K. J.

Somaiya College of Engineering, Mumbai-77

(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

Introduction to Automation and

Course Name: Semester: VI
Mechatronics
Date of Performance: 29/01/2024 Batch No: A3
Faculty Name: Prof. Sandeep Hanumante Roll No: 16010222804
Faculty Sign & Date: Grade/Marks:

Experiment No: 3
Title: Real Time Pressure monitoring of Automation system using S7-1200 PLC

Aim and Objective of the Experiment:

1. Obtain the Real Time Pressure monitoring of Automation system using S7-1200 PLC

COs to be achieved:

CO2. Design PLC based Mechatronics systems

Theory:

Circuit Diagram/ Ladder diagram: Real-time monitoring of pressure using electro pneumatics and
PLC (Programmable Logic Controller) involves integrating sensors, pneumatic components, and a
PLC system to continuously measure and control pressure in an industrial or automation setting.
Here's a generalized overview of how this process might work:

Pressure Sensors:

Install pressure sensors at relevant points in the pneumatic system. These sensors convert pneumatic
pressure into electrical signals that can be interpreted by the PLC.

Sensor Interface:

Connect the pressure sensors to the input modules of the PLC. PLCs have input modules that
interface with various sensors and actuators.

PLC Programming:

Develop a PLC program using ladder logic or other programming languages supported by the PLC.
The program should include logic for reading pressure sensor inputs, processing the data, and
generating control signals based on predefined conditions.

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

Pneumatic Diagram

Sensor symbols

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

Stepwise-Procedure:

1) Make the pneumatic connection with double acting cylinder, 5/2-way single solenoid
valve, flow control valves and cylinder end position switches

2) Test the pneumatic connection

3) Write the ladder program in TIA portal for the continuous cyclic operation of double
acting cylinder.

4) Logic: The cylinder starts from its retracted end position with a delay of 1sec after
pressing the start switch. The cylinder should retract with a delay of 3sec after reaching
its extended position. The operation should continue until the stop switch is pressed.

5) Test the cyclic operation of cylinder using PLC

6) Connect the pressure sensor to measure the actual pneumatic pressure in the pneumatic
setup

7) Make the wiring of all sensors and valve with the S7 1200 PLC

8) Read the real time value of actual pneumatic pressure in TIA portal using NORM_X and
SCALE_X instruction

Observation Table:

PLC output:

Paste the screenshot of the program, photo of the pneumatic setup

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

Post Lab Subjective/Objective type Questions:

1. What is the specification of pressure sensor used in the experiment?

➔ Pressure sensor is used in measuring the input, while cylinder is retracting and while cylinder
is extracting.

2. What are the different types of pressure sensors available? Explain based on its construction
and principle
→ Pressure sensors come in various types based on their construction and sensing principles. Here are
some common types:

1. Strain Gauge Pressure Sensors:

- Construction: Consists of a thin metal diaphragm with a strain gauge bonded to it. As pressure
changes, the diaphragm deforms, causing strain in the gauge.
- Principle: Measures the strain in the gauge, which is proportional to the applied pressure.

2. Piezoelectric Pressure Sensors:

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

- Construction: Utilizes a piezoelectric crystal. When pressure is applied, the crystal generates a voltage
proportional to the pressure.
- Principle: Measures the electrical charge produced by the piezoelectric material in response to
pressure changes.

3. Capacitive Pressure Sensors:

- Construction: Consists of two parallel plates with a diaphragm between them. The capacitance
changes with diaphragm deflection due to pressure.
- Principle: Measures the change in capacitance as a function of pressure.

4. Resonant Solid-State Pressure Sensors:

- Construction: Utilizes a resonating element (e.g., quartz crystal). Pressure-induced changes in the
resonant frequency are detected.
- Principle: Measures the shift in resonant frequency caused by pressure variations.

5. Optical Pressure Sensors:

- Construction: Involves an optical cavity where pressure-induced changes in the cavity length or
refractive index are detected.
- Principle: Measures variations in light properties caused by pressure changes.

6. Mechanical Deflection Pressure Sensors:

- Construction: Employs a flexible diaphragm or bellows that deflects under pressure, mechanically
displacing a lever or piston.
- Principle: Converts mechanical displacement into an electrical signal.

7. Microelectromechanical Systems (MEMS) Pressure Sensors:

- Construction: Miniaturized sensors fabricated using microfabrication techniques.
- Principle: Various principles, such as piezoresistive or capacitive, depending on the specific design.

8. Differential Pressure Sensors:

- Construction: Consists of two pressure-sensitive elements. Measures the difference in pressure
between two points.
- Principle Utilizes various sensing principles, such as strain gauges or capacitors.

The choice of pressure sensor depends on factors like the application requirements, pressure range,
accuracy, and environmental conditions. Each type has its advantages and limitations, making it essential
to select the most suitable sensor for a specific application.

IAM Semester: VI Academic Year: 2023-24

Roll No:
 K. J. Somaiya College of Engineering, Mumbai-77
(A Constituent College of Somaiya Vidyavihar University)
Department of Electronics Engineering

Conclusion:

In conclusion, the real-time pressure monitoring of an automation system using the S7-1200 PLC
involves integrating pressure sensors with the PLC's input modules, programming the PLC to read
and process sensor data, and implementing control logic to manage pressure conditions. The choice
of pressure sensor should align with application requirements. This approach ensures efficient and
accurate pressure control in industrial settings, leveraging the capabilities of the S7-1200 PLC for
seamless automation.

Signature of faculty in-charge with Date:

IAM Semester: VI Academic Year: 2023-24

Roll No: