ME6712/ MECHATRONICS LAB MANUAL

AS PER THE LATEST SYLLABUS OF ANNA UNIVERSITY

FOR VII SEMESTER
B.E-MECHANICAL ENGINEERING
N.KRISHNAMOORTHY,B.E,M.I.S.T.E,M.E,(M.B.A)
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
E-MAIL ID:krishme86@gmail.com
 INDEX

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EX.N0:1

INTRODUCTION OF MECHATRONICS SYSTEM AND SYMBOLS

Aim:

To study about the important features, about Mechatronics system and symbols

Introduction to mechatronics system:

Mechatronics is one of the new and ex1st mg fields on the engineering landscape,
subsuming parts of traditional engineering fields and requiring a broader approach to the design
of system that we can formally call as Mechatronics system. Many industries improving their
works through automation which is based on the inter connection between the elect·0 · ontrol
systems and mechanical engineering. Such control systems generally use mi.c cessors as
controllers and have electrical sensors extracting information from mechal i a uts
through electrical actuators to mechanical systems. This can be considered to be applig:t{ion of
computer based digital control techniques through electronic and electric 1:tces to mechanical
engineering problems. Successful design of Mechatronics can l ad ucts that are extremely
attractive to customer in quality cost-effectiveness.

Mechatronics definition:

Mechatronics may be defined as a multi-disciplinru;¥

integration of electronic engineering, electric en 'ny g, control engineering

ELECTRONIC ELECTRICAL
ENGINEERING ENGINEERING

rvIEC IL TRONICS

CONTROL COMPUTER
ENGINEERING TECHNOLOGY

and computer technology with mechanical engineer ing for the design , manufacture, analysis and
maintenance of a wide range of engineering products and processes. "Mechatronics brings
together areas of technology involving sensors and measurement systems, drive and actuation

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systems, analysis of the behavior of systems mic roprocessorsystems". The integration across the
traditional boundaries of mechanica l eng ineer ing, electr ical engineering, electro nics and
control engineering has to occur at the earliest stages of the design process if cheaper, more
reliable; more flexible systems are to be developed .

Applications of mechatronics engineering:

Mechatronics engineering finds application in the following fields.

► Electronic home appliances
► Electronic entertainment products
► Engine systems (cars)
► Large scale application

Pneumatic System

.------ ---------------· --················· -

I :

Contro'I
valve ®
© PSI &
3._· o-:--< FRL unU Cylinder
Opens when
pr essure
:
·:- - -
i !E)cha usl
Comn,'\nents
re ac he d :--,, =
• •• • • .• ••• • • • ••• • • ---•• ---- - • ----·--•---- --••••--•••- - ---·' common
to mom thalil
G) Reservoir ©- Valves one motion

- Co mpres @- A.ctu
atot
®- sor
®-
®-

Schematic Layout of Pneumatic System

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BASIC COMPONENTS OF A PNEUMATIC SYSTEM

Reservoir (or air tank):

An air tank is provided to store the compressed air required for the operations.

Compressor:

The compressor is used to compress the atmospheric air so as to increase the pressure of the air.

Prime mover:

A Prime mover, usually an electric motor, is used to drive the compressor

Valves:

Valves arc refitted in the system to control air direction, pressure, and fiow "f.,,;
Actuator: '-ii.•
An actuator is provided to conve1i the air energy into mechanic :l fofee'°; Torque to do useful
work.

Fluid-transfer piping:

HYDRAULIC SYSTEM

, - · ·- · · -- · - · - -· ··,
_.,,- 11:t e c;:l rlc •,•,
m otor "..". ... 11..,
.1- "
, ;#'- "' '\ . Raise
_....• M . ""'.......

P re ss ,e............1 ..
F ilter regulato r ,.

© ®
/ j C on lrol I

:exce ss /, Retutn valve -

fluid_./'
• fl ll ld :
3Zzz2ZZZ.Z"ZZ?Z1'ZZZZ:2'ZZZ

_• • •
_ _. _
.•• . _. . _ -- -- _ ..- • a- · •• • . 1- O m:on,
i;=
©-Reservoir @- Val ves
@- Pump ®- Acluator !(linear)
@- P rime 1rro ver ®- Pi l!)ing

Schematic Layout of Hydraulic Svstem

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BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Reservoir (or air tank):

A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid (usually oil).

Pump:

The pump is used to force the liquid into the system.

Prime mover:

A Prime mover, usually an electric motor, is used to drive the pump.

Valves:

Valves are refitted in the system to control liquid direction, pressure, and flo e.

Actuator: •
An actuator is provided to conve1i the liquid energy into mechapica fo e or torque to do useful
work. The actuator is the actual working element of the syst m. uh ctuators can be either
cylinders (to provide linear motion) or hydro motors (to ptovi rotary motion).

