mechatronics lab manual

AMITY SCHOOL OF ENGINEERING AND

TECHNOLOGY

DEPARTMENT OF MECHANICAL AND

AUTOMATION ENGINEERING

SUBJECT: MECHATRONICS

COURSE CODE:- BTM 722

CREDIT UNIT:- 01

LIST OF EXPERIMENTS

Sr.

No.

EXPERIMENTS

1 DESIGN AND EXECUTION OF LIFT CONTROL

2 DESIGN AND EXECUTION OF PICK AND PLACE.

3 DESIGN AND EXECUTION OF FAN OPERATION.

4 DESIGN AND EXECUTION OF WATER LEVEL

CONTROL.

5 DESIGN AND EXECUTION OF SEQUENCING

SWITCHING MOTORS.

6 DESIGN AND EXECUTION OFSTARTER CONTROL

& STAR DELTA FOR ¼ HP AC.

7 DESIGN AND EXECUTION OF SEVEN SEGMENT

DISPLAY MODULE.

8 DIRECT OPERATION OF DOUBLE ACTING

CYLINDER

9 DESIGNING A CIRCUIT FOR SPEED CONTROL OF

DOUBLE ACTING CYLINDER METER IN BY

EMPLOYING 4/2 DC SOLENOID VALVE.


DOUBLE ACTING CYLINDER METER OUT BY

EMPLOYING 4/3 SOLENOID VALVE

11 DESIGNING A CIRCUIT FOR SPEED CONTROL

OFHYDRAULIC MOTOR METER IN CIRUIT BY

EMPLOYING 4/2 DC VALVE.


HYDRAULIC MOTOR METER OUT CIRUIT BY

EMPLOYING 4/3 DCVALVE

13 DIRECT ACTING OF HYDRAULIC MOTOR.

14 DESIGN A SIMPLE PNEUMATIC DIRECT

CONTROL CIRCUIT TO OPEN AND CLOSE THE

GATE OF A FACTORY. BY OPERATING A PUSH

BUTTON VALVE, GATE SHOULD OPEN OR CLOSE.

15 DESIGN A PNEUMATIC CIRCUIT USING A DOUBLE

ACTING CYLINDER AND 5/2 AIR SPRING VALVE TO

OPEN THE MAIN GATE OF A FACTORY WHICH CAN

BE CONTROLLED BY A SECURITY PERSONNEL

FROM THE SECURITY ROOM.

16 DESIGN A PNEUMATIC CIRCUIT USING A DOUBLE

ACTING CYLINDER AND 5/2 AIR SPRING VALVE TO

LIFT THE CARTON BOXES AT THE LOADING POINT.

THE RAISING AND LOWERING SPEEDS ARE TO BE

ADJUSTABLE SEPARATELY.

AJAY SHARMA

FACULTY (MECHATRONICS)

EXPERIMENT NO. 1

OBJECTIVE : TO EXECUTE PICK AND PLACE MODULE REFERENCE

KIT TO BE USED: PLC TRAINER KIT

POSITION INDICATOR CONDITION OF PLKC SWITCH COM USED

RIGHT LIMIT SWITCH I8

LEFT LIMIT SWITCH I9 I8 & I9 INPUTS SWITCH LOW COM2

& COM3

PICK INDICTAION O9 & O4

MOTOR ON O8

DESCRIPTION: The pick and place unit has one motor whose direction and switching can be

controlled by O8.The right and left limit switch gives signal to change the direction by I8 AND I9.Where

as the pick and place is controlled by electro magnet energized, dengerised by O9 and O4 respectively.

MOTOR ON O8

PICK INDICTATION O9 AND O4

RIGHT LIMIT SWITCH I8

LEFT LIMIT SWITCH I9

PROCEDURE: EXECUTION FROM EPROM FOR PICK AND PLACE MODULE

The following procedure must be carrying out to run the program from EPROM:

1. Press RESET ,B.M. AND 3

2. 2. Press RESET, and then EXEC the program

3. Note that EPROM should be inserted in the ZIF properly keeping PIN No. 1 upper side.

RESULT: Execution successful.

PRECAUTIONS:

1. DON’T TOUCH THE CONTROL PANEL WITHOUT PERMISSION.

2. READ ALL INSTRUCTION BEFORE DOING THE EXPERIMENT.

PICK AND PLACE MODULE REFERENCE

EXPERIMENT NO. 2

OBJECTIVE: TO EXECUTE LIFT CONTROLLER MODULE


DESCRIPTION:

Lift controllers has one motor which is controlled by O2- on when its up and down movement is

controlled by O3 - on up direction.O3-off down direction. The request switch of each floor is input I2, I3,

I4 & I5.Where the lift position and clear is generated by O9, O8, O14 & O15

FLOOR POSITION INPUT OUT PUT

GND I2 O9

1ST

I3 O8

2ND

I4 O14

3RD

I5 O15

MOTOR ON (DIRECTION) O2

MOTOR ON upward direction O3

PROCEDURE: EXECUTION FROM EPROM FOR LIFT CONTROLLER MODULE:


1. Press RESET, Shift B.M. and 1

2. Press RESET ,then EXEC the program

Note that EPROM should be inserted in the ZIF properly keeping pin no. 1 upper side.


PRECAUTIONS:



LIFT CONTROLLER MODULE

EXPERIMENT NO. 3

OBJECTIVE: SEQUENCE SWITCH FOR MOTOR MODULE REFERENCE


Alternative Indicator Condition of PLC switch COM used

OR & O5 ALL INPUTS SWITCH COM2 AND

HIGH COM3

DESCRIPTION:

Sequence Switch is controlled by PLC by using COM2 AND COM3.When running module it the

output of 220V AC. Alternatively appears on both sockets. Output can be seen in PLC Main unit

on O4 & O5

PROCEDURE: EXECUTION FROM EPROM FOR SEQUENCE SWITCH MODULE:


1. Press RESET,B.M. and 4

2. Press RESET, and then EXEC the program.


PRECAUTIONS:



SEQUENCE SWITCH FOR MOTOR MODULE REFERENCE

EXPERIMENT NO. 4

OBJECTIVE: STAR DELTA AND MOTOR CONTROL FOR 3 PHASE MODULE REFERNCE


OUTPUT INDICATOR CONDITION OF PLC SWITCH COM USED

O4 ALL INPUT COM1 &

COM3

O5 SWITCH HIGH

DESCRIPTION:

The star & delta connection for 3-phase A.C. motor and its control is done by PLC using contractors.The

motor is switched ON is star for starting and then changed in delta for normal.

When star connected, the applied voltage over each motor phase is reduced by a factor of 1/3 and hence

the torque developed becomes 1/3 of that which would have been developed if the motor was directly

connected in Delta .The line current is reduced to 1/3.

Hence during starting period when motor is star connected, it takes 1/3 as much starting current and

developed 1/3 as much torque would have been developed were it directly connected in Delta. We are

using output O4 & O5 of PLC unit.

PROCEDURE: EXECUTION FROM EPROM FOR STAR DELTA MODULE:

The following procedure must be carry out to run the program from EPROM:

1. Press RESET, B.M. and 5.



PRECAUTIONS:

1. All supply voltages are of 440 V so check all the connections before power ON.

2. Do not change the connections from star to delta immediately, It may spoil the motor.

STAR DELTA AND MOTOR CONTROL FOR 3 PHASE MODULE REFERNCE

EXPERIMENT NO. 5

OBJECTIVE: TANK LEVEL CONTROL MODULE REFERENCE


INDICATOR WATER LEVEL CONDITION OF PLC SWITCH COM USED

PUMP ON O8 LOW (P1) I2 & I3 INPUT COM1 & COM3

MEDIUM (P2) SWITCH

& HIGH (P3) NEUTRAL

DESCRIPTION:

Tank level control is controlled by PLC by using COM 1 and COM 3. Note that input switch I2 and I3

should be in neutral position. The low level (P1) is always high i.e. it always dips in water tank. On

running module the water is running through pump till then the water reaches at high level (P3). On

touching the high level P3 the water flow will stop i.e. pump will stop. Output can be seen in PLC main

unit on O8.

