(Software Part)

Index

S. No. Title of Experiment Remark

1 Introduction to Automation Studio 6.1 Educational Edition:

Overview of Automation Studio Environment
2. Introduction to Fluid Sim: Overview of Fluid Sim-Hydraulics,
Fluid Sim- Pneumatics
3. Introduction to Hydraulics: Design and Simulation of various
Hydraulics circuits
 Design and Simulate the meter-in, meter-out Circuit
 Design and Simulate the series circuits for Hydraulic System
 Design and Simulate the AND operation using
Hydraulic Components
 Design and Simulate the OR operation using
Hydraulic Components
 Design and Simulate the AND operation using
Hydraulic Components

4. Introduction to Electro-Hydraulics:Design and Simulation of

various Electro-Hydraulics circuits
 Design and Simulate the meter-in, meter-out Circuit
 Design and Simulate the series circuits for Hydraulic System
 Design and Simulate the Latching circuit for Hydraulic System
 Design and Simulate the Latching/Unlatching circuit for
Hydraulic System
 Design and Simulate Electrical Control for Multiple
Hydraulic System
 Design and Simulate the meter-in, meter-out Circuit using
Double Solenoid DCV
 Design and Simulate Electrical Control for Multiple
Hydraulic System for Manual Extension and Automatic
Retraction
 Design and Simulate Electrical Control for Multiple
Hydraulic System for Automatic Extension and Retraction
5. Introduction to various design problems in Industrial scenarios
(Hydraulics):Sequence Operation
 Design and Simulate Sequence operation (ABC)+ (ABC)-
 Design and Simulate Sequence operation A+B+A-B- using
Mechanical switch
 Design and Simulate Sequence operation A+B+A-B- using
Electro-
 Hydraulic Aspect
 Design and Simulate A+ A- Sequence using Single acting
cylinder and Limit switches
 Design and Simulate Punching operation using Double acting
cylinder
6. Introduction to Pneumatic: Design and Simulation of various
Pneumatics circuits
 Design and Simulate the circuit for raising and lowering the
car park barrier using single acting cylinder
 Design and Simulate the circuit for pneumatic braking system
 Design and Simulate the circuit for parallel operation of single
acting cylinders
 Design and Simulate the circuit for raising and lowering the
car park barrier using double acting cylinder
 Design and Simulate the circuit for raising and lowering the
car park barrier using double acting cylinder and pilot valve
 Design and Simulate the circuit for entrance door to a store room
 Design and Simulate the Circuit for AND control
involves connecting 3/2 valves together in series

7. Introduction to various design problems in Industrial scenarios

(Pneumatics):Sequence Operation
 Design and Simulate Sequence operation (A)+ (A)-
using Mechanical switch
 Design and Simulate Sequence operation (A)+ (B)+ (A)-(B)
using Mechanical switch
 Design and Simulate Clamping operation
 Design and Simulate Automatic Forward Reverse using Counter
8. Introduction to Electro-Pneumatic:Design and Simulation of
various Electro-Pneumatics circuits
 Design and simulate AND & OR operation using Electro-
Pneumatic
 Design and simulate control operation for Double acting
Cylinder using Electro-Pneumatic
 Design and simulate Latching operation using Electro-Pneumatic
 Design and simulate Timer operation at Retraction using
Electro- Pneumatic
 Design and simulate Timer operation at Extension and
Retraction using Electro-Pneumatic
 Design and simulate Sequence Operation (A+B+C+A-B-C-)
using Electro-Pneumatic
 Design and simulate application of inductive proximity switch
using Electro-Pneumatic
 Design and simulate application of capacitive proximity
switch
9 Introduction to Digital techniques: Design and Simulation of
various Electro-Pneumatics circuits
 Design and simulate Demultiplexer using Digital logic
 Design and simulate sequence operation (A+A-) for Double
acting Cylinder using Digital logic
 Design and simulate sequence operation (AB)+ (AB)- for
Double acting Cylinder using Digital logic
 Design and simulate Decoder using Digital logic
 Design and simulate 1-Bit Comparator using Digital logic

(Hardware Part)
Index

1 Study of Modular Mechatronics System and its components.

 Introduction to various components of assemblyline
 Study of feeder station.
 Study of inspection station.
 Study of buffer station
 Study of process station.
 Study of sorting station

2 To design and assemble the components of distribution or

feeding station.
 Introduction to Feeder station
 Understanding the components of feeder station

3 To design and assemble the components of sorting station.

 Introduction to sorting station.
 Understanding the components of sorting station

4 To study about IOT and RFID application in mechatronics

System.
 Introduction to Internet of Things, RFID
 Experiment 1
Introduction to Automation Studio 6.1 Educational Edition:Overview
of Automation Studio Environment

Theory:
Automation Studio offers a unique combination of user-friendly system design features,
advanced engineering capabilities, dynamic and realistic simulation, comprehensive
animation features, and flexible documentation functionalities in one common
environment. It brings a new dimension that allows manufacturers, OEMs, and end-users
to optimize system implementation, deployment, and maintenance. Whether you are
involved in the design, training, sales, production, or maintenance, Automation Studio
can help your organization by improving quality, speeding up workflow, and boosting
productivity while simultaneously reducing costs and enhancing all aspects of project
communication.

