must be used Chromel-Alumel thermocouples
generate electrical signals, while the wires are being bent, and should not be used on
vibrating systems, unless strain relief loops can be provided.

*Type K is made of Chromel / Alumel, It has a Useful range of temperature is -300F to1800F.
The Maximum temperature 2300F.
 LAB MANUAL

CONTROL ENGINEERING

PROCEDURE

1. Fill the water heater with clean water and connect the cord. Immerse the mercury in
glass thermometer in the water. Take out a type k thermocouple sensor.

2. Connect the plain connecting lead between the two sockets at the side of the mV
indicator. Observe that the mV indicator reads 0mV.

3. Remove the plain connecting leads from the sockets and substitute a type k
thermocouple, placing the plugs in the respective sockets.

4. Put the thermocouple probe in the water heater. Care should be taken not to
submerge the whole probe in the water.

5. Switch on the power to the water heater. As the temperature of the water increases
indicated by the mercury in glass thermometer, observe that the voltage reading on
the mV indicator increases. At specific intervals, record the temperature indicated on
the mercury in glass thermometer together with the voltage reading. Continue the
experiment until the water boils. This experiment demonstrates that voltage is
produced by a pair of dissimilar metals in contact, the magnitude of the voltage being
dependent on the temperature.
 LAB MANUAL

CONTROL ENGINEERING

OBSERVATIONS AND CALCULATIONS

Type K Thermocouple

Temperature (°C) Voltage (mV)

30 0.4
40 0.8
50 1.2
60 1.6
70 2.1
80 2.4
90 3.0
100 3.1
 LAB MANUAL

CONTROL ENGINEERING

3.5

3
Temperature Vs Voltage
2.5
Voltage (mV)

1.5

0.5

0
0 20 40 60 80 100 120
Temperature (▫C)
 LAB MANUAL

CONTROL ENGINEERING

PRECAUTIONS

• Precautions should be taken to shield thermocouple wires from all harsh

atmospheres and liquids.

• Avoid mechanical stress and vibration which could strain the wires.

• Avoid steep temperature gradients.

• Try to use the thermocouple wire well within its temperature rating.

• Use extension wire only at low temperatures and only in regions of small gradients.

• Keep an event log and a continuous record of thermocouple resistance.

 LAB MANUAL

CONTROL ENGINEERING

COMMENTS/CONCLUSIONS:

• Consuming only microwatts of power, it avoids self-heating issues that undermine the
accuracy of traditional resistive sensor solutions.
• The thermal and electric currents obey similar laws. Heat energy flows by virtue of
temperature differences that correspond to voltages (= potential differences) in the
electric case
• From the graph we conclude the linear behavior of the voltage and temperature as the
temperature increases the voltage also start increasing
• There is a deviation little bit in the graph that’s is due to loses and system is not ideal
 EXPERIMENT 13

OBJECTIVE:

To demonstrate the use of wet and dry bulb (whirling) hygrometer, in determining relative
humidity.

APPARATUS
Hygrometer

THEORY:

A hygrometer is an instrument used for measuring the moisture content in the atmosphere.
Humidity measurement instruments usually rely on measurements of some other quantity such
as temperature, pressure, mass or a mechanical or electrical change in a substance as moisture
is absorbed. By calibration and calculation, these measured quantities can lead to a measurement
of humidity. Modern electronic devices use temperature of condensation (the dew point), or
changes in electrical capacitance or resistance to measure humidity differences.

PROCEDURE:

The whirling Hygrometer uses wet and dry bulb thermometers to determine the humidity
effect.

1. Remove the whirling hygrometer from the storage location.

2. Check that the wick connecting reservoir to the wet bulb is in good condition and in
contact with the thermometer bulb.
3. Ensure that the water reservoir is filled with clean water by removing filling plug.
Replace the filling plug.
4. To take the reading, hold the tubular handle of the hygrometer in one hand so that the
frame is free to rotate. Whirl the hygrometer around for a period of 30 seconds to 1
minute to allow wet bulb reading to stabilize.
5. Immediately record the temperatures indicated by dry and wet bulb thermometers. The
dry bulb thermometer indicates the ambient air temperature. The wet bulb thermometer
indicates the reduced temperature due to the effect of evaporation.
6. The relative humidity can be determined using Psychometric Chart.
7. If Hygrometer Tables are available, the humidity may be checked for the readings
obtained. The dew point and vapor pressure may also be determined using such tables.
OBSERVATIONS AND CALCULATIONS:

Temperature
Hygrometer °C
Type Room Ambient
Wet Bulb
16 13

Dry Bulb
19 18
PRECAUTIONS:

• Measurements should be taken very precisely.

• There must be minimum delay in taking reading of the both thermometers.

• Rotate the Hygrometer carefully.

• Do not let the dry bulb get wet, otherwise there will be increase in chances of errors.

• There must be no external Heating/Cooling source near Hygrometer to avoid improper

readings and calculations.

CONCLUSION:

We have come to know that the Humidity Factor in air (room temperature) can easily be
calculated by Hygrometer. Not only Humidity, but other parameters can also be found by the
use of this device.

COMMENTS:
 • Relative humidity is a measurement used to describe water vapor in the air. In general, it
expresses how close the air is to saturation.
• In this activity, hygrometer (Model 116) and psychrometer table are incorporated to
determine the relative humidity of air.
• It has been observed in this session that temperature decrease on the wet-bulb
thermometer and feels cool as liquid water on it evaporates (a process that occurs at a
sub-ambient wetbulb temperature that is dependent on relative humidity).
• Relative humidity was observed different at the different places of the lab.
 EXPERIMENT NO 14

OBJECTIVE

To determine the characteristic of the differential transformer as position transducer by

Process Control Training System

APPARATUS:

➢
Process Control Training System (DL 2314)
➢
➢
Digital Multimeter
Set of leads
Voltmeter

DEPARTMENT OF MECHANICAL ENGINEERING 97

 THEORY:

A Linear Variable Differential Transformer, or LVDT for short, is an electromechanical

position transducer (sensor) which provides accurate and friction less positional feedback
information about the linear mechanical position of an external force or object. As its name
suggests, the linear variable differential transformer works on the same principle as the AC
transformer but instead of supplying a load current or high voltage, it uses basic transformer
principles of mutual inductance to measure linear movement.In our tutorial about mutual
inductance we saw that when two or more long solenoidal coils are wound together onto the
same former or core, the magnetic flux produced by anyone of the coils links to the others with
the magnetic flux produced by the driving coil aiding or opposing the flux produced by the
other coils. Thus any AC current flowing through one coil will induce a voltage into the other
magnetically-coupled coils, and this is the basic principle of the LVDT
Rotary Variable Differential Transformer
Potentiometer-based transducers are easy and simple to use but resistive potentiometers suffer
from mechanical wear due to contact between the sliding wiper and its resistive track as well as
producing electrical noise as the wiper slides along and bounces over the resistive track. Rotary
variable differential transformers operate on the same basic principle as the previous LVDT,
except that a rotary ferromagnetic core is used.
Here the transformers core is not straight, but forms part of a circle (the same as for toroidal
transformers) which allows the sensor to measure the angular displacement of the attached
object. The ferromagnetic moveable core of the RVDT couples with the secondary coils based
on its angular position, thus allowing for the measurement of angular displacement.
The electrical operation of an RVDT is exactly the same as for the linear version in that it is
based on altering the mutual inductance coupling between primary and secondary coils. The
primary coil is still driven by an AC excitation current (typically in the kilo-hertz, kHz range),
which induces an AC current in each of the series-opposing secondary coils. The movable
ferromagnetic core rotates instead of slides within the body.
One of the main disadvantages of the rotary variable differential transformer is that it can only
operate over a relatively narrow range of angular rotation. Although in theory they are capable
of continuous rotation and speed measurement, typical RVDT’s output is only truely linear over
a range of about ±60o or less from their zero null position (0o) due mainly to limitations in the
magnetc coupling. Beyond this the output signal starts to become nonlinear and less useful.
Also their sensitivity is much smaller that their linear cousins producing about 2 to 5mV per
degree of rotation.

