DEPARTMENT OF MECHANICAL ENGINEERING

RACHNA COLLEGE OF ENGINEERING AND TECHNOLOGY, GUJRANWALA)

(A Constituent College of University of Engineering and Technology, Lahore)
DEPARTMENT OF MECHANICAL ENGINEERING

[Link] [Link]

ROBOTICS & AUTOMATION (LAB) ME-342L

LAB REPORT

SUBMITTED BY:

STUDENT NAME: Muhammad Ahmad

STUDENT REGISTRATION NO: 2021-ME-443

SUBMITTED TO:
ENGR. MUHAMMAD KASHIF JAMIL

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LIST OF LAB EXPERIMENTS

SECTION-A (BASIC PROCESS CONTROL TRAINER)

Experiment-1: To Calibrate the Float Level Sensor and Transmitter by using Basic Process Control
Trainer.
Experiment-2: To calibrate Variable Area Flow Meter/Rotameter on Basic Process Control Trainer.

Experiment-3: To Control Level of water in a tank through Pump switching (ON/OFF) on Basic
Process Control Trainer.

Experiment-4: To Control level of liquid in a tank by witching (ON/OFF) Solenoid valve on basic
process control trainer.
Experiment-5: To control the liquid level in a tank by using the Float Level Switch on Basic process
Control Trainer.

SECTION-B (PNEUMATIC CONTROL & ELECTRO-PNEUMATIC TRAINER)

Experiment-6: To validate the use of Pneumatic control trainer for assembly fixture and foundry
ladle.
Experiment-7: To analyze the use of electro Pneumatic control trainer in foundry ladle and assembly
Fixture

SECTION-C (SERVO FUNDAMENRAL TRAINER)

Experiment-8: To validate the steady state characteristics, break load and transient response of motor
in analog servo fundamental trainer.
Experiment-9: To established the characteristics of tachogenerator and the action of simple motor
driven closed loop positions in robotics & automation assembly.

SECTION-D (PLC MODEL IPC-34 TRAINER)

Experiment-10: To analyze the traffic lights and signal control adds on module by using PLC Trainer
model IPC-34
Experiment-11: To analyze the control of water level through adds on module by using PLC Trainer
model IPC-34

SECTION-E (MATLAB)
Experiment-12: To represent LTI system in MATLAB with respect to SISO and MIMO systems
Experiment-13: To find the stability of control and automation system, steady state errors and how to
plot their root locus.
Experiment-14: To design and test supervisory logic of Robot manipulator algorithms in MATLAB

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SECTION-A
BASIC PROCESS CONTROL TRAINER
Experiment No. 1
To Calibrate the Float Level Sensor and Transmitter by using Basic Process
Control Trainer.
Theory:
In this practical the FLT will be calibrated to zero ('zero' being the lowest reading, i.e. 4 mA) without
the sensor connected. The sensor is then connected with the level in the tank at the zero indicator and
its screw adjusted until the DDM reads 4mA again. The zero reading of the sensor and transmitter has
now been calibrated against an empty tank.
The tank is now filled until the level is at the 100 (full) indicators. This is the highest level that will be
reached in the tank. At this level the signal output should be maximum, 20 mA. The span of the
transmitter is adjusted so that the DDM does read 20 mA at the top of the tank.

Apparatus Diagram:

Figure 1 Process Control Unit

Practical procedure:
1. Open manual valve MV2, so that the upper tank is filled to above the zero level. Close MV2 and
then briefly open MV3 until the water level is exactly on zero.
2. Remove float level sensor cable from the float level transmitter. Adjust the zero screw on the float
level transmitter with a small screwdriver so that the DDM
reads exactly 4.0 mA. This is now calibrated to zero.
3. Reconnect the cable from the float level sensor to the Sensor input of the float level transmitter,
and ensure that the tank level is at 0 on the tank scale. Adjust the screw in the center of the float
level sensor wheel so that the DDM reads 4mA again. This has calibrated the sensor potentiometer
to zero. A 4-mA current will signal an empty (zero level) tank.
4. Close manual value MV3 and open MV2 so that the tank fills, lifting the level sensor. Allow the
level to reach 100 (maximum value) on the tank scale. Close MV2 and adjust the span screw on
the float level transmitter so that the DDM is reading 20 mA. This is the maximum current
corresponding to the maximum water level in the tank.
5. The float level sensor and transmitter are now calibrated against the upper tank. A current between
4 mA and 20 mA will be produced which is directly proportional to the water level in the tank.

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Table:
Sr. No Height (H) Current (mA)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
Plot a graph between Liquid level and current.

Flat Level Sensor:

Is float level sensor a discrete-level sensor or continuous level measurement sensor?

Is it a contact type sensor?

Applications of Float Level Sensors:

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Hazards associated with Basic Process Control Trainer:

Controls for Hazards:

Comments:
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Experiment No. 2

To calibrate Variable Area Flow Meter/Rotameter on Basic Process Control

Trainer.
Theory:
In this practical you will measure the 'fill' times for various volumes of water, calculate in each case
the flow rate in liters/min and take the average of all these flow rate values. Finally, you will compare
this average flow rate value with the value indicated by the visual flow meter.
If liquids of high viscosities are used, the limiting factors to calibration are the drainage characteristics
of the tank, which must be such that the residue liquid left after draining has an insufficient volume to
affect the accuracy of the next calibration.
Note however that the resolution of the flow meter is 0.2 l/min, its range is 0.4 l/min to 4.0 l/min, and
water should be used as the liquid.

