FOM Solved Manual

ianl ntals ofMcchatronics(22048)
fll 11
practical No. Ol: Select Sensors, Actnntoa·s, PLC, and Microcontrollcr for
l\lcchah onics systems.
Practical Signiflcnncc-
J.
Scnsors. actuators, Pl Cs, und microcontrollc1s arc the 111t gml part of M ch tronic
systems. Proper s~lcction and integration of them is crncrnl in m h tronii y t m .
Sensors plar an ~rnportant role in modem manufacturing procc control Choo mg
smtablc devices w1sely for the intended application wrll optimize the y t m to ncrate
accurate result.
JI. Relevant Program Outcomes (POs)-
PO l • Basic knowledge: Apply knowledge of basic mathematics, sciences and ba 1c

engineering to solve the broad-based Mechanical engineering problems.
PO 2. Discipline knowledge: Apply mechanical engineering knowledge to solve broad-

based mechanical engineering related problems.
ID, Competency and Skills

This practical is expected to develop following skills for the industry identified
competencies 'Operate and manipulate mechatronics systems as per requirements':
I. Identify various types of sensors, actuators and transducers.
2. Select a Sensor, Actuators and Transducers for a given situation with justification.
3. Select a Programmable Logic Controller (PLC) and microcontroller for given situation
with justification.
IV. Relevant Course Outcome(s)
• CO - a. Identify different instruments, sensors, actuators, microprocessor, software

and mechanical components in mechatronics based systems.
V. Practical Outcome
• Select sensors, actuators, transducers, PLC and Microcontrollers for given application
with justification system.
VJ. Relevant affective domain related Outcomes
l. Follow safety practices.

2. Work as a team leader/ team member.
VIL Minimum Theoretical Background

Sensor is an element which produces a signal relating to the quantity being measured
They convert mechanical, magnetic, thermal, optical, and chemic,ll , ariations into
electric voltages and currents. Depending on what they measure, sensors are usually
categorized as follows
Temperature_ Thermistor, thermocouples, RTD's, IC LM35.
~::-:--------.----------~-~
htra State Board of Technical Education
~\\~VY~ ~\ \.\ ~\ '"M ,~cvv~, h le_

2-v rn (}: rL:!> i 1~ lo .sf o~~ 7-
Fundamentals ut l\.frd111ttonici.(2204M)
Prcs.-.urc - Fibre optic, vacuum, clutic liquid based •~~nomct~rs • J,Vf )'J , efcctrcmic;,
Flow • El!!ctromngnctic. differential pressure, posit,onaf d,splaccm crrt, thermciJ rria
etc.
Level Sensors - Differential pressure, ultrasonic radio frequency. radar, lherni<l
displacement.
Proximity and displacement - LVDT, photoelectric, capacitive, magnetic, ultrasonic;,
Actuators transform the output of a system into controlling action on a mriehine ,n.
device. There are four main types of actuators: Hydraulic, Pneumatic, Electric a~
Mechanical. Examples of actuators include valves, electric motors, sol enoids and hC<l•-
to name few. ~
Programmable Logic Controller (PLC) is a digital electronic device that r,i~

programmable memory to store instructions and to implement function s such as logic
sequencing, timing, counting and arithmetic in order to control machines and processes.
Mocrocontroller is programmable device which takes the input, processes it as per the
program written and generates the output. Microcontroller is the heart of an embedde<l
system which are particularly designed for dedicated applications.
VIII. Experimental Setup

Sensors:
Proximity Sensor
Inductive Proximity Sensor
Photo courtesy Turck, Inc. www.turck.coro
Capacitive Proximity Sensor
Photo court.86y Omron lnduslffal Auton1ar,on
-~-
Temperature Sensor
RTD (PT JOO)
Maharashtrn State Board of Tcc hnacal Education - -----~------~-----z'

m=.:!:_~-~-l~eo:f=M~c~cha==tron==ic=s~(2=2=0_
f unJam_eni.w>
:---
4_8~)-=--=-
--- ----~-- -------
~
Thermocouple
Thermistor
Light Sensor
Photo Diode
Photoelectric sensor
Pressure Sensor
Strain Gauge
Loadcen
Load Cell
3
~
~ashtra State Board of Technical Education
.,.tt:S(22048l
Fund» •als of MediaUU
Ojsplacement Se1150r
Potentiometer
Rotary POT Linear POT
LVDT
Actuators:
Electrical Actuaton
Electric Motor
DC Motor AC Motor
Stepper Motor
Solenoid
Maharashtm State Bon.rd ofTcchnicnl Edu cauon

•
fundamentals of Mecbatronics(2204 8)
i - - - - - - - - - -- - - -_ _:P::....:.:n~e:u.:'.m~a~tic Actuators
Hydraulic Actuators
Programmable Logic Controller (PLC)
Fixed PLC
CPU
Memory
canrr.ncdons
Image Courtesy Rockwell Automation, Inc
Modular PLC
Power supply
module
Modula - -
Cenll'lll •
~ • ' f
Urul (OPU)
MINl'IO,Y
•
•
l
' ♦
Program Da'8
Opacal /
1101at1on
~□
Prog,.rnming drJlCe . . •
frnngc Couitcsy M11sub1sh1 Autonmllon
------
5
~•hara.~htra State Board of Technical Education
tn)Dia1(2.,048 l
Funda.~ ofMecm - -
Microcontn,ller:
and Microcontrollcr.
.
Figure I: Vanous sensors. actuators. PLC
JX. R esources Required
Sr. Name of Suggrsted Broad Specification Quantity

No. Resource
Digiul Inputs:-12 Nos with toggle switches
for applying 24V de inputs.
Digibl Outputs:-12 Nos with 24V operated
Programmable Lamp.
I Logic Controller Analog Inputs: - 02 01
(PLC) Trainer Analog Outputs: - 02
External Power Supply: 24 V DC.
Memory:-16 K data memory +351K Code
Memory +96K upload Memory. -
Operating voltage: 3. 0-5. 5V
Thermocouple Temperarurc Resolution: 0. 25 Degree;
2 Cold junction compensation range: -2o--+-80'C, 01
Using SPI 3 wire communication
Type K temperature range 0-1024'C
OperatingVoltage: 12V DC
---
Weight: 100 gm(Approx.)
3 DC Motor RPM: 300.
Torque: As per RPM 01
No-load cu1Tent = 60 mA(Max)
4. Microcontroller
Load current 300 mA(Max).
A T89S51 40 pin DIP package,+5VDC

operating volateg,4K EEPROM/Flash
---
01
Memory,128 Bytes ofSRAM .Four 8-bit IO
Ports, Two 16-bit timer/counter, 6 interrupts
X. Precautions to be followed
1. Avoid improper handJing of instrument.

2. Follow safety practi b · . .
ces a out mamtammg tools and equipment.
Maharashtra State Board of Technical Education --;
fundamental~ of ~rcchatronics(2204R)
XJ. Procedure
t. Identify the type of application intended.

2. Explore the available sensors/actuators/PLCs/Microcontroll cr in laboratory nccde<I for
identified application.
3. Shortlist the components from the available.
4. Apply the standard selection criteria for each of the component shortlisted.
5. Select the most suitable component for the given application
6. Repeat above steps for different types of sensors/actuators PLCs/Microcontroller
xn. Resources Used

.--
Sr. Broad Specifications Remarks
Name of Recoune
No. Quantity (if any)
Make Details
- O,c/>rn. \ \n€~t :: ,~
1 PLC Did,'~' OU ~k I 1-... 02._
~Owe;{ 8~{>(>~ ;-- 2. 4\/
V
in~ crm c.. 0,1110 ll ~ fL-] \\cN> ot

2
(-2./i ffl 6/
De o~~\-1 ~ '{~\~~-=
3 \2. .\f OC
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1'"'~6)710
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~ I
4
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~\n 'C'... ,V
xm. Actual Procedure Followed .............................................. J"'j'

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htra State Board of Technical Edu
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7
f undamana1s of Mecharromu(2204S I -
xv. Observations and Calculadetll
crtteri• ror .ealOl'S
Table l :Sekdiee
Sr. Name of the seasor Seledio• Criterion used Comments

No.
6elect ~ ---
p, e.2. oe.\ ec~c.. \e-,clm-o'tot~
I
c"o ~\d'6eJn5ef G1h<H\-i on
~~~ Rd~
2 ~ a Cb-\~ Ies ~~~\u'Jf,
Yn eos~~ , un lJ •
l.)
3
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4 ~~ ~ 'f{)e_-\t,{ ~~
CA\,'b~~icrn ;.i
5 ~"om c\,oJe o~~~-\~

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Table 2: Selection criteria for Actuators
Sr.
No. Name of the actuator Selection Criterion
used Comments
1
()C. '(l\010--{ De.. 'tn~ ~ ~(M I ~ ~ w er{ 6~\l-(Le,
b~~•rv'oo~\} lie. =- , \ a ft C f><)~ e,.,,
-
~ e_\l_"(t\di\-{ (. \~~e"a.~ ,et(l\~ ~~ i5
2
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0
s ,~~Qe.,'t" -
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11
3 ~\JJ~ 6\.\~~'d O
"{n~,\o<
\etl'\e. ~~ s~ e.c.,' Q\ eo•n:~. ~nJ
4 t}r~C¼<i.W
I.\, \C..
'1iC\ ~~,
\.\.dive
o.. , \.J ~ rn. k-n
u
n Itr-h, t::-
5 ----
Maharashtra State Board ofTcchn1cal Education

fundamentals ofM1.-ch:it~ 20 Hn
Table ~1: Sl'll•ctlcm rl'lfnln lnr 1•1 ,(;

Sr. Sl'll'l'tlon Crlll'rlon
No. Na1m• of the PLC
lJiml Comments
1\ ,~i..,.1c._\ ~\,'(,\he.
l\~<J ~cc_ "
oJ\\\{'_
2 s, c~t\1
rn~J\.lJe.
~~"liC.~ l>)'1
3 t\-- '~ IJ.~·ed i1'\ o--n'd
r"l. od~\e. 'Jr'\ oJ~,d-t ptc., (t?f
OIJ"rl C
Table 4: Selection criteria for Microcontroller
Sr. Name oftbe Selection Criterion
No. Microcontroller Comments
Used
I ~ (Y1'\'1 o~\tf\~
·1_c:_ i j C 51._ ~ ~-~~...-a -
2 -'r\~1&, ~ 'lo?""~Cfb'J~
XVI. Results
XVII. Interpretations of Results ....
.................................................................. ............ .................... . .... ..... . . .... .............................. ... . ...... .............. . . ..............................................................................
XVID. Conclusions
........................................ ······ ... ······.. .. ... ....... ..... .... ......... .... ... ... ...... .. ... ... .. ........ ........... .. ... .... .
XIX. Practical Related Questions

Note: Below given are few sample questions for reference. Teachers should design more
such questions so as to ensure the achievement of identified COs.
1. List at least three applications of each of the following sensors

9
Maharashtra State Board of Technical Education
8
Fundam<"nWll> ofMechatr0m~f2-204 ) - -- c) Light Sensors
__
- - - ----
~ . SOI' -----....
b) Displacement Sen .
a) Pressure ScnSl)rs f PLCs and compare their features.
O
2 List the various manufacturers tuator for particular application?
3: State the procedure for selecting an ac
(Space for Answers)

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Fundamentals of Mecbatr onics(22 048)
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XX. References/Suggestions for further reading
1. Programmable Logic Controllers by Frank D. Petruzella.

2. Mechatronics by W.Bolton
3. https://nptel.ac.in/courses/112103174/3
Maharashtra State Board of Technica l Educatio n

11
FundamcnUlls of Mcchatrooic,(22048} --
XXI. Assessment Scbemt.1
Perfennaace JncUcatorl
L - - - - -~Pr~oc~ea::_R::::el=•=ted~(;_t_5_M_ar_k_s_)_ _ _ _ _ _T __ 6o ¾ "-
of~th::_e__:_instf'WIJ=:.==-en==ts=----------- - ;---..:30 % .....,

L-~I._J~H~an~dJ~in~g~
r~co~m~p-on_e_n_t_._ _ _ _ _ _ _ _ _ _--t___30%
1-....:2:·_1~S:e:le:c:u·:o:n~o:f~p~ro~pe==-
Product Related ( IO Marks ) 40 ¾
3. Interpretation of result
10 %
4. Conclusions
20 ¾
5. Practical related questions
100 ¾
Total ( 25 Marks )
Name ofStudent Team Members
1. ..............................
2. . ............................ .
3. ······························
4. . ............................. .
f Dated Signature
Marks Obtained of Teacher
I
Process Product Total
Related (15) Related (10) (25)
v.
VI.
vu.
Maharashtra State Board of Technical Ed ucahon

.
ntal ofMechatronics(22048)
F darl1 ::::------ - - -
practical No. 03: Develop Ladder Diagram to verify the functions of Logic
Gates using PLC.
practical Significance-
1.
Logic gates are the basic building blocks of the digital ctcclrontc circuit Mnny
mechatronics systems involves digital signal which have only two possible 1gnal level
i.e. ON and OFF. The students should be able to develop the ladder logic for the given
Boolean arithmetic.
IJ. Relevant Program Outcomes (POs)-
PO 1. Basic knowledge: Apply knowledge of basic mathematics, sciences and basic

PO 3. Experiments and practice: Plan to perform experiments and practices to use the
results to solve broad-based Mechanical engineering problems.
PO 4. Engineering tools: Apply relevant Mechanical technologies and tools with an

Wlderstanding of the limitations.
m. Competency and Skills

1. Develop a ladder logic for different logic gates using PLC software.
2. Programme and troubleshoot PLC for the developed logic.
3. Develop the ladder logic for different logic equations.
• CO - e. Programme PLC for various applications.
Verify the functions of Logic Gates for the given Ladder Diagram by using PLC.
VI. Relevant affective domain related Outcomes

1. Follow safety practices.
2. Maintain tools and equipment.
VU. Minimum Theoretical Background

The PLC, like all digital equipment, operates on the binary principle. The binary means
having only two states. These states are 1 and 0. The 1 and O c~ ~epresent ~Nor O~F,
open or closed, true or false, high or low, or any other two conditions. A logic ~ate _is a
cbtuit with several inputs but only one output that is activated by particular combmations
of lnput conditions.
~
~ State Board of Technical Education 21
~'n ~t'--lkl"fl'\
_.......___ \~\o51D~o7-
.
hmd11mcnt1ds of· Meeh• troniCI 22048
Loafc Gates u1ln1 ,wttchlnl clrculh:
I. NOT G•;~ NOT gate is the inverse of the input.

The output O e NOT truth table
A NOfA
.~ - A (NOT A)
Output 0 1
1 0
Hardwired cfn:ult
Truth table
N.C. pushbullon
+
SingJeilput
2. AND Gate:
The AND gate output is I only if all inputs are I otherwise output is 0.
AND truth table
Inputs Output
A-- A B Y
Inputs ~- y
Output 0 0 0
B--
0 1 0
lwo-input AND 1 0 0
1 1 1
gate symbol
r-~ HardWlred circuit
Light
SW.A
Open (0)
Open (0)
OloNd (1)
Troth table
SW-8
Opeo (0)
Cloeed (1)
Open (0)
Ught
Off (0)
Off (0)
Off (0) ::=0
Logic rep
OIOlld (1) On_ill SW-8
3. OR Gate:
The OR gate output is I if one or more inputs are I otherwise output 1s 0.
OR truth table
Inputs _gytput
A
Inputs
A B y
>---Y
Output 0 0 0
8------•· 1
0 1
1 0 1
Two..jnputOR 1
1 1
gate symbol
~j~
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48 )
~a fM ec ha tro oic s(2 20
~ ... ...UCIClrant
SW-A Truth table

Logic representation
~D~
SW-A SW -8 Li11Jt
SW-8 Open (0) Open (0) Off (0)
Open
Closed
(OJ
(1)
Closed
Open
(1)
(0)
On
On
(1)
(1)
0-
-0 ---
SW -8
Closed (1) Closed (1) On (1)
sive OR) Gate: _

4• X-OR(Excl~ uts are dif ferent and output is O when
both the inputs
bo th the mp
The output 1s l wh en
are same.
Boolean Expression Truth TabJe
X-OR Gata Sy mb ol
s y
. A~D-y
A
Y= A'9 B= AB +A 'ii 0 0 0
0 1 1
B 1 0 1
1 1 0
/: = :: I
..._ _,,, _•_ _ _ _ _

,,,,
_
-/~-· fix If fl
___,._ .... . OfJ '•G
. _
Ex clu siv e NO R) Ga te: bot h the mp uts
5. X-NOR( h inputs are sam e and output
1s O when
is 1 on ly wh en the bot
The out put
are different. Boolaal'I Expression
TIUth Table
X-NOR Gaa. Symhol
B y
A
A=,D-v 0 0 1
Y= A9 B= AB +A B 0 1 0
1 0 0
8 . 1
1 1
Switch A (NO )
0 0
R 1K: Swit ch B (NC )
Swit ch A (NC )
23
Technical Edu cation
Maharashtra State Boa rd of
~ ~ - -- --- - - - -
Fundamentals o f Mechatronics(22048)
Ladder Dlagnnu:
Jff.
J. NOT[Ga:!te!:~=----------------- ----- -:~~

0000 ~
0
0
B.! I •~1
llll76'
0001
2. ANDGate:
o-.o
0000
Lilc=-----------------------r. )-
I-----:::]] I Bt!.16
B1U763
0001
3. OR Gate:
1-0
0000
0
Bll..176'
1.-0
l
Jhl.1763
0001
4. X-OR(Exclusive OR) Gate:

L-0 J.-0
0-0
~~7
0000
0
( )--.
BDl.1763 0
Bol..170
L-0
0
.a.t.1763
[
1
Bol.1763
I
0001
5. X-NOR(Exclusive NOR) Gate:

I:O l-0
0000 0:-0
0
)---h I.
1 0
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_ _-mis ofMechatronics(22048)
~
Vlll· iqerbnental Setup
or...,..IIIIMb PLC
Digital Outputa
10.0 Analog ln1111ta
10.1
102
10.3
10-4
105 I
10_6
10.7
10.a
AnalogOutpuia
10.9
10.10
ID.U
10.U
10.13
10.14
AI-Analcg~ 00.14
lo.JS AD -Analog OlllpUt O0.1s
Figure 1: Experimental setup
IX. Resources Required
Sr. Name of Resource Sug~ested Broad Spec~ ca~on Quantity

No.
PC preloaded with PLC software and 1/0
1 Computer/ Laptop communication facility 01
Digital lnputs:-12 Nos with toggle
switches for applying 24V de inputs. f 1 1 \
Digital Outputs;-\2 Nos with 24V
Programmable Logic operated Lamp.
2 Controller (PLC) Analog Inputs: - 02 01
Trainer Analog Outputs: - 02
Memo +96K u load Memo .
1. Avoid improper handling of instrument.
2. Follow safety practices about maintaining tools and equipment.
XI. Procedure
1. Open the PLC Software.
2. Create new project.
3. Develop ladder diagram for Logic Gates.
4. Test and correct the errors (if any).
5. Download the program on PLC.
6. Make required input output connections to PLC. ..
7. Execute the program and observe the output on lamp by changing switch poS1ttons.
8. Repeat steps 3 to step 7 for different Logic gates.
25

Fundamentals of ec
XII.
M h8cronics(22048)
Resources Used
----
Broad Specifications
Quantity
Sr. Name of Recourse Details
No.
Make
cornpu\eJ(
Lt\r+of
~,m'P"\dij e.. t1
2 I COO It~ ffncilo c1 uJ-r '-' r
3
XIII.
XIV. Precautions Followed
XV. Observations and Calculations
1. NOT Gate: 2.AND Gate:
Switch
Open ,
Lamp Switch A
Open
Switch B
Open
Lamp
Closed a Open Closed C)
Closed Open C
Closed Closed
3. OR Gate:
4. X-OR Gate
I
Switch A Switch B Lamp
Open Open Switch A Switch B Lamp
()
Open Closed Open Open ~
I Open Closed I
Closed
Closed
Open
Closed ,
I
Closed
Closed
Open
Closed () ' Mahara1
Maharashtra State Board ofTechn tea

' 1Ed ucatton
.
-- I mcntals of r-.-
Fun,a~-- kchatronics(22048)
----;._
- ---~
.xvi .
.xvn. Interpretations of Results
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XVIII. Conclusions
·······
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1. Prepare a ladder logic for Y= (A+B)CD.

2. Draw the symbol and truth table for X-NOR gatle. . ~ ~ 11 ing circuit
3. Write the Boolean equation and prepare ladder og1c ior io ow
A----i
8---,
C y
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I fMcchatronics(22048)
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Maharashtra State Board of Technical Education @1
nics(22048)
fundamentals ofMechatro
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···························································· 29
Technical Education
Maharashtra State Bo ard of
8)
FundamcnlJlls of Mcd1a1ronics(2204
F
References/Suggestions for furthe

r reading
XX.
by Frank D. Pctm1,c1Ja
1. Programmable Logic Controllers J.
2. Mcchatronics by W.Bolton
XXI. Assessment Schemes

Weightage
Performance Indicators
0%
Process Related ( 15 Marks )
30 %
I. Handling of the instruments
of ladder logic on PLC. 30 %
2. Development, testing and execution
40%
Product Related ( 10 Ma rks )
10 %
10 %
4. Conclusions
20 %
10 0%
Total ( 25 Ma rks )

.... .... .... .... ... .... ... ..
1.... .... .... .... .... .... .... .... .... ....
-lrl ···· ···· ···· ···· ·· ···· ···· ·
:rv.
2. ···· ···· ···· ···· ···· ···· ···· ···· ···· ····
.... .... .... .... .... ... .... ..
3.... .... .... .... .... .... .... .... .... ....
.... .... .... .... .... .. ... . v.

4. ···· ···· ···· ···· ···· ···· ··· ···· ···· ··· ....
Da ted Sig nat ure

Ma rks Obtained of Te ach er VI.
Process Product To tal
Vil.
vfahara
~ ~ - ,-, ;-:>'iJ
)
Education
Maharashtra State Board of Technical
~e~c~h~at r~o~n~ic~ s(~2:=20~4 ~8~)------- ------------ - - -----...
_!F~un~d~a~m~en~ta~l~s~of~M
Practical No. 05: Develop the ladder diagram and program PLC for Timers
and Counters.
I. Practical Significance-
Many of the industrial processes require a needed action in particular time while in
certain applications it is needed to count the number of times an event occurs like the
number of times a part passes a certain point on a conveyor system.
II. Relevant Program Outcomes (POs)-

POl.Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
PO 2.Discipline knowledge: Apply mechanical engineering knowledge to solve broad
' PO 3. Experiments and practice: Plan to perform experiments and practices to use th
PO4.Engineering tools: Apply relevant Mechanical technologies and tools with
understanding of the limitations.
III. Competency and Skills

This practical is expected to develop following skills for the industry identifi~
competencies 'Operate and manipulaJe mechatronic s systems as per requirement s':
I . Develop a ladder logic for given problem statement using PLC software.
3. Interface hardware with Programmabl e Logic Controller (PLC).

• CO - d. Use actuator for various mechatronics based applications.
Develop ladder diagram and program PLC for simulation of Timer and Counter.

VII. Minimum Theoretical Background
Time':8 find applications in tasks which involve time delay while counter is used for e, e
counting.
PLC Timers:
PLC timers offer several advantages over their mechanical and electronic counterpartS·
general ' there are th ree d 1.ffierent PLC timer types: the on-delay timer (TON), 0 ff- dc:11
iMhaharas~;hhttra~S~tate-iBoanti;;;~r=rT~~·~~=-=------- --------- --~

~ ~,~
\\ ~~;
0 t
\~ \o3 t ti!,~ 1-
Fundamentals of Mechatronics(22048)
timer (TOF), and retentive timer on (RTO) The t .

. h . th . mos common IS the on d I f
w h ic is e basic function. There are also m any oth t' . . - c ay imer,
. er immg configurations all f h' h
can be denve~ from one or more of the basic time-delay functions. ' o w tc
1. TON (Timer On Delay) - Counts time-based intervals when th · t • •
2. TOF (Timer Off Delay) - Counts time-based intervals when thee ~nstructt~on ~s tf:rule.
. . . · ms rue 10n 1s a se.
3 . R TO (Retentive
. Tuner On) - Counts time-based intervals when th c instruction
· · 1s •