Subjects related to hydraulic, pneumatic, electrical and control technologies, the

illustration of concepts and the behaviour of systems are no doubt at the heart of your
requirements. Created in 1986 by Famic Technologies to meet the needs of technical
teaching and training and used in thousands of schools worldwide, Automation Studio is a
unique software solution, which offers intuitive design, animation, simulation and system
analysis features in a versatile and user- friendly environment. It allows teachers to
present more content in less time, improves students’ understanding of concepts and
diagnosis capabilities and brings to schools, colleges and universities an optimal return on
investment.
 Figure 1: Application area of Automation Studio

 Automation Studio is intended to be used by engineers and specialists in:

Introduction to Automation Studio Environment
Learner can monitor the actual circuit operation and find potential design flaws. This helps
validating systems, saving time in prototyping phase, and finding faults at an early stage in
equipment design.
 Experiment 2
Introduction to Fluid Sim: Overview of Fluid Sim- Hydraulics,
Fluid Sim-Pneumatics

Theory:
FluidSIM is a comprehensive software for the creation, simulation, instruction and study of
electro- pneumatic, electrohydraulic and digital circuits. It’s easy to create circuits easily by
using drag-&- drop. Only have to place the items in the circuit as you want to view them and
build the circuit intuitively. Simple and effective. It offers an intuitive circuit diagram editor
with detailed descriptions of all components, sectional view animations, component photos
and video sequences.FluidSIM also offers a new simulation core need not fear a comparison
with more expensive special program, so professionals get a good advantage. Despite
complex physical models and precise mathematical procedures simulation is amazingly
fast.A major feature of FluidSIM is its close connection with CAD functionality and
simulation.

FluidSIM Pneumatics:
It is a teaching tool for simulating pneumatics basics and runs using Microsoft Windows. It
can be used in the combination with the Festo Didactic training hardware or independently.
FluidSIM was developed as a joint venture between University of Padeborn, Festo Didactic
Company and Art Systems software in Padeborn. A major feature of Fluidsim is its close
connection with CAD functionality and simulation. FluidSIM allows DIN-compliant drawing
of electro pneumatic circuit diagrams and can perform realistic simulations. Simply stated,
this eliminates the gap between drawing of a circuit diagram and the simulation of the related
pneumatic system. The CAD functionality of FluidSIM has been specially tailored for
fluidics.

Steps to create a Circuit Diagram:

STEP 1 - Click on FILE at the left-corner side for creating NEW page to work on.
 Fig: - Display of FESTO FluidSIM® 4 version 4.2p/1.67 Pneumatic Software

Fig: -Hierarchal view of Components list of FESTO FluidSIM® 4 version 4.2p/1.67

Pneumatic Software
 Fig: -Detailed view of component lists along with their names and symbols

STEP 2 - Now drag the components from the components list and drop it to the blank space.

Fig: - A simple circuit diagram.

STEP 3 - Add the PART LIST (for displaying the names of components) by clicking on

INSERT→MISSCELENEOUS→PART LIST.
STEP 4 - Add the STATE DIAGRAM by clicking on

INSERT→MISSCELENEOUS→STATE DIAGRAM.

FluidSIM Hydraulics:
It is a teaching tool for simulating hydraulics basics and runs using Microsoft Windows.
It can be used in combination with the Festo Didactic GmbH & Co. KG training hardware,
but also independently. FluidSIM allows DIN-compliant drawing of electrohydraulic circuit
diagrams and can perform realistic simulations of the drawing based on physical models of
the components. Simply stated, this eliminates the gap between the drawing of a circuit
diagram and the simulation of the related hydraulic system. The CAD functionality of
FluidSIM has been specially tailored for fluidics. For example, while drawing, the program
will check whether or not certain connections between
components are permissible. Another feature of FluidSIM results from its well thought-out
didactic concept: FluidSIM supports learning, educating, and visualizing hydraulic
knowledge. Hydraulic components are explained with textual descriptions, figures, and
animations that illustrate underlying working principles; exercises and educational films
mediate knowledge about both important circuits and the usage of hydraulic components. The
development of FluidSIM included special emphasis on both an intuitive and easy-to-learn
user interface. The user will quickly learn to draw and simulate electro-hydraulic circuit
diagrams.

The Hydraulic systems are used in applications where demand for high power and fast
response is required. Such applications include hydraulic industrial mobile machinery,
aerospace hydraulics, wind turbines, etc. Simulation and modeling of a hydraulic systems is
gaining interest in scientific community. The mathematical model of a system is compared
with the model designed by block diagrams in FESTO FluidSIM, which is used to simulate
fluid power system behavior such as hydraulic or pneumatic system. Results obtained from
modeling inFluidSIMshow discrepancies compared to the general mathematical
representation of a hydraulic system.

Steps to create a Circuit Diagram:

STEP 1- Click on FILE at the left-corner side for creating NEW page to work on.

Fig: - Display of FESTO FluidSIM® 4 version 4.2p/1.67 Hydraulic Software

STEP 2 - Now drag the components from the components list and drop it to the blank space.
 Fig: -A simple circuit diagram.

STEP 3- Add the PART LIST (for displaying the names of components) by clicking on

INSERT→MISSCELENEOUS→PART LIST

STEP 4 - Add the STATE DIAGRAM by clicking on

INSERT→MISSCELENEOUS→STATE DIAGRAM.
CONCLUSION:
The electric circuits are designed and the sequences of operations are tested by using FluidSIM®
Pneumatic simulation software.
 EXPERIMENT 3
Introduction to Hydraulics: Design and simulation of
various hydraulics circuits.
3.1 Design and Simulate the meter-in, meter-out Circuit.

