Exp. No.

: 1 Experimental verification of control of hydraulic cylinder circuits

Date: using different DCV.

Aim:
To design and verify the control procedures on hydraulic circuit using different (3/2,
4/2 and 5/2) Direction Control Valves.

Apparatus Required:
• Hydraulic single acting cylinder
• Hydraulic double acting cylinder
• Direction Control Valves (3/2, 4/2, 5/2)
• Power pack (Oil tank, Pump, Filter and Pressure regulator)
• Hydraulic hoses and pipes

Theory:
When the manually operated valve is pressed, the left side configuration of the valve is
come into operation and the pressurized fluid enters into the cover end of the cylinder causing
the cylinder to move forward. The operator actuates the valve to the other side. This now gives
fluid to the piston end of the cylinder retracts.

Procedure:
1. Make the connections both hydraulic and electrical as per the circuit design
2. Turn ON the controls to pump the oil from reservoir to flow across the circuit.
3. The DCV is operated which allows the oil to flow across the circuit in one direction.
4. Then the respective push button is operated to actuate the manually operated DCV.
5. Observe the direction of cylinder, changes with respect to the change in solenoid
actuation

Result:
Thus, the control procedures on hydraulic circuit using different (3/2, 4/2 and 5/2)
direction control valve has designed and tested experimentally.

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 Exp. No.: 2 Experimental verification of control of pneumatic cylinder
Date: circuits using different DCV.

Aim:
To design and verify the control procedures on pneumatic circuit using different (3/2,
4/2 and 5/2) Direction Control Valves.

Apparatus Required:
• Pneumatic single acting cylinder
• Pneumatic double acting cylinder
• Direction Control Valves (3/2, 4/2, 5/2)
• Compressor and FRL Unit
• Pneumatic hoses and pipes

Theory:
When the manually operated valve is pressed, the left side configuration of the valve is
come into operation and the pressurized fluid enters into the cover end of the cylinder causing
the cylinder to move forward. The operator actuates the valve to the other side. This now gives
fluid to the piston end of the cylinder retracts.

Procedure:
1. Run the compressor and store the pressurized air in the receiver tank.
2. Connect the FRL unit inlet to the tank outlet.
3. Make the circuit connection as per the diagram.
4. Turn ON the tank outlet valve and receive the pressurized air to the system.
5. Regulate and set the required pressure (3 - 5 bar) using FRL unit’s regulator.
6. Operate the slide valve of the junction and allow the air into the system.
7. Observe the operation of the system by actuating appropriate valves and controls

Result:
Thus, the control procedures on pneumatic circuit using different (3/2, 4/2 and 5/2)
direction control valve has designed and tested experimentally.

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 Exp. No.: 3 Experimental verification of Metre-in and Metre-out pneumatic
Date: circuits.

Aim:
To design and verify the Metre-in and Metre-out pneumatic circuits.

Apparatus Required:
• Pneumatic double acting cylinder
• 5/2 Direction Control Valves
• Compressor and FRL Unit
• Pneumatic hoses and pipes

Theory:
Meter – in Circuit:
When the manually operated valve is actuated, the left side of the valve configuration
comes into operation and the air enters into the cylinder through the meter in valve. The flow
through that valve can be adjusted to get the required speed of the cylinder which in turn
controls the speed of the piston. After reached the extended stroke and the fluid in the cylinder
is connected to the exhaust and the cylinder returns back by the string force.

Meter – out Circuit:

When the manually operated valve is actuated to its left condition, the air coming out of
the valve enters to the cover side of the cylinder and the piston starts moving forward. At the
same time the fluid present in the rod side of the cylinder goes out through the controlled
passage of the meter out valve. This controlled exhaust creates a positive pressure in the rod
side of the cylinder and the cylinder moves slowly forward. The exhaust passage can be adjusted
and the speed can thus be varied positively. For return stroke also it works in the same
principle.

Procedure:
1. Run the compressor and store the pressurized air in the receiver tank.
2. Connect the FRL unit inlet to the tank outlet.
3. Make the circuit connection as per the diagram.
4. Turn ON the tank outlet valve and receive the pressurized air to the system.

