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1 NPTEL Syllabus Automation & Sensor Interface Laboratory - Web course COURSE OUTLINE Automation & Sensor interface laboratory is an application oriented course with review of automation principles, followed up with step-bystep demonstration of laboratory experiments with professional trainer kits, available in the market. Pneumatic, hydraulic & electrical systems will be introduced and the students will be able to appreciate the integration of various components to achieve specific sequence & logical control of systems, pertaining to industrial automation. A n outline of sizing of fluid power systems to meet load & velocity requirements in the field will be exemplified through case studies. S ensors, PLCs & actuators and their interface using virtual instrumentation platform will be introduced and their field applications will be demonstrated through several innovative laboratory experiments. T h e course material includes several animations, simulation of sequential circuits, videos of industrial applications and case studies for effective comprehension by students. Learning outcome: On learning the lab course the student will be in a position to. Design, simulate and validate sequential logic circuits using pneumatics & electro-pneumatics.. Design, simulate and validate sequential logic circuits using hydraulics & electro hydraulics. 3. Program a PLC for the operation of multi actuator sequential fluidic circuits. 4. Interface sensors with a PC, using virtual instrumentation platform to acquire data and perform control actions. 5. Control of actuators using an industrial PC for field applications. COURSE DETAIL NPTEL Mechanical Engineering Pre-requisites: Working knowledge of Fluid Mechanics principles Knowledge about hydraulic and pneumatic symbols & circuit design Knowledge about sensors & instrumentation Knowledge about dynamics of machinery Additional Reading: The following books by Festo-didactic: Pneumatic Basic Level TP 0 Advance pneumatic Work Book TP0 Fundamentals of Pneumatic Control Engineering Electro-Pneumatics Basic Level TP0 Advance Electro pneumatic Work Book TP0 Sl. No. Description Hours PLC Work Book TP 30 Text Book Hydraulics Basic Level THEORY Review of fundamentals of pneumatics, air preparation and distribution, designation representation of element- actuators, control valves, processing elements and signalling elements. THEORY Constructional details of actuators, cylinder performance characteristics, mounting details configuration and construction of direction control valves-3/ way, 4/ way, 5/ way spool valves. Constructional details of non return, flow, pressure valves, valve Text Book Electro-Hydraulics Basic Level Basic Hydraulic Work Book TP 50 Advance Hydraulic Work Book TP 50 Basic Electro hydraulic Work Book TP 60 Closed Loop Pneumatic Work Book TP Closed Loop Hydraulic Work Book TP 5 Proportional Hydraulic Work Book TP 70 Cutting Cost with Pneumatics Text Book Proportional Hydraulics Basic
2 combinations. 3 THEORY Program control type- sequence control, time control application example, positional sketch, Displacement step diagram, circuit diagram. 4 LAB EXPERIMENT Direct control of single acting pneumatic actuator, double acting pneumatic actuator with speed control (meter-in & meter-out) employing manual single cycle and continuous reciprocation modes of operation. 5 THEORY Co-ordinated motion of multiple pneumatic actuators in a desired sequence using cascade method. 6 THEORY Fringe condition modules for pneumatic systems- start selection, emergency and start restriction modules. 7 LAB EXPERIMENT Integration of fringe condition modules in multiple actuator pneumatic systems. 8 THEORY Review of components in electrical control of pneumatic systems -push button & control switches normally open and closed type, Limit switches, reed switches, proximity switches(capacitive, inductive & optical), pressure switches, relays & contactors, solenoid operated direction control valves, symbols, performance data, ladder diagram, programmable logic controllers, input and output elements. 9 THEORY Review of sequential logic circuit design with Karnaugh Veitch Mapping method for pneumatic control systems, electro pneumatic control systems ladder diagram. 