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Group No:1A
1.3. a. A Programmable Logic Controller (PLC) is a digital electronic
device that uses a programmable memory to store
instructions and to implement functions such as logic,
sequencing, timing, counting and arithmetic in order to control
machines and processes that have specifically designed to
make programming easy. Discuss TWO (2) considerations in
the selection of a PLC.
[4 Marks]

b. A latch circuit is a self maintaining circuit that when energized,

maintains its state until another input is received. Discuss a
possible application for and draw the corresponding ladder
diagram to implement such a circuit.
[6 marks]

c. A PLC may be used to control the sequence of a traffic light.

For the following traffic light sequence:

Red, 5 seconds later, Amber, 5 seconds later, Green, 5

seconds delay, repeat sequence.

i. Draw the corresponding ladder diagram. The sequence

should be fully automatic and start with the Red ‘ON’
immediately.
[10 marks]

ii. Modify the ladder diagram so that it will be able to

sequence two traffic lights simultaneously. The traffic
lights need to be synchronized such that if one traffic
light is showing green, the other must show red.
[5 marks]
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Group No:1B
4. a. Consider a car park barrier system. The in-barrier is to rise for the
vehicle to pass through when it is at the entrance. The out-barrier is
to open when a car is detected at the car park side of the barrier
and will then be lowered when the car has completely cleared the
barrier. There should be a display to indicate that the car park is
full, in which case the in-barrier should not be raised.

i. Sketch an appropriate mechatronic system for the automated

car park barrier system. Identify and state the related
components and instrumentations used.
[6 marks]

ii. Write the pseudocode for the programming logic.

[10 marks]

b. Consider a coin-operated vending machine. The machine will

dispense the chosen beverage if the correct amount of money is
inserted in the collection box. There should be an option to return
the customer's money as well as to indicate that a particular
beverage is out of stock. Sketch an appropriate mechatronic
system for the vending machine. Identify and state the related
components and instrumentations used.
[9 marks]
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Group No:1C
3. a. A hydraulic actuation system is required to operate the
sequence
of operation of a manufacturing system.

i. Design a pneumatic valve circuit to give the sequence A+,

followed by B+ and then simultaneously followed by A-
and B- .
[10 marks]

ii. Sketch the valve positions for different sequence of

operations.
[5 marks]

b. A motor is to give an output of 0.25 revolution per second and

has a step angle of 7.5º. Calculate the number of pulses per
second that is required to be generated by a microprocessor to
the stepper motor.
[4 marks]

c. Draw the displacement diagram of the cam follower shown in

FIGURE Q3 with the angle of rotation. Suggest an application
for this type of actuation.

FIGURE Q3
[6 marks]
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Group No:1D
b. The movement of an item over a conveyor belt to work station is
controlled by a PLC. The presence of the item at the work
station is detected by means of breaking a contact activated by
a beam of light to a photo sensor. Once detected, the item stops
for 100 seconds for an operation to be carried out before moving
on and off the conveyor. The motor which drives the belt is
started by a normally open start switch and stopped by a
normally closed switch. Draw a ladder logic circuit for this
application and explain the operation performed at each step in
the ladder circuit.

[17 marks]
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Group No:1E
4. a. With the aid of an appropriate diagram, describe the operation of
a pilot-operated valve.
[4 marks]

b. A manufacturing plant utilises a hydraulic system shown in

FIGURE.Q4b for its material handling operation. The system
consists of two cylinders, seven valves and four limit switches.
Hydraulic fluid at 50.bar is supplied by a pump with

53.cm3.displacement per revolution operating at 1000 rpm.

a- a+ b- b+
Cylinder 1 Cylinder 2

A B

C D E F

b- b+ a+ a-

Push G
button

FIGURE Q4b

i. Describe the sequence of operation of the hydraulic

circuit if the push button is pushed and held.
[10 marks]

ii. Determine the retraction force and speed of cylinder 2 if it

has 200.mm cylinder diameter and 100.mm rod diameter.
[6 marks]
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Group No:1F

5. FIQURE Q1 illustrates a traffic light. A PLC may be used to control the

sequence of the traffic light. Draw the corresponding ladder diagram for the
following traffic light sequence: Red, 5 seconds later, Amber, 5 seconds later,
Green, 5 seconds delay, repeat sequence. The sequence should be fully
automatic and start with the Red ‘ON’ immediately.
[6 marks]

