Measurements and Automation Laboratory MESBL601

LAB MANUAL
Of

Measurement and Automation

Academic Year 2022-23

Semester VI
Department Mechanical Engineering
Syllabus Revision Year 2023
Last Update On 4 January 2023

RIZVI EDUCATION SOCIETY’s

Rizvi College of Engineering

Off Carter Road, Bandra West, Mumbai- 400050
Measurements and Automation Laboratory MESBL601

⮚ Program Objectives
PO1 Engineering knowledge: Apply the knowledge of mathematics, science,
engineering fundamentals, and an engineering specialization to the solution of
complex engineering problems.
PO2 Problem analysis: Identify, formulate, review research literature, and analyse
complex engineering problems reaching substantiated conclusions using first
principles of mathematics, natural sciences, and engineering sciences.
PO3 Design/development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified
needs with appropriate consideration for the public health and safety, and the
cultural, societal, and environmental considerations.
PO4 Conduct investigations of complex problems: Use research-based knowledge
and research methods including design of experiments, analysis and interpretation
of data, and synthesis of the information to provide valid conclusions.
PO5 Modern tool usage: Create, select, and apply appropriate techniques, resources,
and modern engineering and IT tools including prediction and modeling to
complex engineering activities with an understanding of the limitations.
PO6 The engineer and society: Apply reasoning informed by the contextual
knowledge to assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional engineering practice.
PO7 Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.
PO8 Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
PO9 Individual and team work: Function effectively as an individual, and as a
member or leader in diverse teams, and in multidisciplinary settings.
PO10 Communication: Communicate effectively on complex engineering activities
with the engineering community and with society at large, such as, being able to
comprehend and write effective reports and design documentation, make effective
presentations, and give and receive clear instructions.
PO11 Project management and finance: Demonstrate knowledge and understanding
of the engineering and management principles and apply these to one’s own
work, as a member and leader in a team, to manage projects and in
multidisciplinary environments.
PO12 Life-long learning: Recognize the need for, and have the preparation and ability
to engage in independent and life-long learning in the broadest context of
technological change.
Measurements and Automation Laboratory MESBL601

⮚ Program Specific Objectives

PSO1 Professional & Problem-Solving Skills: The ability to understand and analyse
the problem and develop algorithms & programs for the same, with efficient
design and varying complexity using lifelong learning and principles of computer
engineering in the fields of multimedia, web design, data management &
analytics, networking & security, machine learning & artificial intelligence etc. To
apply standard practices and strategies in software & hardware project
development using open-source programming environments to deliver a quality
product for business success.
PSO2 Successful Career and Entrepreneurship: Ability to acquire logical thinking
capability and problem solving skill in computer engineering as well as diverse
fields to achieve better overall prospects of the employment or to be a successful
entrepreneur and work as an individual and as well as in a team to achieve
solution within the budget and to communicate effectively with the engineering
community and the society and also to have a zest for higher studies.

⮚ Course Outcomes
CO1 Apply inspection gauge to check or measure surface parameters
CO2 Measure surface parameters using precision measurement tools and equipment
CO3 Measure different mechanical parameters using sensors
CO4 Analyze the response of a control system
CO5 Demonstrate the use of automated controls using pneumatic and hydraulic systems
CO6 Implement program on PLC system and demonstrate its application
Measurements and Automation Laboratory MESBL601

INDEX
Sr. Name of Experiment Group Page No.
No.
1 To measure length, height and diameter Metrology 7
of object using vernier caliper and
micrometer

2 To measure the Major, Minor and Effective Metrology 11

diameter of external parallel screw threads
using Floating Carriage Micrometer.

