mechatronics lab manuaol 2.docx

INTRODUCTION TO MECHATRONICS SYSTEM

EXP NO:1 DATE:

To study about the important features, about Mechatronics system.

INTRODUCTION TO MECHATRONICS SYSTEM:

Mechatronics is one of the new and existing fields on the engineering landscape, subsuming parts of traditional engineering fields and requiring a broader approach to the design of system that we can formally call as Mechatronics system.

Many industries improving their works through automation which is based on the inter connection between the electronic control systems and mechanical engineering.

Such control systems generally use microprocessors as controllers and have electrical sensors extracting information from mechanical inputs through electrical actuators to mechanical systems.

This can be considered to be application of computer based digital control techniques through electronic and electric interfaces to mechanical engineering problems. Successful design of Mechatronics can lead to products that are extremely attractive to customer in quality cost-effectiveness.

MECHATRONICS DEFINITION:

Mechatronics may be defined as a multi-disciplinary field of study that implies the synergistic integration of electronic engineering, electric engineering, control engineering and computer technology with mechanical engineering for the design, manufacture, analysis and maintenance of a wide range of engineering products and processes.

“Mechatronics brings together areas of technology involving sensors and

measurement systems, drive and actuation systems, analysis of the behavior of

systems microprocessor systems”.

The integration across the traditional boundaries of mechanical

engineering, electrical engineering, electronics and control engineering has to

occur at the earliest stages of the design process if cheaper, more reliable;

more flexible systems are to be developed.

APPLICATIONS OF MECHATRONICS ENGINEERING:

Mechatronics engineering finds application in the following fields.

• Electronic home appliances

• Electronic entertainment products

• Engine systems(cars)

• Large scale application

Schematic Layout of Hydraulic System

BASIC COMPONENTS OF A HYDRAULICSYSTEM:

Reservoir (or air tank):

A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid

(usually oil).

The pump is used to force the liquid into the system.Primemover:

A Prime mover, usually an electric motor, is used to drive the pump.

Valves:

Valves are refitted in the system to control liquid direction, pressure, and flow rate.

Actuator:

An actuator is provided to convert the liquid energy into mechanical

force or torque to do useful work. The actuator is the actual working element of

the system. The actuators can be either cylinders (to provide linear motion) or

hydro motors (to provide rotary motion).

Fluid-transfer piping:

The hydraulic Piping is provided to carry the compressed liquid from one

place to another.

Schematic Layout of Pneumatic System

BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

Reservoir (or air tank):

An air tank is provided to store the compressed air required for the operations.

Compressor:

The compressor is used to compress the atmospheric air so as to increase

the pressure of the air.

Prime mover:

A Prime mover, usually an electric motor, is used to drive the compressor.

Valves:

Valves are refitted in the system to control air direction, pressure, and flow rate.

Actuator:

An actuator is provided to convert the air energy into mechanical force

or torque to do useful work.

Fluid-transfer piping:

Piping is provided to carry the compressed air from one place to another.

BASIC SYMBOLS USED IN HYDRAULIS AND PNEUMATICSYSTEM:

Symbols DescriptionLINES

-continuous line – flow line

-dashed line - pilot, drain-envelope - long and short dashes around two or more component symbols

CIRCULAR-large circle - pump, motor

-small circle - Measuring devices

-semi-circle – rotary actuatorSQUARE

-one square - pressure control function-two or three adjacent squares - directional control

DIAMOND-diamond - Fluid conditioner (filter, separator, lubricator, heat exchanger)

MISCELLANEOUSSYMBOLS

-Spring

-Flow Restriction

TRIANGLE-solid - Direction of Hydraulic Fluid Flow

-open - Direction of Pneumatic flow

PUMPS ANDCOMPRESSORSFixed Displacement Hydraulic Pump

-unidirectional

-bidirectional

Variable Displacement Hydraulic Pump

-unidirectional

Compressor

-CompressorSymbols Description

MOTORSFixed Displacement Hydraulic Motor

-unidirectional

-bidirectional

Variable Displacement Hydraulic Motor

-unidirectional

-bidirectional

Pneumatic Motor

-unidirectional

-bidirectionalRotary Actuator

-hydraulic

-pneumaticCYLINDERS

Single Acting Cylinder

-returned by external force

-returned by spring or extended by spring forceDouble Acting Cylinders

-single piston rod (fluid required to extend and retract)

-double ended piston rod

Cylinders With Cushions

- single fixed cushion- double fixed cushion

- single adjustable cushion

- double adjustable cushion

Symbols Description

DIRECTIONAL CONTROLVALVESDirectional Control Valve (2 Ports / 2Positions)

-Normally closed directional control valve with 2 ports and 2 finite positions.-Normally open directional control valve with 2 ports and 2 finite positions.