FIGURE Q1
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Group No:2A

6. Consider a car park barrier system. The in-barrier is to rise for the
vehicle to pass through when it is at the entrance. The out-barrier is to
open when a car is detected at the car park side of the barrier and will
then be lowered when the car has completely cleared the barrier. There
should be a display to indicate that the car park is full, in which case
the in-barrier should not be raised. FIGURE Q2 illustrates the
components and instrumentation used in the mechatronic system for
the automated car park barrier system. Write the pseudocode for the
programming logic.
[10 marks]

FIGURE Q2
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Group No:2B
7. A manufacturing plant utilises a hydraulic system shown in FIGURE.Q3
for its material handling operation. The system consists of two
cylinders, seven valves and four limit switches. The cylinders are
intended to operate in the sequence a+, b+, a-, b-, if the push button is
pushed and held.
a. Explain the sequence of operations involved to complete the
cycle.
[5 marks]

b. Construct schematic diagram of the valve positions when

cylinder A is fully extended i.e., a+ and compare the fluid flow
directions
[8 marks]

c. Construct schematic diagram of the valve positions when

cylinder B is fully extended i.e., b+ and compare the fluid flow
directions
[8 marks]

d. Propose the changes required in the circuit to run the hydraulic

system continuously once started.
[4 marks]

FIGURE Q3
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Group No:2C
8. a. In a 4-cylinder IC engine, the sequence of spark ignition is to be
controlled by a mechatronics system. Propose and construct
a schematic of mechanical actuating system to operate a
sequence of micro switches for triggering sparks in a timed
sequence.
[8 marks]

c. An industrial process application is operated by PLC to switch

on a water pump for 120 s into the machine, switch off and
switch on a heater for 60 s to heat the water. The heater is then
switched off and another pump is on to empty the water from the
machine for 120 s.
i. Draw a ladder logic diagram for this application.
[12 marks]

ii. Explain the operation performed at each step in the

ladder diagram.
[5 marks]
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Group No:2D
9. a. A hydraulic cylinder, in a manufacturing line, with a piston
diameter of 100 mm is required to move a work piece through a
distance 50 mm in 20 seconds. A force of 10 kN is required to
perform the operation. Determine the required hydraulic pressure and
flow rate to be supplied to the cylinder to perform the required
operation.
[2 marks]

b. To avoid air becoming trapped in the pressure line to control a valve

and so prevent the valve from switching, the air supply is switched
on and off to valves in groups. This is termed cascade control.
FIGURE Q2 shows the pneumatic circuit with cascade control.
Describe the sequence of operation of the pneumatic circuit.
[8 marks]

1 2

FIGURE Q2
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Group No:2E
10. a. With the aid of appropriate diagrams, describe the operation of
the following:
i. Solenoid valve
ii. Single acting cylinder
[6 marks]
b. Explain with proper sketches, the method of piston speed control
for:
i. meter-in circuit known as supply line throttling
ii. meter-out circuit known as exhaust line throttling
[6 marks]
c. On a hand operated wood cutting machine shown in Figure Q3,
slots are to be milled in a wooden frame. The clamping and
feeding operations have so far been carried out manually. These
operations are to be automated using pneumatic system. Design
and draw a proper pneumatic circuit with the aid of travel–step
diagram and describe the function of the chosen components.
[10 marks]

FIGURE Q3
d. Determine the clamping and the retraction forces of the
clamping cylinder of 200.mm diameter. The rod diameter is
100.mm. Assume the operating pneumatic pressure is 10 bar.
[3 marks]
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Group No:2F
11. a. In a 4-cylinder IC engine, the sequence of spark ignition is to be
controlled by a mechatronics system. Design a mechanical system to
operate a sequence of micro switches for triggering sparks in a timed
sequence.
[6 marks]

b. Programmable Logic Controller (PLC) is a device that has

replaced large banks of electrical logic relays in control panels.
Describe any TWO (2) criteria that are to be considered when
selecting a PLC.
[2 marks]

c. Draw PLC ladder diagrams to represent:

i. An AND circuit and a NAND circuit.

[4 marks]

ii. An OR circuit and a NOR circuit.

[4 marks]

d. Device a circuit that can be used to start a motor and then after
a delay of 50 seconds, start a pump. When the motor is
switched off there should be a delay of 10 seconds before the
pump is switched off. Show the proper ladder diagram and state
the function of each rung.
[9 marks]