Higher Diploma

Digital System in Electrical and Electronics Engineering

Design Assignment

Digital
MohammedSystem Design
Ifam
ICBT student ID: KD/HDEEE/14/14

LJMU STUDENT ID: 1035614

 ICBT Student Number: KD/HDEEE/14/14
ASSESSMENT COVER SHEET

Higher Diploma in Electrical and

Programme Learner name Mohammed Ifam
Electronics Engineering
Design an Embedded Controller for
Assignment title
Seat Belt Controller
Assessor name Mr. Heshara
5503ICBTEL L & Digital System
Unit Code. & title Targeted assessment criteria
Design
Issue date Submission deadline
Date submitted 01/03/2024
Marks Marks
Question allocated awarded
Feedback

Total Marks
General comments

I certify that the evidence submitted for this assignment is the learner’s own. The learner
Assessor declaration has clearly referenced any sources used in the work. I understand that false declaration is
a form of malpractice.
Assessor signature Date
Learner comments
Learner signature Ifam Date 1st March 2024

1
Acknowledgement

I extend my heartfelt gratitude to Mr. Heshara for his invaluable guidance, the ICBT administration for
their consistent support, and my fellow classmates for their collaborative efforts. Thank you all for
contributing to our successful journey – your assistance has been truly appreciated."

Contents
2
Acknowledgement........................................................................................................................................2
Table of figures..............................................................................................................................................4
Task 01........................................................................................................................................................... 5
Task 02........................................................................................................................................................... 6
Task 03........................................................................................................................................................... 8
Truth Table, K-map, and Boolean Equations:.............................................................................................8
Implementation Using Xilinx ISE Software:..............................................................................................10
Task 4........................................................................................................................................................... 14
Task 5........................................................................................................................................................... 17
Truth Table:..............................................................................................................................................17
K-map, and Boolean Equations:...............................................................................................................17
Task 06......................................................................................................................................................... 19
Task 07......................................................................................................................................................... 21
References................................................................................................................................................... 22

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Table of figures
Figure 1: Image processing using FPGAs........................................................................................................5
Figure 2: FSM code for structural design......................................................................................................11
Figure 3: VHDl structural model diagram.....................................................................................................12
Figure 4: Block diagram of washing machine controller..............................................................................14
Figure 5: FSM code for structural design......................................................................................................19
Figure 6: VHDL structural model diagram...................................................................................................20

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Task 01

Objective

The objective of Task 01 is to design and implement a control circuit using pneumatic
components to automate the functions of an auto drilling machine tool. Specifically, this task
aims to achieve seamless operations including material auto loading, drilling, and unloading
using three air cylinders. Through simulation and practical implementation, this objective intends
to enhance understanding and proficiency in pneumatic circuit design, electro-pneumatic
interfacing, and PLC automation integration for industrial applications.

Introduction

The integration of pneumatic systems in industrial automation has revolutionized manufacturing

processes, offering efficient solutions for various applications. In this practical demonstration, the focus
lies on utilizing pneumatic components to construct a control circuit for an auto drilling machine tool.
This circuit employs three air cylinders to automate essential functions such as material loading, drilling,
and unloading.

The setup encompasses a range of pneumatic equipment, including double-acting and single-acting air
cylinders, directional control valves, flow-control valves, and manual valves. Through meticulous
assembly and configuration as outlined in the procedure, the circuit is designed to facilitate sequential
operations with precision and reliability.

By adhering to the provided steps, the pneumatic circuit is constructed on a designated workbench,
ensuring proper positioning and alignment of components. Subsequently, adjustments are made to
regulate air pressure and flow control, crucial for optimal performance.

Upon activation of the control sequence using pushbutton and manual valves, the behavior of the
cylinders is observed, simulating material loading, drilling, and unloading actions. This practical exercise
not only serves as a hands-on learning experience but also underscores the significance of pneumatic
systems in enhancing industrial automation efficiency.

Through this practical demonstration, participants gain valuable insights into the design and
implementation of pneumatic circuits for automated manufacturing processes, laying a foundation for
further exploration and application of pneumatic technology in diverse industrial settings.

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Software analysis

The circuit design was simulated using fluidsim software, providing a virtual environment to
visualize the behavior of pneumatic components and validate the intended control sequence. The
simulation enables us to understand the dynamics of pneumatic systems and troubleshoot
potential issues in a safe and controlled manner.