3 Flatness measurement by Autocollimator / Metrology 16

Interferometry method

4 To study the operation of linear 21

variable displacement transducer Measurements
(LVDT)

5 To study the load/weight measurement using Measurements 26

strain gauge

6 Design and implementation of PID control Measurements 30

strategy for Spring Mass Damper system

7 Study of basic gates using Ladder logic Automation 34

diagrams on PLC

8 Simulation of basic hydraulic and pneumatic Automation 37

circuits

9 Visualisation of DH parameters using Automation 41

Roboanalyser

10 Estimation of accuracy and precision of a Measurements 43

measurement system by using digital
tachometer
 Measurements and Automation Laboratory MESBL601

Attainment of PO’s & PSO’s

Sr. Name of Experiment PO’s PSO’s CO
No. Attained Attained Mapping
1 To measure length, height and diameter of PO1, PSO1,PSO2 CO1
object using vernier caliper and PO2,PO3,PO5
micrometer

2 To measure the Major, Minor and Effective PO1, PSO1,PSO2 CO1

diameter of external parallel screw threads PO2,PO3,PO4
using Floating Carriage Micrometer.

3 Flatness measurement by Autocollimator / PO1, PSO1,PSO2 CO1

Interferometry method PO2,PO3,PO4

4 To study the operation of linear PO1,PO2,PO3 PSO1,PSO2

variable displacement transducer ,PO4 CO
(LVDT) 2,C
O3

5 To study the load/weight measurement using PO3,PO4,PO6 PSO1,PSO2 CO3

strain gauge

6 Design and implementation of PID control PO3,PO4,PO6 PSO1,PSO2 CO4

strategy for Spring Mass Damper system

7 Study of basic gates using Ladder logic PO3,PO4,PO6 PSO1,PSO2 CO6

diagrams on PLC

8 Simulation of basic hydraulic and pneumatic PO3,PO4,PO6 PSO1,PSO2 CO5

circuits

9 Visualisation of DH parameters using PO3,PO4,PO6 PSO1,PSO2 CO6

Roboanalyser
10 Estimation of accuracy and precision of a PO3, PO4, PSO1, PSO2 CO2, CO3
measurement system by using digital PO6
tachometer

.
Measurements and Automation Laboratory MESBL601

⮚ Maintain Discipline in lab.

⮚ Use the instruments as per the instructions

of the Staff.

⮚ Take care of your belongings.

⮚ Use of Mobile phones is strictly prohibited

in lab.

⮚ Eating is strictly prohibited in lab.

⮚ Handle all instruments with proper care.

Measurements and Automation Laboratory MESBL601

⮚ Maintain cleanliness inside lab.

⮚ Keep Chairs in proper place before leaving

the lab.

⮚ Switch off fans and lights when not in use.

⮚ Follow all instructions given by staff.

Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601

Experiment No. 1
AIM: To measure Length, Height and Diameter of given objects by using
Vernier Calipers & Micrometer.

APPARATUS: Vernier Calipers, Micrometer & Objects.

THEORY:

Vernier Calipers
Pierre Vernier, a Frenchman, devised principle of Vernier for precise
measurements in 1631. The Vernier Caliper consists of two scale one is fixed mad the other is
movable. The movable scale, called Vernier Scale. The fixed scale is calibrated on L-shape
frame and caries a fixed jaw. The Vernier scale slides over the main scale and carries over the
movable jaw. Also an arrangement is provided to lock the sliding scale on fixed main scale.

Principle of Vernier Caliper:

The principle of Vernier is based on the difference between two scales or divisions, which are
nearly, but not quite alike for obtaining small difference. It enables to enhance the accuracy
of measurement.

Least Count:
Least count is the minimum distance which can be measured accurately by the Instrument.
Least Count of Vernier Caliper is the difference between the value of main scale division and
Vernier Scale Division.

Thus Least Count =

(Value of Smallest Division on Main Scale)- (Value of Smallest Division on Vernier Scale)
= 1-49/50
= 0.02 mm.
(or)
Least Count =
(Value of Minimum Division on the Main Scale)/ (Number of Division on Vernier Scale )
= 1/50
= 0.02 mm
Measurements and Automation Laboratory MESBL601

Vernier Calipers

PROCEDURE:
Measurements and Automation Laboratory MESBL601

The given component is fixed between the jaws firmly, i.e... In between
fixed jaw and movable jaw. The reading is to be noted down

Procedure for taking the Reading:

1. After closing the jaws on the work surface, take the readings from the main as well as
Vernier Scale. To obtain the reading , the number of divisions on the main scale is first read
off. ‘Ihe Vernier Scale is then examined to determined which of its division coincide or most
coincident with a division on the main scale.
2. Before using the instrument should be checked by zero error. The zero line on Vernier
Scale should coincide with zero on the main scale.
3. Then take the reading in mm on main scale to the left of zero on sliding scale.
4. Now Count the no. of divisions on Vernier Scale from zero to a line which exactly
Coincides with any line on the main scale.