PROCEDURE: Execution from EPROM for Tank Level Control Module:

The following procedure must be carried out to run the program from EPROM:

1. Press RESET ,B.M. and 6

2. Press RESET, and then EXEC. The program


PRECAUTIONS:



TANK LEVEL CONTROL MODULE REFERENCE

EXPERIMENT NO. 6

OBJECTIVE: FAN CONTROL MODDULE REFERENCE


SPEED O/P INDICATOR CONDITION OF PLC SWITCH COM USED

Medium 01 ALL I/P SWITCH High

Minimum 03 ALL I/P SWITCH High COM3

Maximum 00 ALL I/P SWITCH High

DESCRIPTION:

A Controller is controlled by PLC by using COM3. On running Module it is controlled the speed of fan in

three stage Medium, Minimum, and Maximum. These speeds can be seen in PLC Main Unit on Output

LED ie: 01, 03, and 00

PROCEDURE: Execution from EPROM for Fan controller Module:


1. Press RESET, B.M AND

2. Press RESET and then EXEC the program


PRECAUTIONS:



FAN CONTROL MODDULE REFERENCE

EXPERIMENT NO. 7

OBJECTIVE: SEVEN SEGMENT DISPLAY MODULE REFERENCE


DISPLAY ON SEVEN CONDITION OF COM USED

SEGMENT PLC SWITCH

GOOD ALLNPUT COM2

SWITCH HIGH

DESCRIPTION:

Seven segment Display Module is controlled by PLC by using COM2. After execution of

program the GOOD will be display on seven segment Display.

PROCEDURE: Execution from EPROM for Seven Segment Display Module:


1. Press RESET, B.M. and 8



PRECAUTIONS:



SEVEN SEGMENT DISPLAY MODULE REFERENCE

EXPERIMENT NO. 8

OBJECTIVE: REACTION VESSELS MODULE REFERENCE


INDICATOR CONDITION OF COM USED

PLC SWITCH

HEATER ON O1 12 & 13 INPUT COM 1 & COM 3

SOLONID ON I4 SWICTH NEUTRAL

DESCRIPTION:

Reaction Vessels Control is controlled by PLC by using COM 1 & COM 3. Note that input

switch I2 & I3 should be in Neutral position. Set the heating temperature by thermostat, heat the

water by heater. When temperature reaches at set point, heater will stop and solenoid value will

work. Using solenoid value the water will flow in lower tank when level reaches lower set point

the pump will on. Output can be seen in PLC main unit on (solenoid ON).

PROCEDURE: Execution from EPROM for Reaction Vessels Module

The following procedure must be carrying out to the program from EPROM.

1. Press RESET, B.M. and 7



PRECAUTIONS:



REACTION VESSELS MODULE REFERENCE

OIL POWER HYDRAULIC CUIRCUIT TRAINER KIT

COMMONNLY USED SYMBOLS USED IN HYDRAULICS & PNEUMATIC

CURCUITS

EXPERIMENT NO. 9

OBJECTIVE: TO DO THE DIRECT ACTUATION OF DOUBLE ACTING CYLINDER

KIT TO BE USED: OIL POWER HYDRAULIC TRAINER

PROCEDURE:

Connect, operate and analyze circuit as per Schematic diagram of circuit.

RESULT: SUCCESSFUL EXECUTION OF THE EXPERIMENT DONE.

PRECAUTION:

1. DON’T STAND INFRONT OF THE CONTROL PANEL IN OPERATING CONDITION.

2. OPERATE THE SYSTEM UNDER FACULTY’S GUIDANCE

DIRECT ACTUATION OF DOUBLE ACTING CYLINDER

EXPERIMENT NO. 10

OBJECTIVE: TO DO THE DIRECT ACTUATION OF HYDRAULIC MOTOR


PROCEDURE:



PRECAUTION:



DIRECT ACTUATION OF HYDRAULIC MOTOR

EXPERIMENT NO. 11

OBJECTIVE: TO DO THE METER IN CIRCUIT WITH 4/2 SOLENOID VALVE FOR

DOUBLE ACTING CYLINDER


PROCEDURE:



PRECAUTION:



METER IN CIRCUIT WITH 4/2 SOLENOID VALVE FOR DOUBLE ACTING CYLINDER

EXPERIMENT NO. 12

OBJECTIVE: TO DO THE METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR

DOUBLE ACTING CYLINDER


PROCEDURE:



PRECAUTION:



METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR DOUBLE ACTING CYLINDER

EXPERIMENT NO. 13

OBJECTIVE: TO DO THE METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR

SERVO MOTOR


PROCEDURE:



PRECAUTION:



METER OUT CIRCUIT WITH 4/3 SOLENOID VALVE FOR SERVO MOTOR

POST PRACTICAL QUESTIONS

1. A double acting cylinder has a piston diameter of 2 inches and a rod diameter of 3/4". The

piston stroke is 8 inches.

a) If oil can be supplied to either end of the cylinder at a pressure of 1000 psi and a flow of 3

gal/min, calculate the force that can be developed and time of travel (in seconds) during

extension and retraction.

b) Briefly explain why the forces and speeds are different during extension and retraction.

c) Show whether the power developed is the same or different during extension and retraction..