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 5. Regulate and set the required pressure (3 - 5 bar) using FRL unit’s regulator.
6. Operate the slide valve of the junction and allow the air into the system.
7. Observe the operation of the system by actuating appropriate valves and controls

Result:
Thus, the Metre-in and Metre-out pneumatic circuit has designed and tested
experimentally.

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 Exp. No.: 4 Experimental verification of pneumatic sequencing Circuits
Date: (A+B-A-B+)

Aim:
To design and verify the pneumatic sequencing Circuits (A+B-A-B+).

Apparatus Required:
• Pneumatic double acting cylinder
• Lever operated 3/2 DCV
• Pilot operated with spring return 4/2 DCV
• Roller operated 3/2 DCV
• Compressor and FRL Unit
• Pneumatic hoses and pipes

Theory:
Compressed fluid through FRL unit enters to the direction control valves and limit
switches. At the home condition the cylinder A is at the retracted condition and the cylinder B
is in the extended condition. So limit switch a0 & a1 are in actuated condition and power comes
to corresponding DCV. The manually operated DCV is in closed condition initially. If the
manually operated valve is actuated to open condition, fluid is supplied to DCV and limit
switches. Since the limit switch b1 is in pressed condition the air goes to actuate the direction
control valve X and the cylinder moves forward. This causes the release of a0 and the pressing
of a1 at the end of the stroke. The output from a1 goes to Y as pilot and shift it position. This
gives power to the return stroke of cylinder B. At the end of return stroke, b0 is pressed and the
DCV X reversed. This makes the cylinder A to return and at the end a0 is pressed. Due to this
pilot Y is reversed and B moves forward and at the end b1 is pressed. Thus, the cylinders A & B
operate continuously until the manually operated valve is put in close condition.

Procedure:
1. Run the compressor and store the pressurized air in the receiver tank.
2. Connect the FRL unit inlet to the tank outlet.
3. Make the circuit connection as per the diagram.
4. Turn ON the tank outlet valve and receive the pressurized air to the system.

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 5. Regulate and set the required pressure (3 - 5 bar) using FRL unit’s regulator.
6. Operate the slide valve of the junction and allow the air into the system.
7. Observe the operation of the system by actuating appropriate valves and controls

Result:
Thus, the pneumatic sequencing circuit has designed and tested experimentally.

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 Exp. No.: 5
Experimental verification of electro-pneumatic circuits
Date:

Aim:
To design and verify the electro-pneumatic circuit.

Apparatus Required:
• Pneumatic single acting cylinder
• Solenoid operated 4/2 DCV with spring return
• Compressor and FRL Unit
• Pneumatic hoses and pipes

Theory:
At normal condition, the air will go to the cylinder B and that will be in extended condition
and A will be in retracted condition. The circuit is operated by 24 V electrical supply, and the
circuit is shown in figure. When the push button is pressed, the circuit closes and the solenoid
is energized. This makes the valve to actuate and the left side configuration of the valve comes
to working. Now the cylinder A moves forward and B returns back due to spring force. If the
push button is released, the circuit breaks and the solenoid get de-energized. This leads to the
return of DC valve to its normal position and cylinder A returns and B moves forward.

Procedure:
1. Run the compressor and store the pressurized air in the receiver tank.
2. Connect the FRL unit inlet to the tank outlet.
3. Make the circuit connection as per the diagram.
4. Turn ON the tank outlet valve and receive the pressurized air to the system.
5. Regulate and set the required pressure (3 - 5 bar) using FRL unit’s regulator.
6. Operate the slide valve of the junction and allow the air into the system.
7. Observe the operation of the system by actuating appropriate valves and controls

Result:
Thus, the basic electro - pneumatic circuit has designed and tested experimentally.

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 Exp. No.: 6 Design and develop a PLC program to control electro pneumatic
Date: sequencing circuit (A+B-A-B+)

Aim:
To develop a Ladder logic program for the sequencing of electro-pneumatic circuit
(A+B-A-B+).