INTRODUCTION
LVDTs are robust, absolute linear position/displacement transducers; inherently frictionless,
they have a virtually infinite cycle life when properly used. As AC operated LVDTs do not
contain any electronics, they can be designed to operate at cryogenic temperatures or up to
1200°F (650°C), in harsh environments, under high vibration and shock levels. LVDTs have
been widely used in applications such as power turbines, hydraulics, automation, aircraft,
satellites, nuclear reactors, and many others.
The LVDT converts a position or linear displacement from a mechanical reference (zero, or
null position) into a proportional electrical signal containing phase (for direction) and
amplitude (for distance) information. The LVDT operation does not require an electrical
contact between the moving part (probe or core assembly) and the coil assembly, but
instead relies on electromagnetic coupling.

OPERATION

The linear variable differential transformer has three solenoid coils placed end-to-end
around a tube. The center coil is the primary, and the two outer coils are the top and
bottom secondary’s. A cylindrical ferromagnetic core, attached to the object whose position
is to be measured, slides along the axis of the tube. An alternating current drives the
primary and causes a voltage to be induced in each secondary proportional to the length of
the core linking to the secondary. The frequency is usually in the range 1 to 10 kHz.

DEPARTMENT OF MECHANICAL ENGINEERING 98

As the core moves, the primary's linkage to the two secondary coils changes and causes the
induced voltages to change. The coils are connected so that the output voltage is the
difference (hence "differential") between the top secondary voltage and the bottom
secondary voltage. When the core is in its central position, equidistant between the two
secondary’s, equal voltages are induced in the two secondary coils, but the two signals
cancel, so the output voltage is theoretically zero. In practice minor variations in the way in
which the primary is coupled to each secondary means that a small voltage is output when
the core is central.

When the core is displaced toward the top, the voltage in the top secondary coil increases
as the voltage in the bottom decreases. The resulting output voltage increases from zero.
This voltage is in phase with the primary voltage. When the core moves in the other
direction, the output voltage also increases from zero, but its phase is opposite to that of
the primary. The phase of the output voltage determines the direction of the displacement
(up or down) and amplitude indicates the amount of displacement. A synchronous detector
can determine a signed output voltage that relates to the displacement.

The LVDT is designed with long slender coils to make the output voltage essentially linear
over displacement up to several inches (several hundred millimeters) long.

The LVDT can be used as an absolute position sensor. Even if the power is switched off, on
restarting it, the LVDT shows the same measurement, and no positional information is lost.
Its biggest advantages are repeatability and reproducibility once it is properly configured.
Also, apart from the uni-axial linear motion of the core, any other movements such as the
rotation of the core around the axis will not affect its measurements.

Because the sliding core does not touch the inside of the tube, it can move without friction,
making the LVDT a highly reliable device. The absence of any sliding or rotating contacts
allows the LVDT to be completely sealed against the environment.

LVDTs are commonly used for position feedback in servomechanisms, and for automated
measurement in machine tools and many other industrial and scientific applications.

DEPARTMENT OF MECHANICAL ENGINEERING 99

PROCEDURE:

1. Connect, trough leads, bush No.1 of the level sensor to bush No.1 of the
correspondent interface and bush No.2
2. Insert a terminal of a digital volt meter, set in dc, in bush No.13 of the level interface
and other one in the earth bush
3. Connect bush No.18 of the linear driver to the bush of the set point 1, bush No.19 to
bush No.19 and bush No.20 to bush No.20
4. Press the main switch (ON)
5. Start the pump regulating the voltage on set point 1 and bring the level of the water
in the process tank to 8cm
6. Once reached the level, stop the pump setting to 0V the voltage value of set point 1
7. Gradually decrease the level of water in the tank by turning counter-clockwise the
knob needle valve and/or the knob drain valve, back to 6
8. Verify that the voltage value, read the volt meter, corresponds to 0V, otherwise
regulate the offset trimmer until you obtain the desired value: in this way you have
fixed the minimum working point of the level sensor
9. Starting the pump, increase the level of water to 16cm
10. Stop the pump and verify that the voltage value corresponds to 10V, otherwise
regulate the gain trimmer until you obtain the desired value
11. Verify that the voltage and level values are correct by repeating the step from No.7
12. Slowly drain the tank until you reach all the level values shown in Table 1.1 and write
down, for each level, the corresponding voltage value
13. Put OFF the main switch
14. Remove all the connections
15. Represent the characteristic of the level sensor