Use your values of forces and time.

2. Briefly describe the difference between a linear hydraulic cylinder and a regenerative one.

a) Will a single acting cylinder work in either case and, if not, why not?

b) What differential piston area ratio is required for the regenerative system? Will any other ratio

work?

3. Describe the operation of the circuit for speed control of the hydraulic rotary valve motor

circuit

4. For the Hydraulic Motor and cylinder circuit answer the following questions.

a). Describe the sequence of events as the directional valve is move to its various positions.

b). Is this an "open" or "closed" center system?

c). Is the motor reversible or does it always run in the same direction?

d). Can the motor speed be varied? How and when can it be varied?

e). Under what conditions can the motor speed not be varied?

PROGRAMMABLE LOFIC CONTROLLER WITH PNEUMATIC CIRCUITS

In automation, mechatronics plays a great role. Suppose we want to use sensor inputs and give

outputs to motors to control certain machine or plant as shown in Fig 1. Before electronics

becomes popular and cheaper, it has been controlled using pneumatic and/or hydraulic values.

Now a day’s these are replaced by mechatronics systems. Fig 1.2 In mechatronics, we use

electronics in four different ways:

1.Programmable logic controllers -PLC is a digital electronic device that uses a programmable

memory to store instructions for obtaining logic, sequencing, timing, counting and arithmetic in

order to control machine and processes. The advantage of using PLC is that it is possible to

modify a control system without having the input and output devices rewired and without using

new or modified control valves in order to change the required logic. The only requirement being

that an operator has to key in a different set of instructions. The result is a flexible system that

can be used in control systems that vary quite widely in their nature and complexity.

2. Electronics circuits-This is commonly used in mass products or large batch products since

these circuits are especially designed for the purpose. Ex. Control cards, motor driving circuits.

3. Computer controlled machines-Computer acts as a controller taking inputs from sensors and

giving the necessary output signals to the actuators or motors.

Fig 1.2 MECHATRONICS SYSTEM

CONTROLLERS

MOTORS

SENSORS

4. Micro controllers- it is a programmable integrated circuit (IC). Functions of the micro

controllers could be quite similar to PLCs. It is more compact, more flexible in programming and

much cheaper, but more programming is required and less number of inputs and outputs in

general relative to a PLC.

All these devices have advantages and limitations over each other and hence choice of the

controlling method is application dependent. All the above mentioned devices consist of

electronic circuits and they consider digital inputs and digital outputs though some PLCs can

obtain a kind of analogue inputs and outputs. All the above three mentioned

Controllers generally consider a digital voltage inputs and a voltage output.

Sensors and Transducers

The term sensor is used for an element that produces a signal relating to the quantity being

measured. Transducers are defined as elements that when subject to some physical change

experiences a related change. Thus sensors are transducers. However, a measurement system

may use transducers, in addition to the sensor, in other part of the system to convert signals from

one form to other form.

Signal conditioners

Sensors can give different kinds of output from the sensing devices and these outputs have to be

processed or converted as a voltage and the voltage output may have to be converted or

processed to other type of signals in mechatronics systems. This device is known as a signal

conditioner. Operational amplifier and A/D converter are two examples of such devices. Signal

conditioners act a major role between controller and sensors as well as controller and motor or

actuators.

Pneumatic Systems

In early systems, control functions were obtained through pneumatic valves and today replaced

by electronic circuits and still pneumatic signals are still popular and used to control final control

elements because such signal can be used to actuate large valves and other high power control

devices. The main drawback of the pneumatic systems is however the compressibility of air.

Pneumatic is not only used as a control mechanism, but also as actuators and in some cases logic

is conducted through a PLC or an electronic circuit with electro-pneumatic valves to convert the

signals.

