INSTITUTE OF INDUSTRIAL ELECTRONICS ENGINEERING

Course: Industrial Process Control Lab. # 23 Roll #29018

Assessment Of Rubrics For Lab Work

(Higher Taxonomy Level)
Extent of Achievement
Category Description
Level Marks Initial
Equipment Ability to identify & handle ☐Unacceptable (0 – 1)
Identification and equipment and/or its ☐Marginal (2 – 4)
☐Acceptable (5 – 7)
Handling component with safety and ☐Exceptional (8 – 10)
(KS) care.
Display Skills to demonstrate ☐Unacceptable (0 – 1)
Demonstration ☐Marginal (2 – 4)
with improved efficiency. ☐Acceptable (5 – 7)
(S)
☐Exceptional (8 – 10)
Complete Overt ☐Unacceptable (0 – 1)
Capability to perform ☐Marginal (2 – 4)
Response ☐Acceptable (5 – 7)
automatically.
(S) ☐Exceptional (8 – 10)
☐Unacceptable (0 – 1)
Manipulation Skill Capability to reorganize to ☐Marginal (2 – 4)
(S) meet the task. ☐Acceptable (5 – 7)
☐Exceptional (8 – 10)
☐Unacceptable (0 – 1)
Designing Skill Capability to innovate using ☐Marginal (2 – 4)
(S) range of resources. ☐Acceptable (5 – 7)
☐Exceptional (8 – 10)
Sensory skill to investigate ☐Unacceptable (0 – 1)
Observation’s Use ☐Marginal (2 – 4)
observations and generate ☐Acceptable (5 – 7)
(KS)
conclusion. ☐Exceptional (8 – 10)
Ability to troubleshoot errors ☐Unacceptable (0 – 1)
Troubleshoot and try to resolve ☐Marginal (2 – 4)
☐Acceptable (5 – 7)
(KS) with/without the supervision ☐Exceptional (8 – 10)
or guidance.
Report/Lab File ☐Unacceptable (0 – 1)
Ability to Prepare report / Lab ☐Marginal (2 – 4)
(A) ☐Acceptable (5 – 7)
file.
☐Exceptional (8 – 10)

Total Marks: __________ Signature: ___________ Date:__________

General Guidelines:
Unacceptable:Show no evidence of efforts; Work is largely lack of structure or has major flaws.
Marginal:Evidences of efforts are seen; work is more or less structured; substantial improvement
are needed.
Acceptable: Evidences of efforts are seen; work is structured; slight Improvements are needed.
Exceptional: Evidences of efforts are clear; work is very well structured, analyzed and presented.
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

LAB 23
Control elements and process operations of Electro-Pneumatics
OBJECTIVE:
 To understand the process operations of Electro-Pneumatics
 To understand the control elements in Electro-Pneumatics

THEORY:
Pneumatic is a Greek word whose origin is “pneuma” and its meaning is of air. In pneumatic
control system the working medium is air. In electro pneumatic control system the working
medium is air and actuation is done by electric signal and control by relays.
Characteristics of Pneumatics
It may be surprised that the use of pneumatic control became so wide spread in such a
short time. One of the reasons is that with some automation problems, no another medium
can be introduced more easily and economically.
The following characteristic speaks for the application of the Pneumatics:
1. QUANTITY:
Air is available for compression almost anywhere and in unlimited quantities.
2. TRANSPORTATION:
Compressed air can easily be transported in pipelines. Even over longer distances.
There is no need of compressed air return lines.
3. TEMPERATURE:
Compressed air is non sensitive to temperature, fluctuation; this ensures reliable
operation, even under extreme temperature conditions.
4. EXPLOSION PROOF:
Compressed air does not cause any explosion or fire hazards.
5. CLEANNESS:
Air is clean in the event of leakage lines or components. The skipping air does not
cause pollution. This cleanness is necessary in the food, textile and paramedical
industries.
6. CONSTRUCTION:
The operating components are simple constructing and are in expensive.
7. SPEED:
Compressed air is very fast working medium. To start high operating speed can
therefore be attained. The operating speed of pneumatic cylinder is 1-2
meter/seconds.
8. REGULATION:
The speed and force of compressed air and pneumatic devices are infinitely
variable adjustable.