true and retams the accumulated value when the instructi·on goes 1a c. Isc or wh en
power cycle occurs.

4. RES (Reset) -Resets a retentive timer's accumulated value to zero.
When programming timer address, timer base and preset value are specified by
programmer.
1. Time Base- it is the multiplication factor of preset value of timer. Timers can be
programmed with several different time bases: 1 s, 0.1 s, and 0.0 I s are typical time
bases. If a programmer entered 0.1 for the time base and 50 for the number of delay
increments, the timer would have a 5-s delay (50 3 0.1 s 5 5 s). The smaller the time
base selected, the better the accuracy of the timer.
2. Preset Value-represents the time duration for the timing circuit. For example, if a
time delay of 10 s is required, the timer will have a preset of 10 s.
3. Accumulator Value-represents the amount of time that has elapsed :from the moment
the timing coil became energized.
The Timer The control word uses the following three control bits:
I .Enable (EN) bit -The enable bit is true (has a status of 1) whenever the timer
instruction is true. When the timer instruction is false, the enable bit is false (has a
Status of 0).
2. Timer-timing (TT) bit -The timer-timing bit is true whenever the ac_cum~ated
value of the timer is changing, which means the timer is timing. When the timer 1s not
timing the accumulated value is not changing, so the timer-timing bit is false.
_ e (DN) bit -The done bit changes state whenever the accumulated value reaches
3 000
the preset value. Its state depends on the type of timer being used.
TON '- - - - - - - - , J:1/0J TOF

TIMER ON DELAY TIMER OFF DELAY EN)-
Timer T4:0 EN)-~ Timer T4:3
Time base 1.0 Time base 1.0
Preset 10 Preset 15
Accumulated O
AccUmUlated O
Figure 2:OFF-Delay Timer Instruction.
Figure 1: ON-Delay Timer Instruction.
PB1 RTo------i
RETENTIVE TIMER ON
EN)-
Timer T 4:2
10
TJme Base ·
9
Preset 0
Accumulated
tive Timer Instruction.

Figure 3: R et en
------------:-:=-:---::7::--- ---- --------- --~3~9

Maharashtra State Board of Technical Education ~-4!B~i]
~@e~@
FF~u~nd~a~m~e~n~ta~ls~o~f~M~c~c~ha~tr~o~n~ic~s(~2~2~04~8~)_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
..:
PLC Counters: . Funda~
-----
The PLC counter instruction can be a countup or c~untdown. When a counter mstruction -
is used in a program, the programmer must specify the count value and preset value JX.
(Signed positive or negative integer). r-..:clrD-- - - - - - - - , ·
CTU---------,
00UNt.UP COUNTER ct}- COUN"'MXMN COUNTER
COll'ltar C5:0 Ccutter C5:0 c~
P188et 10 PreBet 10
~ 0 kcumUafed 0 D~
Figure'4: COUNT UP Counter Instruction. Figure 5: COUNT DOWN Counter Instruction
The control word uses status control bits consisting of the following:
I.Count-Up (CU) Enable Bit- The count-up enable bit is used with the count-up counter
and is true whenever the count-up counter instruction is true. If the count-up counter
instruction is false, the CU bit is false.
2.Count-Down (CD) Enable Bit- The count-down enable bit is used with the count-down
counter and is true whenever the count-down counter instruction is true. If the count-
down counter instruction is false, the CD bit is false. X.
3.Done (DN) Bit- The done bit is true whenever the accumulated value is equal to or
greater than the preset value of the counter, for either the count-up or the count-down
counter. ,
4.0verflow (OV) Bit- The overflow bit is true whenever the counter counts past as XI.
maximum value
PLC
Dfsi,tallnputs Olgftal Outputs
10.0
'' Analog Inputs O0.0 -,
10.1
10.2 AIO.O ""\
00.1 -,
00.2
I 0..3 I AIO.l ")
00.3 ,-
IOA
' AI0.2 00.4 ,-
-
... . ..--- Lad
I• □
I 0.S ,-,
I 0.6
10.7
I
AI0.3 -i
oo.s
00.6 .
,
-y
10.8
10.9
'
-,
I
Analog Outputs
,-
00.7
00.8 .
,'"'\
,-
"
I
I 0.10 -, N:,0.0
,-)
00.9
... , .
..-,, I
M)0.1 00.10
10.11
A00.2 00 .11 ... , Personal Computer ]
I 0.12
10.13
.,.
A00.3 ' ""
("\ 00 .12
00 .13
--
10.14
10.1S
.,. A I - Analog Input 00 .14
00.15
--,
NJ - AIMllogoutput
\ .
Figure ~ \Experimental setup for PLC.
~~ 1:. ~~
~~ID
~M1.ah:-i::ar:a::sh;:;tr;:a~St;::a:te:"iBo.o::a:r;d:o;f;,;
T:: ec:ihn
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0 - -- - - - - - - - - - - - - - -
Sr. Na me of Re sou rce Sug ges ted Bro ad Specification Quantity
No .
PC preloaded with PLC software and 01
1 Computer/ Laptop I/0 communication facility
Digital lnp uts :-1 2 Nos Inputs wit
h
with toggle switches for applying 24V
de inputs.
Digital Outputs:-12 Nos.Outputs
with
24V operated Lamp. 01
Programmable Logic
uts: - 02 -Analog inputs.
2 Controller (PLC) Trainer An alo g Inp
puts.
An alo g Outputs: - 02 -Analog out
.
External Pow er Supply: 24 V DC
Memory:-16 K data memory +351K
ry.
Code Memory +96K upload Memo
?'· Precautions to be followed

ent.
1. Avoid improper handling of instrum
intaining tools and equipment.
2. Follow safety practices about ma
XI. Procedure
1. Open the PL C Software.
er and counter application.
3. Develop ladder diagram for tim
).
4. Test and correct the errors (if any
nections to PLC.
6. Make required input output con
e the output on hardware.
7. Execute the program and observ
erent ON-OFF timings and counts.
8. Repeat steps 3 to step 6 for diff
Ladder Dia gra m:

t 0
t
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t ~~ C .~ ·.·
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~ Maharashtra State Boa rd of Technic
r.~~~~~s~of~M~ec~h~atr~on~ic~s(~22~0=4
£_un amen
8
~)- - - --------- ~
XII. Resources Used
Broad Specifications Quantity
Sr. Name of Recourse Details
No.
Make
X
2
XIII. Actual Procedure Followed
~ e:.a ~e-
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... .U.\l.dtCJ. ... \Y.l\.~.QU.......... (Y:C)..\]., ......&:f..... \:f.\.i~ ...... .'T.l . ......... ,, ....
~::t~::!i:~eq~r;i,;:~::::::. . :~:~:::~~~~~~~:::: :
Table 1: Observation table for Timer

Timer Delay Base Value of Preset Value of Time Period of
in seconds Timer Timer ON and OFF
5 , ,_ 0
s ,__t;
10 l ~ 0 lo l ()
20 1 ,. 0 1
'2-0 I'"
'
.
Table 2 · Obs erva ti on t a bl e for Counter
Count
-
Counter • " Preset Value of Number of time
Time Period of
•h Counter tlJe Lamp is
ON/OFF ON and OFF
2._
'
t
t,
z___
~
C)N
01')
--.
_,
I
0 .-- ,
i 0 "'
Maharashtra State Board of Technical Ed .
cation
dame,n•. tal-=--s_o_fM_e_ch_a_tro_m_·cs.. . !. {2_:2.. :. . 04~8)!.___
F
~ -
XVI· Results
··~},,,,.··rt-\.,.~····································· .. ······
... ~···\ ...: ..\.1.\ . ~r.il . .....
1 .............................
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·············· ::.:::..:::::::.::::.::
·················•• ......................... ..
\
XVII. Interpretations of Results
\
. e.........l.5.::....v..e~...J.m.~·;;;f····~··········
................................................ .
~
. . ..f5........ ~~=
..... ~~~'\~
G .......q..bl.!.lU.A-:-...... ....w.. _(_ ,.(), ~~ ·~ .....
-.~.... ~·······~~····,••lttt::".......··~·· 0.... ~········
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. ·································· .. ·························································

such questions so as to ensure the achieyement of identified CDs.
1. For a TON timer

a) When is the enable bit of a timer instruction true?
b) When the timer-timing bit of a timer instruction is true?
c) When does the done bit of a timer change state?
2. Develop a ladder logic diagram to tum ON and OFF lamp after every 1 second for 5
times.
3. Design a PLC program that counts the number of times a pushbutton is closed.
.. . . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
[Space for Answers]
ctlJ.-
: : :!)t~:. (~b~::::;;~:::::i:i~:;::::::i:i::~:~::::;::;;~~. . ~.€-···~~.ve.
b ,, L \ i \l"l',.P../ t-.1\-,,,. ~l.-u I Lt~~"'"' r+.:-:r.-,:x.¼..C.-.,.......................... ..
. ...... . .\... .."· ·......._:)-.~ •....-:1:t. l .". 'l-J..<1J ••••••••• _\ .••• 1.• ~.);.\ • /::\. · •• .~. IJ.t • ''f" .. •. •.
43
MahiU'asbtra Slate Board of Technical Education
r
..
..............................······ , .. ,,.......... ... · .. ······--···· ..... ,
·····
•• ••••• •••~.""1.,J • •• ····'•.LJ···· ··· ··· ··· ··· ··· ··· ·~ ~-
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.. ...... ..
... .
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..
....J ··· ··· ··· -~ · .... .... .... .... .......... ...... . .
·····
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........ n..== . ..(\
.. -.:7'J LE y.. .. 0."
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...................................................
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"" "' """"'"'" ·b--··----··"·· ' 1-- ·
t"'
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n_ _ _ _ _
l'- -= ~~ e_B_oar_do_fT_ecM_ic_aI_Ed_uca_tio_
7
'il@ ~g
....
f undamentals ofMec hatron ics(22 048)
·• ........................................................ .
··-y·· ·c·\·· ··············J·· ················:····~·······································
=~
.....'l.bJ...'1he.... .db..e ...h.1.L ..,.c:~':ll.f¥-6.........S.l:.:-~.kiz>. ......!.t .h
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.
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......CII\.............
..... ... '.t"Jir.e............. .o..+....rt:{.me<.ll.......bd. "'u...... llti:.c.~........................................... .
............ ........................ .
... ......... ........................... .... ................... ..... .............................
xx References/Suggestions for further reading

I. Programmable Logic Controllers by Frank D. Petruzella.
3. www.plcacademy.com
XX. Assessment Schemes
Performance Indicators Weightage
Process Related ( 15 Marks ) 60%
1. Hand ling of the instruments 30 %

30%
2. Development, testing and execution oflad der logic.
Product Related ( 10 Marks ) 40%
10%
10%
4. Conclusions
20%
Total ( 25 Marks ) ,'! 100%
....... ...... .
Name ofStud ent Team Members
1...... ...... ...... ...... ..... ····· ....... ....... ..... .
·
2. ······ ······ ······ ······ ······ ······ ······ ······ ······ ······ ······
· ·· ··
3. ······ ······ ······ ······ · ·····• ·"···· ····· ···"·· "····· ··· · ··
...... ...... ...... ...... ...... ...... .
4 .•..•• •••.•• .••.•• •••••• •.••.• ••.
Date d Signature
Mark s Obta ined of Teac her
Prod uct Tota l
Proc ess
Rela ted ..{101 _{25J
Rela ted _(151
-
45
chnica l Education
Maharashtra State Board of Te
f-undamc 111al:,. of Mcchatnmics(22048)_ __
P.-actical No. 05: Develop the ladder diagram and program PLC for Ti~
and Counters. ets Fu
Many of the industrial processes require a needed action in particular tirne Wh
certain applications it is needed to count the number of times an event occur . ile 1n
.
number of times a part passes a certam .
pomt on a conveyor system. s 1tke th
e

POl.Basic knowledge: Apply knowledge of basic mathematics, sciences d
engineering to solve the broad-based Mechanical engineering problems. an basic
PO 2.Discipline knowledge: Apply mechanical engineering knowledge to solve b d
roa.
PO 3. Experiments and practice: Plan to perform experiments and practices to use the
PO4.Engineering tools: Apply relevant Mechanical technologies and tools with an

competencies ~Operate and manipulate mechatronics systems as per requirements':
1. Develop a ladder logic for given problem statement using PLC software.
3. Interface hardware with Programmable Logic Controller (PLC).

• CO- d. Use actuator for various mechatronics based applications.
Develop ladder diagram and program PLC for simulation of Timer and Counter.

Fi

.
T1mers fim d app 1·icattons
· ·
m tasks which involve time delay while counter t·,s used for c:vent
counting.
PLC Timers: 111
· fti l
PLC timers O er severa advantages over their mechanical and electronic · 0 unterpar15 ·
c ff.dela)
general, there are three different PLC timer types : the on-delay timer (TON), 0 M
_M_a_h_ar_a-sh_tr_a-:S::-:t-a t:--e-;:B;-::0::a:rd!.o;,f;TF;:e~chn
~ ic;:a:.1.;-Ed
-------1
~u=c::at~io=n: - - - -- - -- - - - - - - -
~\ \.\ KC\rn ~ \li\evr,

( " \~ ~0 3 ( D3 ~ ?-
n~ta::l:...so=-f_M_ec_ha_t_ro_n_ic_s(:.....2_20_4...:8.L)_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
~
timer (TOF), and retentive tim (RT .
. . . er on 0). The most common 1s the on-delay timer,
which 1s the bas1c function There I • . • .
· are a so many other bmmg configurations all ofwh1ch
can be derived from one or more of the basic time-delay functions. '
1. TON (Timer On Delay) - Counts time-based intervals when the instruction is true.
2. TOF (Timer Off Delay) - Counts time-based intervals when the instruction is false.
3. RTO (Retentive Timer On) - Counts time-based intervals when the instruction is
true and retains the accumulated value when the instruction goes false or when
power cycle occurs.
4. RES (Reset) -Resets a retentive timer's accumulated value to zero.
When programming timer address, timer base and preset value are specified by
programmer.
I. Time Base- it is the multiplication factor of preset value of timer. Timers can be
programmed with several different time bases: 1 s, 0.1 s, and 0.0 l s are typical time
bases. If a programmer entered 0.1 for the time base and 50 for the number of delay
increments, the timer would have a 5-s delay (50 3 0.1 s 5 5 s). The smaller the time
base selected, the better the accuracy of the timer.
2. Preset Value-represents the time duration for the timing circuit. For example, if a
time delay of 10 s is required, the timer will have a preset of IO s.
3. Accumulator Value-represents the amount of time that has elapsed from the moment
the timing coil became energized.
The Timer The control word uses the following three control bits:
I .Enable (EN) bit -The enable bit is true (has a status of I) whenever the timer
instruction is true. When the timer instruction is false, the enable bit is false (bas a
Status of 0).