Hydraulic Systems

Hydraulic Systems are used basically for actuators and motors consisting high power. In Heavy

Machinery equipments hydraulic actuators are used to conduct many tasks. Hydraulic control

valves are used to change the direction of the fluid by giving manual, electro-mechanical or/and

pneumatic signals. However, there are hazards in using

hydraulics due to oil leaks that does not matter in pneumatic systems.

Data bus

Address bus

Control bus

Fig: PLC Architecture

Programmable Logic Controllers

PLC is similar to using a computer but has certain features that are specific to their use as

controllers. These are:

1. They are rugged and designed to withstand vibrations, temperature, humidity and noise.

2. The interfacing for inputs and outputs is inside the controller.

3. They are easily programmed and have an easily understood programming language.

Programming is primary concerned with logic and switching operations.PLCs were first

conceived in 1968. They are now widely used and extend from self-contained units for use with

around 20 digital inputs/outputs to modular systems that can be used for large number if

inputs/outputs, handle digital or analogue inputs/outputs and also carry out PID control modes.

Electronic Control Circuits

Basic electronic control circuits consist of two types, namely combinational logic gates and

sequential logic gates. The advantage of electronic control circuits is construction is cheaper than

pneumatic values, hydraulic values or programmable logic controller, but design is quite costly.

In this course, we will only look at electronic controllers although electronic circuits are used as

signal -conditioning device such as amplifies, voltage dividers or A/D converters.

CPU Memory I/O unit

Program panel

Input channels

Output channels

What is a PLC?

A Programmable Logic Controller, or PLC for short, is simply a special computer device used

for industrial control systems. They are used in many industries such as oil refineries,

manufacturing lines, conveyor systems and so on. Where ever there is a need to control devices

the PLC provides a flexible way to "softwire" the components together.

The basic units have a CPU (a computer processor) that is dedicated to run one program that

monitors a series of different inputs and logically manipulates the outputs for the desired

control. They are meant to be very flexible in how they can be programmed while also providing

the advantages of high reliability (no program crashes or mechanical failures), compact and

economical over traditional control systems.

A Simple Example

Consider something as simple as a switch that turns on a light. In this system with a flick of the

switch the light would turn on or off. Beyond that though there is no more control. If your boss

came along and said I want that light to turn on thirty seconds after the switch has been flipped,

then you would need to buy a timer and do some rewiring. So it is time, labor and money for

any little change.

A PLC Saves the Day

Now consider the same device with a PLC in the middle. The switch is fed as an input into the

PLC and the light is controlled by a PLC output. Implementing a delay in this system is easy

since all that needs to be changed is the program in the PLC to use a delay timer.

This is a rather simple example but in a larger system with many switches and lights (and a host

of other devices) all interacting with each other this kind of flexibility is not only nice but

imperative. Hopefully a light bulb has now turned on over your head.

Programming a PLC

In these modern times a PC with specially dedicated software from the PLC manufacturer is used

to program a PLC. The most widely used form of programming is called ladder logic. Ladder

logic uses symbols, instead of words, to emulate the real world relay logic control, which is a

relic from the PLC's history. These symbols are interconnected by lines to indicate the flow of

current through relay like contacts and coils. Over the years the number of symbols has

increased to provide a high level of functionality.

The completed program looks like a ladder but in actuality it represents an electrical circuit. The

left and right rails indicate the positive and ground of a power supply. The rungs represent the

wiring between the different components which in the case of a PLC are all in the virtual world

of the CPU. So if you can understand how basic electrical circuits work then you can understand

ladder logic.

In this simplest of examples a digital input (like a button connected to the first position on the

card) when it is pressed turns on an output which energizes an indicator light.

http://www.plcdev.com/the_birth_of_the_plc

The completed program is downloaded from the PC to the PLC using a special cable that’s

connected to the front of the CPU. The CPU is then put into run mode so that it can start

scanning the logic and controlling the outputs.

On a program ladder diagram are two basic types of instructions:

Input Instructions: An instruction that checks, compares, or examines specific conditions in

your machine or process.

Output Instructions: An instruction that takes some action, such as turn on a device, turn off a

device, copy data, or calculate a value.

Branch

A branch is two or more instructions in parallel.

There is no limit to the number of parallel branch levels that you can enter. This example shows

a parallel branch with five levels. The main rung is the first branch level, followed by four

additional branches.

You can nest branches to as many as 6 levels. This example shows a nested branch. The bottom

output instruction is on a nested branch that is three levels deep.