Pneumatic circuit 1

Figure 1: Pneumatic circuit 1 Fluidsim simulations

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Pneumatic circuit 2

Figure 2: Pneumatic circuit 2 Fluidsim simulations

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During the simulation of the pneumatic circuit provided in Task 01 using FluidSIM software, several
observations were made regarding the behavior and functionality of the system:

 Sequential Cylinder Operation: The simulation accurately replicated the sequential operation of the
three air cylinders as intended by the pneumatic circuit. When the pushbutton valve was pressed and
released, each cylinder performed its designated function in the desired order of material loading,
drilling, and unloading. This sequential operation is critical for automating industrial processes
efficiently.
 Directional Control: The directional control valves (5/2-Way and 3/2-Way) functioned effectively,
allowing precise control over the direction of movement for each air cylinder. As per the circuit
design, the cylinders extended and retracted in the correct sequence to execute the assigned tasks
accurately.
 Flow Control: The simulation demonstrated the role of flow control valves in regulating the speed of
cylinder movement. By adjusting these valves, the speed of cylinder extension and retraction could
be controlled according to the specific requirements of the application. This ensures smooth and
controlled operation of the system.
 Pressure Regulation: The simulation accurately represented the adjustment of the regulator to 5
kg/cm² and the subsequent application of compressed air to the circuit via the air service unit. This
regulated pressure supply is essential for maintaining consistent and reliable performance of the
pneumatic components throughout the operation.
 Safety Measures: The simulation highlighted the importance of safety measures such as the
installation of unidirectional roller valves at strategic positions along the cylinder strokes. These
valves prevent potential hazards such as over-extension or over-retraction of the cylinders, ensuring
the safety of both the equipment and the operators involved.

Overall, the simulation of the pneumatic circuit provided valuable insights into its functionality and
effectiveness in performing material loading and drilling operations using three air cylinders. It
showcased the practical utility of pneumatic systems in industrial automation, emphasizing their ability to
enhance efficiency and productivity in manufacturing processes.

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Practical observations

Pneumatic circuit 1

Pneumatic circuit 2

During the implementation of the pneumatic circuit outlined in Task 01, several practical observations
were made in the laboratory setting:

 Assembly and Installation: Assembling the pneumatic circuit on the working board required careful
attention to detail, ensuring all components were properly connected according to the provided

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 schematic Figure 1:1 and Figure 1:2. Special care was taken to install the unidirectional roller valves
at specific positions along the stroke of the air cylinders to facilitate smooth and controlled
movement.
 Regulator Adjustment: Adjusting the regulator to 5 kg/cm² was straightforward, ensuring that the
compressed air supply was appropriately pressurized for optimal performance of the pneumatic
system. This step was crucial for maintaining consistent and reliable operation throughout the
experiment.
 Pressure Leak Detection: Before proceeding with the operation of the circuit, the sliding exhaust
valve in the air service unit was opened to apply compressed air. Any detected pressure leaks were
promptly addressed by closing the valve and verifying the integrity of the circuit connections to
prevent air loss and ensure safe operation.
 Flow Control Valve Adjustment: All flow control valves were opened slightly (2 turns CCW) to allow
for controlled airflow within the system. Adjusting these valves ensured that the speed of cylinder
movement could be regulated according to the desired operational requirements, such as material
loading, drilling, and unloading.
 Manual Valve Positioning: The manual valve was positioned accordingly to control the direction of
airflow and subsequent movement of the cylinders during the experiment. This manual control
allowed for manual override and fine-tuning of the pneumatic system's operation.
 Pushbutton Valve Activation: Activating the pushbutton valve (initiated the sequence of cylinder
movements, simulating the material loading, drilling, and unloading processes. Observing the
movement of the cylinders provided valuable insights into the functionality and performance of the
pneumatic circuit in achieving its intended tasks.
 Repeatable Operation: Repeating the pushbutton valve activation after adjusting the manual valve to
the a position allowed for the observation of consistent and repeatable cylinder movements,
indicating the reliability and consistency of the pneumatic system's operation.

Overall, the practical implementation of the pneumatic circuit provided a hands-on learning experience,
allowing for the observation of real-world behavior and performance characteristics of the system
components. These observations helped reinforce theoretical concepts and provided valuable insights
into pneumatic system design and operation.