2. Timer-timing (TT) bit -The timer-timing bit is true whenever the accumulated
value of the timer is changing, which means the timer is timing. When the timer is not
timing, the accumulated value is not changing, so the timer-timing bit is false.
3.Done (DN) bit -The done bit changes state whenever the accumulated value reaches
the preset value. Its state depends on the type of timer being used.
"'ilA TON TOF

TIMER ON DELAY EN)-
~ Timlw T4:0
1.0
TIMER OFF DELAY
Timer T4:3
Timebase Timebase 1.0 oN)
Preset 10
Accumulated 0
DN) Preset
Accumulated
15
0
Figure 1: ON-Delay Timer Instruction. Figure 2:OFF-Delay Timer Instruction.
PB1
RTO------,
RETENTIVE TIMER ON
Timer T4:2
Time Base 1-0 DN)
Preset 9
Accumulated 0
Figure 3: Retentive Timer Instruction.
~ .
tra State Board of Technical Educatlon
39
Fundamentals ol Mcchatrnnics(22048)
PLC Counters:
The PLC counter instruction can be a countup
or countdown . When a counter inst . Fund
a
is used in a program, th~ p~ogrammer mus .fy th l
t spec, e count va ue and presetruct10
Valu: IX.
(Signed positive or negative mteger).
r-t ;m --- - - - - ·
CTU
COUNT-UP COUNTER
Collller C5:0
c0- COUNT-DOWN COUNTER
PTeset
Counter cs:o ct}-
10 Preset 10
Acaln\Dted O Accumula1ed
0~ o
o~
Figure 4: COUNT UP Counter Instruction. Figure 5: COUNT DOWN Counter Instru t·

c ion.
The control wor d uses status control bits cons
isting of the following:
I.Co unt- Up (CU) Enable Bit- The count-up
enable bit is used with the count-up counter
and is true whenever the count-up counter
instruction is true. If the count-up counter
instruction is false, the CU bit is false.
2.Co unt- Dow n (CD) Ena ble Bit- The coun
t-down enable bit is used with the count-down
counter and is true whenever the count-down
counter instruction is true. If the count-
dow n counter instruction is false, the CD bit
is false. X.
3.D one (DN) Bit- The done bit is true whe
never the accumulated value is equal to or
greater than the preset value of the counter,
for either the count-up or the count-down
counter.
4.0v erfl ow (OV) Bit- The overflow bit
is true whe neve r the counter counts past ,ts
maximum value XI.
vm. Experimental Setup
PLC
Digital Input s Dlgltal Outputs
10.0 Analog Inputs
10.1 00.0 I"'\
10.2
10.3
J AIO.O - 00.1
00.2
I
I
AIO.l I
10.4 I \
AI0.2 00.3 I
I0.S
10.6
I 0.7
10.8
AI0.3
Analog Outputa
I
00.4
00.S
00.6
00.'7
(
I I
I
I
1..
~
.. -
•
- D La
10.9 I
00.8 I
AO0.0 C 00.9
I 0.10 I ) I
A.O 0.1 l) 00.1 0
10.11 I
I
A00. 2 ()
10.12
10.13
10.14 I
A00. 3 I )
00.1 1
00 .12
00.1 3
I
I
I \ Personal Computer
J
10.15 \ A I -Ana log Input 00.1 4
AO - Analog output 00.lS CI
Figure 1: Experimental setup for PLC.
M
Mah arash tra State
-:-:;-~~ ~ ~ ~ -- -- -- -- -- -- -------:0
Boar d of Technical l!ducation
I
of Mechatronics(22048)
dafl'lenta 1
5
fun
gesources Required
Jj.
Name of Resource Suggested Broad Specification Quan tity
-~---t
PC preloaded with PLC software and 01
Computer/ Laptop
1/0 communication facility
Digital lnputs:-12 Nos Inputs with
with toggle switches for applying 24 V
de inputs.
Digital Outputs:-12 Nos.Outputs with
Programmable Logic 24V operated Lamp. 01
2 Controller (PLC) Trainer Analog Inputs: - 02 -Analog inputs.
Analog Outputs: - 02 -Analog outputs.
Memory:-16 K datamemory+351K
Code Memory +96K upload Memory.
x. Precautions to be followed

XI. Procedure
3. Develop ladder diagram for timer and counter application.
6. Make required input output connections to PLC.
7. Execute the program and observe the output on hardware.
.
8. Repeat steps 3 to step 6 for different ON-OFF timings and counts
Ladder Diagram: ' Q

E J
\ t)
.,._ ___
--( 111"\tr( 0 ~
Jetctc\ ~nTht"
1
,-~ • 01l Y1\U'
~ase. le Q~ 1-- ---m M-- -+
\g--c A-cc. ~l\e a<
~o \ t - - - - - - t 1- --- --- --- --- ~t
,,_ __ _ _ __,,
60~ f{D )'-- ----
\~o lo
.-.l----+3 1-------1 oo,,.._w r'-l
L t WJ~c..~·.·
oe se_f- {Jc_
~ ' - - - - - HIN
Acc~~ Q.C. . ~. a
41
40 State Board of Technical Education
Fun dam ent als of Me cha tro
nic s(2 204 8)
XI I. Re so urc es Us ed
Sr .
Na me of Re co ur se Br oa d Sp eci fic ati on s
No .
M ak e De tai ls Qu an tit y
I
\
2
~Le ~'''""(c/}' \
3 ~1 1\ ec .M ~
___, fr6 ~w
4 +-
XI II. Ac tua l Pr oc ed ur e Fo llo we

d
··········· ................................ 'f\
r ................
...~..Q .i: .~ ....~e ... . ..... ··'-·-~---6. ..........................................................................
,
(J.&t ~ .................................... ·········
.......C r. u? ~. \k ~T I~........ ~Jro
.~.e.c± ·········· ··
......~ £ ....................... G _ ~ ..:........ ;:.:.·····r··;·t-·······
C J: ....... e ~..........L ....d.n········ ························ ..
t3-J ·························
XI V. Pr ec au tio ns Fo llo we d
XV . Ob se rv ati on s an d Ca lcu lat

ion s
Ta ble 1: Ob ser va tio n tab le

for Ti me r
Ti me r De lay Ba se Va lue of Pr es et Va lue of Ti me Pe rio d of
in sec on ds Ti me r Ti me r ON an d OF F
s •
- 0 s
10 '' ,,
I
~
0 lo
J{
\n
20 1 a. '2_ u ~
Ta ble 2·. Ob ser va tio n tab le

for Co un ter
Co un ter · Pr es et Va lue of Nu mb er of tim e
Co un t
- tl)e La mp is
Ti me Pe rio d of
" Co un ter ON an d OF F
ON /O FF
• 2
t6
l-
4-
DN
01 ''
---
6
-
' -· 0 f'( ----
-- -=- - - - - - - - - - -
- fTec hni cal Edu cat ion
Ma har ash tra S ta t e Bo ard o
- - - - ~ 42 -
~ta.ls ofMech atronics (22048)
~
XVI· Results
::J;b :: ~e~i:::: :~~_;;:~~;i::::::::"w::····\ ·····k· ·····················;::······;·········
:. . r-o-~.rm.e..- . . . .... . . .:.:. :.:.:.\/::~\'-:::~:~~e.···········. . ~···········
..b~· ····:\'--)···th.e.. ........set:tr:l\~. e. ........ n.o..u ....
. . ······················ Ih ..
h'lh.iM.rr.-....... .
c . o U ~ ~.....
·· ....... .
XVII- Interpretations of Result s
:::w::tkh.± i.Yn.e~:::::~;;~:::······::t.:::::~····.k·...······· · ·· · . . . . ..................... ;········

ru.k.f]~
M,../7
'1,.l.\"" ·-······ I\ ~-···t i.)(.b ..(?!L....~...~.. ~
... .:;-1.i:t:"...... "' . ~,' ~ ...l...\,\ p L .... f: C
•••
\ .. -1, ~ L__ "P.L •"-<,.,1·1·• •• •••••:.\.1.\- I1-X'.\ p ... (! . ........ a~rY.\ .b .......... '-
..-k...
.•.•l::¥:"<1lV•·c.. .....'1/2 ..... _,.."Jl ..... J.l;\e
••••••• . • •
~'1/?. <ro ('(Y.),r.: ~
.1..., ~~ \ .1,,,.,
. . . . ....... u.1r. ....l~ fl J..{. ";: ••.• •. /1:: ••;__, ... . r.:~ a LJ +,~
~_.L .L
·· ··· ··· ·· · · .
4 J__
XVUI· Conclusions
·cr.b.r.£....... r:r:><?:.......~·--e·········1·<' .......................;. ···········................................................
•~~~ , 'l'···· ~ bri········ v ..e~·· ····rr .r.\~ ~.~k :-..... &~ ...........
.l. ......
•••• • ~~M.) .\ ~ · · · ...<;.t.. .. .lu .A-:....... ~ ....... d).i_.d:-p.~rh...... J.,£....~ m :..
. ···············• ............................................................................................. .
XIX. Practical Relate d Questi ons

Note: Below given are few sample questions for reference. Teachers should design
more
such questions so as to ensure the achieyement of identified CDs.
I. For a TON timer

a) When is the enable bit of a timer instruction true?
b) When the timer-t iming bit of a timer instruc tion is true?
c) When does the done bit of a timer change state?
2. Develo p a ladder logic diagram to turn ON and OFF lamp after every
1 second for 5
times.
3. Design a PLC progra m that counts the numbe r of times a pushbu tton is
closed.
[Space for Answe rs]

···cti.·1j..................................... ········································································································
: :::~:. .~b~: :::;.;~:::::~:~~:;:::::xi: ~:e::::::: :;;~;;;::::~;::::;:~:~i:~
·······~.\..k-..... o..t .....±iThea........ \'h ..6h\. i..~. ~ ...... r.tr.:f~~..C--.,........................... .
]1~ ::i:; :;~:::::: ~;;_ \;.;:: : ~i~:::i :::::~;~:: ::::~~~~;:~~::::::::::

······~e..... .. ~ C.0.-J..
":(f:).~\\~.,.k.J... ~.~\\\ .(?. .........~.f..... ~
\.. \.-m.CC........ t.t.'\. .....................
········c.~,.n<-A ..... ~~.c .~......~~.~~....~t:c. ........~\\.Yr.\.r.1' .......~~.s....r:ti. ~~,~
...... · · · ~ i n...... i';(. c. ON:vr.,.a \cl.~<~ ......\~~\\.\ C ..... (. b<-.1m3. f.Q
.....,.1:be= .'1.½-. ~..... .
··········':'t::\.ne_..... \~. ~ ~\c;:-;\. ~.\ ~ .....\Jr....... ~.:.<,_ _, ................ ···················· ............ ···········
·.
~::: --:: ---- --- - - - - - : - - - - - - - - - - - - - - - - - - ; 4 0 3
htra State Board of Technic al Educatio n
Fundamentals of Mcchatronics(22048)
~·································::::::::::::::::::.. ················ ............:::::::::::::::::::: ............................................... .

........
........................................ 6
~....,--- 1.............................................................................. .
................ .. t--.........- r ·········································· ·························
··r---~~-t~-t-~• ................... ~ - - r - - .... ........ .... ..................... ··································•.. .
: ::;.:N.:::. :.::.:::~ ::·: ................... __._......_-........ r _··_··_· · ·· · ···~ :::::::::::::::::::::::::::

1 0 ~r---
1 1
... ....... .
.. ...... ············:::::::::::· ::::::::::::::::::... ········:::::::::······ ....................... .
······························································· ·························· ······················· ·····························
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·················
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tals of Mechatronics(22048)
f undafOCil
~
········ ·················································································································································
xx References/Suggestions for further reading

3. www.plcacademy.com
xx. Assessment Schemes

~

~
Process Related ( 15 Marks ) 60 %

1. Handling of the instruments 30%
2. Development, testing and execution ofladder logic. 30 %
Product Related ( 10 Marks ) 40%
3. Interpretation of result 10 %
4. Conclusions 10 %
5. Practical related questions 20 %
Total ( 25 Marks) ~ 100 %

1. .............................. ····· ..... ······ ·· .. .......... ...... .
2. ···································································
3. .......... ................................. ................. ....... .
4........................ ••••. • e. • • . e e • e • . e • • • ♦ee•• e•ee I e • e I. I•• e I a e. I e
-
Dated Signature
Marks Obtained of Teacher -
45
M hatronics(22048) d I 1·
Fundamentals of ec . .t i r door open an C ose app I Cation fu
e are small circm s o
Practical No. 06: Pr P_ "tli t actuators with PLC. Vi
usang d1 eren
I. Practical Significance- . t rfacing is the most essential requirement .

C and it's hardware me . in
Programming the PL d hould be able to develop the logic for the give
. • d try The stu ents s . n
the mechatrorucs m us . . I nted in industrial environment.
problem statement which can be imp eme
p am Outcomes (POs )- . .
II. Relevant rogr kn ledge of basic mathematics, sciences and basj
POI Basic knowledge: App 1Y ow . . c
. b d b d Mechanical engmeenng problems.
engineering to solve the roa - ase . . 1d
. . . 1 d . A ly mechanical engmeenng know e ge to solve broad.
PO 2.D1sc1pline know e ge. PP
based mechanical engineering related problems. . .
PO 3. Experiments and practice: Plan to perform experunents and practices to use the
III.
-
Competency and Skills
1. Develop a ladder logic for given problem statement using PLC software.

• CO - c Use sensors for different mechatronics applications.
• CO - d. Use actuator for various mechatronics based applications.
Prepare small circuits for door open and 1 . .
PLC. c ose application using different actuators with
VI.
Relevant affective domain related O t
1. Follow safety practices. u comes
3. Work as a team leader/ team member. X
VII. Minimum Theoretical B k
ac ground
Use of PLC Software D l
, eve opment of L dd D.
and execute the ladder pro a er tagram in PLC Software, dO\vnload, test
gram and hardware connections on PLC tr .
amer.
M
Maharashtra State Board of Technical Educ~aii;tio;n~ - - - - - - - - - - - - - - - - --:
}I\l Ac-l rn C,, '--l Actr,,, l~ rm'o 1e_ 46
\ ~ lo 5 1~':};;, 1-- 0J f'f1 ~ f"2..3J>

~ ofMechatron ics(22048)
f ei,ertDlen tal Setup

vJJf.
PLC
~ ~
~ ~ DICn-AL ~ Door
OUTPUTS '-y" Open/Cl ..
Actu11t n
~•m
Figure 1: Experimental setup for 0

oor Open and Close Application using PLC .
IX. ._,urces Required

-
...
Ir.
Name of Resource Suggested Broad Specification
PC preloaded with PLC software and 1/0
-
Quantity
1 Computer / Laptop 01
communication facility
Digital Inputs:-12 Nos with toggle
r
switches for applying 24V de inputs.
Digital Outputs:-12 Nos with 24V
Programm able Logic operated Lamp.
'2 Controller (PLC) Analog Inputs: - 02 01
'
Memory +96K upload Memory.
-
Door Open and Close module with facili ty
of sensing the arrival and departure of 01
3 Door Open and Close person within a particular distance from
~
door.
Precautions to be followed
I. Avoid improper handling of instrument. .

2 Foll c. • b ut maintainin g tools and equ1pment.
· ow sa1ety practices a o
47
!_f~un~d~am~e~nta~l~s~of~M~ech~a~
tro::'...n~ic~s(c22~0:_:4~8)~------ - - - - - - - --
- - - -- ---...
XI. Procedure
3. Develop ladder diagram for
door ope n antl clo se application.
4. Test and correct the errors
(if any).
5. Download the program on
6. Make required input outputPLC.
connections of do or op en/ clo
se mo du le w ith PL C.
7. Execute the program and obs
erve the opening and clo sin g
8. Repeat steps 3 to step 7 for of door.
different ON and OF F timing
s an d dis tan ce.
Ladder Diagram:
0 ~ 0
~
H J.
J::CJ -r: (:J

1\yr,(.<J otJ
+- -- -- -- ' r:-~3 i- -- -- -- .. .. .J T ,'f '\" " ~~ o
1'\"ft\ tro hct1'o i,
() ~e m r~
ft-COt f'fn 0
rJ -r-
o
c __ __Llt) l - - -__ __ .I.. .-
XII. Resources Us ed
Sr. Br oad Sp eci fic ati on s