Circuit Diagram:
Parts List:

State Diagram:

Result: The designing and simulation of meter-in and meter-out circuit was performed
successfully using fluid sim hydraulics.
3.2 Design and simulate the series circuits for hydraulic
system.
Circuit Diagram:
Parts List:

State Diagram:

Result:
The designing and simulation of series circuit was performed successfully using
fluid sim hydraulics.
3.3 Design and Simulate the AND operation using Hydraulic
Components.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of AND operation was performed successfully using fluid
sim hydraulics.
3.4 Design and Simulate the OR operation using Hydraulic
Components.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of OR operation was

performed successfully using fluid sim hydraulics.
 EXPERIMENT 4
Introduction to Electro-Hydraulics: Design and Simulation of
various Electro-Hydraulics circuits.
4.1: Design and Simulate the meter-in, meter-out Circuit.
Circuit Diagram:
Parts List:

State Diagram:

Result: The designing and simulation of meter in and meter out circuit was performed
successfully using fluid sim hydraulics.
4.2: Design and Simulate the series circuits for Hydraulic System.
Circuit Diagram:
Parts List:

State Diagram:

Result: The designing and simulation of series circuit was

performed successfully using fluid sim hydraulics.
4.3: Design and Simulate the Latching circuit for Hydraulic
System.
Circuit Diagram:
Parts List:

State Diagram:

Result: The designing and simulation of latching circuit was performed successfully
using fluid sim hydraulics.
4.4: Design and Simulate the Latching/Unlatching circuit for
Hydraulic System.
Circuit Diagram:
Parts list:

State diagram:

Result: The designing and simulation of latching/unlatching circuit was performed

successfully using fluid sim hydraulics.
4.5: Design and Simulate Electrical Control for Multiple
Hydraulic System.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of Electrical Control for Multiple Hydraulic
System was performed successfully using fluid sim hydraulics.
4.6: Design and Simulate the meter-in, meter-out Circuit
using Double Solenoid DCV.
Circuit Diagram:
Parts List:

State Diagram:

Result: The designing and simulation of meter in and meter out circuit using double solenoid
DCV was performed successfully using fluid sim hydraulics.
4.7: Design and Simulate Electrical Control for Multiple
Hydraulic System for Manual Extension andAutomatic
Retraction.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of Electrical Control for Multiple Hydraulic System
for Manual Extension andAutomatic Retraction was performed successfully using fluid sim
hydraulics.
4.8: Design and Simulate Electrical Control for Multiple Hydraulic
System for Automatic Extension and Retraction.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation ofElectrical Control for Multiple Hydraulic System for
Manual Extension andAutomatic Retraction was performed successfully using fluid sim
hydraulics.
 EXPERIMENT 5
Introduction to various design problems in Industrial
scenarios (Hydraulics): Sequence Operation.
5.1: Design and Simulate Sequence operation (ABC)+
(ABC)-
Circuit Diagram:
Parts List:

State Diagram:

Result: The designing and simulation of Sequence operation (ABC)+ (ABC)- was
performed successfully using fluidsim hydraulics.
5.2: Design and Simulate Sequence operation A+B+A-B-
using Mechanical switch.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation ofSequence operation A+B+A-B- was performed
successfully using fluid sim hydraulics.
5.3: Design and Simulate Sequence operation A+B+A-B-
using Electro-Hydraulic Aspect.
Circuit Diagram:

State Diagram:
Parts List:
Result: The designing and simulation ofSequence operation A+B+A-B- using
Electro- Hydraulic Aspect was performed successfully using fluid sim hydraulics.
5.4: Design and Simulate A+ A- Sequence using Single acting
cylinder and Limit switches.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation ofA+ A- Sequence using Single acting cylinder
and Limit switches was performed successfully using fluid sim hydraulics.
5.5:Design and Simulate Punching operation using Double
acting cylinder.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of design and Simulate Punching operation using
Double acting cylinder was performed successfully using fluidsim hydraulics.
 EXPERIMENT 6
Introduction to Pneumatic: Design and Simulation of
various Pneumatics circuits.
6.1: Design and Simulate the circuit for raising and lowering the
car park barrier using single acting cylinder.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit for raising and lowering the car park
barrier using single acting cylinder was performed successfully using fluidsim pneumatics.
6.2:Design and Simulate the circuit for pneumatic braking
system.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit for pneumatic braking system was
performed successfully using fluidSim pneumatics.
6.3:Design and Simulate the circuit for parallel operation of
single acting cylinders.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit parallel operation of single acting
cylinders was performed successfully using fluidsim pneumatics.
6.4:Design and Simulate the circuit for raising and lowering the
car park barrier using double acting cylinder.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit for raising and lowering the car park
barrier using double acting cylinder was performed successfully using fluid sim pneumatics.
6.5: Design and Simulate the circuit for raising and lowering the
car park barrier using double acting cylinder and pilot valve.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit for raising and lowering the car park
barrier using double acting cylinder and pilot valve was performed successfully using fluid
sim pneumatics.
6.6: Design and Simulate the circuit for entrance door to a
store room.
For safety reasons, the entrance door to a storeroom in a supermarket must open
and close slowly. A double acting cylinder is used to slide doors.

Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of the circuit for entrance door to a store room was
performed successfully using fluidsim pneumatics.
6.7: Design and Simulate the Circuit for AND control
involves connecting 3/2 valves together in series.
A company logo is to be stamped onto boxes using single acting cylinder. To
prevent accidents, the machine will operate when the operator has both hand on
the start buttons, if either button is released. If either button is released, the
machine will stop.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of the circuit for AND control involves connecting 3/2
valves together in series was performed successfully using fluid sim pneumatics.
6.8: Design and Simulate the Circuit for OR control involves
connecting 3/2 valves together in series.
Circuit Diagram: -

Parts List:
State Diagram:

Result: The designing and simulation of the circuit for OR control involves connecting 3/2
valves together in series was performed successfully using fluid sim pneumatics.
 Experiment 7
Introduction to various design problems in Industrial scenarios
(Pneumatics): Sequence Operation
7.1: Design and Simulate Sequence operation (A)+ (A)- using
Mechanical switch.
Circuit Diagram: -

Parts List:
State Diagram:

Result: The designing and simulation of the circuit for sequence operation (A)+ (A)- using
Mechanical switch was performed successfully using fluidsim pneumatics.
7.2: Design and Simulate Sequence operation (A)+ (B)+ (A)-
(B) using Mechanical switch.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit for Sequence operation (A)+ (B)+ (A)-
(B)- using Mechanical switch was performed successfully using fluidsim pneumatics.
7.3: Design and Simulate Clamping operation.
Circuit Diagram:

Parts List:
State Diagram:

Result: The designing and simulation of the circuit for clamping

operation was performed successfully using fluidsim pneumatics.
7.4: Design and Simulate Automatic Forward Reverse using
Counter.
Circuit Diagram:

Parts List:

State Diagram:
Result: The designing and simulation of the circuit for Automatic Forward Reverse using
Counter was performed successfully using fluid sim pneumatics.
 Experiment 8
Introduction to Electro-pneumatic: Design and Simulation of
various Electro-pneumatic circuits.
8.1: Design and simulate AND & OR operation using
Electro- Pneumatic.

Circuit Diagram:

:
Part list & State Diagram:
Result: The design and simulation of AND & OR operation performed
successfully using fluid sim pneumatics.
8.2: Design and simulate control operation for Double acting Cylinder
using Electro-Pneumatic.

Circuit Diagram:
:

Part List & State Diagram:

Result: The design and simulation of double acting cylinder using electro- pneumatic is performed
successfully.
8.3: Design and simulate Latching operation using Electro-

Pneumatic.

Circuit Diagram:

Part List & State Diagram:

Result: The design and simulation of latching operation using electro-
pneumatic is performed successfully.
8.4: Design and simulate Timer operation at Retraction using
Electro- Pneumatic.

Circuit Diagram:
:

Part list and diagram:

Result: The design and simulation of timer operation at retraction using electro-
pneumatic is performed successfully.
8.5: Design and simulate Timer operation at Extension and
Retraction using Electro-Pneumatic.

Circuit Diagram:
:

Part list & state diagram:

Result: The design and simulation of timer operation at extension and retraction using
electro-pneumatic is performed successfully.
8.6: Design and simulate Sequence Operation (A+B+C+A-B-C-)
using Electro-Pneumatic.

Circuit Diagram:

Part list & state diagram:

Result: The design and simulation of sequence operation using electro- pneumatic is
performed successfully.
8.7: Design and simulate application of inductive proximity switch
using Electro-Pneumatic.

Circuit Diagram:

Part list and state diagram:

Result: The design and simulation of inductive proximity switch using

electro-pneumatic is performed successfully.

8.8: Design and simulate application of capacitive proximity
switch using Electro-Pneumatic.

Circuit Diagram:

Part list and state diagram:

Result: The design and simulation of application of capacitive proximity switch using
electro-pneumatic is performed successfully.
 Experiment 9

9.1: Design and simulate demultiplexer using Digital

logic.

Circuit Diagram:

Digital logic:
Part list :

Result: The design and simulation of demultiplexer using the digital logic is performed
successfully.
9.2: Design and simulate sequence operation (A+ A-) for Double
acting Cylinder using Digital logic.

Circuit Diagram:

Digital Logic:
Part list & state diagram:
Result: The design and simulation of Sequence operation for double acting cylinder
using the digital logic is performed successfully.
9.3: Design and simulate sequence operation (AB)+ (AB)- for
Double acting Cylinder using Digital logic.

Circuit Diagram:

Digital logic:
Part List and state diagram :
Result: The design and simulation of Sequence operation (AB)+(AB)- for double
acting cylinder using the digital logic is performed successfully.
9.4: Design and simulate Decoder using Digital logic.

Circuit Diagram:

Digital logic:
Part list

Result: The design and simulation of Decoder using the digital logic is performed
successfully.
9.5: Design and simulate 1-Bit Comparator using Digital logic.

Circuit Diagram:

Digital Logic:
Part List:-

Result: The design and simulation of 1-Bit comparator using the digital logic is
performed successfully.
 HARDWARE

Experiment 1

Study of Modular Mechatronics System and its components.Introduction

to various components of assembly line.

Study of feeder station.

Study of inspection
station. Study of buffer
station.
Study of process
station. Study of sorting
station.

Theory:
Introduction to various components of assembly line
These Mechatronics systems are fully functional models of actual
applications, mimicking hybrid, real life, industrial automation scenarios.
Various Automation and Handling Task modules such as feeding,
conveying, pick & place, transporting, forming and storage modules are
available. Wide range of Modular Manufacturing Systems like Processing
station, Conveyor station, Automated Storage and Retrieval System and
other production stations that are suitable for modular assembly are
available. A wide variety of project assignments and learning objectives help
students to build hybrid systems by integrating important automation
technologies, such as Pneumatics
Electrica
l PLC
Mechanical
Sensors

Study of feeder station:

Functional Description:

The Feeder Station separates the components from the Stack Magazine and
distributes the components one by one via Rotary pick and place module for
further processing. The Station consists of the following major parts
FRCLM module
Dispensing module
Rotary Pick and Place
module Valve module
I/O Interface Module
Profile Table work
bench PLC control
Control Console

Fig: Feeder Station (Stack Magazine and vacuum switch module for
distribution of work piece for inspection)

Technical Specifications

MODEL MMS01
Size in cm 54x70x134
Installation Vertical
Ambient Temperature 60°C Max
Medium Filtered Compressed air
Operating Pressure range (Bar) 6-8 bar
Operating voltage 230V AC, 50HZ
 Power Consumption 180 W (224 VA)
Sensors and actuator operating 24V, DC
voltage
Material of construction Aluminum, mild steel, Plastic.etc.