DIAGRAM:

Figure 2 Process Control Unit

Practical Procedure:
1. Completely empty the upper tank, and then close all manual valves connected to the upper tank.
Note that you do not need to worry about the state of the solenoid valves, since they are normally
fully closed. You do need however to make sure that the servo valve is fully open, as discussed in
the Flow/Level rig familiarization assignment.
2. Switch on the pump with the switched ac switch on the front of the Process Interface.
3. Adjust MV2 to give a nominal flow of approximately 1.2 liters/min, as shown on
the visual flow meter.
4. Switch off the pump and empty the upper tank using MV3. When the tank is empty, close MV3.
5. Now, simultaneously start the pump and the stop-watch and measure the time taken for the level in
the tank to reach the 20 mark.
6. Stop the pump and calculate the flow rate, using the level to volume correspondence you found in
the previous practical.
7. Empty the upper tank and repeat the above procedure to obtain the time to reach the 40 mark.
Calculate the flow rate for this.
8. Repeat the procedure for levels of 60, 80 and 100 and then calculate the average flow rate from
your five readings. Compare this average with the reading from the visual flow meter.
9. Now, repeat the whole procedure for nominal flow rates of 2.4 liters/min and 3.6 liters/min and
compare again your calculated averages with the actual visual flow meter readings.
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10. Calculate the average flow rate and compare it with the reading from the visual flow-meter.
Calculation for Volume Filled in Tank:
Sr. No. 1: Volume Filled (L) =

Sr. No. 2: Volume Filled (L) =

Sr. No. 3: Volume Filled (L) =

Sr. No. 4: Volume Filled (L) =

Sr. No. 5: Volume Filled (L) =

Table:
Volume Time Flow rate
Sr. No
filled (L) (mints) (L/min)
1
2
3
4
5
Average flow rate

Applications of Rotameter:

1.
2.
3.
4.
5.

Comments:
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Experiment No. 3

To Control Level of water in a tank through Pump switching (ON/OFF) on Basic

Process Control Trainer.
Theory:
On/off control will be used to control the water level in the tank by automatically turning on and off
the centrifugal pump.
The on-off control section of the PI includes a comparator and Schmitt trigger arrangement with
variable hysteresis control and logic inputs to control the switched power supplies.
The output from the Schmitt Trigger, which will be in one of two states depending on the deviation of
the measured signal from the reference signal, is controlling the supply to the centrifugal pump by
providing a logic signal to input D.
The current source will supply the reference signal to the on/off control apparatus and will be
connected to input B on the front of the PI. This reference signal will provide a desired tank water
level. The measured value from the FLT will be connected to input A.
The pump should be on while the tank water level is less than the desired level and should switch off
when the measured level has passed the desired level by an amount set by the hysteresis value. Once
the measured level has dropped enough to trigger the Schmitt trigger, the pump should switch on
again.
The reference signal is connected to the inverting input of the comparator, so that while the measured
level is less than the desired level the deviation is negative. When the measured value has passed the
desired level, the deviation becomes positive. Considering the hysteresis curve of a Schmitt trigger,
this is an inverted action, since the output will switch from positive to negative as the deviation is
moving from negative to positive.
Care should be taken when setting manual valve MV3, connected to the upper tank. This should be
open enough for the level in the upper tank to increase when the pump is on and decrease when the
pump is off.
This valve is controlling the times taken to rise and to fall between the two limits set by the hysteresis
level.

Apparatus Diagram:

Figure 3 Process Control Unit

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Practical Procedure:
1) Servo valve should be fully open. If not, connect the current source to the servo valve and supply
20 mA to open it, then replace the leads.
2) Set the manual valve MV3 (below the upper tank) to approximately 50% open. Fully open manual
valve MV2 (before the visual flow meter). Set the ac supply output switch, on the front panel of
the PI, to the logic input position. Set the DDM to current (mA).
3) Set the current source to an intermediate position and the hysteresis control to the minimum
position.
4) Switch on the PI. When the behaviour of the process has become steady, vary the hysteresis level
in steps and observe the effect on the operation of the system. Set the hysteresis level back to a
low value and now vary the current source output in steps and observe the effect on the system.

Block diagram:
Make the block diagram of this water level control system.

Comments:
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Experiment No. 4

To Control level of liquid in a tank by witching (ON/OFF) Solenoid valve on basic

process control trainer.
Theory:
A better way of controlling the tank level is to use a different 2-state device a solenoid valve. The
solenoid valve is designed with repeated switching in mind and is much more suitable for on/off
control. This will be investigated now.
Solenoid valve SV1 could replace the pump as the device that cuts the flow on and off. The valve must
be open when the tank level is below desired level, and closed when above desired level.
But there is another way of controlling level which exhibits a non-inverting action. This is to use
solenoid valve SV2, connected to the upper tank. It lets water flow from the upper to the sump tank.
Now, when the actual tank level is above the desired level the valve should switch on, open, so that
more water can flow out. When the actual level is below the desired level it should switch off, close, so
the water level can rise.
To accomplish this the reference signal from the current source is fed into input A (which is the non-
inverting input to the comparator) and the measured signal from the FLT is fed into input B. Now,
while the measured level is less than the desired level the deviation is positive and will become
negative when the measured level is greater than desired. This is the reverse of the last practical.
Translating this to the action of the comparator and Schmitt trigger together, the output should switch
from negative to positive as the deviation changes from negative to positive. This is a non-inverting
action.
Since the solenoid valve is to be controlled, the output of the Schmitt trigger will now feed the logic
input E of the switched 24Vdc output to SV2.
As before, care must be taken when setting the position of manual valve MV3. For the operation of
this on/off control example to be as expected, the level in the tank should go up when SV2 is closed
and down when it is open. It may take a little trial and error to get this right.

Apparatus Diagram:

Figure 4 Process Control Unit

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Perform Practical:
1) Ensure that manual valve MV2 is fully open. Initially set manual valve MV3 to be approximately
50% open.
2) When the practical is running you will have to adjust this to get the correct behavior; the tank level
should rise when SV2 is closed, and fall when it is open. Set the 24Vdc o/p switch to logic input
E, and the ac supply output switch to ON. Set the current source output to an intermediate value
and the hysteresis to the minimum.
3) Switch on the PI. SV2 will be closed initially. Once the behaviour of the process has settled down
and the correct position of MV3 has been found, vary the hysteresis level in steps and observe the
effect on the operation of the system.
4) Set the hysteresis back to minimum and now vary the current source output in steps and observe
the effect on the system.
5) Set the current source to an intermediate level and the hysteresis to minimum. Swish around the
water in the upper tank (with a spoon, ruler or the like) and observe the effect on the process.
Increase the hysteresis in small steps and repeat for each step.