Na me of Re cou rse
No . Qu an tit y Re ma rk s
Ma ke De tai ls (if an y)
Maharashtra State Board of Techni

cal Educati on
j 48
tal,.,s o:::.f~M_cc_ha_tr_on_ic--'s(_22_04_8):___ _
~
Actual Procedure Followed
XUI,
xv. Observations and Calculations
Sr. Distance of person Status of door

No. from door (open/closed)
1
3
0
XVI. Results '

.... Y:\.~ ...... d~v.~.a(:>.... tl:he_ ....d~d.l!. ....c.trr'-t\~i:t .......k •. J.~.......
...... .O..f..ern ..... ~.... dDie .......~{)-('.)•\,.. Ca}.M.~.~............................................... .
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XVIII. Conclusions
:::~~:::1~~:::::::~::::::~~Q~~:::::::;::s~~~:\i:::::::ii~~~~~; :::::::
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......oll.~-:tr.rn.+. .......d , ~ . ~ ~.... µ,.~\.~······{).L.C. ............................................. .
such questions so as to ensure the achievement of identified CDs.
I. Explain the sensors used in door open and close applications.

2. Name any two actuators can be used in door open and close applications?
49
~~ ~~
Fundamen
~~
tals ofMc
:.:
chatr onics
:=
(2204 8) ...
:.: :.! .- -- -- -- -- -- -- - --
[Sp a cc for Answers]
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........................................................................................................................
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......................................................................
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.............................................................................................
...................................................................................................
...................................................................................................
..
Maharashtra State Board of Tech nical Fducation
50
run<lamentals ofMcchatnrnics(22048)
XX. References/Suggestions for furt her read ing

1. Prog ramm able Logic Controllers by Fran
k D. Pctruzclln .
Weightage
Process Related ( 15 Marks )
60%
1. Han dling of the instruments
30%
2. Dev elop men t, testing and execution of ladd
er logic. 30%
Product Related ( 10 Marks )
40%
3. Interpretation of resu lt
10%
4. Con clus ions
10%
S. Prac tical relat ed questions
20%
Total ( 2S Mar ks)
100 %
Nam e of Stud ent Team Members

1. ..... ..... ..... ..... ..... ..... ..... ..... ..... ..
..
2. ····· ····· ····· ····· ····· ····· ····· ····· ····· ····
3. ····· ····· ····· ····· · ..... ..... ..... ..... ..... .. .
4. ····· ····· ····· ····· ····· ····· ····· ····· ····· ····
Marks Obtained Dat ed Signature

Process of Tea cher
Product Total

52
--:: :t C - , - - , Cl
1
tals ofMechatronics(22048)
~ :.:.-------"----'--------
prac tical No. 08: Build Electro-Pneum at·IC c1rcmt
• . r R . • •
1or aw matenal rejection
application.
practical Significance-
I.
Electro-pneumatic c~ntrol systems have wide range of applications in mechatronics
systems. Raw matenal rejection, object sorting, packaging, stamping, embossing are
some of the examples. A thorough knowledge of Electro-pneumatic control systems
along with PLC programming can lead to design various industrial applications.

POl.Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
P02.Discipline knowledge: Apply mechanical engineering knowledge to solve broad-
P03. Experiments and practice: Plan to perform experiments and practices to use the
P04.Engineering tools: Apply relevant Mechanical technologies and tools with an

I. Develop a ladder logic for given problem statement using PLC software.
• CO - c. Use sensors for various mechatronics based applications.

• CO - d. Use actuators for various mechatronics based applications.
Build Electro-Pneumatic circuit for given application.

VU. Minimum Theoretical Background: .

Electro pneumatic system consists of electrical control system operating pneumanc
systems. The object sensing can be accomplished by using proximity or IR sensor. The
rejection of object can be done through single or double acting cylinders.
Maharashtra State Board of Technical Education 59
\<.__~mble., ~'.\ ~rn ~~~""7

Fundamentals ofMcchatronic
s(22048)
VI II. Ex per im ent al Se tup
ft&K CTO fl
OfU Vl!N I .. uu cv
1a 1N
□
CON V'l: YOf t ■ Cl. T
ULL-.:;;:=-....-- -- -- -- ir -. D -T -. ::
MO "fO fl .. N.U MA flC = = = .- -- -- -1 tt -ACCt .. T011t
ACT UAT Ollt
91N
PL C
Fig ure 1: Experimental setup

I (a
for raw material rejection Ap plic
atio n usi ng PLC.
, IR/P RO XY Pne um atic

Sen sor Act uat or
,/
Figure 2: Sample Trainer for

raw materi al rejection Ap plic atio n.
Sr. Name of
No. Resource Suggested Br oa d Specificati
on Qu an tity
1 Co mp ute r/ PC pre loa ded wit h PL C sof twa
Laptop re and I/O
com mu nic ati on fac ilit y 01
Digital lnputs:-12 No s wit h
tog gle sw itc hes for
Pro gra mm abl e applying 24V de inp uts .
Logic Digital Outputs:- 12 No s wit h
2 Controller 24 V op era ted
La mp . 01
(PL C) Tra ine r
Analog lnputs : - 02
Analog Outputs: - 02
-
Board of Technica l Fducation~
Maharashtra State - ----------
----------
6-0
tals ofMechatronics(22048)
undarnen
Memory:-16 K data memory+351 K Code
-- Memory +96K upload Memory.

Raw Material Rejection Module with facility to
detect, sort and reject the objects.
The module should contain a sensor (IR or
Proxy) and Pneumatic actuator controlled by
PLC.
Raw Material Pneumatic actuator:
Rejection • Type: Single/Double acting pneumatic 01
3
Module cylinder.
• Bore Size: 8 mm
• Stroke:15 mm.
• Operating Temperature= 10-40°C.
• Working Medium = Compressed air upto 4
bar pressure.
x. Precautions to be followed
XI. Procedure
3. Develop ladder diagram for raw material rejection system.
6. Make required input output connections between PLC and material rejection module.
7. Execute the program by placing an objects on conveyer belt.
8. Repeat the step No. 7 for different objects.
XII. Resources Used

Name of Recourse Quantity
No. (if any)
Make Details
l"C.\Cla c.o,i)rh
~
()LC- 60.f-r(u\k;tR
Co m u ,-e__'t
2 (.) Lc_ ~ ,T'.e1 Ol~-t'~I ~(P : l~t\\S'
~\\ 01' 1ktt' ~,~ : l(No ~
3 ~Cl'O "ft\a \oo:t' ~ eJl,trt-d \-i' (_
e· 'on rte t~~.\-e6
4
ff\ oJ \\' e-
~Qe t t~"'c}e/
bl
61
r
Fund ame ntals ofMcchat1 onics(22048)
~~e.n. . .:ih.e.......?.l.C::: ..::~1.~J.f~-Qi.e::::::·.:::·.:::::::::::::::::::::::::::::·.::·.::::::: ·.: ·.·.·.·.

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4......... .
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s0-s tft r\,
.:!)
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AJ '.n1 ~
~.\l_.
............
XV. Observ ations and Calculations
Ob ject Typ e of Object Action Tak en

Num ber
Metallic Non-Metallic Acc epted Rej ecte d
1 ~ ~
2
~ L-
3
4
~ v- -
5
v- - \_.- ----
XVI. Results
XV II. Interpretations of Results
XVIII. Conclusions
·····B:··:::::·.·.·~ ie u~ ···,···························································•·
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··································································
--- :-: --; ;-; B rd of Technica l

Maharashtra State oa Education
62
tals of Mechatronics(2204 8)
~~---'-------'------
practicaJ Related Questions
XIX·
1. List the types and specifications of pneumatic actuator.
2. Give the selection criteria to select a pneumatic actuator for particular application.
3. List the advantages of pneumatic actuator.
[Space for Answers]

·····························~·············································································································
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Fundamentals of Mc
chatrnnics(2204 8)
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................................................ ........................................................................... ................
................................ ................................................ ..........
-M-ah-ar-ash-tr= - - - - :7 " :~ ................................................
................ . .........
a State Board of Techn
ica l Education
~ :: :- ;- ;~ :- :: - - - - - - - - - - -
- - -- --;-;-
64
ts ofMechatrnnics(22048)
Fundarncnta
References/Suggestions for further reading
XX· I. Programmable Logic Controllers by Frank D. Petruzella.
3. www.nptel.ac.in/courses/l 12103174/13
4. https://www.youtube.com/watch?v=hPCc3_tRJQc
,.\ssessment Schemes
XXI.
,----
--
~
Process Related ( 15 Marks)
Weightage
60%
1. Handling of the instruments. 30%
~
2. Developmen t, testing and execution of ladder logic. 30%

,-----
Product Related ( 10 Marks) 40%

~
3. Interpretation of result. 10%

~
4. Conclusions .
10%
'
5. Practical related questions. 20%
Total ( 25 Marks) 100%
-
Name of Student Team Members

1. . .....•........ ............... ...•.........
2. . .••....•...... .•••.......... .....•.......•
3. .............. .............. .............. ..
4. .............. .............. .............. ..
Marks Obtained Dated Signature 1
of Teacher
I I I

Fundamentals of Mcchatronics(22048
)
Practical No . 09: Develop the lad
der diagram for Pedestrian Tr
aff ic Lig ht
controller usi ng PLC.
1. Practical Signifi can ce-
There are som e tas ks" hich req
uire tim e delaying. Thi s req uire
tim er feature available in PLCs. me nt can be me t wit h
The kno wle dge of Tim er is ess ent
turn on and off certain processes ial wh en it com es to
or com pon ent s wit h required del
ay.
II. Relevant Pro gra m Outcomes (PO
s)-
PO l.B asi c kno wle dge : Ap ply
kno w led ge of bas ic ma the ma
eng ine erin g to solv e the bro ad- bas tics , scie nce s and basic
ed Mecha nic al eng ine erin g pro ble
PO2.Discipline knowledge: Ap ms.
ply me cha nic al eng ine erin g kno
bas ed me cha nic al engineering rela wle dge to sol ve bro ad-
ted pro ble ms.
PO 3. Experiments and practic
e: Pla n to per for m exp erim ent s
results to solve bro ad- bas ed Me and pra ctic es to use the
cha nic al eng ine erin g pro ble ms.
PO4.Engineering tools: Ap ply
rele van t Me cha nic al tec hno log
und erst and ing of the limitations. ies and too ls wit h an
ID. Competency and Skills

Thi s practical is expected to
develop foll ow ing slcills for
com pet enc ies 'Operate and ma the ind ust ry ide ntif ied
nipulate mechatronics sys tem s
1. Dev elo p a lad der logic for giv as per req uir em ent s':
en pro ble m stat em ent usi ng PL C
2. Pro gra mm e and troubleshoot sof twa re.
PL C for the dev elo ped logic.
3. Interface traffic light lamps wit
h Pro gra mm abl e Log ic Con trol
ler (PL C).
IV. Rel eva nt Course Outcome(s)
• CO - c Use sensor for different
me cha tron ics bas ed app lica tion
• s.
CO - d Use actuator for various
me cha tron ics bas ed app lica tion
• CO - e. Pro gra mm e PL C for var s.
ious applications.
Dev elo p ladder diagram and pro
gra m PL C for sim ula tion of
controller. a ped estr ian
traffic
VI. Rel eva nt affective domain rela

ted Outcomes
1. Fol low safety practices.
2. Ma inta in tools and equipment.
3. Wo rk as a team leader/ team me
mb er.
VII . Mi nim um Theoretical Backgroun

d
PL C sup por ts the use of timers.
Thr ee different PL C tt' me • typ
.
(TO N), Off-de lay timer (TOF), r o dl ·
and Retentive tim er on (RTO).es are - n- e ay ttm er
tate Board of Techm1-;;;ca~IEF:d11t:,c;;

;:; alT;
io:n- - - - - - - - - -
Maharas htra S -- - - -- - - - -
\~0- "f'\ b\ e. t\ \J}'\ c\n Cx1:'J. ~ "<""') 66
'~'o-s la ~8 7f-
~~ G ~6
~s~of'
= .-'.M::..e::c~ha:..:.tr:....:o_ni_cs_,_(2_2_0_48--=-)- - - - - - -~ -
Fundamental
J] la
PLC
DIGITAL 0 GITAL
INPUTS OUTPUTS
=(£
·
l!J·
a
Traffic Light Module
Figure 1: Experim ental setup for pedestri an traffic light controller using PLC.
PIIC2t• TAAFFfC LtGfff CONtROI. Sltt!A.IIUOH ffllDIJlE
Figure 2:Sampl e traffic light controller module.
a tate Board of Technical Education 67

run dam cnt als of Mcchatrn
nics(22048)
T4 2 T O N - -Re d tim e
-- --,
TIM ER ON DE LA Y Ou tpu ts
Tim er EN L2
T4 .0
ON Tim eb ase • .0
DN)
ei
Pre set 30 Traffic lights \
Acc um ula ted O
Gre en tim e R& d
TL :0 TO N
r-e
TIM ER ON DE LA Y
Tim er T4 ·1
ON Tim e bas e 1.0
Pre set 25
Acc um ula ted O
T4: 1 TO N A.m ber tim e

TIM ER ON DE LA Y
Tim er T4 :2
EN
ON Tim e bas e 1 .o
Pre set 5 DN)
Ac cun ua ted o
T4 :0
EN
*----c-(
DN
~
T 4:2
[ *-----------\(Anllli
EN
T 4:2
ON
Figure 3:SampleLadder
logic for one La ne ..
IX . Re sou rce s Required
Sr.
No . Na me of Resource
Suggested Br oa d Specific
ation Qu an tity
1 Computer/ Laptop PC preloaded wi th PL C sof
tw are an d I/O
communication facility 01
Digital lnputs:-12 No s wi I
th toggle sw itc he s
for applying 24V de inputs \
.
Programmable
Digital Outputs:-12 No s
Lamp.
wi th 24 V op era ted I
2 Logic Controller Analog Inputs: - 02 \
(PLC) Trainer 01
Analog Outputs: - 02
External Power Supply:
24 V DC.
Memory:-16 K data memo
ry +3 51 K Co de
Memory +96K upload Me
mory.
3 '\ _~ffic Light
Module 4 way junction Traffic Lig
ht module
\ 01
-
x. Pr eca uti on s to be follow
ed
Av oid improper handling
1 of instmment.
~Fo llo w safety practices
2 about maintaining tools and
equipment.
----~~
- T hni
Maharashtra State Board of ec cal Education
68
mentals ofMechatronics(220
48)
fun da1~:::=.~ ------- '------------
~. Procedure
I . Open the PLC Software.
3. Develop ladder diagram for pedestrian traffic controller.
6. Connect traffic light module with PLC.
7. Execute the program.
8. Repeat steps 3 to step 7 for different ON and OFF timings.
XII. Resources Used

Name of Recourse Quantity
No. (if any)
Make Details
u, ,?r\i
1 c_o'Yt\?c~ terr
\)LC- ~CJ.\ne
2
~,' ~ ~
~le
3
-\--- ,ynJt..\ Ie_ \
4
~-yme_Q PO-- l'P'~
w\cre.- 5' ~ '-4'

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..1J....C.~',!elop. ....... \a.J.cl.fl1S:..... d~.C\~~........~ ....... f.e. 4.le.6.~.QJr.\ ........ .
······~·~~c. ......C.(!X\~.t\.ea.,................................................ .................................. .

