Advanced Manufacturing Systems (MVS4A11-MVSMCA4)

Continuous Assessment #2

Date 07th March 2022

Time 180 min
Marks 100

Internal Examiner: Prof JR Ren

External Moderator: Prof. SZ Du

Notes
1. Answer ALL questions.
2. This paper contains 4 questions.
3. Number all answers according to the numbering in question paper.
4. Make sure that you understand what the question requires before attempting it.
5. No pencil work will be marked. Please use pen for parts to be marked.
6. Answer all questions in English.
7. Explain answers and give all the necessary steps – simply giving the answer is
not sufficient.
8. Late submission penalty: a 5% reduction from the actual mark achieved.
9. Submit into Blackboard system, NO EMAILS!

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Question 1 – Basic understandings (55)

1.1 Give out the definition of (a) Automation, (b) Mechanization, (c) Program of Instructions.
(3’)
1.2 Explain the basic elements of an automated system. (3’)
1.3 Explain the choice of close-loop and open-loop control systems. (3’)
1.4 What is safety monitoring in an automated system, and what are the reasons for safety
monitoring? (3’)
1.5 Explain the levels of automation in a production plant (3’)
1.6 What is industrial control? (3’)
1.7 Explain the difference between an event-driven change and a time-driven change in discrete
control. (3’)
1.8 What are the hardware components for automation and process control? (3’)
1.9 What is the resolution of an analog-to-digital converter? (3’)
1.10 What are transfer functions of sensors? (3’)
1.11 What is numerical control, and what are the basic components of a numerical control
system? (3’)
1.12 What makes industrial robots commercially and technologically important? (3’)
1.13 What is a ladder logic diagram, and what is a programmable logic controller? (3’)
1.14 What are components of the PLC, and what are advantages to use PLC? (3’)
1.15 What are common languages for programming PLCs? (3’)
1.16 What is the difference between a Mass Flow Meter and a Mass Flow Controller? (3’)
1.17 Given a Mass Flow Meter was calibrated in plant by N2 gas at normal conditions, can
it be used for air flow measurement? (3’)
1.18 What is the Calibration Sheet of a Mass Flow Meter, and why is it important to keep it
well? (4’)

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Question 2 – Transfer Functions of Sensors (15)

During calibration, an iron/constantan thermocouple emits a voltage of 1.05 mV at 20 °C, and

28.42 mV at 600 °C. The reference temperature is to be set to emit a zero voltage at 0 °C.
Assume the transfer function of this thermocouple is a linear relationship between 0 °C and
600 °C.
(a) Determine the transfer function of this thermocouple.
(b) Determine the temperature that is corresponding to a voltage output of 25 mV.
(c) Determine the voltage output that is corresponding to a temperature of 380 °C.
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Question 3 – Digital Flow Meter (15)

A digital flow meter operates by emitting a pulse for each unit volume of fluid flowing through
it. The particular flow meter of interest has a unit volume of 80 cm3 per pulse. In a certain
process control application, the flow meter emitted 5 665 pulses during a period of 3.5 min.
(a) Determine the total volume of fluid that has flowed through the flow meter.
(b) Calculate the flow rate of fluid flow.
(c) What is the pulse frequency (Hz) corresponding to a flow rate of 65 000 cm3/min?

2
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Question 4 – Mass Flow Controller (15)

A mass flow controller has been manufactured and its transfer function has been proved as a
linear relationship between 0 SLM and 50.03 SLM. The output signal is 4 mA when the passing
flowrate is 0 SLM, and the output signal is 20 mA when the passing flowrate is 50 SLM. Here
SLM = Standard Liter per Minute.
(a) Determine the controlling function of this mass flow controller.
(b) What is the flowrate set-point corresponding to an output signal of 18 mA?
(c) What is the output signal when the flowrate is set at 35 SLM by the end-user?