Fluid-transfer piping:

DESCRIPTION

LINES

-continuous line - flow line

-dashed line - pilot, drain

-envelope - long and short dashes around two

or more component symbols

CIRCULAR

-large circle - pump, motor

0 ---------+--------------------1
0 -small circle - Meas ur ing dev ices

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 -semi-circle - rotary actuator

SQUARE -one square - pressure control function -two or

three adjacent squares - directional control

□
DIAMOND -diamond - Fluid conditioner (filter, separator,
lubricator, heat exchanger)

MISCELLANEOUS SYMBOLS
NJ -Spring

TRIANGLE
-- -Flow Restriction
•
V

Fixed Displacement Hydraulic Pump

-unidirectional

-bidirectional

Variable Displacement Hydraulic Pump -unidirectional

r,b.
k;.J

Compressor

-Compressor

MOTORS
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Fixed Displacement Hydraulic Motor
unidirectional

bidirectional
Q
Variable Displacement Hydraulic Motor -unidirectional

-Compressor

Rotary Actuator

hydraulic

pneumatic

finder

, returned by spring or extended by spring force

Double Acting Cylinders

single piston rod (fluid required to extend and

retract)

double ended piston rod

DIRECTIONAL CONTROL VALVES

Directional Control Valve (2 Ports / 2 Normally closed directional control valve with
Positions) 2 ports and 2 finite positions.

Normally open directional control valve with 2

ports and 2 finite positions.

Direct ional Control Valve (3 Ports / 2 Positions)

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 -Normally closed directional control valve with
3 ports and 2 finite positions.

-Normally open directional control valve with

3 ports and 2 finite positions.

Directional Control Valve (5 Ports/ 3 Positions) Normall A Pneumatic Valve

-directional control valve with 5 ports and 3
* ll]
[!U finite positions

CONTROL METHODS
l=L general symbol (without showi_n"g'i h
type) t-'1
<J:==C pushbutton
>----- --- -- I - ---
-- =--.........--------<
-lever

=C

eek valve -free flow one direction, blocked

' flow in other direction
pilot operated check valve, pilot to close

pilot operated check valve, pilot to open

to isolate one part of a system from an alternate

art of circuit
PRESSURE CONTROL VALVES
Line pressure is limited to the setting of the
valve, secondary part is directed to tank

line pressure is limited to and proportional to

an electronic signal

When the line pressure reaches the setting of

the valve, valve opens permitting flow to the
secondary port. The pilot must be externally
drained to tank.
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 r -C◄11
pressure downstream of valve is limited to the
1 • w.i
setting of the valve
Conditionin2 unit
,- - - - - - ---,
I Q I -compound symbol of filter, regulator,

!L<l>E J +
- -- -- -· J
, _ .
<>! lubricator unit

Result:

Thus the important feature Mec hatron ics system was studied.

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EX.N0.2

DESIGN AND CIRCUITS OF SINGLE ACTING CYLINDER USING PNEUMATIC

TRAINER KIT

Aim:

To design and circuit of single acting cylinder using Pnemnatics trainer kit

Apparatus requried:

l .PnetUTiatic trainer kit

2. Compressor

3. Hose

4. Single acting cylinder

5.Sliding valve

6.FRLUnit

7. 3/2 Direction control valves (DCV) hand lever with spimg c trol

Procedure:
,.

3.Then the compressed air from1•

-
1. The compressed air is supplid to the sliding va

2. The FRL unit is used to filter and lubri

sl
,
n
...JPro ugh FRL unit

lie cylinder system.

e is passed to 3/2 DCV

4. The out put of DCV is co ctet.l tcYth' e single acting cylinder.

5.Byusing hand liver the flow direction of fluid can be actuated.

6.The pressure of compressed air can be adjusted in the pressur e

gauge .
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NORMAL POSITION

S.AC

FRIL U N IT
rr ·------------------------------1

_ _ _ _ _ _ _ _ _ l
u_
C o m p r e s so r

ACTUATED POSITION

Result:

Thus the design of single acting cylinder circuit was operated in Pneumatic Trainer Kit.
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EX.N0.3

DESIGN AND CIRCUITS OF DOUBLE ACTING CYLINDER USING PNEUMATIC

TRAINER KIT

Aim:

To design and circuit of double acting cylinder using Pneumatics trainer kit

Apparatus requried:

I.Pneumatic trainer kit

2. Compressor

3.Hose

4. Single acting cylinder

5.Sliding valve

6.FRLUnit

7. 3/2 DCV hand lever with spirng control s•

Procedure:
,.
2. The FRL unit is used to filter and
lubri
3.
-
1. The compressed air is supplid to the sliding va " rough FRL unit