Study of inspection station:

Functional Description:
The Inspection station measures the height of the components received
from its downstream station and transfers the correct and incorrect
components to appropriate slides.
The Inspection station consists of
following FRCLM module
Inspection module
Inspection slide
module Valve
module
I/O Interface
Module Profile
Table work bench
PLC control
Control Console
Inspection station checks the jobs for height of about 25 mm using analog
sensors and provisions has made to detect work piece presence with the help
of optical sensor. An arrangement is provided to transfer the right work piece
by a slide to the next station and send faulty rejected work piece to the
rejection bay.
Station consists of anodized profile table, filter regulator and lubricator unit
with pressure gauge, on/off valve quick push connections and couplings
mounted with suitable mountings for easy assembly and disassembly.

Fig: Inspection Station

Technical Specifications

MODEL MMS01
Size in cm 68x64x135
Installation Vertical
Ambient Temperature 60°C Max
Medium Filtered Compressed air
Operating Pressure range (Bar) 6-8 bar
Operating voltage +/- 10% 230V AC, 50HZ
Power Consumption 180 W (224 VA)
Sensors and actuator operating 24V, DC
voltage
Material of construction Aluminum, mild steel, Plastic.etc.

Study of buffer station:

Functional Description:
Buffer Station ensures steady flow of components to the process station by
allowing one component at a time for processing. It can store upto 5 work
pieces at a time and if the count has exceeded 5, it communicates with the
downstream stations to STOP the processing activities until the count reaches
5. Buffer Station consists of the following
FRCLM
module
Conveyor
module Valve
module
I/O Interface
Module Profile
Table work bench
PLC control
Control Console
Buffer station is capable of buffering up to 5 jobs. Buffering process should
be controlled by a separator using up stream and down stream light barriers
sensors. Retro reflective sensor detects the inserted job and keeps tag on the
nos. of jobs buffered precisely while the separator module passes the job to
the next station if the transfer point is free. The buffer station waits for the
signal from the down stream station & as soon as it receives the signal is
transferred. The end position of all pneumatic actuators is detected by using
Magnetic sensors.
The station consists of anodized profile plate, filter regulator and lubricator
unit with pressure gauge, on/off valve quick push connections and
couplings mounted with suitable mountings for easy assembly and
disassembly.

Fig: Buffer Station

Technical
Specifications

MODEL MMS01
Size in cm 55x64x106
Installation Vertical
Ambient Temperature 60°C Max
Medium Filtered Compressed air
Operating Pressure range (Bar) 6-8 bar
Operating voltage +/-10% 230V AC, 50HZ
Power Consumption 180 W (224 VA)
Sensors and actuator operating 24V, DC
voltage
Material of construction Aluminum, mild steel, Plastic.etc.
Study of process station:
Functional Description:
Demonstrates processes like inspection ,drilling and transfer of finished
components to the next station.
Electrical rotary table models common industrial processes.
• Sensors locate parts at pickup and processing points
• Proximity sensors locate correct alignment of rotary table
• Sample applications such as machining and quality control

Fig: process station

Study of sorting
station:
Functional
Description:
Finished components are sorted to the appropriate bay based on their
material and colour and moves them via an electrical conveyor belt.
• Sensor array to distinguish colors
• Linear motion to set deflectors
• Proximity sensors verify process completion
• Optical sensors monitor number of parts in each slide
Fig: Sorting Station
 Experiment 2

To design and assemble the components of distribution or feeding station.

Introduction to Feeder station
Understanding the components of feeder station

Feeders:
Feeder line is part of an electric distribution network. An electrical wiring
circuit in a building which carries power from a transformer or
switch gear to a distribution panel. Different feeders are connected to the
feeder bus to feeds different loads like, motor loads, lighting loads, industrial
machinery loads, air conditioner loads, transformer cooling system loads
etc. All feeders are primarily protected by switch fuse unit and in addition to
that, depending upon the types of load connected to the feeders, the different
switchgear devices are chosen for different feeders.

Types of Feeder:

1. Motor Feeder
2. Industrial Machinery Load Feeder
3. Lighting Load Feeder

Motor Feeder:
Motor feeder should be protected against over load, short circuit, over
current up to locked rotor condition and single phasing.

Industrial Machinery Load Feeder:

Feeder connected industrial machinery load like oven, electroplating bath etc.
are commonly protected by MCCB and switch fuse units
Lighting Load Feeder:
This is protected similar to industrial machinery load but additional earth
leakage current protection is provided in this case to reduce any damage to
life and property that could be caused by harmful leakages of current and fire.
 Distribution Feeder Systems

Let’s take a look at the four most common distribution feeder systems
applied nowadays. There are few other variations, but we will stick to the
basic ones. It’s very important to understand why and where each of
distribution feeder systems (topologies) are used, because whatever you do
(design of secondary substations, performing testing of secondary
switchgears or transformers or planning etc.) this would be the very first
thing to know.