Block diagram:
Make the block diagram of this water level control system.

Comments:

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Experiment No. 5
To control the liquid level in a tank by using the Float Level Switch on Basic
Process Control Trainer.
Theory:
The Float Switch:
The float switch is binary in operation: open or closed. It can give no clue as to how much over or
under the desired level the water in the tank is. This makes it a device suitable for on/off control only.
It will take the place of the float level sensor, which produced a current signal proportional to the
actual tank level. The solenoid SV1 will be used to switch flow on and off. This exhibits the same
action (inverted) as the pump, from the point of view of the Schmitt trigger.
The float switch uses the FLT to convert its signal into the 4-20 mA format. The FLT, then, must be
recalibrated for this new device. The calibration for the float switch is very simple and should be
carried out as follows before beginning the practical.
The float switch is connected to the FLT with the barrel in its lowest position (this means that the reed
relay is open) and the zero screw on the FLT adjusted to read 4 mA on the DDM. The barrel is then
held in its highest position (this will close the relay) and the span screw on the FLT adjusted to read 20
mA on the DDM.
What is difference between float level switch and float level sensor?

Apparatus Diagram:

Figure 5 Process Control Unit

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Practical Procedure:
1. Ccalibrating all necessary equipment (the current source, and the float level transmitter)
Set the manual valve MV3 (below the upper tank) to approximately 50% open. Fully close MV2 and
fully open MV1 so that all the flow passes through SV1. Set the ac supply output switch to ON and the
24 V dc switch to the logic input position. Set the DDM to current (mA). Set the current source to an
intermediate position, the hysteresis control to the minimum position and the float switch position to
approximately half way up the tank.
2. Switch on the PI. Adjust MV3 so that the system operates correctly: the level rises when SV1 is
open and falls when it is closed. When the behavior of the process has become steady, vary the
hysteresis level in steps and observe the effect on the operation of the system.
3. Set the hysteresis level back to a low value and now vary the current source output in steps and
observe the effect on the system. Set the current source back to its initial position, and now give the
upper tank a gentle shake while the system is operating. Observe the effect.

Block diagram:
Make the block diagram of this water control system.

Applications of Float Level Switch:

Comments:
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SECTION-B
PNEUMATIC & ELECTRO PNEUMATIC CONTROL TRAINERS
Experiment No. 6
The Use of Pneumatic Control Trainer for Assembly Fixture and Foundry Ladle

Figure 6 Assembly Fixture

Figure 7 Foundry Ladle

Theory:
Splined shafts are to be assembled into bushes, the assembly requires a press fit. The shafts are placed
manually into the bush a push button is than actuated to extend a single acting cylinder through a
linkage as the cylinder extends the shaft is pressed home. The cylinder is to retract as soon as the push
button is released.
In a foundry molten metal is to be poured from a ladle a double acting cylinder is used to lift the ladle.
To extend the cylinder a push button must be actuated to retract the cylinder a second push button must
be actuated. The cylinder will remain in the last position that it is sent to until the opposite push button
is actuated.

Equipment Required at Assembly fixture:

a) 1 off single acting cylinder
b) 1 off 3/2 way push button operated, spring return direction control valve
c) 1 off distribution manifold with ON/OFF valve
d) 4 mm pneumatic tubing as required
Equipment Required at foundry ladle:
a) 1 off double acting cylinder.
b) 2 off 3/2 way push button operated spring return direction control valves
c) 1 off one-way flow control valve
d) 1 off pneumatic on/off slide valve.
e) Pneumatic tubing as required.

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Figure 8 Pneumatic Circuit Diagram for Assembly fixture

Figure 9 Pneumatic Circuit Diagram for Foundry ladle

Note: Label the diagram.

Operational procedure:
1. Ensure that the ON/OFF valve is in the OFF position.
2. Connect tubing between the manifold and port 1 f the push button valve.
3. Connect tubing between the port 2 of the push button and the inlet port of the single acting
cylinder.
4. Fit the blanking plugs into all unused manifold ports.
5. Check your assembled circuit against the circuit diagram.
6. Select the ON/OFF valve to the ON position.
7. Operate and hold down push button observe what happens.
8. Release the push button and again observe what happens.
9. Compare your observation with written circuit explanation for assembly fixture.
10. Following the pneumatic circuit diagram connect tubing between the ON/OFF valve air
distribution manifold and port 1 of the two push button valves for foundry ladle.
11. Connect tubing between the port 2 of the push buttons and the inlet port of the single acting
cylinder.
12. Fit the blanking plugs into all unused manifold ports.
13. Set the flow control valve to its maximum position by turning the knurled adjuster anti-clockwise.
14. Operate and hold down push button 1.1 to extend the cylinder.
15. Release the push button1.1then operate and hold button 1.2 to retract the cylinder.
16. Now using push buttons 1.1 and 1.2 alternately to operate the cylinder adjust the flow control
valve clockwise to obtain a cylinder extend travel time of 3 seconds.
17. Compare your observation with written circuit explanation.
18. Turn off the air supply at the manifold.

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19. Remove all tubing.
Circuit Explanation:
The push button valve controlling the single acting cylinder is of the 3/2 way, normally closed type. In
the at rest condition the air supply to the valve is closed the output which is connected to the cylinder
is open to exhaust thereby allowing the cylinder to be retracted due to the internal return spring.
Upon operation of the push button the supply is connected to the output and the exhaust is closed this
allows compressed air to travel into the cylinder, the piston and piston rod will now extended.
Immediately the push button is released it reverts to its initial position, the air supply is closed and the
air in the cylinder is allowed to flow to exhaust the cylinder is now free to retract.
When the push button 1.1 is operated and held air is supplied to the rear chamber f the cylinder. The
cylinder will then extend, as it does the air in the front chamber travels through a throttle of the one-
way flow control valve 1.3 and can therefore be controlled thereby slowing down the extend speed.
When the push button 1.1 is released and push button 1.2 is operated and held air flows into the front
chamber of the cylinder via the bypass of the on-way flow control 1.3 at a no-restricted rate. Air from
the rear chamber of the cylinder flows through ports 2 and 3 of the push button valve 1.1 valve 1.1 to
atmosphere. The cylinder will retract.
On-way flow control valves are available as in line units or as units that can be fitted directly into the
cylinder port. The closer that the valve is placed to the cylinder the better the controlling will be.
What was the pressure at which the operation is performed pneumatically?