69
f'und nmcntals ofMcchatronics(22(H X) _
Table I: Measuremen t of Signal Timings

Signal Timings in Seconds
Step Signal ,--
Lane A Lane B Lane C Lane D

Red C'N
1 Yellow
OFF
Green
~Fr
2
Red
Yellow
o~-~
DFF
Green
Red
ON
(!) F-F'
3 Yellow
Green
OFf:
01'/
Red
4 Yellow
ON
(') Ff!-
Green
fj E/2
XVI.
~. ~ _I
.w e .....1.e.Qm.. 1lL.d.ev.e,\.i)(>... .tlne.. ... \QJ. __ ...fu:..... .o...t'.1~ttt)
..... o.l ....~~e.~.,.n .....+.r.c.t.~. .c.. .... \.,~%-h·~······c . .~~.lle~ ................
1
······•\J..,i\.n.-~ .......tLc. ...................................................... ··················································

················································································································································
~:::::1~~ : ~e::I~lJ.e;: :J;~~::::&::::::::

... ~-~..S':h:o.~:n r.\=.-~'.c... . \.I~ it: ..... nm,.~Jl.er.ic. ..
: : :
.u.~n~
: : : :
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XVIII. Conclusions
such questions so as lo ensure the dchievement of identijied COs.
1. State the procedure of changingthe ON and OFF 1imings of traffic signals.
Maharas h tra Sta te Board ofTechnical Fducation

70
of Mecha tronic s(220 48)
5
., List diffe rent types of timers used in PLC 1adder logi. d.

dd 1 . . c tagram?
l)raW the la er ogic to control traffi
Ir
30 son ic Signals for fo llowi ng condition.

,. i. Red-
·· Green- 25 s on
u.
iii. Yellow- 5 son
[Spac e for Answers]
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:::::::~:::::tii1::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
F..~~············· ········································ ·················
. ...... ·~,. ..__ .~ ... ~_-!:;el)')\-:t ve ... A\.ff.\e..it ...... o.n............. ········· ..................................... .
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1n C'-\ "ff\ \J \.~\r-eq 0
y,.,1aharasbtra State B 71
Oard ofTcc hnical Educa tion
Fundamentals nf i'. lcl·hatrnnici
.(22 0.J~ )
'1"""'A ' f\
···· ···· ···· ··•, .~•. .<.--.............. ___ _:_~---,
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aharashtra State Board of Technical Edu
cation
72
I u • ~ t a / , ofMechao-oni~(22048J ----------
XX. References/Suggestions for further reading .
1
Programmable Logic Controllers by Frank D. Petruzella.
2 _• Mechatronics by W.BoJton
Process Related ( 15 Marks) Weightage
2. Development, testing and execution of ladder logic. 30%

30%
Product Related ( 10 Marks)
3. Interpretation of result 40%
4. Conclusions 10%
10%
20%
Total ( 25 Marks)
100 %
'Ille ofStudent Team Members
N• J. ·····••···•··········•····· ····················· ···················

2 ........ .
···· ······································· ....
3.. . . . . . . . . . . . . .. . . . ························ ..........................
. .........
4. .............. ..... ••............................•...... ....
Dated Signature
Process
Related 15
73
hmd amc ntals ol Mcc hauo nics (2204
8)
Practical No. 10: Develop ladder dia

gram and pro gra m PL C fo r Lif t
I
elevator control.
l. Practical Sig nifi can ce-

Programming the PLC and it's hardwa
re interfacing is the mos t essential
the mcchatronics industty. The stud req uire men t in
ents should be able to dev elop the log
problem statement which can be imp ic for the given
lem ente d in industrial environment.
11. Rel eva nt Pro gra m Ou tco mes (PO

s)-
PO I.B asic kno wle dge : Apply kno
wle dge of bas ic mathematic s, scie
engineering to solve the broad-based nce s and basic
Mechanical engineering problems.
PO 2.D isci plin e knowledge: Apply
mechanical engineering kno wle dge
to solv e broad-
bas ed mechanical engineering related
problems.
PO 3. Exp erim ent s and practice:
Pla n to perform exp erim ents and pra
results to solve broad-based Mechanica ctic es to use the
l engineering problems.
PO 4.E ngi nee rin g tools: Apply rele
van t Mechanical technologies and
und erst and ing of the limitations. too ls wit h an
ill. Com pet enc y and Skills

Thi s practical is expected to dev
elop following skills for the ind
competencies 'Operate and manipu ustr y identifie d
late mechatronics systems as per req
1. Develop a ladder logic for given pro uire men ts':
blem statement using PLC soft war e.
2. Pro gra mm e and troubleshoot PLC
for the dev elop ed logic.
3. Interface hardware wit h Programmab
le Logic Con trol ler (PLC).
IV. Rel eva nt Cou rse Outcome(s)

• CO - c. Use sensor for different
mechatronics bas ed applications.
• CO - d. Use actuator for various
mechatronics bas ed applications.
• CO - e. Pro gra mm e PLC for vari
ous applications.
V. Pra ctic al Ou tco me

Develop ladder diagram and program
PLC for simulation of a Lift/ Ele vato
r con trol .
VI. Rel eva nt affective dom ain related
Ou tco mes
1. Follow safe ty practices.
3. Wo rk as a team lead er/ team mem
ber.
VII. Min imu m The ore tica l Backgroun

d
Use of PLC Software, Development
of Ladder Diagram in PLC Software,
and execute the ladder prngram and dow nlo ad, test
hardw,\l'e connections on PLC trainer.
Maharashtra State B0 ard of Technical l•ducalion

74
~~ ~I f\ (Jo '-l ~\ "rr) ~" \il b\ e, \~\0-5lt)~81'
2-o ril ~ ~ £
~arnentals ofMechatronics(2204~)
----
[ START ] PLC
f'LOOR
[ STOP J c:::::) I L'IDICAT0R
[CALI.LIFT] ELEVATOR.
I DOOR.OPEN
Lift/Elevator 1\.Iodule
Figure 1: Experimental setup for Lift/Elevator controller using PLC.
DIGIIAL ,~~u rs \:
~i~
i'),I ! ~ ~' ~
OUT?UiS
-{fl' @ -~! {f) {! )l 1~ ~ . \~ 1(!' (~ -, j '; \~) I,~

01-0 01- 1 01-2 01- 3 U! • Dl-5 01-b 01-7 00-0 DC-I D0 - 2 D0 -3 oo-, 00-3 CO-!, D0-7 00- 8 oo-q
2av GN Q
-~ 1
0
M-50 PLC CONTROL PANEL FOR LlFT CONTROL MODULE
~ ~ \~
-
STA RT LIFT CALL LlFT LIFT-FL DOR
i~-·l .,m.
FORT H .
FLOOR
·'
01 _ 3 DO- ~ DO-
-iii!-
.,-
01- 0
STOP LIFT
TH:RO -
FL OOR
\
. : OI- 4
.... .
·!-
O
D-all"
}. ~ECON D. DI- S 00-2-

, r DOR .
.if,a. ... - @I-
DH
"lRSl
. 00~
ti) 01-6
. 00 - ~
DOOR OPEN . . .. -iii>-
-
• DJ -2
.i:im}.
GROUND.
r1.00R
....
D1 -7
F igure 2:Samp leL'1ft/Elevator controller module.

D□-4- ,!(Ii~
D0- 9
~
~
,_ - (\

Q uantity
Sr.
Name of Reso urce Sugge Stc d Broad Specification
No.
PC preloaded with PLC so~are and I/0 01
I Computer/ Laptop communication fac1hty
75
~htra State Board of Technical Education

Fundamentals of l\kchatronics(22048)
Digital lnputs:-12 Nos with toggle

switches for applying 24V de inputs.
Programmable Logic operated Lamp.
2 Controller (PLC) Analog Inputs: - 02 01
Memory:-16 K data memory+ 35 lK Code
Memory +96K upload Memory.
Lift/Elevator Module with faciljty to start,
3 Lift/Elevator Module stop, call the lift and Visual Indication of 01
Floor Number and Door open indication.
XI. Procedure
I. Open the PLC Software.
3. Develop ladder diagram for Lift/Elevator controller.
4 . Test and correct the errors (if any).
6 . Make required input output connections of elevator control module with PLC.
7. Execute the program.
8. Repeat the steps for different floors.
XII. Resources Used
Sr. Broad Specifications

No. Name of Recourse
Quantity Remarks
Make Details (if any)
1 Com p~~ \.u1+h. LL
2 ~ ..r = 112 1')0 5'

o/c) ""-(Q_ 1{~2 1
3 r;.,'~( e\eVi L:t-ft/ el
I
~Jvte "'''th
4 rnoJ \l \e c/ \t'j 1o
~re'{'f. 5/e:Jp
Maharashtra State Board of Tec hnical Education

76
fun damentals of Mechatronics(2 2048)
Xf 11. Actual Procedure Followed

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XV. Observation s and Calculations \Jew~ '(1\cN~~
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.................................................................................................................................................
~ State Board of Technical Education 77

asbtra
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XVIII. Conclusions
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·········
Note: Below given are few sample questions for reference. Teachers should design
more
such questions so as to erzsure the achievement of identified COs.
1. Explain the hardware changes needs to be made so as to increase the numbe

.
r of
floors.
2. State the factors need to be considered so as to increase the Load Carryi ng
capacity of
the elevator.
[Space for Answers]
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Mahara s h tra St ate B oard of Technical Education

fundamentals ofMechatronics(220 48)
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..................................................................................... .. . . ... . ............ ······ .. -· ....
79

Fuo d amcn tals of Mcch atrnni cs(22 048)
xx. References/Suggestions for fu..thcr read ing

1· Prog ramm able Logic Cont rolle rs by Fran k D. Petru zella .
2. Mech atron ics by W.B olton
xx. Asse ssme nt Sche mes
Perf orma nce Indi cato rs Wei ghta ge
Process Related ( 15 Mar ks) 60%

1. Hand ling of the instr umen ts 30%
2. Deve lopm ent, testin g and exec ution of ladd er logic 30%
.
Prod uct Related ( l O Mar ks ) 40%
3. Inter preta tion of resul t 10%
4. Conc lusio ns 10%
5. Prac tical relat ed ques tions 20%
Tota l ( 25 Mar ks) 100 %
Nam e ofStud ent Team Mem bers
1. ...... ...... ...... ...... ...... ...... .....
2 . ...... ...... ...... ...... .. ······ ···· ....
3. ······ ······ ······ ······ ······ ······ ·····
Mar ks Obta ined Date d Sign atur e

of Teac her
Proc ess Prod uct Tota l
Rela ted (15) Rela ted (10) (25)
Maha rasht ra State Boar d of Tech nical Education

80
Practical No. 11: Develop ladder diagram and program PLC for Washing
Machine control.
Practical Significance-
Programming the PLC and it's hardware interfacing is the most essential requirement in
the mechatronics industry. The students should be able to
develop the logic for the given
problem statement which can be implemented in industrial environment.

PO1.Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
PO2.Discipline knowledge: Apply mechanical engineering knowledge to solve broad-
based mechanical
engineering related problems.
PO3. Experiments and practice: Plan to perform experiments and practices to use the
results to solve broad-based Mechanical
engineering problems.

Thispractical is expected to develop following skills for the
industry identified
competencies Operate and manipulate mechatronics systems as per requirements":
1. Develop a ladder logic for
given problem statement using PLC software.
2. Programme and troubleshoot PLC for the
developed logic.
3. Interface hardware with
Programmable Logic
Controller (PLC).
CO-c. Use sensor for different mechatronics based
applications.
CO d. Use actuator for various mechatronics based
-
applications.
CO e. Programme PLC for various
applications.
-
Develop ladder diagram and program PLC for simulation of a washing machine control.

1. Follow
safety practices.
2. Maintain tools and
equipment,
VIL. Minimum Theoretical Background

Use of PLC Software, Development of Ladder Diagram in PLC Software, download, test
and execute the ladder program and hardware connections on PLC trainer.
ashtra State
Board of Technical Education 81
Kamble Nu tan Getu a lo 5l6387

20 mE239
VIIL. Experimental Setup
PLC WATER WATER

START INPUT OUTPUT
DICITAL DICITAL WASH RINSE SPIV
INPUTS CYCLE
STOP OUTPUTS CYCLE CYCLE
CYCLE COMPLETE
Washing Machine Module
Figure 1: Experimental setup for Washing Machine using PLC.

POWER
SUPPLY DIGITAL INPUTs DI61TAL OUTPUTS
z40 GND DI-0

DI-1D0-0 DO-1 DO-2 DO-3 DO-4 DO-5 DO-6
WASHING MACHINE
INPUT CONTROL WASH ING MACHINE OUTPUT CONTROL
WATER
START IN
WATER
OUT
DO-0 DO-1
DI-0
MOTOR WASH
ON
CYCLE
DO-2 DO-3
STOP
RINSE
CYCLE SPIN
CYCLE
DI-1 DO-4 DO-5
CYCLE
cOMPLETE DO-6
Figure 2: Sample Washing Machine Module.
Sr.
Name of Resource Suggested Broad Specification
No. Quantity
Computer/ Laptop
PC preloaded with PLC software and
/O communication facility 01
Technical Education
Maharashtra State Board of 82
Eundamentalsof Mechatronics(22048)
Digital Inputs:-12 Nos with toggle

switches for applying 24V dc inputs.
operated Lamp.
Programmable Logic Analog Inputs: - 02 01
Controller (PLC) Trainer Analog Outputs: - 02

Memory:-16 K data memory +351K
Code Memory +96K upload Memory.
Washing Machine
Washing Machine Modulewithfacility
for indication of various cleaning cycles 01
Module
namely Wash, Rinse and Spin.
Precautions to be followed
1. Avoid improper handling
of instrument.
XI. Procedure
3. Develop ladder diagram for Washing Machine control.
7. Execute the program and observe the output on hardware in following sequence.
Water IN
ii. Motor ON
ii. Wash cycle
iv. Rinse cycle
v. Spin cycle
vi. Water OUT
vii. Cycle Complete
8. Repeat steps 3 to step 7 for different timings of Wash, Rinse and Spin cycle.
XII. Resources Used
Broad Specifications Remarks

Sr. Quantity
No. Name of Recourse if any)
Make Details
PCOeloOad e wl th
Comu tes PLC sof tuerrd. cm)
La phop Tlo comnam coa ticm
LLcil
83
Diar'kd Inpus
2Plc
TocTmes 2Nos5
Washins machne
3 Aa shina
machiNe m aculetth cil
ModulLe
XIII. Actual Procedure Followwed

***********************************"****************..
*******
***** * ******
Pen..LCStada.
.Ss. e. i.C..
*******************************
*********************** "
*********** .
************.*..
******
********

e**********************************
*********************************************
.avai.d.. m.Q.R...namd.li.ng. ..n.Slm eAn..
laLD.Sae..ranc.cRSdbCLA.dåntsu.i.nih.
... . q M . m t n . . .. **.* ******************************************* **
Ladder Diagram:

CTU
'Coumteg up
C o t n t (SO
Prescl2
A CCume 2
00
ToN
Timer on delry
Time T4t0
ON time.base lto
rest3d
A CCum
DN
Times cm deay
ime. TAto
Tine.besclioON
poeset 6oC
ACeume oC
TFE
DN Tme.d dele IeN
TIne T4
Ttne. ba_e
preset 6oc
PCCum ooC
ENÓ
XVI. Results
Deoent.. puts. Ou.tpuks... .ct.

.3.C.sesssstorus-ssot
-ur.cleel.o.the2na.L).aching.a.chine, ************ra*****ars**********d*dr**d**eo***