DEPARTMENT OF MECHANICAL ENGINEERING 100

OBSERVATIONS AND CALCULATIONS

Level (cm) 15 14 13 12 11 10 9 8 7 6

Voltage (v)
9 8 7 6.6 5 4 3 2 1 0
 Voltage Vs Level

10
9
8
7
6
Level (cm)

5
4
3
2
1
0
0 2 4 6 8 10 12 14 16
Series1 Series2 Series3
Voltage (V)

With the help of this experiment we become able to know the characteristics of
LVDT. We use level sensor to study these characteristics. When we change the
level of the fluid and we see that there is a variation of voltage in LVDT. The
variation of voltage is very quick, there is no time lag. This means the LVDT has a
good accuracy. So we can use LVDTs to measure the leaner displacement.

PRECAUTION

• Connect the wires properly

• See the liquid level correctly

COMMENTS
LVDT is to alter the linear motion to an electrical signal, whereas RVDT is used to
calculate the angular displacement
To determine a liquid level using a submersible pressure transducer, take a
continuous pressure measurement from the tank bottom or measurement point where
the transducer diaphragm is placed.By measuring liquid density, liquid height can be
accurately measured.
Mostly that error generating for example human error eye contact,time deference
and etc.
 EXPERIMENT 15

OBJECTIVE:

A. To measure the static gain

B. To determine the diagram of the process characteristic.

APPARATUS:

Process Control Training System

Digital Multimeter
Set of Leads

THEORY:

LVDT is an acronym for Linear Variable Differential Transformer. It is a common type of

electromechanical transducer that can convert the rectilinear motion of an object to which it is
coupled mechanically into a corresponding electrical signal.
Rotary Variable Differential Transformer or RVDT is an inductive transducer which converts
angular displace to an electrical signal. Unlike LVDT, the input of this transducer is differential
value of rotary variable i.e. angular rotation (dƟ) to generate voltage output.
INTRODUCTION
An LVDT (linear variable differential transformer= is an electromechanical sensor used to
convert mechanical motion or vibrations, specifically rectilinear motion, into a variable electrical
current, voltage or electric signals, and the reverse. Actuating mechanisms used primarily for
automatic control systems or as mechanical motion sensors in measurement technologies. The
classification of electromechanical transducers includes conversion principles or types of output
signals.
In short, a linear transducer provides voltage output quantity, related to the parameters being
measured, for example, force, for simple signal conditioning. LVDT Sensor devices are sensitive
to electromagnetic interference. Reduction of electrical resistance can be improved with shorter
connection cables to eliminate significant errors. A linear displacement transducer requires three
to four connection wires for power supply and output signal delivery.

Physically, the LVDT construction is a hollow metallic cylinder in which a shaft of smaller
diameter moves freely back and forth along the cylinder’s long axis. The shaft, or pushrod, ends
in a magnetically conductive core which must be within the cylinder, or coil assembly, when the
device is operating.