9. OVERLOAD PROOF:
Pneumatic tools and operating equipment can be subjected to loads even at
standstill and are therefore overload proof and no damaged by stalling.
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

In order to be able to establish clear demarcations on the field of applications of

pneumatics, it is also necessary to become familiar with negative characteristics.
1. PREPARATION (OF AIR):
Compressed air are requires good preparations. It must not be contain any dirt or
moisture.
2. COMPRESSIBLE:
It is not possible to achieve uniform and constant piston speed with compressed air.
3. FORCE REQUIREMENTS:
Compressed air is only economical up to certain force requirement, based on the
normal operating pressure of 7 BAR. The limit is 20000-30000newtons (2000-
3000KG.FT) depending on the travelling speed.
4. EXHAUST AIR:
Exhaust air is noisy, however this problem has been largely solved by absorbing
materials and by other techniques.
5. COST:
Compressed air is relatively in expansive medium. The high energy costs are largely
compensated for the expensive components and high performance devices.

In pneumatics the following aspects should be of great importance:

 SUPPLY:- AIR
 SIGNALING :- ELECTRICAL SIGNAL
 DIRECTION CONTROL VALVE :- VALVE
 WORKING ELEMENT :- CYLINDER

1. SUPPLY:
It is the main part of electro-pneumatic system and used to turn ON and OFF the
pneumatic system.
It consists of a compressor. Parts of compressor are as follows:
a. Head.
b. Piston.
c. Valve.
d. Motor.
e. Tank.
f. Pressure gauge.

2. SIGNALING:
In pneumatic control system, the electrical signal usually of 24V.
3. DIRECTION CONTROL VALVE:
These valves are used to control the direction of the air. In circuit diagram, there is
one pneumatic circuit and other is electric.
The numbering or designation is done like 3/2 valve signal solenoid valve. In this
designation ‘3’ tells that there is a supply, working element and exhaust. No ‘2’ tells
about the switching position ON and OFF. Single solenoid is a type of actuation.
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

4. WORKING ELEMENT:
In this category we use single acting cylinder or double acting cylinder as a working
element according to the requirement.

Control Engineering:
The term control is often applied to the complete system in which controlling takes place,
and not only to the control operation itself.
SIGNAL:
Signal represents information that representation may refer to the valve or change in the
valve of the physical parameter and cab be related to the transmission, processing and
storage of information. There are numerous types of signals:
a. Analogue signal.
b. Binary signal.
c. Digital signal.
d. Discrete signal.
VALVE:
Pneumatic control systems, consists of signaling components (signaling devices i.e. relays)
and working section. The signaling and control components affect the operating sequence
of the working devices known as valves. Valves are components for controlling or
regulating the start, stop and to control the direction of the pressure or the flow of pressure
medium.
Valves can be divided into five groups, according to their function.
a. Direction control valve.
b. Non return valve.
c. Pressure control valve.
d. Flow control valve.
e. Plug or shut off valve.
DIRECTION CONTROL VALVE:
Direction control valve are devices which affects the path of air flow, cheaply with respect to
start, stop and direction of flow.

REPRESENTATION OF VALVE IN A CIRCUIT:

Circuit symbols are used to represent the valves in circuit diagram. These circuits symbol
provides information regarding to design but nearly indicate the function of valve. The
control state of valve represents as square (switching position).
 The no. of square shows the number of switching positions of the valve.
 Pneumatic lines/pipes are indicated by drawn lines an arrow indicates the
direction of flow.

MANIFOLD WITH 3/2 WAY HAND SLIDE VALVE: (DIRECTION CONTROL VALVE)
The unit consists of many ports with;
a. 8 wheel push pull coupling.
b. Hand slide (means there is manual actuation).
c. Mounted on a plug in plate.
FUNCTION:
The manifold has a single common inlet to be passed into the control system through
8 separate outlets. The 3/2 way end slide valve fitted to the common inlet operated by
sliding the blue sleeve backward and forward to switch the air supply to the control system
ON and OFF.
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