So, these are the distribution feeder systems we’ll speak about

1. Radial
1.2.Radial
Parallel feeders
3. Ring main
4. Meshed systems
Many distribution systems operate using a radial feeder system. A typical
radial feeder system is shown schematically in Figure 2. Radial feeders
are the simplest and least expensive, both to construct and for their
protection system.This advantage however is offset by the difficulty of
maintaining supply in the event of a fault occurring in the feeder.A fault
would result in the loss of supply to a number of customers until the fault
is located and cleared. The next level of reliability is given by a ‘parallel
2. Parallel feeders

A greater level of reliability at a higher cost is achieved with a parallel feeder. A typi

In the event of a line fault only one of the feeder sets of cables will be affected, thus allow

To improve the reliability factor it may be possible to have the separate

sets of cables follow different routes. In this case the capital cost is double
that of afeeders
Parallel radial feeder but common
are more there is aingreater
urban reliability factor
areas or for for the
feeders line.
to large
This may be justified if the load is higher, more customers are being
supplied,
single or therewhere
customers, are loads
load such as hospitals
shedding which require
in an emergency may behigh levels of
possible.
3. Ring main

A similar level of system reliability to that of the parallel arrangement can

be achieved by using ring main feeders. This usually results from the
growth of load supplied by a parallel feeder where the cabling has been
installed along different routes. These are most common in urban and
industrial environments.

Whilst the start and finish ends of the ring are at the same location, power is
delivered by both pathways of the ring into substations located around the
ring.

Should a fault occur on a feeder cable at any point around the ring the
faulty section may be isolated by the operation of the protecting circuit
breakers, at the same time maintaining supply to all substations on the ring.
In typical urban / suburban ring main arrangements, the open ring is
operated manually and loss of supply restored by manual switching.

This gives the advantages of ring main systems as line voltage drops are
reduced at the various load substations there is a ‘firm’ supply (i.e. an
alternative path is available if the primary one fails) to each load substation.

4. Meshed systems

In transmission and sub-transmission systems, usually parallel, ring or

interconnected (mesh) systems are used. This ensures that alternative
supply can be made to customers in the event of failure of a transmission line or eleme

The extra expense can be justified because of the much greater load and number of custom

The general rule is that where large loads or numbers of customers are involved, then some
 Experiment 3

To design and assemble the components of sorting station.

 Introduction to sorting station.
 Understanding the components of sorting station

1 Description of functions
1.1Brief description
The automated sorting station (see Figure 1) is used to separate plastic and
metal components. A component is fed to the conveyor via a chute. The
conveyor starts as soon as the component has been detected. If a
component made of metal is on the conveyor, it is detected, transported up
to the height of the metal magazine and pushed by a cylinder into the metal
magazine. If no metal is detected, the component is made of plastic. The
plastic component is transported to the end of the belt, where it falls into
the plastic magazine. As soon as a component is sorted, the next
component can be fed.

1.2 Technology

Diagram Figure 1: Technology

 Diagram Figure 2: Control panel

1.3 Switching on The station is switched on with the main switch Q0. Relay
K0 (main switch "ON") is energized and provides the supply voltage for the
sensors and actuators. This operating state is indicated by indicator light P1
(main switch on)

1.4 Operating mode selection once the station has been switched on, two
operating modes are possible: manual mode or automatic mode. The operating
mode is selected using switch S0. The selected operating mode is indicated by
indicator lights P2 (manual mode) and P3 (automatic mode).

1.5 EMERGENCY STOP In the absence of feedback from the

EMERGENCY STOP (A1), all drives must be stopped immediately.
When feedback from the EMERGENCY STOP function is present
again, the station may only start up again after another start signal.
Activation of the EMERGENCY STOP is indicated by indicator lights
P4 (EMERGENCY STOP activated).

1.6 Manual mode The station is set up in manual mode.

1.6.1 Retracting and extending the cylinder after pushbutton S5 (cylinders M4

extend) is pressed, cylinder M4 is extended. When the frontend position is
reached (extended position), the cylinder pauses in this position. After
pushbutton S4 is pressed, the cylinder retracts. A change of direction is to be
possible at any time. When the two pushbuttons are pressed simultaneously,
no motion should take place.
 1.6.2 Conveyor motor in manual mode With pushbutton S3 (pushbutton
manual mode conveyor M1 forwards), motor Q1 (conveyor motor M1
forwards fixed speed) is moved forward in manual mode. With pushbutton S4
(pushbutton manual mode conveyor M1 backwards), motor Q2 (conveyor
motor M1 backwards fixed speed) is moved backward in manual mode. When
the two pushbuttons are pressed simultaneously, no motion should take place.
For safety reasons, only the preset speed may be used here. Output Q3
(conveyor motor M1 variable speed) must therefore be deactivated.
1.6.3 Initial state At station start or after release of EMERGENCY STOP, the
station must be moved in manual mode to a defined operating state (initial
state). In the initial state, the conveyor is empty and stopped and the cylinder
is retracted.

1.7 Automatic mode In automatic mode, the station executes the process (see
also Brief description).

1.7.1 Starting and stopping If the station is in the initial state, automatic mode
starts when pushbutton S1 (automatic start) is pressed. When pushbutton S2
(automatic stop) is pressed, automatic mode is ended again as soon as the
initial state has been reached. If EMERGENCY STOP has been tripped or the
operating mode changed, automatic mode is ended immediately (without
return to the initial state). The current state is indicated by indicator light P6
(automatic mode started).