OPERATION
Linear variable differential transformers (LVDT) are used to measure displacement. LVDTs
operate on the principle of a transformer. An LVDT consists of a coil assembly and a core. The
coil assembly is typically mounted to a stationary form, while the core is secured to the object
whose position is being measured. The coil assembly consists of three coils of wire wound on the
hollow form. A core of permeable material can slide freely through the center of the form. The
inner coil is the primary, which is excited by an AC source as shown. Magnetic flux produced by
the primary is coupled to the two secondary coils, inducing an AC voltage in each coil. The
frequency is usually in the range 1 to 10 kHz.
The main advantage of the LVDT transducer over other types of displacement transducer is the
high degree of robustness. Because there is no physical contact across the sensing element, there
is no wear in the sensing element.
An LVDT measures displacement by associating a specific signal value for any given position of
the core. This association of a signal value to a position occurs through electromagnetic coupling
of an AC excitation signal on the primary winding to the core and back to the secondary
windings. The position of the core determines how tightly the signal of the primary coil is
coupled to each of the secondary coils. The two secondary coils are series-opposed, which means
wound in series but in opposite directions. This results in the two signals on each secondary
being 180 deg out of phase. Therefore phase of the output signal determines direction and its
amplitude, distance.
The core causes the magnetic field generated by the primary winding to be coupled to the
secondary’s. When the core is centered perfectly between both secondary’s and the primary, as
shown, the voltage induced in each secondary is equal in amplitude and 180 deg out of phase.
Thus the LVDT output (for the series-opposed connection shown in this case) is zero because the
voltages cancel each other.
Displacing the core to the left causes the first secondary to be more strongly coupled to the
primary than the second secondary. The resulting higher voltage of the first secondary in relation
to the second secondary causes an output voltage that is in phase with the primary voltage.

Likewise, displacing the core to the right causes the second secondary to be more strongly
coupled to the primary than the first secondary. The greater voltage of the second secondary
causes an output voltage to be out of phase with the primary voltage.
To summarize, “The LVDT closely models an ideal zeroth-order displacement sensor structure
at low frequency, where the output is a direct and linear function of the input. It is a variable-
reluctance device, where a primary center coil establishes a magnetic flux that is coupled through
a center core (mobile armature) to a symmetrically wound secondary coil on either side of the
primary. Thus, by measurement of the voltage amplitude and phase, one can determine the extent
of the core motion and the direction, that is, the displacement.”[1] Figure 6 shows the linearity of
the device within a range of core displacement. Note that the output is not linear as the core
travels near the boundaries of its range. This is because less magnetic flux is coupled to the core
from the primary. However, because LVDTs have excellent repeatability, nonlinearity near the
boundaries of the range of the device can be predicted by a table or polynomial curve-fitting
function, thus extending the range of the device.

PROCEDURE

After checking the knowledge of the prerequisites, he gives to the students the sheet 4.1 which
shows the connection of the SET POIN 1 with the pump interface and sets the process simulation
panel as follows:

• DELIVER VALVE fully open (turn the knob counter-clockwise)

• MOTOR VAVLE fully open (angular rotation=o)
• SOL VALVE open (ON) using interface ON-OFF Driver
• MAN VALVE fully open (turn the knob counter-clockwise)
 • DRAIN VALVE fully closed (turn the knob clockwise)
• NEEDLE VALVE fully closed (turn the knob clockwise)
• AIR VALVE fully open (turn the knob counter-clockwise)

Level of water in the PROCESS TANK 10 cm

1. Connect, through leads, bush N 18 of the LINEAR DRIVER to the bush of SET
POINT 1, bush N 19 to bush N 19 and bush N 20 to bush N 20.
2. Insert the terminal of the digital voltmeter, set in dc, in the bush of SET POINT 1 and
other one in the earth bush (sheet 4.1 Fig. 4.1)
3. Press the main switch (ON).
4. Start the pump regulating the voltage on the SET POINT 1 at 10V.
5. Wait until the water level has reached 15/16 cm.
6. Gradually turn counter-clockwise the knob NEEDLE VALVE and/or the knob DRAIN
VALVE to maintain the level of water in the tank at 15/16 cm.
7. Wait until the level is stabilized (10, 15 minutes).
8. If this does not happen, regulate again the knob NEEDLE VALVE and/or the knob
DRAIN VALVE to maintain the level at the constant value of 15/16 cm.
9. Repeat the procedure from step N 4 for all the voltage values listed in the Table 4.1
and write down the result.
10. Put OFF the main switch.
11. Remove all the connections.
12. Represent the diagram of the process characteristic in Fig 4.2
Voltage apply to the
10 9 8 7 6
pump (V)

Flow (Lit/hr) 282 240 192 150 120

Level (cm) 15 15 15 16 16

Flow Vs Level
16.2

16

15.8
Level (cm)

15.6

15.4

15.2

15

14.8
0 50 100 150 200 250 300
Flow (Lit/hr)

PRECAUTIONS:

• Use the apparatus carefully

• Undue force applied to the motor terminals will cause stress inside the motor to cause
failures of the internal parts.