***************o*********oao* oeaenoeosonoonoososoe**
"**

* o****** ******************oe* ****d*oao suo
************************************ ********a****************************
...e. i.n,..os.e..A2.aSh...0.p.i.m. S
ma. .0rws...
**eouso**********************eroere*******
. la
************************************* ***************** oe*****enoeoe*s***o*p.*o**************************
XVIII. Conclusions
******* ***************************
*********************************************** *******
. .Rah... c.Me.log...loudlde.a...iAoacla..
e. .AG n.}n a.cne
0pam.m.e..a. LG.
*****************************************************************************************************************************
few sample questionsfor reference. Teachers should design

more
Note: Below given are

available in market and list the
1. Study any one model of washing machine currently
various sensors and actuators used.
be made so as to increase the washing
2. Explain the hardware changes needs to
capacity of a machine.
Space for Answers|

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**********
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**** * **********
******************************************* *************
aN *
neo.....
****** *************
85
vanarashtra State Board of Technical Education
Fundamentals of Mchatronics(22048)
e*
*****************
*****************
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*********
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************* *****************
ds.ce...hamke.. L.s. .Carf.5.e.

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****************.**e,
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******-
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****
***
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Masaist..o.f..Ma.sai.n.c. **** *******
CAsAx. .a.c.himc. *************
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****************
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****************
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**************
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******a********************
************************************ ************************************* ******************

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*************
**
******************************************* *** YY
***** ********* * ****
******* **********************
****
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a * * *****
****************************** **************************** ********* . . ..
******** ** ********* *****
ss
********************************** ********** YM
****************** . .
*****"* ***
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******************
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M YYY
*********** s ... ***** *****
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***************************************************eeses eeeea.a..
********** **************
**** * * *
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********************* ..
**********
********* * *** ******

86
Fundamentals of Mechatronics
(22048)

XX.
XXI. ASsessment Schemes

60 %
Process Related ( 15 Marks)
30%
1. Handling of the instruments
30 %
2. Development, testing and execution of ladder logic.
40 %
Product Related ( 10 Marks)
10 %
10 %
4. Conclusions
20 %
100 %
Total ( 25 Marks)

1.
2.
3.
Dated Signature
Marks Obtained
of Teacher
Related 15)| Related (10) (25)
87
narashtra State Board of Technical Education
Fundamenta ls ot l'vkr h111111n1cs( 22 0 IR)
~~-- ~ - - ~ - ~ -~ --- ._
P ract •ical No. 12: Develop Lachkr o·mg,.,am And Program PLC For Tank
Level Control.
.
Prog rammmg . · .~ · is the most essent,a · I •
the Pl C and it's hardware tntct ,acmg requ1reme t ·
. n 1n
the mcchatronics industry. The students should be able
~o dev~ lop th e logi c for the given
problem statement which can be implemented in indus
trial environment.

. .
POI.Basic knowledge: Apply knowledge of basic
mathematics, sciences and basic
engineering to solve the broad-based Mechanical engin
eering probl ems.
P02. Disc iplin e knowledge: Apply mechanical engin
eering knowledge to solve broad.
P03. Experiments and practice: Plan to perform
experiments and practices to use the
results to solve broad-based Mechanical engineering
problems.
P04. Engi neer ing tools: Apply relevant Mechanica
l technologies and tools with an

This practical is expected to develop following
skills for the industry identified
competencies 'Operate and manipulate mechatronics
systems as per requirements':
1. Develop a ladder logic for given problem statement using
PLC software.
2. Programme and troubleshoot PLC for the developed
logic.
3. Interface hardware with Programmable Logic Cont
roller (PLC).

• _CO - c. Use sensor for different mechatronics based
applications.
• CO - d. Use actuator for various mechatronics based
applications.
Develop ladder diagram and program PLC for simulation
of a tank level control.


Use of PLC Software, Development of Ladder Diagram
in PLC Software. download, test
and execute the ladder program and hardware connectio
ns on PLC trainer.

88
·\L__cl\'1\~Je ~\1. ~f'f' ) {~~ )..e\ O
'
fundamentals ofMechatronics(22048)
VJII. Experimental Setup
PLC
lllCBLEVIL
L'IDICATOK
f"Lm, LEn~J
~IUTO R
DIGITAL
~ OUTPns
~ l\ATERPmlP
. .;;;a;;- I
- i
Figure 1: Experimental setup for Tanlc Level control.
~ ) ~ ) @@
0 JIU f Al. lll'VfS
f·~, 1
L.; _J
·LEVEL CON TROL NODULE
,.. ~
M!Cllf. "-C
~l O •
·--~,- HllfllC.
COl-.ot.
&.OflC
,.
LIWIL COltf
Figure 2: SampleTank Level controller module.
a.ources Required
Quandty
Sr. Name of Suggested Broad Specificadon
~No. Resource 01
Computer/ PC preloaded with PLC software and VO
1
~
Laptop communication facility
89
State Board of Technical Education
Fundamentals ofMecha tronics(2204 R)
r------.---- ----r::D-:;l~
- - -=-=====~~=~~;,----.----
gi;:-ta::--;l,f-:n·puts:- 12 Nos wi th toggle switc ,es
for applyin g 24V de inputs. tc,l
N
Digital Outputs:- 12 os wr 'th 24V opera
Programmable Lamp.
2 Logic Controller Analog Inputs: - 02 01
(PLC) Trainer Analog Outputs: - 02
Memory:- 16 K data memory +351K Code
Memory +96K upload Memory. . . - - - r ---..J
Tank Level Tank Level Controller Modulewith fac1hty to
3 Controller sense, indicate and control the High and Low 01
Module level.
1. A void improper handling of instrument.
XI. Procedure
3. Develop ladder diagram for tank level controller.
7. Execute the program and observe the output on hardware.
Ladder Diagram:
Maharashtra State Board of Techni cal Education

90
Fundamentals of Mechatronics(2lo )
48
XII. Resources Used
Sr.
No. Name of Recourse Broad Specifications
Quantity Remarks
Make Details
(if any)
2 a(o/~ 'YT\~Q ~ e._ ~

L,~c ic Un1°)l) 1' f';r
..1}. .o ? ero ......:.th .es.... ..£.1-,,C......... ,5.Qf.±.w.g'rt.c. ~.......... ... ......................

~.......~¼e.,......... '.'X).C.Q............~~.~c_~~ .........................................................
.~ .. J)c.~e.\.n('.l......l.ct.o!de':l:.. ct1.._~·······k. ::¼l«-1'.I,,__ ..\e~.J ............
·········••U.lr'.).~).l.,e_.~........................................................................................................ .
Status of the Action to be

Level of
Step Level taken on Motor
the tank
indicator (ON/OFF)
-
Low \Cl 6/· o M \ D ~~
1 Medium Sa· I 1> C) ~ \ DN
High 3o ·r ~ o~~ \ oN \.
Low
2 Medium
High
XVI.
Results ............................. .·················
.....L......................
.., rr\.-... cl......... ~ \..J-L (.IY"-\ ~r.1:.,.-:-:R........... ..........~.....'.)\~~··················
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....................................................... . ..................................... ···························
-: - -. . -:----_--~=--- --
~htra State Board of Technical Education ---- 91
Fundamentals ofMcchatronics(2204R)

··~·····················....................................v..........~
.... ······ :··;·e.···l··,-···· ....;;;,•<xb:~~:;.l:::::::::.::::······
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::::::::::::: :::::: : ······---- :::::::::::::::::::::::::::::::::::::::::::::::::::::

XVIII. Conclusions
·····················{ .................................... y•······· .. i···············L•~f.d.·· d ]ctantJ~ ·····
...\~.e-. ....... \.~':"f.h ..... ~•········~f_vp.1/'I ... ~·~····· ··l·;v~-·1··· ·······•• .... .
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,7
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•••••••••••••• .O~. .. '. LJ.l,l'.11.\.~.. ... .... .... .. . . ••••• •• • .
' _\ r ~- ...................... .... ................. ...... .
......\n.~.,.~.1.:\.~::ir........................ .............. ·························
XIX. Practical Related Questions Id d •

· are few sample questions
Note: Below given · fior re;ere
,.r, nee Teachers shou eszgn more
·
1. Explain the functions of level sensors.
. . d?
2. Name any five applications where measurement of Ieve1 ts requrre ·
[Space for Answers]
:~j:::::~:::::::\~vti::::::::;::;~;;;:::::::::~:;.::~::::::i~:~:~~:c~. .~~tl\:h~ . ·········

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.........................................................................................................................................................................
····················· .. ····· .................................................................................................................................... .
.......... ........ .. ................................ ............................................................................................................................
Maharashtra State Board of Techn•·cal Education 92

funoa111c11ctu :n:rrwn:,c;rn nrurnc:,yrr,,. .,....-~- - ~- _- ~- - ~ - ~ - - - ~ - - -
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................. ................. ....J
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fundamentals of Mechatronics(22048)
······ ·········································································································
······· . ·············································· ······································································
····························································································································································
·············· ················································································· ·························································
································································· ···························································································
················································ ··············································· ·····························································
················································ ·································· ················ ··························································
XX. References/Suggestions for further reading
l. Programmable Logic Controllers by Frank D. Petruzclla.

Process Related ( 15 Marks ) 60%
2. Development, testing and execution of ladder logic. 30%
Product Related ( 10 Marks ) 40 %
3. Interpretation of result 10%
4. Conclusions 10%
Total ( 25 Marks) 100%
1. . ... .. .. ......... .... ... .. ...... ............ . .
2. ······ ········ ···· ···· ···· ········· ··········
3. ··· ······ ····· ····· ····· ···· ······· ··· ···· ··· ·
Dated Signature
-:-:---_ :-::----- - - - - - -- - - - - - - - - 99~3

~htra State Board of Technical Education
Practical No. 14: Speed control of

stepper motor using 8051 microcontroller.
Many mechatronics applications are based on embedded

systems which is the dedicated
hardware that is controlled by the software.
Microcontroller is a key element of
embedded systems which can be
the hardware and
programmed. The students should be able to interface
develop the given problem
statement which can accommodate the
industrial needs.

POI.Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
engincering to solve the broad-based Mechanical engineering problems.
PO2.Discipline knowledge: Apply mechanical engineering knowledge to solve broad-
based mechanical
results to solve broad-based Mechanical
engineering problems.
Thispractical is expected to develop following skills for the industry identified
competencies Use of microcontroller for various mechatronics based applications
1. Develop and debug the program for stepper motorusing relevant software.
2. Download the hex file in program memory of 8051 microcontroller.
3. Interface stepper motor module with 8051
development board, run the program and
observe the rotation of motor.
.CO-d. Use actuator for various mechatronics based

applications.
CO-f Use microcontroller for various mechatronics based
applications
Develop and execute a program for 8051 microcontroller for speed control of stepper
motor.
VI Relevant affective domain related Outcomes

3. Work as a team leader/ team member
Education 100
Maharashtra State
Board
of Technical
KCmnble Nulm auq 3l0S0397
28 me3Y
Stepper motors are DC motors that move in discrete steps. By energizing the coils in
particular sequence, the motor will rotate, one step at a time. As the microcontroller port
pins lack the sufficient current to drive the stepper motor coils, a driver circuit like IC
ULN2003 is needed to interface stepper motor.
VIIL. Experimental Setup
12V DC A
8051 MICROCONTROLLER IC
XTALT PO0IADO
PO.1AD17
P02AD2
TAL2 PO3IAD3 5
PO4/AD4
5/AD5 DRIVER IC
Po.BADO
PO.7ADZ ULNEOUA ShepperMolor
20AS
22A10
F23A1
F2AT
P26/A13
RD
Figure 1: Experimental setup for speed control of stepper motor using 8051 microcontroller