Apparatus Required:
• Pneumatic single acting cylinder
• Solenoid operated 4/2 DCV with spring return
• Compressor and FRL Unit
• Pneumatic hoses and pipes
• PLC Trainer kit with peripherals

Theory:
Compressed fluid through FRL unit enters to the direction control valves and limit
switches. At the home condition the cylinder A is at the retracted condition and the cylinder B
is in the extended condition. So limit switch a0 & a1 are in actuated condition and power comes
to corresponding DCV. The manually operated DCV is in closed condition initially. If the
manually operated valve is actuated to open condition, fluid is supplied to DCV and limit
switches. Since the limit switch b1 is in pressed condition the air goes to actuate the direction
control valve X and the cylinder moves forward. This causes the release of a0 and the pressing
of a1 at the end of the stroke. The output from a1 goes to Y as pilot and shift it position. This
gives power to the return stroke of cylinder B. At the end of return stroke, b0 is pressed and the
DCV X reversed. This makes the cylinder A to return and at the end a0 is pressed. Due to this
pilot Y is reversed and B moves forward and at the end b1 is pressed. Thus, the cylinders A & B
operate continuously until the manually operated valve is put in close condition.

Procedure:
1. Write a Ladder logic program in the PLC software and upload the same tom PLC.
2. Check the electrical connections between pneumatic circuit and PLC.
3. Run the compressor and store the pressurized air in the receiver tank.
4. Connect the FRL unit inlet to the tank outlet.
5. Make the circuit connection as per the diagram.

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 6. Turn ON the tank outlet valve and receive the pressurized air to the system.
7. Regulate and set the required pressure (3 - 5 bar) using FRL unit’s regulator.
8. Operate the slide valve of the junction and allow the air into the system.
9. Observe the operation of the system by actuating appropriate valves and controls

Result:
Thus, the basic electro - pneumatic circuit has designed and tested experimentally.

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 Exp. No.: 7 Simulation of hydraulic and pneumatic circuits using simulation
Date: software

Aim:
To simulate the hydraulic and pneumatic circuits in simulation software

Apparatus Required:
• Simulation software (Autosim/Automation studio)
• PC with power supply

Theory:
When the manually operated valve is pressed, the left side configuration of the valve is
come into operation and the pressurized fluid enters into the cover end of the cylinder causing
the cylinder to move forward. The operator actuates the valve to the other side. This now gives
fluid to the piston end of the cylinder retracts.

Procedure:
1. Turn on the system and enter into software.
2. Open New file and save the same in appropriate location.
3. Start designing the circuit using Hydraulic section.
4. Use respective valves, actuators, fluid conditioners, power circuits etc., while
designing.
5. Save the file again after completion of circuit design.
6. Go to online simulation mode and test the circuit for its operation.
7. Quit simulation mode and close the file

Result:
Thus, the basic hydraulic and pneumatic circuits simulated in software and the outputs
are evaluated.

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Exp. No.: 8
Design and develop a PLC program for logic gates
Date:

Aim:
To write the PLC program for the logic gates and simulate using PLC software

Apparatus Required:
• Simulation software (LogoSoft / WPLSoft)
• PC with power supply

Theory:
Name Symbol Function Truth Table

A F
NOT F=Ā 0 1
1 0

A B F
0 0 0
AND F = AB 0 1 0
1 0 0
1 1 1

A B F
0 0 0
OR F=A+B 0 1 0
1 0 0
1 1 1

A F
Buffer F=A 0 0
1 1

A B F
0 0 1
NAND F = ̅̅̅̅̅
𝑨𝑩 0 1 1
1 0 1
1 1 0

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 A B F
0 0 1
NOR F = ̅̅̅̅̅̅̅̅
𝑨+𝑩 0 1 0
1 0 0
1 1 0
A B F
̅+ 𝑨
F = 𝑨𝑩 ̅𝑩 0 0 0
EX-OR 0 1 1
= A ⊕B
1 0 1
1 1 0

̅𝑩̅ A B F
F = 𝑨𝑩 + 𝑨
0 0 1
EX-NOR = A⊙B 0 1 0
= ̅̅̅̅̅̅̅̅̅
𝐀⊕𝐁 1 0 0
1 1 1

Procedure:
1. Write the PLC program for the logic gates in any PLC software.
2. Check and simulate the program. If error exists, recheck and edit the program.
3. Check the hardware and wiring connections.
4. Select the correct hardware interface configuration and interface the PLC with PC using
RS232/Ethernet/USB cable.
5. Ensure the PLC in RUN Mode.
6. By giving signal to inputs in various combinations and check the outputs.
7. If need, Redo the whole process with different inputs.

Result:
Thus, the PLC program for the logic gates has written and simulated in software.

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 Exp. No.: 9 Design and develop a PLC program to control lights in sequence
Date: using PLC timers

Aim:
To write the PLC program to control lights in sequence using PLC timers and simulate
using PLC software

Apparatus Required:
• Simulation software (LogoSoft / WPLSoft)
• PC with power supply

Theory:
A good lighting design includes a good controls design. Lighting controls play a critical
role in lighting systems, enabling users manually or automatically to turn the lights ON and OFF
using a switch; and/or adjust light output up and down using a dimmer. This basic functionality
can be used to generate these benefits for the lighting owner i.e., flexibility to satisfy user visual
needs; and/or automation to reduce energy costs and improve sustainability. By reducing
lighting ON time, intensity or zoning, lighting controls reduce both demand and energy
consumption.

According to a Lawrence Berkeley National Laboratory (LBNL) study, popular lighting

control strategies produce 24-38% average lighting energy savings, which reduces building
operating costs. Because of strong energy savings, the majority of state commercial building
energy codes require a wide range of controls in new construction. In existing construction, the
controllability of LED lighting results in an ideal pairing with controls, combining to minimize
energy costs. Lighting controls are input/output devices and systems. The control system
receives information, decides what to do with it, and then adjusts lighting power accordingly.
Here we see a basic lighting circuit (switch leg). Power travels along the circuit to energize a
group of lights. This lighting system supplies illumination. In recent years, lighting controls have
evolved two additional capabilities:

• Adjust light source color, including shade of white light.

• Generate data via measuring and/or monitoring.

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Procedure:
1. Write the PLC program for the logic gates in any PLC software.
2. Check and simulate the program. If error exists, recheck and edit the program.
3. Check the hardware and wiring connections.
4. Select the correct hardware interface configuration and interface the PLC with PC
using RS232/Ethernet/USB cable.
5. Ensure the PLC in RUN Mode.
6. By giving signal to inputs in various combinations and check the outputs.
7. If need, Redo the whole process with different inputs.

Result:
Thus, the PLC program to control the lights in sequence using PLC timers has written and
simulated in software.

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 Exp. No.: 10 Design and develop a program to count the number of products
Date: arrived in a conveyor setup

Aim:
To write the PLC program to count the number products arrived in conveyor setup
and simulate using PLC software

Apparatus Required:
• Simulation software (LogoSoft / WPLSoft)
• PC with power supply

Theory:
The PLC gets interfaced with conveyor setup. The proximity sensor used has a range of 300
mm which is given as input to the PLC. When the sensor detects any object on the conveyor belt, it
emits a beam of electromagnetic radiation. The signal gets recorded and updated in PLC to display
on the displaying device. A relay is connected to the PLC which is used to control high current circuits
using low current signals. When 12V supply is given from the battery further connected to a motor,
the motor generates back emf which may damage the PLC. Hence relay is used between motor and
PLC. To count the number of objects passed through the conveyor, PLC reads the signals from the
proximity sensor continuously and make an increment in program itself and make the whole value to
display.

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Procedure:
1. Write the PLC program for the logic gates in any PLC software.
2. Check and simulate the program. If error exists, recheck and edit the program.
3. Check the hardware and wiring connections.
4. Select the correct hardware interface configuration and interface the PLC with PC
using RS232/Ethernet/USB cable.
5. Ensure the PLC in RUN Mode.
6. By giving signal to inputs in various combinations and check the outputs.
7. If need, Redo the whole process with different inputs.

Result:
Thus, the PLC program to count number of parts arrived in conveyor setup has written
and simulated in software.

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 Exp. No.: 11
Design and develop PLC Program to Control Traffic Light
Date:

Aim:
To write the PLC program to control traffic light sequence and simulate using PLC
software

Apparatus Required:
• Simulation software (LogoSoft / WPLSoft)
• PC with power supply