Comments:
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Experiment No. 7
To analyze the use of electro Pneumatic control trainer in foundry ladle and assembly Fixture

Figure 10 Assembly fixture

Figure 11 Foundry Ladle

Theory:
Splined shafts are to be assembled into bushes, the assembly requires a press fit. The shafts are placed
manually into the bush a push button is than actuated to extend a single acting cylinder through a
linkage as the cylinder extends the shaft is pressed home. The cylinder is to retract as soon as the push
button is released.
In a foundry molten metal is to be poured from a ladle a double acting cylinder is used to lift the ladle.
To extend the cylinder a push button must be actuated to retract the cylinder a second push button must
be actuated. The cylinder will remain in the last position that it is sent to until the opposite push button
is actuated.
Equipment Required for assembly fixture.
1. 1 off single acting spring return cylinder.
2. 1 off 3/2 way solenoid actuated spring return direction control valve.
3. 1 off Electric push button
4. 1 off pneumatic on/off slide valve.
5. 1 off 24V D.C. Power supply.
6. Pneumatic tubes as required.
7. Red and blue electric lead as required.
Equipment Required for Foundry ladle.
a) 1 off double acting cylinder.
b) 1 off 5/2 double solenoid actuated directional control valve.
c) 2 off electric push button with normally open contacts and momentary operation.
d) 2 off electric relay.
e) 1 off pneumatic on/off slide valve.
f) 1 off 24V D.C power supply.
g) Pneumatic tubing as required.
h) Red and blue electric leads as required.

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Figure 12 Electric Circuit diagram for assembly fixture and foundry ladle

Figure 13 Pneumatic Circuit Diagram for foundry ladle and assembly fixture

Note: Label above diagrams.

Operational Procedure:
1) Connect a compressed air supply regulated to between two and three bar pressure to the inlet port of
the on/off slide valve.
2) Connect 24V D.C power supply to the electric distribution manifold.
3) Actuate the air on/off slide valve to the off position.
4) Ensure that the electric power supply is switched off.
5) Following the pneumatic circuit diagram connect tubing between the on/off valve air distribution
manifold, 3/2 solenoid operated spring return valve and the single acting cylinder.
6) Now following the electric circuit diagram connect electric leads between the red/blue electric
manifolds, electric push button and the solenoid on the 3/2 directional control valve.
7) Check the assembled circuits against the circuit diagrams.
8) Switch on the 24V DC power supply.
9) Actuate the air on/off valve to the on position.
10) Depress and hold down the electrical push button and observe the action of cylinder.
11) Release the push button and observe the action of the cylinder.
12) Switch off both the electric power supply and the compressed air supply.
13) Remove all pneumatic tubing and electric leads.
14) Compare our observation with the written circuit explanation.
15) Connect a compressed air supply regulated to between two and three bar pressure to the inlet port
of the on/off slide valve.
16) Connect 24V D.C power supply to the electric distribution manifold.
17) Actuate the air on/off slide valve to the off position.
18) Ensure that the electric power supply is switched off.
19) Following the pneumatic circuit diagram connect tubing between the on/off valve air distribution

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manifold, 5/2 solenoid operated valve and the double acting cylinder.
20) Now following the electric circuit diagram connect electric leads between the red/blue electric
manifolds, electric push button and the solenoid on the 5/2 directional control valve.
21) Check the assembled circuits against the circuit diagrams.
22) Switch on the 24V D.C power supply.
23) Actuate the air on/off valve to the on position.
24) Depress and release the electrical push (S1) button and observe the action of cylinder.
25) Depress and release the electrical push (S2) button and observe the action of cylinder.
26) Switch off both the electric power supply and the compressed air supply.
27) Remove all pneumatic tubing and electric leads.
28) Compare your observation with the written circuit explanation.

Circuit Explanation:
In this exercise the switch (S1) is connected direct to the solenoid (Y1) when the switch is operated
and the contacts are closed the current will flow to the solenoid, which is then energise and 3/2 way
valve is therefore actuated and air passes to the rear of the cylinder. The cylinder extends and remains
extended until the solenoid Y is de-energised allowing the 3/2 way valve to reset and exhaust the
cylinder which will then retract by means of an internal spring.
Operation of push button switch S1 allows current to flow and energise relay K1 upon being actuated
the contacts of this relay will close and this will then allow current to flow and energise the solenoid
Y1. When Y1 is energised the 5/2 way valve switches and air will pass to the rear of the cylinder with
the front of the cylinder exhausting the cylinder therefore extends and remains extended until the
second push button switch (S2) is operated. When S2 is operated it energises relay K2 closing the
contacts of this relay, current will then flow via these contacts and energise the solenoid Y2 which
resets the 5/2 way valve to the condition as drawn, the cylinder subsequently and rear of the cylinder
exhausting.

What was the pressure at which the operation is performed pneumatically?

What are the Jigs and Fixtures and their applications?

Differentiate between Single acting cylinder and Double acting cylinder?

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Comments:
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SECTION-C (SERVO FUNDAMENRAL TRAINER)

Experiment 8
To validate the steady state characteristics, break load and transient response of motor in analog
servo fundamental trainer.
Apparatus:
1. Analogue Unit 33-100
2. Mechanical Unit 33-100
3. Oscilloscope

Theory:
The performance of motors in servo systems plays a critical role in various industrial applications such
as robotics, automation, and control systems. Understanding the steady state characteristics, break
load, and transient response of a motor is essential for designing and optimizing servo systems. In this
experiment, we focus on validating these key parameters for a motor integrated into an Analog Servo
Fundamental Trainer.
The main objective of this experiment is to validate the following characteristics of a motor within an
Analog Servo Fundamental Trainer:
• Steady state speed and torque characteristics.
• Break load capability.
• Transient response to sudden changes in load or input signals.
Steady state characteristics such as speed, torque, and current are measured to understand the motor's
behavior under constant load conditions. The break load test determines the maximum load the motor
can handle before reaching its limit. Additionally, transient response tests are conducted to assess the
motor's ability to respond to sudden changes in load or input signals. The experiment employs practical
setups and measurements to gather data, providing insights into the motor's performance in real-world
scenarios.