1.7.2 Conveyor control If light sensor B4 (chute occupied) detects a

component, the conveyor motor starts. The component slides onto the
transport conveyor and is further conveyed. If inductive sensor B5 detected a
metal component, this is transported up to light sensor B6 (part in front of

cylinder M4). The conveyor is then switched off. As soon as B3 (sensor motor
M1 active) no longer supplies a signal, the Cylinder control (see below) is
activated and moves the component into the metal magazine. As soon as the
cylinder is retracted again, the sorting station is back in the initial state. If a
metal component was not detected by sensor B5, this is recognized when light
sensor B6 (part in front of cylinder M4) is reached. The plastic component is
then transported to the end of the conveyor. It is detected there by light sensor
B7 and conveyed after a delay time into the plastic magazine at the end of the
conveyor.
1.7.3 Cylinder control If a metal component reaches light sensor B6 (part in
front of cylinder M4) and the conveyor has stopped, cylinder M4 moves to the
front-end position B2 (cylinder M4 extended), thereby pushing the metal
component from the conveyor into the metal magazine. Cylinder M4 then
moves to the rear end position B1 (cylinder M4 retracted).

1.7.4 Speed control (conveyor speed) In automatic mode, the motor can be
moved at a fixed or variable speed. Fixed speed requires signal "1" at Q1
"Conveyor motor M1 forwards fixed speed" or Q2 "Conveyor motor M1
backwards fixed speed". For variable speed, Q3 "Conveyor motor M1
variable speed" must be activated and a "manipulated value for motor speed"
(analog value +/-10 V corresponds to +/- 50 rpm or 10 m/s) must be specified
at U1. Signal "1" must not be present at Q1 "Conveyor motor M1 forwards
fixed speed" or Q2 "Conveyor motor M1 backwards fixed speed". Otherwise,
U1 has no effect on the speed of the conveyor.

1.7.5 Speed control A speed control can be integrated for control of the
conveyor speed. This uses the speed sensor for evaluating the current speed. A
speed of 5 rpm corresponds to a conveyor belt speed of 1 m/s.

1.8 Indicator lights As soon as relay K0 (main switch "ON") becomes

energized, indicator light P1 (main switch on) lights up. If switch S0 (mode
selector manual/automatic) is set to Manual, the indicator light P2 (manual
mode) lights up. If switch S0 is set to Automatic, the indicator light P3
(automatic mode) lights up. If the EMERGENCY STOP function has tripped,
P4 (EMERGENCY STOP activated) lights up. If automatic mode has been
selected and the station is in the initial state, P5 (automatic mode started)
flashes to signal that automatic mode can be started. As soon as automatic
mode has been started, P5 lights up.

2 Description of components of the station

2.1 Manual operation
2.1.1 Pushbuttons The utilized pushbuttons can supply either a "0" or "1"
signal. Depending on whether you have planned them as normally closed or
normally-open contacts (see Reference list), they supply a "1" or "0" signal
when not actuated. The signal changes to "0" or "1" only while the pushbutton
is being pressed.
2.1.2 Switches The utilized switches can also supply either a "0" or "1" signal.
Depending on whether you have planned them as normally closed or
normally-open contacts (see Reference list), they supply a "1" or "0" signal
when not actuated. The signal changes to "0" or "1" when the switch is
actuated. This signal is present as long as the switch is not actuated again.

2.1.3 Feedback from EMERGENCY STOP pushbutton EMERGENCY

STOP pushbuttons are pushbuttons with an additional mechanical lock and
are connected to a safety relay. They thus behave like a switch. The
EMERGENCY STOP feedback from the safety relay is planned as a normally
closed contact for safety reasons. If a wire break occurs, therefore, this
feedback is no longer present and the station responds as if an EMERGENCY
STOP has tripped.

2.2 Sensors
2.2.1 Position switches A main switch is actuated to switch on the station.
This energizes a relay and supplies the power to the station. A position switch
provides feedback on the operation of the relay. 3.2.2 Limit switches The limit
switches supply a signal when the cylinder is either fully retracted or
extended. The limit switches are implemented as normally-closed or
normally-open contacts.

2.2.3 Light barriers / optical sensors The light barriers supply a "1" signal as
soon as an object is in the sensing range

2.2.4 Metal detection / Inductive sensor The inductive sensor supplies a "1"
signal as soon as a metallic object enters its sensing range. In the case of non-
metallic objects, the signal remains at "0".

2.2.5 Motor speed The motor speed is recorded by an incremental encoder at

the conveyor motor and provided as an analog value via a transducer. The
speed falls within the range from -50 rpm to 50 rpm. That corresponds to a
conveyor belt speed of -10 m/s to +10 m/s. In addition, pulses are received at
"Sensor conveyor motor M1 active" that can also be used for positioning. The
resolution is 20 pulses per total conveyor belt length (10 m).
2.3 Actuators
2.3.1 Conveyor motor The conveyor motor drives the conveyor belt. It has
multiple signal combinations so that the conveyor belt can be moved at fixed
or variable speed in both directions. Fixed speed requires signal "1" at Q1
"Conveyor motor M1 forwards fixed speed" or Q2 "Conveyor motor M1
backwards fixed speed". For variable speed, Q3 "Conveyor motor M1
variable speed" must be activated and a "manipulated value for motor speed"
(analog value +/-10 V corresponds to +/- 50 rpm or 10 m/s) must be specified
at U1. Signal "1" must not be present at Q1 "Conveyor motor M1 forwards
fixed speed" or Q2 "Conveyor motor M1 backwards fixed speed". Otherwise,
U1 has no effect. Simultaneous activation of signals Q1 and Q2 causes the
conveyor to stop and must be prevented by the control program.

2.3.2 Cylinders Cylinder M4 is controlled using two separate signals.

Activation of one signal (M3) causes the cylinder to extend and activation of
the other signal (M2) causes the cylinder to retract. The signals must not be
activated simultaneously, otherwise an undefined state occurs and the cylinder
pauses at its position. This must be prevented by the control program
.
2.3.3 Displays All indicator lights are located on the control panel. If signal
"1" is present, these indicator lights illuminate.
 Experiment 4

To study about IOT and RFID application in mechatronics System.

 Introduction to Internet of Things, RFID

Iot:
The Internet of things (IoT) describes the network of physical objects—
“things”—that are embedded with sensors, software, and other technologies
for the purpose of connecting and exchanging data with other devices and
systems over the Internet.

The definition of the Internet of things has evolved due to the convergence of
multiple technologies, real-time analytics, machine
learning, commodity sensors, and systems. Traditional fields of embedded
systems, wireless sensor networks,control systems, automation (including
home and building automation), and others all contribute to enabling the
Internet of things. In the consumer market, IoT technology is most
synonymous with products pertaining to the concept of the "smart home",
including devices and appliances (such as lighting fixtures, thermostats,
home security systems and cameras, and other home appliances) that support
one or more common ecosystems, and can be controlled via devices
associated with that ecosystem, such as smartphones and smart
speakers.
There are a number of serious concerns about dangers in the growth of IoT,
especially in the areas of privacy and security, and consequently industry and
governmental moves to address these concerns have begun including the
development of international standards.
Top 10 benefits of Internet enabled mechatronics:

1. Lower cost and better function

Each component must have a positive impact on the financial bottom line.
Less wiring and connectors, fewer components and sensors, less labor
invested, reduced time spent in setup and maintenance and maximized
operational uptime all substantially reduce the overall cost of ownership and
operation.

2.Lessspace
By building the driver, controller and amplifier into a smart motor, less panel
space is needed, which saves material, time, labor and overall cost.

3.Simplifie wiring
Combining the driver, controller and amplifier means fewer sensors are
needed, especially when an encoder is used, fewer I/O connections, and a less
complicated wiring schemes.

4.Reduced troubleshooting
With fewer components and less wire connections, the job of tracing down
problems that may arise is greatly reduced.
5.Streamlined commissioning
Machine installation and start up is made easier with pre-programmed homing
routines and with the ability to make changes at an individual axis without
working through the PLC. This distributed control model frees the installation
team to work on multiple axes simultaneously, and report progress through
Internet connectivity. It also allows an operator to make in-process
adjustments at an individual axis without affecting the PLC or entire
production line.

6.Modular integration
Standardized smart robot modules make integration into multiple axes or
multiple machines a natural and easy process.

7.Automated adjustment
Switching a packaging or assembly line to a different size or part can become
automated and “recipe driven,” increasing manufacturing flexibility and
speed. Such adjustments eliminate time consuming manual changes.

8.Maximize uptime
Real-time monitoring of temperatures, friction, motor torque and other
performance related data can be routed to a mobile device allowing operators,
maintenance or engineers to proactively handle issues related to maximizing
machine uptime.

9.Preventative maintenance
Established time frames for periodic maintenance based on cycles, number of
pieces run or other dynamic conditions can easily be monitored and reported
to any IoT connected device, such as a work station, tablet or mobile phone,
allowing teams to proactively keep equipment running at peak efficiency.

10.Increased output
All of these things are working together in an IoT connected motion system,
driving greater flexibility, less downtime, increased performance and greater
bottom line output for manufacturers, assembly lines, packaging equipment
and production equipment.
RFID:
Radio-frequency identification (RFID) uses electromagnetic fields to
automatically identify and track tags attached to objects. An RFID tag consists
of a tiny radio transponder; a radio receiver and transmitter. When triggered
by an electromagnetic interrogation pulse from a nearby RFID reader device,
the tag transmits digital data, usually an identifying inventory number, back to
the reader. This number can be used to track inventory goods.
There are two types of RFID tags:

 Passive tags are powered by energy from the RFID reader's

interrogating radio waves.
 Active tags are powered by a battery and thus can be read at a greater
range from the RFID reader; up to hundreds of meters. Unlike a barcode,
the tag doesn't need to be within the line of sight of the reader, so it may be
embedded in the tracked object. RFID is one method of automatic
identification and data capture (AIDC).
RFID tags are used in many industries. For example, an RFID tag attached to
an automobile during production can be used to track its progress through the
assembly line; RFID-tagged pharmaceuticals can be tracked through
warehouses; and implanting RFID microchips in livestock and pets enables
positive identification of animals.
.

>>How RFID Works

How RFID Works

A RFID system is made up of two parts: a tag or label and a reader. RFID tags
or labels are embedded with a transmitter and a receiver. The RFID
component on the tags have two parts: a microchip that stores and processes
information, and an antenna to receive and transmit a signal. The tag contains
the specific serial number for one specific object.
To read the information encoded on a tag, a two-way radio transmitter-
receiver called an interrogator or reader emits a signal to the tag using an
antenna. The tag responds with the information written in its memory bank.
The interrogator will then transmit the read results to an RFID computer
program.

There are two types of RFID tags: passive and battery powered. A passive
RFID tag will use the interrogator’s radio wave energy to relay its stored
information back to the interrogator. A batter powered RFID tag is embedded
with a small battery that powers the relay of information.
In a retail setting, RFID tags may be attached to articles of clothing. When an
inventory associate uses a handheld RFID reader to scan a shelf of jeans, the
associate is able to differentiate between two pairs of identical jeans based
upon the information stored on the RFID tag. Each pair will have its own
serial number.

RFID applications:

Manufacturing and Processing

– Inventory and production process monitoring
– Warehouse order fulfillment
Supply Chain Management
– Inventory tracking systems
– Logistics management
Retail
– Inventory control and customer insight
– Auto checkout with reverse logistics
Security
– Access control
– Counterfeiting and Theft control/prevention
Location Tracking
– Traffic movement control and parking management
– Wildlife/Livestock monitoring and tracking