Directional Control Valve (3 Ports / 2Positions)-Normally closed directional control valve with 3 ports and 2 finite positions.-Normally open directional control valve with 3 ports and 2 finite positions.

Directional Control Valve (4 Ports / 2Positions)-directional control valve with 4 ports and 2 finite positions

Directional Control Valve (4 Ports / 3Positions)-directional control valve with 4 ports and 3 finite positions*-(center position can have various flow paths)

Directional Control Valve (5 Ports / 2 Positions) Normally A Pneumatic Valve

-directional control valve with 5 ports and 2 finite positions

Directional Control Valve (5 Ports / 3 Positions) Normally A Pneumatic Valve

-directional control valve with 5 ports and 3 finite positions

CONTROLMETHODSManual Control

-general symbol (without showing the control type)

-pushbutton

-lever

-foot pedal

Mechanical Control

-plunger or tracer

-springSymbols Description

-roller

-roller(one direction only)

Electrical Control

-Solenoid (the one winding)

Pilot Operation-pneumatic

-hydraulic

Pilot Operated Two-Stage Valve

-Pneumatic: Sol first stage

-Pneumatic: Air pilot second stage

-Hydraulic: Sol first stage

-Hydraulic: Hydraulic pilot second stage

CHECK VALVES, SHUTTLE VALVES, RAPID EXHAUSTVALVES

-check valve -free flow one direction, blocked flow in other direction

-pilot operated check valve, pilot to close

-pilot operated check valve, pilot to open

Shuttle Valve-to isolate one part of a system from an alternate part of circuit

Rapid Exhaust Valve/Pneumatic

-installed close to an actuator for rapid movement of the actuator

PRESSURE CONTROLVALVES

Pressure Relief Valve(Safety Valve) Normally Closed

- Line pressure is limited to the setting of the valve, secondary part is directed to tank

Symbols Description

Proportional Pressure Relief

- line pressure is limited to and proportional to an electronic signal

Sequence Valve

- When the line pressure reaches the setting of the valve, valve opens permitting flow to the secondary port. The pilot must be externally drained to tank.

Pressure Reducing Valve- pressure downstream of valve is limited to the setting of the valve

FLOW CONTROLVALVES

Throttle valve

-adjustable output flowFlow Control Valve

-with fixed output (variations in inlet pressure do not affect rate of flow)-with fixed output and relief port to reservoir with relief for excess flow (variations in inlet pressure do not affect rate of flow)-with variable output

-fixed orifice-metered flow toward right free flow to left

-pressure compensated flow control fixed output flow regardless of load-pressure and temperature compensated

-with variable output and relief port to reservoir

Flow Dividing Valve

-flow is divided equally to two outputs

SHUT-OFFVALVE-Simplified symbol

Symbols

Description

FILTERS, WATER TRAPS, LUBRICATORS AND MISCELLANEOUS APPARATUSFilter or Strainer

-filter

Water Trap

-with manual drain

-with automatic drained

Filter With Water Trap

-with manual drain

-automatic drain

Air Dryer- refrigerant, or chemical removal of water from compressed airline

Lubricator

-oil vapor is indicted into airline

Conditioning unit

-compound symbol of filter, regulator, lubricator unit

-Simplified Symbol

RESULT:

Thus the important feature Mechatronics system was studied.

NORMAL POSITION

OPERATION OF SINGLE ACTING CYLINDER USING DCV

EXP NO:2a DATE:

To operate a single acting cylinder using the Directional Control Valve (DCV)

in Pneumatic Trainer Kit.

APPARATUSREQUIRED:

FLUIDSIM(P) Software

3/2 Hand Levered Spring Return DCV

FRL Unit

PROCEDURE:

Draw the circuit in FLUIDSIM software and check the connections.

Connect the FRL unit to the main air supply.

The various components are connected as per circuit.

Block the valve openings if necessary.

Check the leakage of air supply and correct it.

Open the valve and operate the cylinder.

ACTUATED POSITION

RESULT:

Thus the single acting cylinder was operated using DCV in Pneumatic Trainer Kit.

NORMAL POSITION

OPERATION OF DOUBLE ACTING CYLINDER USING DCV

EXP NO:2b DATE:

APPARATUSREQUIRED:

Double Acting Cylinder

FRL Unit

PROCEDURE:

Draw the circuit in FLUIDSIM software and check the connections.

Open the valve and operate the cylinder

ACTUATED POSITION

RESULT:

Thus the double acting cylinder was operated using DCV in Pneumatic Trainer Kit.

NORMAL POSITION

OPERATION OF DOUBLE ACTING CYLINDER WITH AND LOGIC

CIRCUIT

EXP NO: 2c DATE:

To operate a double acting cylinder using AND logic circuit in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

4/2 Pilot Operated DCV

3/2 Hand Levered DCV

Two Pressure Valve

FRL Unit

PROCEDURE:

Draw the circuit in FLUIDSIM(P) software and check the connections.

ACTUATED POSITION

RESULT:

Thus the double acting cylinder using AND logic circuit was operated

NORMAL POSITION

OPERATION OF DOUBLE ACTING CYLINDER WITH OR LOGIC

CIRCUIT

EXP NO: 2d DATE:

To operate a double acting cylinder using OR logic circuit in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

3/2 Hand Levered DCV

Shuttle Valve

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the double acting cylinder using OR logic circuit was operated

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF MULTIPLE CYLINDERS USING CASCADING METHOD (A+B+B-A-)

EXP NO: 2e DATE:

To operate a single cycle automation of multiple cylinders in cascading method (A+B+B-A-) in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

3/2 Roller Operated Spring Return DCV

3/2 Push Button Spring Return DCV

Limit Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the single cycle automation of multiple cylinders was operated

by cascading method (A+B+B-A-) in Pneumatic Trainer Kit.

NORMAL POSITION

IMPULSE PILOT OPERATION OF SINGLE ACTING CYLINDER

EXP NO: 2f DATE:

To operate a single acting cylinder using an impulse pilot valve in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

3/2 Pilot Operated Spring Return DCV

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the single acting cylinder was operated using an impulse pilot valve

NORMAL POSITION

CONTROLLING THE SPEED OF THE CYLINDER USING METERING IN VALVE CIRCUIT

EXP NO: 2g DATE:

To control the speed of double acting cylinder using Metering In valve circuit in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Flow Control Valve

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the speed of double acting cylinder was controlled using Metering In

valve circuit in Pneumatic Trainer Kit.

NORMAL POSITION

CONTROLLING THE SPEED OF THE CYLINDER USING METERING OUT VALVE CIRCUIT

EXP NO: 2h DATE:

To control the speed of double acting cylinder using Metering Out valve circuit in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Flow Control Valve

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the speed of double acting cylinder was controlled using Metering Out

valve circuit in Pneumatic Trainer Kit.

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF DOUBLE ACTING CYLINDER USING LIMIT SWITCH

EXP NO: 2i DATE:

To operate automatic operation of a double acting cylinder in a single cycle using limit switch in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Limit Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the single cycle automation of double acting cylinder was operated by

using limit switch in Pneumatic Trainer Kit.

NORMAL POSITION

MULTI CYCLE AUTOMATION OF DOUBLE ACTING CYLINDER USING LIMIT SWITCH

EXP NO: 2j DATE:

To operate automatic operation of a double acting cylinder in a multi cycle using limit switch in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Limit Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the multi cycle automation of double acting cylinder was operated by

using limit switch in Pneumatic Trainer Kit.

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+ B+ A-B-)

EXP NO: 2k DATE:

To operate the Single Cycle Automation of Multiple Cylinders in Sequence

(A+ B+ A-B-) in Pneumatic Trainer Kit.

APPARATUS REQUIRED:

3/2 Push Button Spring Return DCV

Limit Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

sequence (A+B+A-B-) in Pneumatic Trainer Kit.