Methodology:
Steady State Characteristics:
• Apply a constant load to the motor.
• Measure and record steady state speed, torque, and current.
• Vary the load to observe changes in motor performance.
Break Load Test:
• Gradually increase the load applied to the motor until it reaches its maximum capacity.
• Record the load value at which the motor fails or shows signs of reaching its limit.
Transient Response Analysis:
• Apply step changes in input signals or load conditions.
• Measure and analyze the motor's response time, settling time, overshoot, and damping
characteristics.
Data Collection and Analysis:
• Collect data for each test scenario using the data acquisition system.
• Analyze the collected data to validate the motor's steady state characteristics, break load, and

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transient response.
Procedure:
• By adjusting P3, we set the motor speed to 2000 rpm with the break fully upwards.
• Then we connected the DVM to the armature current (1V/amp) Output on the mechanical unit.
• Then we set the break to each of its six positions in turn and for each setting we recorded and
plot the speed and the armature current.
• The plot has the general form of the figure c.

Observations and Calculations

Sr. No Input Vol Break Speed Techo Vol Armature
(V) Position (RPM) (V) Current (I)

1 4.94 0 5100 4.62 0.26

2 4.94 2 4260 3.75 0.84
3 4.94 4 3250 2.98 0.72
4 4.94 6 2560 2.27 0.88
5 4.94 8 2070 1.84 0.95
6 4.94 10 1940 1.73 0.98

Graphs
Speed vs Break Position
60005100
5000 4260
Speed (RPM)

4000 3250
3000 2560
2070 1940
2000
1000
0
0 2 4 6 8 10 12
Break Position

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Speed vs Techo Vol

6000

5000

Speed (RPM)
4000

3000

2000

1000

0
0 1 2 3 4 5
Techo Vol

Results and Discussion:

• The experiment results will provide insights into the motor's performance under different
operating conditions.
• Analysis of steady state characteristics will reveal the motor's speed-torque relationship and its
response to varying loads.
• The break load test will determine the motor's maximum load capacity, crucial for system
design and safety considerations.
• Transient response analysis will highlight the motor's ability to respond quickly and accurately
to changes in the input signal or load.
Comments:
• Through practical experimentation and analysis, this study aims to validate the steady state
characteristics, break load, and transient response of a motor in an Analog Servo Fundamental
Trainer.
• The findings will contribute to a better understanding of motor performance in servo systems
and inform the design and optimization of such systems for various industrial applications.

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Experiment 9
To established the characteristics of Tacho-generator and the action of simple motor driven
closed loop positions in robotics & automation assembly.

Apparatus
1. Tacho-generator (DC)
2. Simple DC motor
3. Closed-loop position control system
4. Power supply
5. Multimeter
6. Oscilloscope (optional)
7. Robot/automation assembly (for demonstration)
8. Connecting wires and cables

Thoery
Tacho-Generator
A tacho-generator, also known as a tachometer generator, is a device that converts mechanical rotation
into electrical signals. It consists of a rotor and a stator, similar to an electric motor. When the rotor
rotates, it induces an electromotive force (EMF) in the stator windings, producing an output voltage
proportional to the rotation speed. The tacho-generator provides feedback on the motor's speed and
position, which is essential for closed-loop control systems.
Closed-Loop Position Control System
A closed-loop position control system is a feedback control system that continuously monitors the
position of a mechanical component and adjusts the control input to maintain the desired position. The
system consists of:
1. Sensor: Measures the current position of the mechanical component (in this case, the tacho-
generator provides the feedback signal).
2. Controller: Compares the desired position with the current position and generates an error signal.
3. Actuator: Adjusts the control input to the motor to reduce the error signal and maintain the desired
position.
The closed-loop system uses the feedback signal from the tacho-generator to adjust the motor speed
and maintain precise control over the mechanical position. This is essential in robotics and automation,
where precise positioning and control are critical.
DC Motor

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A DC motor is a type of electric motor that uses direct current (DC) to produce rotational motion. It
consists of a rotor and a stator, with the rotor rotating when an armature current flows through it. DC
motors are widely used in robotics and automation due to their simplicity, reliability, and ease of
control.
Robotics and Automation
Robotics and automation systems require precise control and positioning to perform tasks efficiently
and accurately. Closed-loop position control systems, like the one demonstrated in this experiment, are
essential in these systems to maintain precise control over mechanical positions. The tacho-generator
provides the necessary feedback signal to ensure accurate positioning, while the closed-loop system
adjusts the motor speed to maintain the desired position.

Procedure
Step 1: Set up the apparatus

• Connect the tacho-generator to the DC motor

• Connect the power supply to the motor
• Connect the closed-loop position control system to the motor and tacho-generator
• Connect the multimeter and oscilloscope (if using)
Step 2: Calibrate the tacho-generator

• Rotate the motor shaft and measure the output voltage using a multimeter
• Record the voltage values for different rotation speeds
Step 3: Demonstrate closed-loop position control

• Set a desired position using the closed-loop system

• Observe how the system adjusts the motor speed to maintain the set position
• Record the motor speed and position values using the multimeter and oscilloscope (if using)
Step 4: Integrate with robot/automation assembly (if available)

• Connect the closed-loop system to the robot/automation assembly

• Demonstrate how the system controls the robot's position and movement

Observations and Calculations

Sr. No Input Voltage Speed (RPM) Tacho Voltage
(V) (V)

1 1 1350 1.20

2 2 2250 1.98

3 3 3280 2.87

4 4 4270 3.70

5 5 5250 4.64

6 6 6370 5.60

7 7 7240 6.45

8 8 8310 7.34

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9 9 8330 7.37

10 10 8350 7.36

Graph

Speed vs Input Voltage

9000
8000
7000
Speed (RPM) 6000
5000
4000
3000
2000
1000
0
0 2 4 6 8 10 12
Input Voltages

Input Voltage vs Tacho Voltage

8
7
6
Input Voltage

5
4
3
2
1
0
0 2 4 6 8 10 12
Tacho Voltages

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Speed vs Tacho Voltage

9000
8000
7000
6000

Speed (RPM)
5000
4000
3000
2000
1000
0
0 2 4 6 8
Tacho Voltages

Results and Discussion:

This experiment successfully demonstrated the characteristics of tacho-generators and the functionality
of closed-loop position control systems in robotics and automation. The results showed that the tacho-
generator provides accurate feedback on speed and position, and the closed-loop system effectively
maintains precise control over mechanical positions.

Comments:
This experiment has practical implications for industries where precise control and automation are
crucial, such as manufacturing, robotics, and mechatronics. The knowledge gained from this
experiment can be applied to real-world applications, contributing to improved efficiency and accuracy
in robotic and automation systems

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Experiment 10
Design and Implementation of a traffic light control system using PLC Logic
Apparatus:
1. Programmable Logic Controller (PLC)
2. Traffic light signals (red, yellow, green)
3. Vehicle presence sensors (e.g., inductive loop sensors or cameras)
4. Pedestrian crossing signals (if applicable)
5. Human Machine Interface (HMI) for visualization and control
6. Power supply unit
7. Wiring and interconnecting cables
8. Win Pro-ladder for logic

Theory:
Programmable Logic Controller (PLC)
A Programmable Logic Controller (PLC) is a digital computer used for automation of
electromechanical processes, such as control of machinery on factory assembly lines, amusement
rides, or light fixtures. PLCs are used in many industries and machines, from simple lighting control
systems to complex factory automation systems.
PLCs are used in a wide range of industries and applications, including:
• Manufacturing: PLCs are used to control machinery on factory assembly lines, such as
conveyor belts, robotic arms, and packaging machines.
• Process Control: PLCs are used in industries such as oil and gas, chemical manufacturing,
and water treatment to control processes such as mixing, heating, and cooling.
• Process Control: PLCs are used in industries such as oil and gas, chemical manufacturing,
and water treatment to control processes such as mixing, heating, and cooling.
• Building Automation: PLCs are used to control heating, ventilation, and air conditioning
(HVAC) systems, lighting, and security systems in commercial buildings.
• Transportation: PLCs are used in traffic control systems, railway signaling systems, and
airport baggage handling systems.
• Entertainment: PLCs are used in amusement rides, stage lighting systems, and audiovisual
equipment.

PLCs have several advantages over traditional relay-based control systems, including:
• Flexibility: PLCs can be easily reprogrammed to accommodate changes in the manufacturing
process or to add new features.
• Reliability: PLCs are more reliable than relay-based systems because they have fewer moving
parts and are less susceptible to wear and tear.

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• Cost: PLCs are often more cost-effective than relay-based systems because they require less
wiring and are easier to install and maintain.
• Diagnostics: PLCs have built-in diagnostic features that make it easier to troubleshoot
problems and identify faulty components.
• Integration: PLCs can be integrated with other systems, such as supervisory control and data
acquisition (SCADA) systems, to provide a comprehensive control solution.
Overall, PLCs are an essential tool for automating industrial processes and improving efficiency,
reliability, and safety.

Information of simulator:
1- XO -auto ON/OFF switch for PLC
2- X1-Manual ON/OFF switch for PLC
3- X2-Start pulse (Push Button for PLC)
4- YO-Y2 First set 1 output red, yellow, green from PLC
5- Y3-Y5 second set 2 output red, yellow, green from PLC
6- Y6-Y8 third set 3 output red, yellow, green from PLC
7- Y9-Y11 Fourth set 4 output red, yellow, green from PLC
8- Indication ON/OFF
9- ON/OFF switch (to energized panel)
10- DC 24 V terminal
11- Fuse for protection
12- Lamp for indication Red, Yellow, Green set 2
13- Auto switch
14- Manual switch
15- Push button (start)
16- Lamp for indication Red, Yellow, Green set 1
17- Lamp for indication Red, Yellow, Green set 4
18- Lamp for indication Red, Yellow, Green set 3
Software:
• WIN-PROLADDER FATEK
Logic diagram:

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Program description:
Simulator consists of following,
1- 24VDC INPUT supply connected to 24VDC ‡ terminals ON/OFF switch will energized the
simulator with protected fuse and also indication. Supply use from PLC main trainer.
2- It has three input for PLC X0, X1, X2 XO is auto instruction to start in a sequence (ON/OFF).
X1 is manual starter only Yellow light is flashing (ON/OFF) X2 is start pulse (push button) for starting
the program.
3- OUTPUT Description
Set 1 is consists of following outputs.
YO----RED
Y1__YELLOW
Y2--GREEN (Parallel Connected)
Right Turn
YO----RED
Y2-_GREEN
Set 2 is consists of following output
Y3---RED
Y4----YELLOW
Y5----GREEN
Right turn
Y3----RED (Parallel Connected)
Y5----GREEN
Set 3 is consists of following output
Y6---RED

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Y7----YELLOW Y8----GREEN
Right turn
Y6---RED (Parallel Connected)
Y8----GREEN
Set 4 is consists of following output
Y9_---RED
Y10----YELLOW Y11----GREEN
Right turn
Y9----RED (Parallel Connected)
Y11----GREEN

Logic Diagram Explanation:

1. We start by configuring the X2 and X0 contacts to be normally closed which activates the Y2 (GREEN
LED, S1).
2. Since Y2 serves as an input for Y3 (RED LED, S2), Y8 (GREEN LED, S3), Y9 (RED LED, S4) they
also be activated. We insert the timer between theses output to control their timing accordingly.
3. The normally closed Y3 (RED LED, S2) serves as an input triggering Y4 (YELLOW LED, S2) and
Y10 (YELLOW LED, S4), initiating their respective timers.
4. We configured the input as normally closed Y3 (RED LED, S2) and Y4 (YELLOW LED, S2) contacts
act as an input for Y0 (RED LED, S1), Y5 (GREEN LED, S2), Y6 (RED LED, S3) and Y11 (GREEN
LED, S4). When both Y3 and Y4 are off the Y0, Y5, Y6 and Y11 are activated for their respective
preset times.
5. The normally closed contacts Y0 (RED LED, S1), Y2 (GREEN LED, S1) and Y4 (YELLOW LED, S2)
along with normally open contacts Y5 (GREEN LED, S2) act as an input for Y1 (YELLOW LED, S1)
and Y7 (YELLOW LED, S3). When Y0, Y2 and Y4 are off Y5 will turn on leading the activation of
output Y1 and Y7.
Advantages:
1. Efficiency: Optimizes traffic flow and minimizes congestion by dynamically adjusting signal timings
based on traffic demand.
2. Safety: Enhances road safety by providing clear and coordinated signal indications for drivers and
pedestrians.
3. Flexibility: Allows for easy modification of signal timings and sequences to accommodate changing
traffic patterns or road conditions.
4. Reliability: PLC-based control ensures reliable operation and minimal downtime compared to
traditional relay-based systems.
5. Scalability: Can be easily expanded or upgraded to control traffic at multiple intersections or integrate
with intelligent transportation systems.

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Connections:

Comments:
• The Traffic Light Signal Control System using PLC provides an efficient and reliable solution for
managing traffic flow at intersections.
• By leveraging PLC technology and advanced control algorithms, the system enhances road safety,
minimizes congestion, and improves overall traffic management effectiveness.
• With real-time monitoring and flexible control options, it offers a scalable and adaptable solution for
urban traffic control needs.

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Experiment 11
Design and Implementation of a Water Level Indicator System for Tanks using PLC Logic
Apparatus:
• Programmable Logic Controller (PLC)
• Water level sensors (e.g., float switches or ultrasonic sensors)
• Solenoid valves or pumps for water control
• Human Machine Interface (HMI) for visualization and control
• Power supply unit
• Wiring and interconnecting cables
• Win-proladder Software for logic making

Theory:
Applications of PLC
• Process Control: PLCs are used in industries such as oil and gas, chemical manufacturing, and
water treatment to control processes such as mixing, heating, and cooling.
• Building Automation: PLCs are used to control heating, ventilation, and air conditioning
(HVAC) systems, lighting, and security systems in commercial buildings.
• Transportation: PLCs are used in traffic control systems, railway signaling systems, and
airport baggage handling systems.
• Entertainment: PLCs are used in amusement rides, stage lighting systems, and audiovisual
equipment.
PLCs have several advantages over traditional relay-based control systems, including:
• Flexibility: PLCs can be easily reprogrammed to accommodate changes in the
manufacturing process or to add new features.
• Reliability: PLCs are more reliable than relay-based systems because they have fewer
moving parts and are less susceptible to wear and tear.
• Cost: PLCs are often more cost-effective than relay-based systems because they require
less wiring and are easier to install and maintain.
• Diagnostics: PLCs have built-in diagnostic features that make it easier to troubleshoot
problems and identify faulty components.
• Integration: PLCs can be integrated with other systems, such as supervisory control and
data acquisition (SCADA) systems, to provide a comprehensive control solution.

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Overall, PLCs are an essential tool for automating industrial processes and improving efficiency,
reliability, and safety.
Program Description:
There are two pumps P1, P2 which are connected to YO, Y1, to fill water level up to 100%, five nos.
of switches are giving the sense of level increased step by step. Operating the switches XO to X4 two
nos. of output valve are also for water level, drain operate switch X5, switch X6 output valve &
Output valve 2, make a program according to the said description and check it.

Information of Simulator unit:

1- XO- for PLC terminal (level Indication switch) 20%.
2- X1- for PLC terminal (level Indication switch) 40%.
3- X2- for PLC terminal (level Indication switch) 60%.
4- X3- for PLC terminal (level Indication switch) 80%.
5- X4- for PLC terminal (level Indication switch) 100%.
6- X5- for PLC terminal (Switch Indication for output valve).
7- X6- for PLC terminal (Switch Indication for output valve 2).
8- X7- for PLC (Not Use).
9- YO from PLC output (for Pump 1).
10- Y1 from PLC output (for Pump 2).
11- Y2 (Not Use).
12- Indication Led's for level monitor.
13- 24VDC terminal to connect DC 24V supply from PLC.
14- Level monitor switch from X0 to X4.
15- ON/OFF switch for (Opening /closing valve 1)
Software:
• WIN-PROLADDER FATEK
Logic Diagram:

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Connection:

Comments:
The Water Level Indicator Tank using PLC logic offers an effective solution for monitoring and
controlling water levels in tanks. By utilizing PLCs and advanced control algorithms, the system
ensures efficient utilization of water resources while minimizing the risk of overflow or shortage.
It provides users with real-time data visualization and control options, enhancing overall system.

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SECTION-E
MATLAB
Experiment No. 12
To represent LTI system in MATLAB with respect to SISO and MIMO systems
Objectives:

This experiment has following two objectives:

1. We will learn commands in MATLAB that would be used to represent such systems in terms
of transfer function or pole-zero gain representations.

[Link] will also learn how to make preliminary analysis of such systems using plots of poles and
zeros locations as well as time response due to impulse, step and arbitrary inputs.

List of Equipment/Software:

Following equipment/software is required:

MATLAB

Deliverables:

• Observations and solutions to exercises provided at the end.

• Oral verification of results

Linear Time-Invariant Systems in MATLAB:

Control System Toolbox in MATLAB offers extensive tools to manipulate and analyze linear
time-invariant (LTI) models. It supports both continuous-and discrete-time systems. Systems can
be single-input/single-output (SISO) or multiple-input/multiple-output (MIMO).

Examples of Creating LTI Models:

Building LTI models with Control System Toolbox is straightforward. The following sections
show simple examples. Note that all LTI models, i.e. TF, ZPK and SS are also MATLAB
objects.