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Discussion

1. Circuit Response:
 The pneumatic circuit exhibited the expected response during both software analysis and
practical implementation. Upon activation of the pushbutton valve, the cylinders performed their
designated functions of material loading, drilling, and unloading in the specified sequence.
 The directional control valves accurately directed the airflow to the cylinders, facilitating their
extension and retraction as required by the circuit design.
 Flow control valves effectively regulated the speed of cylinder movement, ensuring smooth and
controlled operation throughout the cycle.
2. Problems Encountered and Solutions:
 Pressure Leaks: One common issue encountered during both software analysis and practical
implementation was pressure leaks. These leaks could occur due to improper connections or
faulty seals in the pneumatic components. The solution involved careful inspection of
connections and components, followed by tightening or replacement of any faulty parts to
prevent air loss and ensure proper functioning.
 Incorrect Valve Positions: Misalignment or incorrect positioning of valves, particularly the manual
valve, could lead to improper airflow direction and malfunctioning of the cylinders. This issue
was resolved by carefully adjusting the valve positions according to the circuit diagram and
ensuring proper alignment with the intended airflow path.
 Inconsistent Cylinder Movement: In some instances, inconsistent cylinder movement was
observed, leading to erratic operation. This problem was often attributed to inadequate pressure
regulation or improper adjustment of flow control valves. Adjustments were made to the
regulator and flow control valves to optimize airflow and ensure consistent cylinder movement.
3. Comparison of Results:
 Software Analysis vs. Practical Implementation: Overall, the results obtained from software
analysis closely matched those observed during practical implementation. Both methods
demonstrated the functionality and performance of the pneumatic circuit in executing material
loading and drilling tasks using the specified sequence of cylinder movements.
 Advantages of Software Analysis: Software analysis offered the advantage of visualizing the
pneumatic circuit's behavior in a simulated environment, allowing for quick testing and
troubleshooting without the need for physical components. It provided a convenient platform for
experimentation and design validation.
 Advantages of Practical Implementation: Practical implementation, on the other hand, provided
a hands-on learning experience, allowing for a deeper understanding of real-world pneumatic
systems and their operational challenges. It offered insights into the physical aspects of
component interaction, pressure regulation, and troubleshooting techniques.

In conclusion, while software analysis and practical implementation each have their advantages, a
combination of both approaches can provide a comprehensive understanding of pneumatic system
design and operation. This integrated approach allows for effective learning and problem-solving in
industrial automation applications.

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Task 02

Objective

The objective of Task 02 is to comprehend the sequential operation of two air cylinders
controlled by single-solenoid valves, complemented by limit switches and an electrical circuit. The
primary aim is to facilitate the execution of a specific sequence denoted as A+B+B-A-. Through
this task, we will gain insights into the coordination of pneumatic and electrical components to
achieve precise and synchronized movements of the cylinders. By mastering this sequence
operation, we will enhance our understanding of industrial automation principles and the
integration of pneumatic systems with electrical control for efficient and reliable manufacturing
processes.

Introduction

In Task 02, we delve into the intricate coordination between pneumatic and electrical systems, exploring
the sequential operations of two air cylinders. This hands-on exercise aims to master the A+B+B-A-
sequence, a fundamental process in industrial automation. By assembling both pneumatic and electrical
circuits as outlined, we embark on an experiential journey into the heart of industrial automation
principles.

With a lineup of essential equipment including double-acting air cylinders, single-solenoid valves,
pushbutton switches, relays, and limit switches, we set the stage for a comprehensive exploration of
synchronized control systems.

Following a meticulous step-by-step procedure, we meticulously assemble the circuits, infusing life into
our setup with compressed air and electrical power. Through the keen observation of the sequential
movements triggered by our pushbutton switches, we witness the precise orchestration of cylinder
extension and retraction, mirroring the prescribed A+B+B-A- sequence.

This practical endeavor not only grants us practical insights into the seamless integration of pneumatic
and electrical systems but also hones our skills in circuit assembly, troubleshooting, and sequential
control logic — indispensable assets in the realm of industrial automation.

