Lecture - 1 - 12-9-2019

V1 & V2
Automation Industry
Dr. Hisham El-Sherif

MCTR704 – Mechatronics Lab
Introduction
In automation industry every mechatronic system has some

sensors to measure the status of the process variables.
The analogy between the human controlled system and a
computer controlled system is describe as follows:-
-The operator observes the behavior of the system, makes a
decision and then, using his muscular power to take a
particular control action is taken.
-The sensors replaces the eyes for observation, actuators
replace the muscle, and the computer replaces the human
brain.

Brain for decision making
Eye for sensing
Muscles for actuation
Inp Process Outpu

ut t
Input Output

Automation system has these four basic functional blocks:-
1- Process to be controlled.
2- Actuators.
3- Sensors.
4- Controller.

The main components of any automated system; mechanical
structure, sensors, actuators decision making, power sources
and human interface.
Mechanical Process
Solenoids Strain Gauge Input

Thermocouple
Actuat Sensor Signal
Filters
Accelerometer
ors
DC Motors s
Potentiometer
Condition
Amplifiers
A/D,D/D
ing
Output Digital
Displ Signal Logic circuits
Control
PLC
LED,ay
LCD,CRT
Condition
A/D,D/D PWM Microcontroller
Amplifiers
ing
Proximity Sensors
Optical – Through-beam Inductive Capacitive
Optical – Retro-reflective Reed switch Symbols
Optical - Diffuse Inductive magnetic Connection

Optical Sensors
(Through-Beam)

Type : Through-beam
Transmitter Receiver

Type : Through-beam

Type : Through-beam
Target

Type : Through-beam

Type : Through-beam

Type : Through-beam

Type : Through-beam

Type : Through-beam

Type : Through-beam

Type : Through-beam

Type : Through-beam Target
Long sensing distance: up to 30 metres with some devices

Will detect all but very transparent materials
Must be accurately aligned
Optical Sensors
(Retro-Reflective)

Type : Retro reflective
T
Transmitter /Receiver R
Reflector
(prismatic)

T
Reflector (prismatic)

T
Reflector
(prismatic)

Type : Retro reflective Target
T
Reflector
(prismatic)

T

T

T

T

T

T

T
Sensing distance : 1/2 to 1/3 of through-beam type
Not suitable for reflective or transparent targets
Target should be larger than the reflector
Optical Sensors
(Diffuse)

Type : Diffuse Target
T

Type : Diffuse
T

Type : Diffuse
T

Type : Diffuse
T

Type : Diffuse
T

Type : Diffuse
T

Type : Diffuse
T
Sensing distance: much less than reflex type, actual distance depends on colour and reflective nature of the surface
Larger targets result in longer sensing distances
Not suitable for dirty environments

Inductive Sensors

High frequency magnetic field
(300 to 800 kHz)
Active surface
Resonant circuit coil
LED indicator
Connection cable

Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Target
Sensor
Oscillation
Amplitude
Sensor ON
output
signal OFF
Will detect any conductive material
Quoted distances are for mild steel
Sensor performance can be affected by:
• Temperature
• Target material
• Target dimensions

Reed Switch

Glass Tube filled Reed contacts LED indicator
with nitrogen

24v

24v

Interference from other magnetic fields must be avoided.
If positioned in mid stroke, switching point will vary depending on direction of approach.
Maximum current must be limited to avoid burning of the reed contacts.

Capacitive Sensor

Electrostatic field
Sensor is looking for a change in capacitance
in the active field
Active surface
Active electrode
Earth electrode
LED indicator
Adjusting screw
Connection cable

Target

Capacitive sensor
Detects any material denser than air (as long as there is enough of
it)
Can be adjusted for sensitivity
Can be affected by dusty environments

Capacitive Application
By this variable potentiometer, the Sensor

is adjusted so that it does not ‘see’ the
wall of the vessel.

As the level rises the fluid affects the sensor
field.

Until the sensor switches.

Sensor Symbols

Inductive
Capacitive
+ 18 to 30 Volts DC.
Optical
Output Magnetic
Ultrasonic
Normally open
0V
Normally closed

Capacitive Sensor with Normally open
function
+ 18 to 30 Volts DC.
Output
0V

Sensor Connection

24v DC
PNP Type
• Output is Positive
+ 18 to 30 Volts DC
• Positive switching
Output
0V
0v

24v DC
NPN Type
• Output switches
+ 18 to 30 Volts DC
through to 0v
• Negative switching
Output
0V
0v

Sensor Shapes

Basic
Pneumatics

What are Pneumatics ?
 Mechanisms which use air pressure to apply
mechanical force and displacement (work)
Properties of Compressed Air
 Availability
 Easily stored in large volumes
 Simplicity in design and control
 Provides linear and rotary movement
 Low system cost due to low component cost
 Components have long working life resulting in longer system reliability
 Environmentally friendly
 Safety issues are minimized e.g.. Fire hazards; unaffected by overloads
(actuators stall or slip)
 Pneumatic actuators in a system do not produce heat (except for
friction)
A Basic Pneumatic System
Air Production and Distribution System

Compressor

Motor

Pressure
Switch

Tank

Check Valve

Drain

Drain

Refrigerated Air Dryer

Line Filter

Air Consumption System
Air Line Take-off

Drain

Conditioning Unit

Directional Valve

Actuator

V2-1
Pressure Regulating Component
 Filter – can remove impurities from compressed air before it is fed to the
pneumatic components.
 Pressure regulator – to stabilize the pressure and regulate the operation of
pneumatic components
 Lubricator – To provide lubrication for pneumatic components

From Out side Air
Compressor (Reciprocating) V3
Storage Tank
Industrial Reciprocating Compressor
Work Shop Reciprocating Compressor

Compressor (Air Screw)

Air Treatment Inlet Filter
 Used to remove large Atmospheric air carries both
moisture and dust
particle dirt from entering the
system.
 Used to prevent excessive
wear of cylinder, piston
rings and other moving parts
in the initial stage of the
system

V4-1
Air Receiver
A pressure Vessel (Tank) normally made of metal and installed either
horizontally or vertically. This vessel provides a volume of air to be utilized by
the system and reduced the loading and unloading of the compressor.
Air Receiver (Tank)

V4
Air Dryer
Compressed air cannot hold the same amount of moisture as non compressed
air. Once the air is compressed, some of the moisture condenses in the tank and
is removed through a drain valve. The remaining moisture will rust internal
components of the system and must be removed. One way this is done by
sending the air through an air conditioned chamber which will condense more of
the moisture which is present.

4
Industrial Pneumatic Preparation Room
3
1 Air supply and first stage filter 4
2 Compressed air
3 Second stage filter
4 Compressed tank and water drain
5 Refrigerate air

Common Types of Cylinders V5
Mechanical Load
Cylinder
Single Acting Cylinder
Piston
A cylinder in which air pressure is
applied to the movable element
(piston) in only one direction
Spring Return Cylinder

A cylinder in which a spring returns
the piston assembly
Ram Cylinder
A cylinder in which the movable
element is the piston rod

V6
Double Acting Cylinder
A cylinder in which air pressure may
be alternately applied to the piston to
drive it in either direction
Double Acting - Double Rod Cylinder

Double acting cylinder with a piston rod
extending from each end.
The piston rods are connected to the same
piston. Double rod cylinders provide equal
force and speed in both directions

Linear Actuators
Machine Vice
Power Chuck

V7&V8

V8-1
Rotary Actuators

V9
Sizing of a Cylinder
Certain parameters must be known
 Total evaluation of the load must be made ( basic load + any friction + force
required to accelerate the load).
 Force needed to exhaust the air from the other end of the cylinder.
 Control valves.
 Once the load and required force characteristics are determined the working
pressure should be assumed
 The cylinder size is calculated

Pneumatic Symbols
Compressor with fixed capacity
Air receiver and ‘T’ junction
Air Filter
Air Lubricator
Pressure Regulator
V10&V11
How is the pressure regulated?

As it moves out as exhaust, and the spring
share some.

Pneumatic Valves
Single Valve Electrically Activated With Spring Return
Single Valve Pneumatically Actuated
Single Valve Electrically Actuated
Multi Set Valves Electrically

Actuated with Spring Return
Single Valve Mechanically Activated With

Dr. Hisham El-Sherif Spring Return
Pneumatic Valves

Spool Types

Spool Valve 5/2

Matched Valve
Pneumatically Activated
Pneumatically Activated

V12 & V13 &V14

3/2 Directional Control Valve
Normally Closed Normally Open
5/2 Directional Control Valve

V15
Shuttle Valve

Basic Rules
 A pneumatic circuit diagram represents the circuit in static form and assumes
there is no supply of pressure.
 The pneumatic symbol of a directional control valve is formed by one or more
squares.
 The inlet and exhaust are drawn underneath the square, while the outlet is
drawn on the top.
 Each function of the valve (the position of the valve) shall be represented by a
square.
 If there are two or more functions, the squares should be arranged horizontally

 Arrows "↓↖" are used to indicate the flow direction of air current. If the external
port is not connected to the internal parts,
 The symbol “┬” is used. The symbol “⊙” underneath
 The square represents the air input,
 The symbol “▽” represents the exhaust.
 The pneumatic symbols of operational components should be drawn on the

outside of the squares.
 They can be divided into two classes: mechanical and manual

Methods of Valve Actuation V16

Auxiliary Symbols

Basic Principles of Drawing Pneumatic Circuit Diagrams
Point 1 When the manual switch is not operated, the spring will restore the valve to its
original position. (figure shows Cylinder in its retracting position)
Point 2 From the position of the spring, one can deduce that the block is operating. The
other block will not operate until the switch is pushed.
Point 3 Air pressure exists along this line because it is connected to the source of
compressed air.
Point 4 As this cylinder cavity and piston rod are under the influence of pressure, the piston
rod is in its restored position.
Point 5 The rear cylinder cavity and this line are connected to the exhaust, where air is
released.

The Setting of Circuit Diagrams
 When drawing a complete circuit diagram, one should place the pneumatic
components on different levels and positions, so the relations between the
components can be expressed clearly.
 This is called the setting of circuit diagrams.
 A circuit diagram is usually divided into three levels: Power Level, Logic
Level and Signal Input Level

Drawing
Area

Different Kinds of Basic Pneumatic Circuits
A basic circuit is a pneumatic circuit designed to perform basic tasks, such as
 Flow Amplification.
 Signal Inversion.
 Memory.
 Delay.
 Single Acting Cylinder Control.
 Double Acting Cylinder Control.

Flow Amplification
Cylinders with a large capacity require a larger flow of air.
we should first operate manually a small control valve and use it to operate the
pneumatic control system with large flow capacity. This is called flow amplification.

Signal Inversion
The Figure shows the pneumatic diagram in how directional control valves can
be switched.
When operating control valve 1, control valve 2 will stop producing pressure
output. When control valve 1 ceases operation and is restored to its original
position, control valve 2 will resume its output. Therefore, at any given time, the
pressure output of control valve 1 is the exact opposite of that of control valve 2.

Memory Function
Memory is a common basic function. It can keep a component at a certain state
permanently until there is a change of signals. When control valve 1 is operated
momentarily (that is, pressed for a short time), the output signal of the 5/2
directional control valve 3 will be set to ON. The signal will stay that way until
control valve 2 is operated momentarily and generates another signal to replace
it, causing it to stay permanently at OFF.

V18 & V20
Delay Function
A pneumatic delay circuit can delay the operating time of the next control valve. Its
principle of operation involves the use of an orifice to slow down the flow of air and
control the time of pneumatic operation.
1- ON-Signal Delay
The circuit delays the output of the next control valve. When control valve 1 is
operated, the one way flow control valve will slow down the flow of air, thus
delaying the signal output of the outlet of control valve 2 (A), resulting in a
persistent ON-signal. The time when control valve 2 will be restored to its original
position is not affected.
When switch is Pressed

figure shows static mode
2- OFF-Signal Delay
The circuit diagram shows an OFF-signal delay circuit, which delays the output of
the next control valve. This circuit is similar to an ON-signal delay circuit. The only
difference is that the one way flow control valve is connected in the opposite
direction. Therefore, when control valve 1 is operated, the outlet of control valve 2
(A) will continue to output signals. However, when control valve 2 is restored to its
original position, the release of air is slowed down by the one way flow control
valve, resulting in a persistent OFF-signal.