Example of Creating Transfer Function Models:

You can create transfer function (TF) models by specifying numerator and denominator
coefficients. For example,

C/R = s / (s2+2s+1)
>>num = [1 0];

>>den = [1 2 1];

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>>sys = tf(num,den)

Transfer function:

A useful trick is to create the Laplace variable, s. That way, you can specify polynomials using s
as the polynomial variable.
>>s=tf('s');

>>sys= s/(s^2 + 2*s + 1)

Transfer function:

Transfer Function From Single Differential Equation:

By considering the right hand side of differential equation as numerator and left hand side of
differential equation as denominator, the transfer function can be determined as represented
below.
For example:

Suppose, M=5, fv=3, and K=1

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Transfer function from Differential Equations:

Consider the following system:

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Consider,
M1=15, M2=14
fv1=fv2=fv3= 1
K1=K2=K3=2

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Example of Creating Zero-Pole-Gain Models:

To create zero-pole-gain (ZPK) models, you must specify each of the three components in vector
format. For example,

>>sys = zpk([0],[-1 -1],[1])

Zero/pole/gain:

produces the same transfer function built in the TF example, but the representation is now ZPK.

This example shows a more complicated ZPK model.

>>sys=zpk([1 0], [-1 -3 -.28],[.776])

Zero/pole/gain:

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Plotting poles and zeros of a system:

pzmap:

Compute pole-zero map of LTI models.

Pzmap(sys)

Description:
pzmap(sys) plots the pole-zero map of the continuous- or discrete-time LTI model sys. For SISO
systems, pzmap plots the transfer function poles and zeros. The poles are plotted as x’s and the
zeros are plotted as o’s. You can use the functions sgrid or zgrid to plot lines of constant
damping ratio and natural frequency in the s- or z- plane.
Example:

Plot the poles and zeros of the continuous-time system.

Consider; C/R=H=(2s2+5s+1)/(s2+2s+3)

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pzmap(sys1,sys2,…,sysN)

Description:
pzmap(sys1,sys2,…,sysN) plots the pole-zero map of several LTI models on a single figure. The
LTI models can have different numbers of inputs and outputs.
Consider; C/R=H=(2s2+5s+1)/(s2+2s+3)
C/R=L=(s+1)/(3s2+5s+7)

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[p,z] = pzmap(sys)

Description:
When invoked with left-hand arguments, [p,z] = pzmap(sys) returns the system poles and zeros
in the column vectors p and z. No plot is drawn on the screen.

Simulation of Linear systems to different inputs:

impulse, step, ramp and parabolic response

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You can simulate the LTI systems to inputs like impulse, step and other standard inputs and
see the plot of the response in the figure window. MATLAB command ‘impulse’ calculates
the unit impulse response of the system, ‘step’ calculates the unit step response of the
system. When invoked without left-hand arguments, all these commands plots the response
on the screen.

Impulse Response:

To obtain an impulse response

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Step Response:

>>step(H)

Time-interval specification:

To contain the response of the system you can also specify the time interval to simulate the
system. For example,

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Ramp and Parabolic Response:

You could get the ramp and parabolic response by dividing your transfer function by s and s2
respectively, and then taking the step response.

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Experiment No. 13
To find the stability of control and automation system, steady state errors and how to plot their
root locus.
Objective:
The objective of this lab session is to familiarize about the MATLAB commands used to find the
stability of control systems, steady state errors, and how to plot their root locus.
Stability of Control Systems:
The following MATLAB command is used to determine the stability of control systems.
>>B = isstable(sys)
B = isstable(sys) returns a logical value of 1 (true) if the dynamic system model sys has stable
dynamics, and a logical value of 0 (false) otherwise.
Example:
Determine the stability of the system shown in figure below.

Because the logical value is zero, therefore the system is unstable.

Steady-State Error:
The following MATLAB command is used to find the steady state error of the system.
>>SP=5; %input value, if you put 1 then is the same as step(sys)
>>[y,t]=step(SP*sys); %get the response of the system to a step with amplitude SP
>>sserror=abs(SP-y(end)) %get the steady state error

Example:
Find the steady state error for the above system.

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Root-Locus:
The following MATLAB command is used to plot the root locus the system.
>>rlocus(sys)
rlocus(sys) calculates and plots the root locus of the open-loop SISO model sys. This function
can be applied to any of the following negative feedback loops by setting sys appropriately.
Example:
Plot the root-locus of the following system.

>>h = tf([2 5 1],[1 2 3]);

>>rlocus(h)

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You can use the right-click menu for rlocus to add grid lines, zoom in or out, and invoke the
Property Editor to customize the plot. Also, click anywhere on the curve to activate a data
marker that displays the gain value, pole, damping, overshoot, and frequency at the selected
point.

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Time-Domain Characteristics:
The following MATLAB command is used to find the rise time, settling time, peak time, and
percent overshoot, etc.
>>S = stepinfo(sys)
S = stepinfo(sys)computes the step-response characteristics for a dynamic system model sys. The
function returns the characteristics in a structure containing the fields:
• RiseTime — Time it takes for the response to rise from 10% to 90% of the steady-state
response.
• SettlingTime — Time it takes for the error |y(t) - yfinal| between the response y(t) and the
steady-state response yfinal to fall to within 2% of yfinal.
• SettlingMin — Minimum value of y(t) once the response has risen.
• SettlingMax — Maximum value of y(t) once the response has risen.
• Overshoot — Percentage overshoot, relative to yfinal).
• Undershoot — Percentage undershoot.
• Peak — Peak absolute value of y(t)
• PeakTime — Time at which the peak value occurs.
Example:
Recall system ‘h’ again and computes all above.

Time-Domain Characteristics on Response Plot:

This example shows how to display system characteristics such as settling time and overshoot on
step response plots.

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You can use similar procedures to display system characteristics on impulse response plots or
initial value response plots, such as peak response or settling time.
Create a transfer function model and plot its response to a step input at t = 0.
Example:
>>H=tf([8 18 32],[1 6 14 24]);
>>stepplot(H)

Display the peak response on the plot.

Right-click anywhere in the figure and select Characteristics > Peak Response from the menu.

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A marker appears on the plot indicating the peak response. Horizontal and vertical dotted lines
indicate the time and amplitude of that response.

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Click the marker to view the value of the peak response and the overshoot in a datatip.

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