• Do not place any flammable material near the motor and driver to avoid fire or burn
injuries.

• Cover the output shaft while the motor is in operation to avoid injury

CONCLUSION:
1. First check the voltage from multimeter that must be 10V.
 2. Voltage should be between 50 to 60.
3. Level of water must be 50 to 60.
4. Design of circuit must be proper.

COMMENTS:

By the mean of this experiment we know the working of the LINEAR VARIABLE
DIFFERENTIAL TRANSFORMER (LSVD).

Moreover after performing the above experiment we shall be able to know ow to connect a
circuit in the correct way in order to get accurate results and to save time.

We can perform more experiments such as volume control pressure control after we understand
the working or operation of the above experiment.
 LAB MANUAL

CONTROL ENGINEERING

EXPERIMENT NO 16

OBJECTIVE:

b. To study of behavior of Photoconductive cell on voltage difference

APPARATUS:

➢ Transducer and instrumentation Trainer.

➢ Set of Leeds
 LAB MANUAL

CONTROL ENGINEERING

THEORY:

PHOTOVOLTAIC:

Photovoltaic (PV) is a method of generating electrical power by converting solar radiation

into direct current electricity using semiconductors that exhibit the photovoltaic effect.
Photovoltaic power generation employs solar panels composed of a number of solar cells
containing a photovoltaic material. Materials presently used for photovoltaic include mono
crystalline silicon, polycrystalline silicon, amorphous silicon, cadmium telluride, and copper
indium gallium selenite. Due to the growing demand for renewable energy sources, the
manufacturing of solar cells and photovoltaic arrays has advanced considerably in recent
years.
 LAB MANUAL

CONTROL ENGINEERING

The amount of power available from a PV device is determined by;

i. The type and area of the material;

ii. The intensity of the incident light and

iii. The wavelength of the incident light

APPLICATIONS OF PHOTOVOLTAIC:-

Photovoltaic can be used in a variety of applications including:

i. Consumer products such as watches, toys and calculators

ii. Emergency power systems

iii. Vaccine and blood storage refrigerators for remote areas

iv. Aeration systems for ponds

v. Power supplies for satellites and space vehicles

vi. Portable power supplies for camping and fishing

 LAB MANUAL

CONTROL ENGINEERING

PROCEDURE:

1. Firstly, check the apparatus, it should be showing zero reading initially.

2. Pass 12V from the apparatus as the input to the instrument.

3. Check out the photovoltaic (LDR) apparatus.

4. At 12V the light intensity is less as compare to light intensity at higher voltage range.

5. Check out the light intensity in apparatus.

6. By examine, the light intensity increases while increasing the voltage from 12V to
24V.

7. There is a linear relationship between voltage and light intensity.

8. If we draw a graph between the above two said quantities, it will be a straight line.

9. Check the light intensity in apparatus.

No. of Observations Input Voltage Output Voltage

1 0 0
2 5 170.3
3 12 1.349
4 24 2.00
 LAB MANUAL

CONTROL ENGINEERING

CIRCUIT DIAGRAM:
 LAB MANUAL

CONTROL ENGINEERING

PRECAUTIONS:

• Use the apparatus carefully

• Apply connections appropriately

CONCLUSION:

We can conclude from this apparatus:

• This apparatus converts energy from one form to another form (solar energy into
electrical energy).
 LAB MANUAL

CONTROL ENGINEERING

COMMENTS:

• Photovoltaics (PV)is the conversion of light into electricity using semiconducting

materials that exhibit the photovoltaics effect, a phenomenon studied in physics,
photochemistry, and generation and as photo sensors.
• In this sessions we learn the interface or structure of transducer and instrumentation
trainer
• We observe that when we increase the input voltage the light intensity will increasing
and the output voltage also increase which is shown in the graph