Single Acting Cylinder Control
Single acting cylinders can be controlled manually. However, they can also be
controlled by two or more valves. This is called logic control. Examples of logic
control include ‘OR’ function, ‘AND’ function, ‘NOT’ function, etc.
1- Direct Control and Speed Control

If a single acting cylinder is connected to a manual 3/2 directional control valve,
when the control valve is operated, it will cause the cylinder to work manually.

One way Flow Control Valve

Throttle Control Valve
Only controls the air flow from any direction

Supply Air Throttling (Meter-in)
Air Flow controlled for cylinder expansion

Supply Air Throttling (Meter-out)
Air Flow controlled for exhaust

2- OR Function V15
The single acting cylinder can be operated by two different circuits. when either
control valve 1 or control valve 2 is operated, the cylinder will work. Therefore, the
circuit possesses the OR function. However, if the output of two 3/2 directional
control valves are connected through the port of a triode, the air current from
control valve 1 will be released through the exhaust of control valve 2, and so the
cylinder will not work. This problem can be solved by connecting a shuttle valve to
the port of the triode.

V19
3- AND Function
Another name for an AND function is interlock control. This means control is
possible only when two conditions are satisfied. A classic example is a pneumatic
system that works only when its safety door is closed and its manual control valve
is operated. The flow passage will open only when both control valves are
operated. The cylinder will work only when both valve 1 and 2 are operated.

4- NOT Function
Another name for a NOT function is inverse control. In order to hold or lock an
operating conveyor or a similar machine, the cylinder must be locked until a signal
for cancelling the lock is received. Therefore, the signal for cancelling the lock
should be operated by a normally open type control valve. The figure shows how
the normally closed type control valve 1 can be used to cut off the normally open
type control valve 2 and achieve the goal of changing the signal.

Double Acting Cylinder
1- Direct Control
The only difference between a single acting cylinder and a double acting cylinder
is that a double acting cylinder uses a 5/2 directional control valve instead of a 3/2
directional control valve. Usually, when a double acting cylinder is not operated,
outlet ‘B’ and inlet ‘P’ will be connected. In this circuit, whenever the operation
button is pushed manually, the double acting cylinder will move back and forth
once.
In order to control the speed in both directions, flow

control valves are connected to the inlets on both sides
of the cylinder. The direction of the flow control valve is
opposite to that of the release of air by the flow control
valve of the single acting cylinder.
Connecting the circuit in this way allows the input of
sufficient air pressure and energy to drive the piston.

2- Single Control
A cylinder always has to maintain its position in a lot of situations, even after the
operational signal has disappeared. This can be achieved by the use of a circuit that
possesses the memory function.
The extension path of a double acting cylinder is activated by control valve 1, while
retraction is governed by control valve 2. Control valve 3, on the other hand,
maintains the position of the cylinder by maintaining its own position. Control valve
3 will be changed only when one of the manual control valves is pushed.
If both control valves 1 and 2 are operated at the same time, control valve 3 will be
subject to the same pressure and will remain in its original position.

Electro Mechanical Control - Classical Control
Note :
1- Select the reference power lines. Higher and lower
potentials.
2- Vertical steps will have a number, parallel connections
are considered as step.
3- The load is connected direct to the lower potential, no
contacts in between.
4- The circuit operation consists of the following:
Initialization or circuit activation/deactivation
Control contact at each major step.
Operation conditions

Example : Tank Level Control
 The figure shows a fluid grounded tank where the fluid level is controlled by the pump
(220VAC) operation.
 The tank higher and lower levels is monitored by two sensors S1 & S2
 The fluid is supplied from the inlet tube.
 To maintain the tank level the pump will start automatically as soon as the fluid
reaches the upper higher level, this is monitored by S1.
 The pump will starts operation and continue till the fluid reaches the lower level which
is monitored by sensor S2, the pump will automatically stop.


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V1 & V2

Dr. Hisham El-Sherif

In automation industry every mechatronic system has some

Dr. Hisham El-Sherif

Inp Process Outpu

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Solenoids Strain Gauge Input

Optical – Through-beam Inductive Capacitive

Optical – Retro-reflective Reed switch Symbols

Optical - Diffuse Inductive magnetic Connection

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Dr. Hisham El-Sherif

Long sensing distance: up to 30 metres with some devices

Dr. Hisham El-Sherif

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Dr. Hisham El-Sherif

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Resonant circuit coil

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By this variable potentiometer, the Sensor

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