Thus total reading =

[ Main scale reading ] + [No. of divisions with a division on Main Scale ] X Least Count.
( OR )
TR = MSR + VC X LC

5. Take the reading for 4 times.

SLNO. MSR VC TR

Average

The length / dia / height =

Average of the readings = ( Trial 1+2+3+4) / 4= ------------------ mm

Micrometer
The micrometer has an accurate screw having about 10 to 20 threads/cm and revolves in
a fixed nut. The end of the screw is one tip and the other is constructed by a stationary anvil.

LEAST COUNT = Pitch scale division / Number of threads

Pitch scale division = Distance moved / number of rotation
Measurements and Automation Laboratory MESBL601

Uses:
• Outside micrometer is used to measure the diameter of solid cylinder.
• Inside micrometer is used to measure the internal diameters of hollow cylinders
and spheres.

Micrometer
SLNO. MSR VC TR

Average

RESULT & CONCLUSION:

Length / Diameter / Height = ----------------------- mm

Sr No
1
2

PRE- LAB QUESTION:

1] Why least count is required?
2] Uses of Vernier and micrometer at Junior college level.

POST LAB QUESTION:

1] In Quality Control tool uses of micron level linear measurement.
Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601

Experiment No. 2
AIM: To measure the Major, Minor and Effective diameter of external
parallel screw threads using Floating Carriage Micrometer.
APPARATUS: Floating Carriage Micrometer, Wires, Specimen, Master, Hooks etc.

THEORY:
In order to ensure the manufacture of screw threads to the specified
limits laid down in the appropriate standard it is essential to provide some means of
inspecting the final product. For measurement of internal threads thread plug gauge is used
and to check these plug gauges Floating Carriage Micrometer is used for measuring Major,
Minor and Effective diameter.

FLOATING CARRIAGE MEASURING MACHINE:

DEFINITIONS RELATED TO PARALLEL SCREW THREADS

Major Diameter: The diameter of an imaginary cylinder (termed the major cylinder) which
Just embraces the crests of the external thread or the roots of an internal thread.
Measurements and Automation Laboratory MESBL601

Minor Diameter: The diameter of an imaginary cylinder (termed the minor cylinder) which
just embraces the roots of an external thread or the crests of an internal thread.

Simple effective(or Pitch) Diameter: The diameter of an imaginary cylinder(termed the

pitch cylinder ) which intersects the surface of the thread in such manner that the intercept on
an generator of the cylinder between the points where it meets the opposite flanks of the
thread groove is equal to one half the basic of the thread.
PROCEDURE:
Two Wire Method:
The effective diameter of a screw thread may be ascertained by placing two wires or rods of
identical diameter between the flanks of the thread, and measuring the distance over the
outside of these wires. The effective diameter is then calculated as
E=T+P
Where T= Dimension under the wires
=M—2d
M=dimension over the wires, d= diameter of each wire

The wires used are made of hardened steel to sustain the wear and tear in use. These are
given a high degree of accuracy and finish by lapping to suit different pitches. Dimension T
can also be determined by placing wires over a standard cylinder of diameter greater than the
diameter under the wires and noting the reading R1 and then taking reading with over the
gauge, say R2. Then T=S - (R1 - R2).
P=It is a value which depends upon the diameter of wire and pitch of the thread.
If P= pitch of the thread, then
P= 0.9605p−1.1657d (for Whitworth thread).
P= 0.866p—d (for metric thread).
to give the effective diameter. The expression for
the value of P in terms of p (pitch),
d(diameter of wire) and x (thread angle) can be derived as follows:
In Fig. since BC lies on the effective diameter line
BC= ½ pitch=½ p

OP=dx2 2

PA=d2cosecx2-1
Measurements and Automation Laboratory MESBL601

PQ=QC cotX2 = P4cot X2

AQ=PQ−AP= (p cot X2)4 – dcosecx2-12
AQ is half the value of P
.’. P value=2(AQ) =p∕2 cot( x∕2) −d (cosec(x∕2)−1)
Two wire methods can be carried out only on the diameter measuring machine described for
measuring the minor diameter, because alignment is not possible by two wires and can be
provided only by the floating carriage machine..
RESULT & CONCLUSION: Effective diameter screw thread

Sr Outpu
No t
1
2

PRE LAB QUESTION:

1] Explain external thread terminology.

POST LAB QUESTION:

1] Working principle of floating carriage micrometre.
Measurements and Automation Laboratory MESBL601

Experiment No. 3
AIM: Flatness measurement by Autocollimator / Interferometry method.

APPARATUS: Various optical flat surface Objects.

THEORY:
Measurements and Automation Laboratory MESBL601

Interferometry method applied for flatness testing

Introduction
The easiest and best way to test the flatness of a flat lapped or polished surface is with
an optical flat. Such surfaces are found on micrometers, measuring machines, gage blocks,
snap gages, ring seals, valve seats and precision flat lapped parts. The surface must be
sufficiently finished to reflect light; ordinary ground surfaces are too irregular to show light
wave interference bands.
However, unless the material is extremely soft or porous, a few rubs on a flat lap will smooth
off the top of the grinding ridges and enable bands to be seen in monochromatic light.

WORKING:

The Phenomenon of Interference Bands

When there is an extremely thin wedge between two flat surfaces a series of
interference bands or fringes appear. The bands occur at right angles to the slope of the
wedge. Monochromatic light sources provide a highly diffused light of this wave length.
Dark bands occur because light reflections from the two surfaces which form the wedge
interfere with each other where the thickness of the wedge is one half or multiples of one half
the wave length of the light. The parallel bands thus form at zones where the wedge thickness
changes by 1/2 wave length. Between each pair of dark bands the reflections reinforce each
other and produce bright bands. When viewed perpendicularly in light, the dark bends are
located where the air wedge thickness changes by equal intervals.
Measurements and Automation Laboratory MESBL601

Procedure for Making Flatness Tests

Remove the dust from the surface of the work and the optical flat with a camel hair brush.
Burrs and nicks should be removed by using an appropriate deburring stone. Place the work
under the monochromatic light. Place a clean piece of optical tissue (or any other clean
paper) over the work piece. Place the optical flat on top of the paper; the optical flat may be
on the bottom in cases where a reflex light is used.
Hold the optical flat steady with one hand and draw the paper out from between the work
piece and the optical flat with the other hand. If bands do not appear, repeat this procedure.
This will reduce the possibility of scratching the optical flat and the work piece--as in
scrubbing both pieces together. The bands should be viewed from a distance at least 10 times
the diameter of the optical flat and with the line of vision as nearly perpendicular to the flat
as possible. If the bands are straight, parallel and evenly spaced, the surface is flat. If the
bands are curved or are unevenly spaced, the surface is not flat.

Amount of Flatness Error

The amount that the bands curve, with reference to the distance between them, indicates the
amount of flatness error.

OBSERVATIONS:

Fringe pattern in concave and convex surfaces

Measurements and Automation Laboratory MESBL601

Fringe pattern in curved, concave and convex surfaces

● a, b –Flat surfaces
● c- Spherical and Concave
● d- Curved more in one direction
● e- Smooth cylindrical surface
● f- ridge or valley in the middle

Different Fringe patterns

OBSEVATION TABLE:

Sample No No of fringes Observed Flatness Error ( nƛ/2 )

RESULT & CONCLUSION:

Using monochromatic light and optical flat we have measured

flatness error.
Measurements and Automation Laboratory MESBL601

PRE LAB QUESTIONS:

1] Explain principle of interference
2] what is monochromatic light.

POST LAB QUESTION:

1] Explain interferometer limitations.
Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601

Experiment No. 4
Aim: To study the operation of linear variable displacement transducer (LVDT).

Apparatus: Lab LVDT trainer kit, connection wires, etc.

Theory: The term LVDT stands for the linear variable differential transformer. It is
the most widely used inductive transducer that covert the linear motion into
the electrical signals. They are very accurate inductive transducers as
compared to other inductive transducers.

Construction of LVDT
Main Features of Construction are as,
⮚ The transformer consists of a primary winding P and two secondary winding S1 and
S2 wound on a cylindrical former (which is hollow in nature and will contain core).
⮚ Both the secondary windings have equal number of turns and are identically placed
on the either side of primary winding
⮚ The primary winding is connected to an AC source which produces a flux in the air
gap and voltages are induced in secondary windings the frequency of a.c. applied to
primary winding may be between 50 Hz to 20 kHz.
⮚ A movable soft iron core is placed inside the former and displacement to be measured
is connected to the iron core which made up of nickel iron alloy which is slotted
longitudinally to reduce eddy current losses.
⮚ The iron core is generally of high permeability which helps in reducing harmonics
and high sensitivity of LVDT.
⮚ The LVDT is placed inside a stainless steel housing because it will provide
electrostatic and electromagnetic shielding.
⮚ The both the secondary windings are connected in such a way that resulted output is
the difference of the voltages of two windings.

Figure Cross-Sectional View of LVDT Core and Windings

Principle of Operation and Working

As the primary is connected to an AC source so alternating current and voltages are
produced in the secondary of the LVDT. The output in secondary S1 is e1 and in the
secondary S2 is e2. So the differential output is, eout = e1 - e2 This equation explains the
principle of Operation of LVDT.
Measurements and Automation Laboratory MESBL601

Now three cases arise according to the locations of core which explains the working of
LVDT are discussed below as,

1. CASE I When the core is at null position (for no displacement) When the core is at
null position then the flux linking with both the secondary windings is equal so the induced
emf is equal in both the windings. So for no displacement the value of output eout is zero as
e1 and e2 both are equal. So it shows that no displacement took place.

2. CASE II When the core is moved to upward of null position (For displacement to
the upward of reference point) In the this case the flux linking with secondary winding S1
is more as compared to flux linking with S2. Due to this e1 will be more as that of e2. Due
to this output voltage eout is positive.

3. CASE III When the core is moved to downward of Null position (for displacement
to the downward of reference point) In this case magnitude of e2 will be more as that of e1.
Due to this output eout will be negative and shows the output to downward of reference
point.

Output VS Core Displacement

A linear curve shows that output voltage varies linearly with displacement of core.

● The amount of change in voltage either negative or positive is

proportional to the amount of movement of core and indicates amount
of linear motion.
● By noting the output voltage increasing or decreasing the direction of
motion can be determined
Measurements and Automation Laboratory MESBL601

● The output voltage of an LVDT is linear function of core displacement.

Ideally the output voltage at null position should be equal to zero. However, in actual practice
there exist a small voltage at the null position. This may be on account of presence of
harmonies in the input supply voltage and also due to harmonics produced in the output
voltage on account of use iron core. There may be either an incomplete magnetic or electrical
balance or both which result in a finite residual voltage is generally less than 1% of the
maximum output voltage in the linear range. Other cause of residual voltage are stray
magnetic field and temperature effects.

Observation table

Sr No. Displacement in mm Display reading in mV

5
Measurements and Automation Laboratory MESBL601

10

Procedure:
1) Connect the primary winding to the a.c. excitation source.
2) Connect the secondary winding.
3) Adjust the magnetic core in the center position so that the display reads
minimum (practically it is not possible to get zero reading due to its fixed
losses in transformer winding coupling is called residual emf and position
of the coil is called null position.) Adjust the both amplitude and
frequency knob so get null position and sufficient span in both minus and
plus directions, axially.
4) Manually displace the knob in plus direction (from null position) every
1mm (or 2 mm) and note down the display reading in mV.
5) Repeat the procedure for minus direction and note down the mV value.
6) Translate the readings.
7) Plot the graph for displacement verses mV.

Conclusion: From experiment and observations, it is conclude that magnitude of

displacement is linearly proportional to the mV output.

Questions

1) What is the principle of operation of LVDT? How can it be used as a

secondary transducer
2) What is the resolution of the instrument?
3) State few practical applications of LVDT
Measurements and Automation Laboratory MESBL601

Experiment No. 5
Aim: To study the weight measurement using strain gauge.
1) To calculate voltage output.
2) To calculate weight of strain gauge.
Apparatus: Strain gauge load cell Trainer Kit, Weight box with assorted weights (2gm,
5gms, 20 gms, 25 gms, 50 gms, 100 gms, 200 gms), DMM.
Measurements and Automation Laboratory MESBL601

Theory: Strain gauge is a passive resistive transducer based on the principle of

conversion of mechanical displacement or strain to resistance change.
Strain is defined as the change in length (ΔL) per unit length (L) of a given
material. (ΔL /L) is expressed in micro strains. The stress ( due to applied
weight ) versus the strain (ΔL/L ) is a linear curve, when stress is below
elastic limits and becomes nonlinear beyond the limit.
The Gauge Factor of a Strain Gauge is S = [ ]. S is also known as Sensitivity.

Where,
GF= 1 + ν
ν = poisons ratio
= σ/E
σ= stress
e= Young’s modulus

For a cantilever beam with point load at its end;

M=Wx
y=t/2
I=bt3/12

σ = My/I =
ε = σ/E
From equivalent it’s apparent that when R1/R2 the voltage output V will be
zero under this bridge. Any change in resistance in or and OR bridge will
result in nob zero output voltage.
By using two strain gauges in active and other is configuring where 1 gauge is
active and other placed transverse to applied load. Therefore the strain has
effect on the second gauge called the dummy gauge.
Now use calibrate the weight equation so we get weight of cd and convert it to
Newton.
W=
Add the standard weight (W) to the hanger and hang it from the force end of
the strain gauge so total force of strain gauge is R= W1+W4.

Observation Table

Table I : ( on un-ruled page )

S.No: Weight ( gms ) Display reading ( µS )

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10

Procedure: The experiment procedure consists of the following steps:

a.i. Connect the 230 V ac, 50 Hz mains cord to the Mains supply.
a.ii. Switch on the Mains supply.
a.iii. Adjust the bridge balance knob so that the display reads 0 (or
minimum).
a.iv. Apply different denominations of weights (in combinations) and for
weight (combination) note down the display value.
a.v. Tabulate the readings and plot the graph ( weight ( gms ) vs
display reading (µS ).

Conclusion : The performance characteristics of strain gauge element has been studied.

Questions:

1) How is the principle of operation of the strain gauge?

2) What is the principle of measurement of strain gauge?
3) Explain the measurement circuit in a strain gauge

Maximum Strain: 0 – 1999 Micro Strain. (Draw on un-ruled page).

Measurements and Automation Laboratory MESBL601

Graph: ( draw on a graph sheet )

Measurements and Automation Laboratory MESBL601

Experiment No. 6
Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601

Questions

1) What is the effect of P, PD and PI control on the performance parameters?

2) What is the steady state error in PID control?

Experiment No. 7
Measurements and Automation Laboratory MESBL601

Study Of Basic Gates Using Ladder Logic Diagrams on PLC

Aim: To study the basic gates (AND, OR, NOT) using ladder logic program on PLC.

Theory:

Basic gate logic is used in various systems (electronics, electrical, hydraulically, pneumatic
etc.) in the field of mechatronics gate circuit are used to operate solenoid, motor and pump,
relay actuator and controller.

AND & OR gate have two or more input and single output. Input may be electrical signal/
electronic signal corresponding is 0 and 1 (0 volt, 5 volt, for example) or switch operation
corresponding is 0 and 1. (Open and close position) for switches valve position etc. the basic
symbol shown in the adjoining figure. NOT gate row single input and single output, when it’s
its input is 0, the output will be 1and vice versa. For switches etc, input may be 0 (open) or 1
(close) ladder logic diagram is a graphical representation of signal flow and circuit
operations. It has two supply lines (phase and neutral or dc supply, and ground or + and –
symbol where purely pneumatic or purely hydraulic).

All the operating circuit components are connected between the above two lines, so that the
circuit operation can be easly trace and studied without going through complex circuit
diagrams.

Various gates their truth table ladder logic diagram instruction list are shown the adjoining
figure. These are applicable is ELECTRICAL, ELECTRONICS, PNEUMATIC
HYDRAULIC CIRCUIT. For simplicity two input AND & OR GATE are shown. For
electrical, electronic circuit it may be switches integral circuit, for pneumatic systems it may
be valve with actuator
Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601
Measurements and Automation Laboratory MESBL601

HYDRAULIC CIRCUITS:

Hydraulic circuits are used in high power and high load applications such as earth
moving equipment. The pressure used in industrial applications is about 140 bar or 14
MPa.

For more precise control, valves actuated by electrical signals are employed, instead
of manually operated valves.

Components:
Basic hydraulic power system is as shown in the Fig. H1 and consists of the
components described.
Measurements and Automation Laboratory MESBL601

Fig. H1: Typical Hydraulic system with linear actuator

1. Oil reservoir which has suction lines to pump and other lines of system returning
oil to tank
2. Electric motor – (or engine)
3. Positive displacement Pump- like vane pump, gear pump or axial piston pump
4. A relief valve to limit the maximum pressure developed to
5. Directional control valve (DC Valve) which controls direction of high pressure oil
to actuator, and to tank from actuator.
6. Actuator – a hydraulic cylinder for linear motion of load (connected to piston
rod), or a hydraulic motor when load actuation is rotation.
7. Filter:Oil filter is provided either in pump suction or return line.
8. Pressure gauge to indicate the pressure developed by the pump.
9. Flow lines – flexible hoses or rigid pipes connecting various system components.

Schematic (Symbolic)Representation of a 3-position, 4-port valve.

A 3-position 4-port Directional Control valve is schematically shown in Fig.H2.

Ports:Thevalve has port P connected to hydraulic pump; Port T is connected to the
tank. Two ports A & B areconnected to either side of the hydraulic cylinder.
Thus there are 4 ports.

Fig.H2
Spool positions: The spool operated by a lever (for manual operation) takes 3
positions, which are shown in 3 blocks in Fig.H2.
Flow directions in the three positions are explained as per
Fig.H3. In Position 2, the neutral position, all ports are
blocked.
Hence no flow from supply port to any
port, and no movement of actuator piston.
Moving the spool to left end, ie Position 1, means Thatleft block is operative, where
connections P to A and B to T are established.
Measurements and Automation Laboratory MESBL601

Fig. H3

Similarly Position 3 of spool means, P - B and A -T are connected.

Thus there are 4 ports and 3 valve positions. Hence the valve is called
3-position, 4- port Directional Control Valve.
(In the experiment, there are 2 tank ports, and it is a 3-position, 5 port DC valve).

Experiment 1: Control of a Double Acting Cylinder:

A double acting cylinder is one in which the piston rod can be moved forward or
backwards by supplying high pressure fluid to piston or rod side chamber of the
actuator. The fluid flow to the required side is controlled by movement of the spool
of the DC valve (or a lever actuating the spool)
Operation:
The circuit connection is as shown in Fig.H4.
In Position 2, the supply oil is blocked in the valve, as the two ports A&B connected
to the actuator are blocked.