Theory:
There are two methods to solve this problem. One is by using stack operation and the
other one is by using sequencer output method. Sequencer output method is best suited for this
problem since very less configuration is needed and program length is also reduced. In this
method, we need to assign SQO instruction by configuring all the parameters given in the
instruction.
• File : It is the starting address for the registers in the sequencer file.
• Mask : Mask is the bit pattern through which data flow happens from source to the
destination address. If there is 1 in the masking, it passes values and if 0, it blocks the
data flow.
• Dest : It is the address of the input to which the Sequencer Output instruction moves the
data.
• Control : Is the address that contains the parameters with control information for the
instruction. EN, DN and ER are bit which sets according to the status of sequencer output.
EN and DN bits are set just as in timers. ER bit stands for Error bit, it is set when a negative
position/length value is detected by the processor, or zero length value.
• Length : It is the number of steps of the sequencer file starting at position 1. Position 0 is
the start-up position.
• Position: It indicated the steps that is desired to start the sequencer instruction. The start
position is all zeros, this is represented as the neutral position; so no outputs will be
turned ON in position 0.
• So to start the actual function of output sequence, Position 1 is determined as starting
sequence while programming. Integers or Bit Registers are used as Destination Address.
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Procedure:
1. Write the PLC program for the logic gates in any PLC software.
2. Check and simulate the program. If error exists, recheck and edit the program.
3. Check the hardware and wiring connections.
4. Select the correct hardware interface configuration and interface the PLC with PC
using RS232/Ethernet/USB cable.
5. Ensure the PLC in RUN Mode.
6. By giving signal to inputs in various combinations and check the outputs.
7. If need, Redo the whole process with different inputs.

Result:
Thus, the PLC program to control the traffic light has written and simulated in software.

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 Exp. No.: 12 Design and develop PLC program to maintain the pressure head
Date: in bottle filling system.

Aim:
To write the PLC program to maintain pressure head in bottle filling system and
simulate using PLC software

Apparatus Required:
• Simulation software (LogoSoft / WPLSoft)
• PC with power supply

Theory:
Solid state level switches cannot be used here since level has to be continuously
monitored. Pressure is proportional to level. As level of a tank increases, pressure also
increases. Level gauges are highly sensitive to very small variations. Many companies such as
Rockwall Automation and Endress+Hauser manufacture pressure gauges to measure liquid
level of a tank. Output of this gauge is terms of pressure so we have to convert pressure into
equivalent current output. But let us assume here that maximum pressure that means when
tank is full, it gives 20mA output and when tank is empty, it gives 4mA output which is in
standard form 4-20mA. Use conversion instructions to convert this 4-20mA data into registers.
To do this, Analog modules for PLCs are used. These modules convert 4-20mA into equivalent
digital level signals.

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 Output of this Analog modules are stored in Hex form which are then processed by the
processor and hex output is generated again. Just like Analog input modules, Analog output
modules are used convert digital output data into equivalent current signals to operate power
supply circuit which varies output accordingly, to drive the final control element, here control
valve.

Procedure:
1. Write the PLC program for the logic gates in any PLC software.
2. Check and simulate the program. If error exists, recheck and edit the program.
3. Check the hardware and wiring connections.
4. Select the correct hardware interface configuration and interface the PLC with PC
using RS232/Ethernet/USB cable.
5. Ensure the PLC in RUN Mode.
6. By giving signal to inputs in various combinations and check the outputs.
7. If need, Redo the whole process with different inputs.

Result:
Thus, the PLC program to control the lights in sequence using PLC timers has written and
simulated in software.

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 Exp. No.: 12 Design and develop a PLC program to sort parts for quality
Date: control on conveyor

Aim:
To write the PLC program to sort parts in conveyor and simulate using PLC software

Apparatus Required:
• Simulation software (LogoSoft / WPLSoft)
• PC with power supply

Theory:
To detect the parts, detector such as proximity switch, optical sensors or any other sensor
is used. Connect output of this detector to Input Module of PLC which sets and resets image
memory according to parts’ detection. Give this detection, as an input to Up Counter which is
incremented with each part’s detection. Set counter preset value to 1000. Operate Solenoid for
a few seconds until the part is diverted for quality check.

Procedure:
1. Write the PLC program for the logic gates in any PLC software.
2. Check and simulate the program. If error exists, recheck and edit the program.
3. Check the hardware and wiring connections.
4. Select the correct hardware interface configuration and interface the PLC with PC
using RS232/Ethernet/USB cable.
5. Ensure the PLC in RUN Mode.
6. By giving signal to inputs in various combinations and check the outputs.
7. If need, Redo the whole process with different inputs.

Result:
Thus, the PLC program to sort parts in conveyor has written and simulated in software.
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