NORMAL POSITION

OPERATION OF SINGLE ACTING CYLINDER USING SINGLE SOLENOID VALVE

EXP NO: 3a DATE:

To operate a single acting cylinder using the single solenoid valve in Electro

Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Input / Output Relay Box

3/2 Solenoid Operated Spring Return Valve

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the single acting cylinder was operated using single solenoid valve

in Electro Pneumatic Trainer Kit

NORMAL POSITION

OPERATION OF DOUBLE ACTING CYLINDER USING SINGLE SOLENOID VALVE

EXP NO: 3b DATE:

To operate a double acting cylinder using the single solenoid valve in

Electro Pneumatic Trainer Kit.

APPARATUS REQUIRED:

FLUIDSIM (P) Software

4/2 Solenoid Operated Spring Return Valve

FRL Unit

PROCEDURE:

Draw the circuit in FLUIDSIM (P) software and check the connections.

ACTUATED POSITION

RESULT:

Thus the double acting cylinder was operated using single solenoid valve

in Electro Pneumatic Trainer Kit.

NORMAL POSITION

OPERATION OF DOUBLE ACTING CYLINDER USING DOUBLE SOLENOID VALVE

EXP NO: 3c DATE:

To operate a single acting cylinder using the double solenoid valve in

Electro Pneumatic Trainer Kit.

APPARATUS REQUIRED:

4/2 Solenoid Operated Valve

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the double acting cylinder was operated using double solenoid

valve in Electro Pneumatic Trainer Kit.

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF DOUBLE ACTING CYLINDER

EXP NO: 3d DATE:

To operate automatic operation of a double acting cylinder in a single cycle

using electrical switch in Electro Pneumatic Trainer Kit.

APPARATUS REQUIRED:

4/2 Solenoid Operated DCV

Electrical Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the single cycle automation of double acting cylinder was operated

by using electrical switch in Electro Pneumatic Trainer Kit.

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+B+B-A-)

EXP NO: 3e DATE:

To operate the Single Cycle Automation of Multiple Cylinders in sequence (A+B+B-A-) in Electro Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Electrical Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

sequence (A+B+B-A-) in Electro Pneumatic Trainer Kit.

NORMAL POSITION

MULTI CYCLE AUTOMATION OF DOUBLE ACTING CYLINDER

EXP NO: 3f DATE:

To operate automatic operation of a double acting cylinder in a multi cycle

APPARATUS REQUIRED:

Electrical Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

Thus the multi cycle automation of double acting cylinder was operated by

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+B+A-B-)

EXP NO: 3e DATE:

To operate the Single Cycle Automation of Multiple Cylinders in sequence (A+B+A-B-) in Electro Pneumatic Trainer Kit.

APPARATUS REQUIRED:

Electrical Switch

FRL Unit

PROCEDURE:

ACTUATED POSITION

RESULT:

sequence (A+B+A-B-) in Electro Pneumatic Trainer Kit.

NORMAL POSITION

ACTUATION OF SINGLE ACTING CYLINDER WITH ON DELAY TIMER USING PLC

EXP NO: 4a DATE:

To simulate the single acting cylinder with ON Delay Timer using PLC.

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Draw the circuit diagram.

Provide +24V and –24V from PLC trainer to panel.

Open the Codesys software in desktop.

Interface PLC with PC using RS232cable.

Write a ladder diagram.

Output of PLC (Q1) is direct connecting to input of solenoid coil.

Following the opening procedure of Codesys software.

Check the ladder diagram.

Connect the air supply to FRL unit.

Run the PLC.

Sometimes delay the cylinder should be activated.

ACTUATED POSITION

RESULT:

Thus the actuation of single acting cylinder with ON Delay Timer was done using PLC.

NORMAL POSITION

ACTUATION OF SINGLE ACTING CYLINDER WITH OFF DELAY TIMER USING PLC

EXP NO: 4b DATE:

To simulate the single acting cylinder with OFF Delay Timer using PLC.

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Interface PLC with PC using RS232 cable.

Run the PLC.

ACTUATED POSITION

RESULT:

Thus the actuation of single acting cylinder with OFF Delay Timer was done using PLC.

NORMAL POSITION

OPERATION OF SINGLE ACTING CYLINDER WITH AND LOGIC USING PLC

EXP NO: 4c DATE:

To simulate the Operation of Single Acting Cylinder with AND Logic using PLC

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Run the PLC.