TECHNICAL DATA;
 MEDIUM:- compressed air
 DESIGN: - Slide valve.
 PRESSURE: - 10 bar.
 ACTUATING FORCE AT 6 BAR; - 10 Newton
 CONNECTION: - 1/8”
There are some common symbols used in pneumatic system to show the actuation types
for the convenient references. These symbols are as follows:
a. Manually actuated.
b. Mechanically actuated.
c. Roller actuation.
d. Actuation by single solenoid.
e. Actuation by double solenoid.
f. Actuation by layer.
DESIGN:
The design symbol of valve decisively affects its service life,the actuating force needed,
possible modes of actuation and size of valve. Distinctions are made according to the type
of design e.g. poppet valves and slides valves.
SERVICE UNIT:
The following aspects are going to be considered and discussed under this heading.
DESIGN: -
It consists of swill mounted service unit comprise of:
 Filter.
 Regulator.
 Gauge.
 Lubricator.
 Quick coupling switch.
FUNCTION:
The filters include a water separator and clean the compressed air of dirt, pipe scale and
rust. The regulator regulates the incoming compressed air to the working pressure, which
has been set and even out fluctuations in pressure. An arrow in the body of the valve
indicates the direction of flow. The lubricator oil mixes metered oil mist to the air. After
cleaning the mist infection in the proportional to the input of the air. The gauge indicates the
pressure in the pneumatic control system.
TECHNICAL DATA:
 MEDIUM; - Compressed air
 DESIGN:- Sintered filter with water separator piston type relieving
regulator
 UPSTREAM:- Lubricator
 Maximum pressure:- 14 BAR
 MAXIMUM OPERATING:- 12 BAR
 DIAMETER OF THE PORES:- 0.04mm
 CONNECTION:- 1/8 inches
 WORKING PRESSURE:- 12 BAR

Electro Pneumatic Control System

These converter systems are solenoid valve, which have the task of converting electrical
signal to pneumatic signal.
MINIFOLD:
This is a 3/2 way valve. It consists of the many folds with eight outlets (quick push pull) with
built in valve coupling. This unit is mounted on plug plate.
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

FUNCTION:
The minifold has single common inlet and the compressed air is fed to this inlet is passed
into the control system through eight separate outlets. The 3/2 way sliding the ‘blue sleeve’
backward and forward operates hand sliding valve fitted to the common inlet, to switch the
air supply to the control system ON and OFF position.
TECHANICAL DATA:
 MEDIUM:- Compressed filtered air
 DESIGN:- Slide valve
 PRESSURE RANGE:- 10 BAR
 ACTUATING FORCE:- 10 NEWTON
 CONNECTION:- 1/8 inch, ¼ inch

3/2 Way Single Solenoid Valve

This section consists of the following parts;
 Solenoid coil.
 Indicator plug with LED.
 Plug in plate (mounted).
FUNCTION:
Through application of current to the solenoid coil, the valve is actuated and subsequently
returns into its original position by a returning spring, when the signal is removed.
The LED indicates the operating status. The solenoid coil consume a maximum of power
and heat up very slightly. The function of LED is independent of the valve.
Through application of current to solenoid coil the valves is actuated and subsequently
return to its original position by a return spring. When the signal is removed LED the
solenoid coil consume a maximum power and heat up very slightly indicates the operating
system. The functioning of the LED is indicated by the polarity of the current.
This device is directly actuated from one side with spring return on the other. It is closed in
the normal position. When an electrical signal is applied to the coil, the armature is raised
from the sealing seat by the magnetic field. The compressed air flow from port ‘P’ to the
outlet port ‘A’, exhaust passage are in the armature tube is blocked by the armature if
magnetic field or the solenoid coil is switched off the return spring passes the armature
back against the spring seat. The passage of compressed air from P to A is blocked and
residual air from the compressed air line is exhaust through port A to B in the armature
tube. This type of valve is used in control system with single acting cylinder, for controlling
other valves and for supplying air and to isolate it OFF from control system.
5/2 Way Single Solenoid Valve
5/2 way single solenoid valve’s unit consists of;
 Solenoid coil.
 Indicator inserts plug plate using LED.
FUNCTION:
In 5/2 solenoid valve, an electrical signal triggers a changeover of the armature. The
compressed air flows through the air duct to the valve servo piston and switches. In the
middle of the valve, a sealing disk (poppet valve) is used to open the passage from 1P 1o
4A or 2B. Exhausting takes place from 4A to 5R and from 2B to 3S. When the electric
signal is removed, the return spring brings about the normal position: 1P connected to 2B.
TECHANICAL DATA:
 MEDIUM:- Air
 DESIGN: - Indirectly actuated from one side with the return spring and
manual over side.
 PRESSURE: - 8 BAR.
 SWITCHING POSITION AT 6 BAR:- 15 m sec
 CONNECTION:- 1/8 inch
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