Sr. Suggested Broad Specification Quantity

Name of Resource
No. PC preloaded withsoftwareto
develop and download the program 01
Computer
in microcontroller memory.
8051 development board with +5v
Microcontroller Development supply, facility for 1O port
01
2 expansion, inbuilt (or add-on)
Board
steppermotor module.
with microcontroller.
1. Avoid improper connections of stepper motor
2. Follow safety practices about maintaining tools and cquipment.
XI. Procedure
1. Open theprogramming software.
3. Develop the assembly language program for steppermotor
4. Test and debug the program for errors (if any).
101
cable.
serial (RS232 or USB)
5. Connect the 8051 board with PC using software
microcontroller using program burning
6. Download the .hex file in 8051 microcontroller.
port of 805I
. Interface stepper motor module with appropriate
motor.
8. Execute the program and observe
the rotation of stepper
of the motor by varying the delay
9. Repeat steps 3 to step 8 for different speeds
Space for 8051 Program:

Stxot
Detine Paot ascm outpF Pav
5et caumied R25 ie. 18o TotIHi_
.et CoumBeo s4-6 tutl sfee Cade
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Read SteP Code
orn membot
Seme 6te Co de to ste po6

moto
wait tes tmc addira deld
Ceam ènt eTRI
e Coe memhRS DeCoemem
COunts R,X Reo-Coumte So
XII. Resources Used
R 02
Name of Broad Specifications

Sr. Remarks
No. Recourse Make Details
Quantity (if any)
C
Com puted PlLe sttur
elelop I Edov
Deditins
Po s dee lof
Deve. lopment Baam wf
3
+SV SPrl
102
Maharashtra State Board of'Technical Education
Page No
Deto
ORG O000k
o 2, E Sct AGol
r ATN-[AoV P2t 03H
cALL DELAy
Moy
A cALL DELAY
MY 4 dacH
A cAL OPLAY
MATNN
DELAY Moy 2 OFEH
Loop 2 mo Pg t CEH
6EH
Loo P 03N Ra L0oP
DytP oo
NO
Page No.
Date
gotenS Sa £ huame
Pxolen Soddoane
Seleck eldde Compgn.ent
al
5
raci.cal
plated ltthe Canponemt at
4
Cooskm
Then mdke
Landoa
5 cE onAT 2gcS m CmContpall.ex
C slectpcth t Lte
Coaicdn kel Softugare
Ple n he
BOCedue
Eellion dauble click
2 T Ca be oQem el so rtucn hoa
Selcot Omoect Nea noieC
lXadt cn
Save he iecc
ile ymaime Asm SVC
F6)Seaxch AT3 3CS oak
x Cie
Ncr ale
I h emeel meo dexileiee Sfeppee
Topdm
modos assembly
aetc ght Sidle
) Gon the o
Sale Nme
XIV windoa mant click
lo) eyen ai
Table 1: Full Step (4-step sequence) Table 2: Half Step (8-step sequence)
motor Windings of stepper motor

StepWindingsof stepper Step
No. D
No.
AB C B C
0 0
7
8
XVI. Results ***********************************************************************************************************************************

Sd.Cu..C...
m.
a S J..ea..dRN . lD
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al ***************************************************************************
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XVII. Interpretations of Results ***********************************************

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**********************************************
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XVIIL. Conclusions . *******
a1.a2.
***************************
.cl.ekelaf.
Rela).. ...**
am..
. *********a*e********.************************************************ ************ ******eo***
103
A,0]LCO.a...
aharashtra State Board of Technical Education

reference. Teachers should design
rs should
design more
Note: Below given arefew sample questions for COs.
e n s u r e the
achievement of identified
Such questions so as to
motor?
. change the direction and speed of stepper
How to
motor.
2. List the industrial applications of stepper
3. What is the role of driver circuit in interfacing of stepper motor with microcontroller?
Space for Answers|

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Mechatronics(22048)
ndamentals of
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XX. The 8051 Microcontroller and Embedded System using Assembly and C
Muhammad Ali Mazidi
2 The 8051 Microcontroller by Kenneth Ayala
3. www.engineersgarage.com

Process Related ( 15 Marks) 60 %
30 %
1. Handling of the instruments
and execution of ladder logic. 30 %
2. Development, testing
Product Related ( 10 Marks) 40 %
10%
10
4. Conclusions
20
5 Practical related questions
100 %
Total ( 25 Marks)
Members
Name of Student Team
I. ..
2.
3...
Dated Signature
Marks Obtained
ofTeacher
Total
Product
Process (25)
Related (15)|Related (10)
105
Maharashtr State Board Technical

Education
Practical No. 15: Interfacing of relay with 8051 microcontroller
Relays find application in industries where it is needed to switch on/off a high
current/high voltage device such as electric heater, motor from a low current device like
microcontroller. Relays also provide isolation between these circuits.
II. RelevantProgram Outcomes (POs)-

POL.Basic knowledge: Apply knowledge of basic mathematics, sciences and basic
PO2.Discipline knowledge: Apply mechanical engineering knowledge to solve broad
based mechanical
II. Competency and Skills
competencies Use of microcontroller for various mechatronics based applications
1. Develop and troubleshoot the program for the
developed logic using relevant
software.
2. Download the .hex file in
program memory of 8051 microcontroller.
3. Interface hardware with 8051
development board, execute the program and observe
the output.
CO-d. Use actuator for various mechatronics based

CO- f. Use microcontroller for various
applications.
mechatronics based applications
Develop and execute a
program for 8051 microcontroller for interfacing of relay.
1. Follow
safety practices.
2. Maintain tools and
equipment.
3. Work as a team leader/ team
member.

As the port pins of
microcontroller 8051 can't provide sufficient current to energize the
coils of the relay the driver circuit is
necessary. The driver circuit can be implemented
using transistor like BC547 or IC ULN2803.A
freewheeling or flyback diode is normally
Education 106
Fdmble Nuem Cqudm 19/0Sl03P7
2o mEls7
connected across the relay coils to protect the transistor from damage due to back emf
generated in relay coil when transistor is turned off
VII. Experimental Setup
MICROCONTROLLER
ATEOCS1
XTALT PO.0'ADO ES
P0.2ADZ 3 DC MOTOR
XTAL2 FO.SAS 35 RELAY
on 5IAD 1N4148
PO.8'AD
OAIAD7
Fz0A8
n 22
2
F2.3/A11 2 2
F24At2 2
OA3
P2.841 9
C57
P2.7IA15
3.00RXD
P3.1/DXD 1
PZ P3 2INTD
Pa.3iNT
P3.5711 8
microcontroller
Figure 1: Experimental setup for relay interfacing with 8051
IX Resources Required
Sr. Name of Resource Suggested Broad Specification Quantity

No. PC preloaded with software to
develop the program and download 01

Computer the hex file in microcontroller
memory.
8051 development board with +5v
Microcontroller 01
Development Board
supply, facility for IO port expansion
facility 01
Relay: 12V/SV Relay
Transistor: BC547 01
Resisitors:4.7K
01
3 Relay interfacing circuit
Freewheeling Diode: 01
01
IN4148/1N4007
microcontroller.
and motor with
. Avoid improper connections of relay
voltage(230V AC) load
2. Follow safety practices to handle high
XI. Procedure
. Open the programming software.

107
iaharashtra State Board of Technical Education

Fundamentals of Mechatronics (22048)
3. Develop the program in assembly

language for relay interfacing
4. Test and debug the program for errors
(if any).
5. Connect the 8051 board with PC
using
serial cable (RS232 orUSB).
6. Download the .hex file in code
memory of 8051 microcontroller using program
burning software.
7. Interface relay circuitry with appropriate port of 8051 microcontroller.
8. Connect motor/lamp to
relay and switch onpower supply.
9. Execute the program and observe the
switching on/off of the motor/lamp.
10. Repeat above steps by exchange connections between NO and NC pins of relay.
Space for 8051 Program:

Stao-t
De Pne lotgs an aut Pu Qe
Step Caimkr g 5 l8o Rela Hn
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Sent Sep Gde bstepges maies
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Count R2 Coumde
XII. Resources Used Sto
Sr. Broad Specifications
Name of Recourse Remarks
No. Make Details
Quantity (if any)
Computes
2 OD Coyhroll Faci fo
develbe Oo
Reld tos deci
ult Resisto 4

Page No
PoOcedune
Ke lli.m dablelfce
T Cmbe O pem kell3oftudare
windo
eD
Save he ooie pA olt
acakau dpoPantse
5To
6) SFarah T Pacst ok
le Nen ak
h enere u m eL) KLe t ne
Shepoes mos
9 o the almek om nt ilole
Calnda ht clicl Sdve Tame as
PaoeS 50dddme
Fu
intertacing
for relay
in assembly
language
Develop the
program
3.
for errors (if any).
4. Test and debug the program
cable (RS232 or USB).
board with PC using serial
5. Connect the 8051
Page No
Data
Fa prote s
DDSe oDeu
aedero
2 s e l e aA elated C om ponen
PonertaEuwlnd(na2
3 pla ced ct the Com

4 hen maee. peK Cenme CAion
5CLice ak AT 835E Ymi Coe Cntre lle

TC3Seleed path K tex i v e
Coeate nke Sothwame
lay the pecCq
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Ser B Pa 0
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END
Mechatronics(22048)
Fundamentals of
Actual Procedure Followed

XIL.
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Observations and Calculations

XV.
Logic level on port pin Motor status
(ON/OFF)
When NO terminal of relay is used for connection
LOW
o FF
HIGH ON
When NC terminal of relay is used for connection
LOW
ON
HIGH ON
Table 1: Observation of motor ON/OFF
XVI Results *** *************************************************************a********a***

. ********* *************
s***************. C a n . . . e k R l o . . d . . . A . C ..ARrEAm
.S.eal.
iC.o). .A.I.LA. **********************a*******************
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d.adl..... .hEpp¬K. Oog
XVII. Interpretations of Results .Cte.

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XVIII. ConclusionssAci.ppR6. moadd?..L61,n.sa.Keloa. d.a..m.t.cem.cLactae/l.coc
. e . C s . . .
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******** *** ***** 109
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Education
Technical
Viaharashtra State Board of

Such questions so as to ensure the achievement of identified COs.
1. Compare the features of various families of microcontroller currently available in

market.
2. What is advantage ofusing optocoupler in 8051 interfacing?
Space for Answers
* ************.
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Education
110
amentals of Mechatronics(22048)
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X. References/Suggestions
The 8051
for further
reading
Microcontroller and
Embedded System using
Muhammad Ali Mazidi Assembly and
The 8051 Microcontroller by
Kenneth Ayala
3. www.engineersgarage.com
Process Related (15
Weightage
Marks) 60 %
Handling of the instruments
30 %
2 Development, testing and execution of ladder logic. 30 %
Product Related (10
Marks) 40 %
10 %
Conclusions 10 %
Total (25 Marks) 100 %
1. ...
2.
3. ...so*****
Marks Obtained
Dated Signature
ofTeacher
Maharasht State Board of Technical Education 111

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ianl ntals ofMcchatronics(22048)

JI. Relevant Program Outcomes (POs)-

PO l • Basic knowledge: Apply knowledge of basic mathematics, sciences and ba 1c

PO 2. Discipline knowledge: Apply mechanical engineering knowledge to solve broad-

ID, Competency and Skills

IV. Relevant Course Outcome(s)

• CO - a. Identify different instruments, sensors, actuators, microprocessor, software

VJ. Relevant affective domain related Outcomes

l. Follow safety practices.

VIL Minimum Theoretical Background

~\\~VY~ ~\ \.\ ~\ '"M ,~cvv~, h le_

Programmable Logic Controller (PLC) is a digital electronic device that r,i~

VIII. Experimental Setup

Inductive Proximity Sensor

Photo courtesy Turck, Inc. www.turck.coro

Capacitive Proximity Sensor

Photo court.86y Omron lnduslffal Auton1ar,on

RTD (PT JOO)

Maharashtrn State Board of Tcc hnacal Education - -----~------~-----z'

Rotary POT Linear POT

Maharashtm State Bon.rd ofTcchnicnl Edu cauon

Programmable Logic Controller (PLC)

Image Courtesy Rockwell Automation, Inc

JX. R esources Required

Sr. Name of Suggrsted Broad Specification Quantity

A T89S51 40 pin DIP package,+5VDC

1. Avoid improper handJing of instrument.

t. Identify the type of application intended.

xn. Resources Used

in~ crm c.. 0,1110 ll ~ fL-] \\cN> ot

xm. Actual Procedure Followed .............................................. J"'j'

Sr. Name of the seasor Seledio• Criterion used Comments

5 ~"om c\,oJe o~~~-\~

Maharashtra State Board ofTcchn1cal Education

Table ~1: Sl'll•ctlcm rl'lfnln lnr 1•1 ,(;

XVII. Interpretations of Results ....

XIX. Practical Related Questions

1. List at least three applications of each of the following sensors

(Space for Answers)

... {?..p\.i..~~c% ......LJ..~:m~~\ed..,,.O.'£... s . ~ r , ~..... ~~C ..CMT}f---·· -- ~·

~?).... :0. .~n.¾.':Q'........~ .... ~e.J.l~.~'lf.P.."\f?.TI.l:......-:6:~~.\~......................................

XX. References/Suggestions for further reading

1. Programmable Logic Controllers by Frank D. Petruzella.

Maharashtra State Board of Technica l Educatio n

of~th::_e__:_instf'WIJ=:.==-en==ts=----------- - ;---..:30 % .....,

Name ofStudent Team Members

Maharashtra State Board of Technical Ed ucahon

IJ. Relevant Program Outcomes (POs)-

PO 1. Basic knowledge: Apply knowledge of basic mathematics, sciences and basic

PO 4. Engineering tools: Apply relevant Mechanical technologies and tools with an

m. Competency and Skills

IV. Relevant Course Outcome(s)

• CO - e. Programme PLC for various applications.

VI. Relevant affective domain related Outcomes

VU. Minimum Theoretical Background

Loafc Gates u1ln1 ,wttchlnl clrculh:

I. NOT G•;~ NOT gate is the inverse of the input.

r-~ HardWlred circuit

OIOlld (1) On_ill SW-8

SW-A Truth table

iMhaharas~;hhttra~S~tate-iBoanti;;;~r=rT·=-=------- --------- --~