ACTUATED POSITION

RESULT:

Thus the single acting cylinder is actuated with AND logic using PLC

NORMAL POSITION

OPERATION OF SINGLE ACTING CYLINDER WITH OR LOGIC USING PLC

EXP NO: 4d DATE:

To simulate the Operation of Single Acting Cylinder with OR Logic using PLC

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Run the PLC.

ACTUATED POSITION

RESULT:

Thus the single acting cylinder is actuated with OR logic using PLC.

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+B+B-A-) USING PLC

EXP NO: 4e DATE:

To simulate the Single Cycle Automation of Multiple Cylinders in sequence (A+B+B-A-) using PLC

APPARATUS REQUIRED:

Compressor

FRL Unit

Flow Control Valve

Codesys Software.

PROCEDURE:

Open the versa pro software in desktop.

Both Outputs of PLC (Q1, Q2, Q3 and Q4) are direct connecting to inputs

of solenoid coils.

Check the ladder diagram Sometimes delay the cylinder should be activated.

ACTUATED POSITION

Run the PLC.

Observe the working of double acting cylinder is automatic

reciprocating using the circuit A+B+B-A-.

RESULT:

Thus the single cycle automation of multiple cylinders is operated in

sequence (A+B+B-A-) using PLC.

NORMAL POSITION

CONTROL OF DOUBLE ACTING CYLINDER WITH UP COUNTER USING PLC

EXP NO: 4f DATE:

To simulate the double acting cylinder with UP Counter Using PLC

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Run the PLC..

ACTUATED POSITION

RESULT:

Thus the double acting cylinder is actuated with UP Counter using

NORMAL POSITION

CONTROL OF DOUBLE ACTING CYLINDER WITH DOWN COUNTER USING PLC

EXP NO: 4g DATE:

To simulate the double acting cylinder with DOWN Counter Using PLC

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Run the PLC.

ACTUATED POSITION

RESULT:

Thus the double acting cylinder is actuated with DOWN Counter

using PLC

NORMAL POSITION

AUTOMATION OF SINGLE ACTING CYLINDER USING PLC

EXP NO: 4h DATE:

To simulate the Automation sequence of Single Acting Cylinder Using PLC.

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Run the PLC.

Observe the working of single acting cylinder is automatic reciprocating.

ACTUATED POSITION

RESULT:

Thus the automation of single acting cylinder is done by using PLC.

NORMAL POSITION

AUTOMATION OF DOUBLE ACTING CYLINDER USING PLC

EXP NO: 4i DATE:

To simulate the Automation sequence of Double Acting Cylinder Using PLC.

APPARATUS REQUIRED:

Compressor

FRL Unit

Codesys Software.

PROCEDURE:

Run the PLC.

Observe the working of double acting cylinder is automatic reciprocating

ACTUATED POSITION

RESULT:

Thus the automation of double acting cylinder is done by using PLC.

NORMAL POSITION

SINGLE CYCLE AUTOMATION OF MULTIPLE CYLINDERS IN SEQUENCE (A+B+A-B-) USING PLC

EXP NO: 4e DATE:

To simulate the Single Cycle Automation of Multiple Cylinders in sequence (A+B+A-B-) using PLC

APPARATUS REQUIRED:

Compressor

FRL Unit

Flow Control Valve

Codesys Software.

PROCEDURE:

Open the versa pro software in desktop.

Both Outputs of PLC (Q1, Q2, Q3 and Q4) are direct connecting to inputs

of solenoid coils.

Check the ladder diagram Sometimes delay the cylinder should be

activated.

ACTUATED POSITION

Connect the air supply to FRLunit.

Run the PLC.

Observe the working of double acting cylinder is automatic

reciprocating using the circuit A+B+A-B-.

RESULT:

Thus the single cycle automation of multiple cylinders is operated in

sequence (A+B+A-B-) using PLC.

NORMAL POSITION

OPERATION OF SINGLE ACTING CYLINDER USING DCV

EXP NO:5a DATE:

in Hydraulic Trainer Kit.

APPARATUSREQUIRED:

FLUIDSIM (H) Software

3/2 Solenoid DCV

PROCEDURE:

Draw the circuit in FLUIDSIM (H) software and check the connections.

Check the leakage and correct it.

ACTUATED POSITION

RESULT:

Thus the single acting cylinder was operated using DCV in Hydraulic Trainer Kit

mechatronics lab manuaol 2.docx

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