Fig.H4
In Position 1, P is connected to A port connected to the piston side of actuator. Hence
the piston is pushed to right. The oil trapped in the rod-side chamber is connected to
the Tank (or reservoir) and is free to flow to tank.
In postion 3, Pressure line P is connected to port – B which is connected to rod side
and pushes the piston to left. The oil in the piston-side chamber is connected to tank
port of the valve and flows to tank.
Note: The pump develops as much pressure as is required to move the
load.
Procedure:
1. Set relief valve pressure setting to zero.
2. Connect various hoses from supply and tank to the valve. Connect A & B ports to
either side of actuator
3. Turn motor on.
4. Keep the valve in neutral position (Position2)
5. Increase relief valve pressure setting to 5 bar, observing the pressure gauge.
Measurements and Automation Laboratory MESBL601

Now the valve spool is moved to left or right to observe the movement of the piston
rod in forward or reverse directions.

PNEUMATIC CIRCUITS
Pneumatic circuits are used in relatively low load applications. These are usually
employed in industrial automation where pneumatic cylinder operations follow as per
a predetermined logical sequence.

The fluid used is high pressure airfrom air compressor, usually upto10 bar pressure
(10Kgf/Cm2 or 1 MPa).

Following experiments are conducted.

Experiment 1: Control of Single Acting Cylinder

A 2-postion, 3-port valve as shown in Fig.P1 is used. The two positions are effected
by push button or lever.

Fig. P1
Circuit connections as per valve position are shown in Fig. P2.
In Position 1, pressure port is connected to piston side of cylinder, and causes the
piston rod to move to right. In Position 2 of the valve, actuator piston side port is
connected to exhaust port T, while P port is blocked. The rod now retracts back due to
spring force.

Position 1 Position 2
Measurements and Automation Laboratory MESBL601

Fig.P2: Operation of Single acting cylinder

Measurements and Automation Laboratory MESBL601

Procedure :
Load the SmallArm robot in the environment
Change the angle of joint 1 by an angle of 25 deg
Check the D-H parameters
Change the angle of joint 2 by an angle of 25 deg
Check the D-H parameters
Change the angle of joint 3 by an angle of 25 deg
Check the D-H parameters
Change the angle of joint 4 by an angle of 25 deg
Check the D-H parameters
Change the angle of joint 5 by an angle of 25 deg
Check the D-H parameters
Change the angle of joint 5 by an angle of 25 deg
Check the D-H parameters and the final end effector position
Measurements and Automation Laboratory MESBL601

Experiment No. 10
Aim To study the operation Speed measurement using by digital tachometer

Apparatus: Laboratory speed measurement device

Operation: The speed transducer induced at sourse and detector with a tooth wheel
positioned and aligned in between them n such a way that light sourse, tooth
detector are collinear. The portions f the teeth cut the light path thus
generating corresponding electrical pulse such as tooth wheel rotates. The
tooth wheel rotates. The tooth wheel is connected to the shaft of small
electrical motor, as the motor speed changed with speed wheel potentiometer,
the rotatinal speed of tooth wheel also changed in turn there is change in no of
Measurements and Automation Laboratory MESBL601

pulses genrated by transducer. The pulses are shaped band subsequently fed to
counter and display, through internal gate, gate pulse circuit and flip flop
output. The speed is varied by varying the position of speed control
potentiometer.

R.P.M DEMONSTRATOR (TACHOMETER)

Procedure:
a.i. Keep the speed control potentiometer to minimum position.
a.ii. Switch on the main supply.
a.iii. In the minimum position of potentiometer 30, 60,
90,120,150,180,210,240,270 and for each position note down the
display reading.
a.iv. Tabulate the reading
a.v. Draw the graph, plot position vs display reading.

Observations Table

Loading

% % Precison
Input path Q˳ Accur
Q˳1 Q˳2 Q˳3 Q˳4 Q˳5
on knot Q¡ acy
RPM
Measurements and Automation Laboratory MESBL601

Unloading
% % Precision
Input path Q˳ Accu
Q˳1 Q˳2 Q˳3 Q˳4 Q˳5
on knot Q¡ racy
RPM

Conclusion:
Speed measurement control using with digital tachometer trainer kit was
carried out different speed characteristics.
Questions
1) What do you understand by accuracy and precision?
2) What is meant by hysteresis loss?
Measurements and Automation Laboratory MESBL601