Single Acting Cylinder

The single acting cylinder consists of following parts;
 Trip cam (head of the cylinder).
 Quick push pull elbow (used for connections).
 Plug plate for mounting.
Single acting cylinders are subjected to compressed air pressure from one end only. They
can carry out solely in one direction. Compressed air is needed only for one direction of
motion. The return travel of the piston is achieved by built in spring or by external force. The
spring force or the built in spring is rated to return the position to its original position at
adequate speed. I n single acting cylinder with built. In springs the stroke is limited by the
overall length of the spring. For this reason the single acting cylinders are constructed with
stroke length of approx. 100mm. These working components are mainly used for clamping,
ejecting, inserting, lifting, feeding etc.
A flexible material (perbunan) is used for sealing: that is fitted. On a metal or plastic piston,
during motion, the sealing edges slides over the bearing surface of the cylinder. In the
second version the operating stroke is executed by the spring and compressed is used for
return travel.
APPLICATION:
Breaks on Lorries, rail engines and heavy vehicles.
ADVANTAGE:
Breaking action in the event of power failure.
TECHANICAL DATA:
 MEDIUM:- compressed air
 DESIGN:- piston cylinder
 MAXIMUM WORKING PRESSURE: - 10 BAR.
 MAXIMUM STROKE: - 50mm.
 FORCE (AT 6 BAR):- 250 NEWTON
 SPRING RETURN FORCE (AT 6 BAR):- 17.80 NEWTON
 CONNECTIONS:- 1/8 inch

Double Acting Cylinder

In case of double acting cylinder, the force exerted by compressed air, which moves the
piston in two different directions, a specific force is applied during forward as well as return
travel. Double acting cylinders are used, in particular, for applications where the return
motion is also required to perform a working function. In principle, the stroke length of such
cylinders is unlimited, but the risk of bucking and bending of the extended piston rod must
bne born in mind. Here too sealing is by means of sealing rims and pistons and
diaphragms.
TECHANICAL DATA:
 MEDIUM:- compressed air
 DESIGN:- piston cylinder
 MAXIMUM WORKING PRESSURE:- 10 BAR
 MAXIMUM STROKE LENGTH:- 10 mm
 FORCE (AT 6 BAR):- 267 NEWTON
 RETURN FORCE (AT 6 BAR):- 220 NEWTON
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC
Electrical Signal Processing device (Relay)
MEANING AND ORIGIN:
The word ‘relay’ is French word and its meaning is ‘to pull’. Actually this word is used in
meaning of to pull to lead team of horses. Now a day, relays are used in control and
regulation of installation and machine in practice. A relay must meet a certain requirement
as follows:
 Very little maintenance.
 High switching speed.
 Easily acceptable to various operating voltages and high currents.
 High operating speed i.e. short switching time.

WHAT IS RELAY?
Relays are devices for switching and controlling requiring a low current of energy. They are
chiefly used for signaling processing. A relay can be considered as “an electromagnetically
operated switch for particular contact ratings”.
DESIGN:
In practice there are many ways of constructing a relay but the functional principle is same.
OPERATION:
When voltage is applied to coil, an electric current is produced and flows through the
windings of the relay. A magnetic field is build up and causes armature to pull into the core
of the coil. The armature mechanically joined to contacts, which are either open or close.
This switching is maintained as long as the voltage is applied. When the voltage is
removed, the armature is restored to its original position by spring. In practice, the circuit
symbol are used for relay, this simplified representation facilities the reading of the circuit
diagram. The relay is represented by K 1, K2, K3, K4 …….The electric actuator is represented
by A1 and A2 (coil terminals).
CONTACTORS:
Contactors are electro magnetically actuated switches, capable of switching high leads at
low load of control power. The numbering used for switching is follows:
 1-2 CLOSE
 3-4 OPEN
ADVANTAGES:
1. Easily adoptable to various operating voltages.
2. Not much affected by environment temperature.
3. Relay still operates reliable at temperatures of 80°c to -40°c.
4. Relating high resistance between contacts ON and OFF state (open).
5. Several independent circuits can be switched by a single relay.
6. There is an electrical insulation between control circuit and main circuits.
DISADVANTAGES:
1. Work surfaces of contacts are affected by oxidation.
2. Large space required as compared to transistors.
3. Noise is created during switching.
4. Limiting switching speed of 3msec to 17msec.
5. Contacts are affected by contamination.
When switching a relay data sheet should be consulted. These specify all values such as
current, voltages, power ratings, number of switching operations etc.
RELAY SPECIFICATIONS:
 RESPONSE TIME: approx. 08-22msec
 DC ENERGIZING TIME: approx. 02-20msec.
 MAXIMUM NUMBER OF SWITCHING CYCLES; approx. 15 cycles
 OPERATING VOLTAGES: 3,6,12,24,36,48,60,110.220.240 volts
 DC VOLTAGES: 16,24,36, 48,60,90, 135,220 volts
 OPERATING POWER: 1,1.5 watt (DC)/ 2,2.2 watt (AC)
 MAX POWER RATING OF COIL: 3 to 3.4 VA
CONCLUSION:
In this lab we have theoretically learnt about the Electro-Pneumatic System, from this lab we get
the understanding about the operations of Electro-Pneumatics and the control elements in
Electro-Pneumatics. The core aim of this lab is to get basic understanding of the components to
be used later.
INSTITUTE OF INDUSTRIAL ELECTRONICS ENGINEERING
Course: Industrial Process Control Lab. # 24 Roll #29018

Assessment Of Rubrics For Lab Work

(Higher Taxonomy Level)
Extent of Achievement
Category Description
Level Marks Initial
Equipment Ability to identify & handle ☐Unacceptable (0 – 1)
Identification and equipment and/or its ☐Marginal (2 – 4)
☐Acceptable (5 – 7)
Handling component with safety and ☐Exceptional (8 – 10)
(KS) care.
Display Skills to demonstrate ☐Unacceptable (0 – 1)
Demonstration ☐Marginal (2 – 4)
with improved efficiency. ☐Acceptable (5 – 7)
(S)
☐Exceptional (8 – 10)
Complete Overt ☐Unacceptable (0 – 1)
Capability to perform ☐Marginal (2 – 4)
Response ☐Acceptable (5 – 7)
automatically.
(S) ☐Exceptional (8 – 10)
☐Unacceptable (0 – 1)
Manipulation Skill Capability to reorganize to ☐Marginal (2 – 4)
(S) meet the task. ☐Acceptable (5 – 7)
☐Exceptional (8 – 10)
☐Unacceptable (0 – 1)
Designing Skill Capability to innovate using ☐Marginal (2 – 4)
(S) range of resources. ☐Acceptable (5 – 7)
☐Exceptional (8 – 10)
Sensory skill to investigate ☐Unacceptable (0 – 1)
Observation’s Use ☐Marginal (2 – 4)
observations and generate ☐Acceptable (5 – 7)
(KS)
conclusion. ☐Exceptional (8 – 10)
Ability to troubleshoot errors ☐Unacceptable (0 – 1)
Troubleshoot and try to resolve ☐Marginal (2 – 4)
☐Acceptable (5 – 7)
(KS) with/without the supervision ☐Exceptional (8 – 10)
or guidance.
Report/Lab File ☐Unacceptable (0 – 1)
Ability to Prepare report / Lab ☐Marginal (2 – 4)
(A) ☐Acceptable (5 – 7)
file.
☐Exceptional (8 – 10)

Total Marks: __________ Signature: ___________ Date:__________

General Guidelines:
Unacceptable:Show no evidence of efforts; Work is largely lack of structure or has major flaws.
Marginal:Evidences of efforts are seen; work is more or less structured; substantial improvement
are needed.
Acceptable: Evidences of efforts are seen; work is structured; slight Improvements are needed.
Exceptional: Evidences of efforts are clear; work is very well structured, analyzed and presented.
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

LAB 24
Electro-Pneumatics based cutting Device

OBJECTIVE:
 To understand the working of 2-way solenoid valve
 To understand the operation of single acting cylinder
 To construct pneumatic and electric circuit for a cutting device

TASK:
Using a cutting device, sheets of paper are to be cut to size. By pressing two push button
switches the cutting blade is advanced and the sheet of paper is cut. After releasing one
push button switch the cutting blade is returned to the sheet position
 INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

CIRCUIT DIAGRAMS
PNEUMATIC:

ELECTRIC:
INSTITUTE OF INDUSTRIAL ELECTRONIC ENGINEERING IPC

RESULTS:
1)In this circuit diagram we use the make switch K1 ,General make switch is
tailoredaccording to the component (RELAY) that actuates it.
In this circuit when the push button is pressed the solenoid coil V1 is closed & the single
solenoid valve is actuated.The piston rod of the single acting cylinder advances to the forward
end position.

1)After releasing the pushbutton switch,the electric circuit for the solenoid coil V1 is
openedand the solenoid valve is switched back to its initial position. The piston rod
returns to its rear end position.
CONCLUSION:

In this lab we have designed Electro-Pneumatics based cutting Device by using single acting
cylinder and solenoid valve.By this lab we automate the task as result of that it reduces
human effort as well as saving time

CONCLUSION:
In this lab, By using electro-pneumatics we have constructed a circuit for a
cutting device in which we have used a 2 way solenoid valve and a single acting
cylinder, by using a cutting device, sheets of paper are to be cut to size