Rung Condition :

The controller evaluates ladder instructions based on the rung condition preceding the instruction

(rung-condition-in).

Only input instructions affect the rung-condition-in of subsequent instructions on the rung.

If the rung-condition-in to an input instruction is true, the controller evaluates the instruction and

sets the rung-condition-out to match the results of the evaluation.

If the instruction evaluates to true, the rung-condition-out is true.

If the instruction evaluates to false, the rung-condition-out is false.

An output instruction does not change the rung-condition-out.

If the rung-condition-in to an output instruction is true, the rung-condition-out is set to

true.

If the rung-condition-in to an output instruction is false, the rung-condition-out is set to

false

INTRODUCTION TO PNEUMATICS

The reason for using pneumatics, or any other type of energy transmission on a machine, is to

perform work. The accomplishment of work requires the application of kinetic energy to a

resisting object resulting in the object moving through a distance. In a pneumatic system, energy

is stored in a potential state under the form of compressed air. Working energy (kinetic energy

and pressure) results in a pneumatic system when the compressed air is allowed to expand. For

example, a tank is charged to 100 PSIA with compressed air. When the valve at the tank outlet is

opened, the air inside the tank expands until the pressure inside the tank equals the atmospheric

pressure. Air expansion takes the form of airflow.

To perform any applicable amount of work then, a device is needed which can supply an air tank

with a sufficient amount of air at a desired pressure. This device is positive displacement

compressor.

Common Types of Cylinders

There are many different cylinder types. The most common are listed below:

Single acting cylinder - 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.

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 form each end. The piston rods are connected to the same

piston. Double rod cylinders provide equal force and speed in both directions.

Directional Control Valves

To change the direction of airflow to and from the cylinder, we use a

directional control valve. The moving part in a directional control valve will

connect and disconnect internal flow passages within the valve body. This

action results in a control of airflow direction. The typical directional control

valve consists of a valve body with four internal flow passages within the

valve body and a sliding spool.

Shifting the spool alternately connects a cylinder port to supply pressure or

the exhaust port. With the spool in the position where the supply pressure is

connected to port A and port B is connected to the exhaust port, the cylinder

will extend. Then, with the spool in the other extreme position, supply

pressure is connected to port B and port A is connected to the exhaust port,

now the cylinder retracts. With a directional control valve in a circuit, the

cylinder's piston rod can be extended or retracted and work performed.

Functional Types of Directional Control Valves

One method of classifying a directional control valve is by the flow paths that

are set up in its various operating conditions. Important factors to be

considered are the number of individual ports, the number of flow paths the

valve is designed for and internal connection of ports with the movable part.

Two-Way Directional Valve

A two-way directional valve consists of two ports connected to each other

with passages, which are connected and disconnected. In one extreme spool

position, port A is open to port B; the flow path through the valve is open. In

the other extreme, the large diameter of the spool closes the path between A

and B; the flow path is blocked. A two-way directional valve gives an on-off

function.

Three-Way Directional Valve:

A three-way directional valve consists of three ports connected through

passages within a valve body that are shown here as port A, port P and

port Ex. If port A is connected to an actuator, port P to a source of pressure

and port Ex is open to exhaust, the valve will control the flow of air to

(and exhaust from) Port A. The function of this valve is to pressurize and

exhaust one actuator port. When the spool of a three-way valve is in one

extreme position, the pressure passage is connected with the actuator

passage. When in the other extreme position, the spool connects the

actuator passage with the exhaust passage.

VARIOUS TYPES OF VALVE SYMBOLS:

ISO SYMBOLS FOR AIR TREATMENT EQUIPMENT

Pneumatics Circuits and Applications

Pneumatic circuit design consideration:

When analyzing or designing a pneumatic circuits, the following four important considerations

must be taken into account:

• Safety of operation

• Performance of desired functions

• Efficiency of operation

• Costs

The typical cost for the compressing air to 100 psig is about $0.35 per 1000 ft^3 of

standard air.

BASIC PNEMATICS LAYOUT:

Example : Air pilot control of double-acting cylinder

Purpose: To operate a double-acting cylinder remotely through the use of an

air pilot-actuated DCV.

EXPERIMENT NO.14

Objective: Design a simple pneumatic direct control circuit to open and

close the Gate of a factory. By operating a push button valve, gate should

open or close.

Component List

a) FRL Unit.

b) 3/2 Push Button Valve.

c) Single Acting Spring Return Cylinder.