0 LAB EXPERIMENT Co-ordinated motion of multiple actuator, electro pneumatic systems in a desired sequence using hard wire programmed control systems. LAB EXPERIMENT Co-ordinated motion of multiple actuator, electro pneumatic systems in a desired sequence using memory programmed via PLC control system. Text Book Proportional Hydraulics Basic Level Sensors for Handling and Processing Technology Grippers and their Applications Rationalization with Handling Technology Clamping with Compressed Air and Vacuum Modular Pick and Place Devices Rationalization of Small Work piece Feeding Sensor Application Compressed Air as an Energy Carrier Fluid Muscle Applications Work Book Servo Pneumatic Positioning The following books/ tutorials by National Instruments: Richard Figliola, Donald Beasley, "Theory and Design for Mechanical Measurements" Wiley publications, 4th edition,005. Rahman Jamal, Herbert Pichlik, "LabVIEW Applications and Solutions", Prentice Hall, 998 Alexander Hornberg, "Handbook of Machine Vision", Wiley - VCH,006 B. E. Paton, "Sensors Transducers Labview", Prentice Hall PTR, 998 John Essick, "Hands-On Introduction to LabVIEW for Scientists and Engineers",Oxford University Press, Hyperlinks: Coordinators: Dr. K.A. Jagadeesh Dr. P.R. Thyla Dr. P.V. Mohanram Mr. C. Manoharan
3 PLC control system. THEORY Sizing of components in a typical pneumatic system for specified load and velocity requirements. 3 THEORY Review of power hydraulic systems, fundamental physical principles of hydraulics, simple calculation involving pressure drop, temperature rise, power consumption. Hydraulic oil-characteristics & requirements. Mr. K. Sadesh Mr. N. Ganeshkumar Mr. S. Udhayakumar 4 THEORY Review of components of hydraulic system pumps, motors, cylinders, different types of control valves designation methods of actuation, power supply system, hoses, filters etc., circuit diagram with technical data. Typical industrial application circuits including synchronizing circuit, fail safe circuit, and two-hand safety circuit. 3 5 LAB EXPERIMENT Co-ordinated motion of multiple hydraulic actuators in a desired sequence. 6 LAB EXPERIMENT Familiarisation and understanding of the following hydraulic circuits:. Inlet & outlet flow control (meter-in & meter-out circuit). Differential circuit 3. Hydraulic motor circuit 4. Accumulator circuit 5. Counter balance circuit 5 7 THEORY Analysis of accumulator systems and sizing of accumulator. 8 THEORY Sizing of components in a typical hydraulic system for specified load & velocity requirements accounting for pressure drop across various elements. 9 THEORY Review of data acquisition fundamentals. Time domain and frequency domain analysis. Signal conditioning and calibration concepts for various sensors. Development of PC based virtual instrumentation application for data acquisition and analysis. Data logging & reporting, examples, tutorials. 5
4 0 LAB EXPERIMENT Interfacing of hot wire anemometer with data acquisition system to measure the air flow rate and calibration of the same. Measurement of pressure drop across pneumatic valves using differential manometer for different field conditions. LAB EXPERIMENT Interfacing of an LVDT with a PC for monitoring the velocity and acceleration of linear pneumatic actuator with different levels of cylinder cushioning and piston velocities. LAB EXPERIMENT Experimental determination of the natural frequency of vibration of a single degree of freedom system using a stepper motor to excite the system at various frequencies. 3 LAB EXPERIMENT Measurement of damping ratio of a machine tool base from free vibration studies using an impact hammer and an accelerometer pick up with data acquisition system. 4 LAB EXPERIMENT Interfacing of an accelerometer with data acquisition system to capture the vibration signals under dynamic environment and perform condition monitoring of a rotating equipment. 5 LAB EXPERIMENT Development of strain gauge set up to measure strains in a statically loaded machine structure and calibration of the same. 6 LAB EXPERIMENT Interfacing of a thermocouple to monitor temperature in a thermal chamber and controlling a fan and heating source to maintain the temperature of the chamber within a specified tolerance limits. 7 LAB EXPERIMENT Interfacing of electrically operated multiactuator controlled pneumatic system with a PC using virtual instrumentation platform. Total 45 References: Anthony Esposito, "Fluid Power with Application", Pearson
5 Education (Singapore) Pvt., Ltd, Delhi, India, Fifth Edition, First Indian Reprint, 003. Peter Rohner, "Fluid Power Logic Circuit Design - Analysis, Design Method and Worked Examples", Wiley publications, 979. Srinivasan R, "Hydraulic and Pneumatic Controls", Vijay Nicole Imprints Pvt., Ltd., McGraw-Hill Education (India) Pvt. Ltd., nd edition, 004. A joint venture by IISc and IITs, funded by MHRD, Govt of India
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