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Pneumatic and electrical circuit (1)

Software analysis

Figure 3: Pneumatic and electrical circuit (1) simulations

13
Practical observations

Figure 4: Pneumatic and electrical circuit arrangement

Figure 6: A+ (Cylinder A extended) Figure 5: B+ (Cylinder B extended)

Figure 7: B- (Cylinder B retracted) Figure 8: A- (Cylinder A retracted)

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Pneumatic and electrical circuit (2)

Software Analysis

Figure 9: Pneumatic and electrical circuit (2) simulations

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Practical Observation

Figure 10: Pneumatic and electrical circuit arrangement

Figure 11: B+ (Cylinder B extended)

Figure 12: A+ (Cylinder A extended)

Figure 13: B- (Cylinder B retracted) Figure 14: A- (Cylinder A retracted)

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Pneumatic and electrical circuit (3)

Software Analysis

Figure 15: Pneumatic and electrical circuit (3) simulations

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Practical Observation

Figure 16: Pneumatic and electrical circuit arrangement

Discussion

 Circuit Response:

In simulating and executing the Task 02 circuits, the response observed was generally in accordance with
the intended sequence of operations. Upon activation of the pushbutton switches (PB1, PB3, PB4), the air
cylinders extended and retracted as expected, following the sequence A+B+B-A-. The combination of
pneumatic and electrical components facilitated precise control over the cylinder movements,
demonstrating effective coordination between the two systems.

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 Problems Encountered and Solutions:

During both the simulation in Fluidsim software and the practical experimentation in the lab, some
challenges were encountered. One common issue was potential air leaks in the pneumatic circuits,
leading to inconsistent cylinder movements or failure to complete the desired sequence. This problem
was addressed by thoroughly checking the connections, tightening any loose fittings, and ensuring proper
sealing of components. Additionally, proper adjustment of the regulator and careful monitoring of the air
pressure helped mitigate air leakage issues.

Another challenge involved misalignment or malfunctioning of limit switches, which could disrupt the
sequencing of cylinder movements. This issue was resolved by inspecting and realigning the limit
switches as necessary, ensuring they were properly triggered by the moving parts of the circuit. In some
cases, faulty limit switches were replaced to ensure reliable operation.

 Comparison of Results:

Overall, there was a notable consistency between the results obtained from the software analysis and the
practical experimentation. The simulated circuits in Fluidsim accurately reflected the behavior of the
actual pneumatic and electrical systems in the lab, providing a reliable platform for understanding and
testing the Task 02 sequences. However, certain nuances and real-world factors, such as air pressure
variations and mechanical tolerances, influenced the performance of the circuits during the practical
experimentation. Despite these minor differences, the fundamental principles and functionalities of the
circuits remained consistent between the software analysis and the lab experiments.

In conclusion, both the software analysis and practical experimentation contributed to a comprehensive
understanding of the Task 02 circuits, allowing for the identification and resolution of challenges
encountered during the process. This integrated approach facilitated effective learning and
troubleshooting, enhancing proficiency in pneumatic and electrical control systems.

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Task 03

Objective

The objective of Task 03 is to explore speed and direction control within industrial automation by
combining a step motor with an encoder and utilizing hardware high-speed counters to count the output
pulses. Through a series of structured procedures, participants will gain hands-on experience in
configuring the step motor control circuit, creating ladder diagrams, and observing the motor's behavior
under various input configurations.

Introduction

Task 03 delves into the realm of industrial automation, focusing on the precise control of speed and
direction using a step motor and encoder combination. This practical exercise aims to provide us with a
comprehensive understanding of motion control principles and the integration of hardware and software
components in achieving desired motor performance.

Equipped with a PLC Trainer, personal computer, and Step 7 software, participants embark on a journey
to explore the intricacies of step motor control. The procedure involves meticulous steps, from circuit
configuration to ladder diagram creation, culminating in the observation of the step motor's operation
under different input settings.

As we progress through the tasks, they are guided to observe safety precautions and exercise caution
when interacting with rotating parts. Through iterative experimentation, we gain insights into the
dynamic interplay between direction, steps, and speed settings, paving the way for enhanced efficiency
and precision in industrial motion control applications.

By immersing themselves in this hands-on experience, we not only deepen our understanding of motion
control concepts but also develop critical skills in circuit configuration, ladder diagram programming, and
project implementation using PLC systems.

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Software Analysis

Ladder program

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Practical observations
In this practical, we'll be utilizing a PLC trainer unit.

Figure 17: PLC trainer unit

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