Description:

a) FRL – Unit (Filter Regulating and Lubricating Unit):

This is positioned between Air source and the components. This unit plays an important

roll in pneumatic systems. The FRL Unit provides compressed clean and oil – enriched air

at a constant pressure to the system.

b) 3/2 Pus Button Valve: This component has three air ports and two positions (pressed

or released). P is an air inlet port, A is a working port (Out Let Port) and R is an Exhaust

Port. The valve is activated by a manual push button and returned by spring force.

c)Spring Return Cylinder: When pressurized air enters through Port, it pushes the piston

out of the cylinder, thereby contracting the spring. When no air pressure is applied, the

spring expands, drawing the piston back into the cylinder.

Procedure:

Select the components from component library. Load the single acting cylinder, place at

the top of the Screen. Load 3/2 push button valve and place between cylinder and

conditioning Unit (FRL). The FRL Unit will be at the bottom by default. Before starting

simulation FRL unit parameters (i.e. Pressure and Flow) are to be set by double clicking

on it. Connect the components as per the circuit, as show in Fig.No.1 Click on Simulation

icon or from main menu to start simulation and observe the following.

Result:

When the push button is pressed, the spring in the valve is compressed, allowing air to

flow through the valve to the cylinder. Air passes through the rear port of the cylinder and

pushes the piston rod out. (Thereby opening the gate).

When the push button released, the spring in the valve expands. Air is exhausted from the

cylinder and airflow to the cylinder is blocked. The spring in the cylinder is able to

expand; the piston rod retracts (thereby closing the gate)

.

Fig no:1

EXPERIMENT NO. 15

Objective: Design a pneumatic circuit using a double acting cylinder and

5/2 Air Spring Valve to open the main gate of a factory which can be

controlled by a security personnel from the security room.

Component List:

a) FRL Unit:

b) 5/2 Air Spring Valve.

c) 3/2 Push botton Valve

d) Double Acting Cylinder.

Description:

5/2 Air Spring Valve:

This component has five airports and two positions. P is an air inlet port; A& B are

working ports (Outlet ports). R& S are air Exhaust Ports and Y is pilot Operated port.

Double Acting Cylinder:

This cylinder has two inlet ports A & B. Air entering from A port extends the piston,

Air at the other side is exhausted through B port. If air enters through B port piston rod

of the cylinder will retract while air exhausts from the A port.

Procedure:

Load the double acting cylinder and place at the top of the screen. Load 5/2 Air Spring

Valve and place below the cylinder. The FRL Unit will be at the bottom by default.

Connect the components as per the circuit, as show in fig. No.2

Result:

When the Push button valve is activated, allowing air to flow through the 5/2air spring valve to

the rear port of the cylinder then piston rod extends. (There by opening the gate). When the Push

Button is released, allowing the air to flow through the valve to the front port of the cylinder. The

cylinder piston rod retracts.

Fig no:2

EXPERIMENT NO. 16

Objective: Design a pneumatic circuit using a double acting cylinder and 5/2

Air Spring valve to lift the carton boxes at the loading point. The raising and

lowering speeds are to be adjustable separately.

List of components:

a) FRL Unit

b) 5/2 Air Spring Valve

c) 3/2 Push button Valve.

d) Double Acting Cylinder

e) Flow Control valves -2 Nos.

Description:

a) Flow Control Valve:

This valve are used to regulate airflow. Example, to control the piston speeds of the

cylinder. The air can flow only via the cross section, which is adjustable by means of the

throttle screw. The user can change the settings by double clicking on it. The settings vary

from 2 to 16.

Procedure:

Select the components from components library and place the double acting cylinder at the

top of the Screen. 5/2 air Spring valve below the cylinder. The Flow Control Valve is

placed between cylinder and Air Spring Valve. The FRL Unit will be at the bottom by

default. Connect the components as per the circuit, as show in Fig No.3.

Result: When the Push Button is pressed, allowing air to flow through the valve to the

one port of the cylinder. The air enters from the rear port of the cylinder and pushes the

piston rod out. (Thereby opening the gate). When the push-button Valve released,

allowing the air to flow through the valve to the front port of the cylinder. Then the

cylinder piston rod retracted (thereby gate is closed). Adjust the throttle valve screws and

observe the variation in piston speed.

Fig.No.3

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