, lie cylinder system.

n
Then the compressed air fromjre slfding :tv
e is passed to 3/2 DCV

4. The out put of DCV is co t tcYth' e single acting cylinder.

5. Byusing hand liver the fl ow direction of fluid can be actuated.

6.The pressure of compressed air can be adjusted in the pressure

gauge.
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NORMAL POSITION

DAC

(L _ _ _ _ _ _
___I
Co m p r e s so r

ACTUATED POSITION

Result:

Thus the design and circuit of double acting cylinder was operated in Pneumatic Trainer Kit.
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EX.N0.4

DESIGN AND CIRCUIT WITH LOGIC SEQUENCE (AND & OR GATE)

USING PNEUMATIC TRANTER KIT

Aim:

To connect and testing of design and circuit of logic sequence of single acting cylinder.

Apparatus requried:

I. Pneumatic trainer kit

2. Compressor

3.Hose

4. Single acting cylinder

5.Sliding valve

6.FRLUnit

7. 3/2 DCV hand lever with spirng control

Procedure:
·s
').:'-
AND GATE

And gate involves two switches in se_ ice l 1ywhen switch A and Bare closed in the
valve. An AND gate is an inter lock control s:>r an operation and gives 1 and signal and the
power is on giving a I signal ere can be output a I signal and the machine operation.

A.B=Q
The relatio nship between to a logic gates and the output can be tabulated in the form known
as truth table.

OR GATE

1. An OR gate with inputs A and B gives an output of a 1 when A or Bis 1.

2. An OR gate is valves involves two switches in parallel.

3. When switch A or Bis closed then there is a current.

4. Thus the single acting cylinder is actuated

A+B=Q

The input and output are tabulated in truth table.

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AND GATE DIAGRAM

ANO gate

A A

.
I

)---- _ II

.
R

TRUTH TABLE p p

A B Q= A .B
0 0 0
0 I 0
I 0 0
I I I

OR GATE DIAGRAM

OR gate

A A

_ I
p
R n
p .
R

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TRUTH TABLE

A B Q=A+B
0 0 0
0 1 1
1 0 1
1 1 1

Result:

Thus the design of circuits with logic sequence (AND & OR Gate) has been drawn and
performed.

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EX.N0.5

AUTOMATIC RETRACTION OF DOUBLE ACTING CYLINDER

USING PNEUMATIC TRAINER KIT

Aim:
To connect and testing of automatic retraction of double acting cylinder using pneumatic trainer
kit

Apparatus required:

Double acting cylinder

5/2 valve
Sliding valve
FRL unit
Pressure gauge

Procedure:

I.The compressed air is supplied to this slide valve through t

2. The FRL unit is used to filter regulator lubricate th vatfo n system

3. Then the compressed air from the sliding valv . esse-it to 5 / 2 DCV.

4. The output of direction control valve i t ed to the double acting cylinder.

5. By using hand lever the f:l ir aircan actuated.

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D iag
ram

_I_ -l

,-
C:JIJB LE ,!.,CTIr-..G L !: V E R

W.'I T S V!JITC H

5/2 DCV VALVIE

Resul:t
Thus the automatic retraction of double acting cylinder circuit was done.
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EX.N0.6

DESIGN OF CIRCUITS WITH LOGICAL SEQUENCE (AND GATE) USING

ELECTRO PNEUMATIC TRAINER KIT

Aim:-

To design the circuit with logical sequence AND Gate using electro pneumatic trainer
kits.

Apparatus required:-

!. Single acting cylinder

2. Solenoid actuated DCV
3. Sliding valve
4. Switches

Procedure:-

AND GATE
And gate invo lves two switches in services on whcl'iswitch A and B are closed
in the current.

An AND gate is an int er lo ck contro- S}'.stem for an operation and gives· 1 and
s ignal and the power is on giving a I s ignal then tli can be output a l signal and the machine
operation. -

A.B=Q ""'
The relationzsh 1'.j_ e o a logic gates and the output can be tabulated in the
form known as truth table.

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 -37
- 2 '"l
"" ' I-- . .....

-:l,,
li-.. ..

A
,.
'U
l _ _ i- - ---
•
._.,..
w
l-..:
o, 0 a -
>-
I
0 a - - -
--"·7)
-·
•
X Q 0 -

Result:
Thus the design of circuits with logic sequence (AND Gate) has been drawn and
performed.

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EX.N0.7

DESIGN OF CIRCUITS WITH LOGICAL SEQUENCE (OR GATE) USING ELECTRO

PNEUMATIC TRAINER KIT

Aim:-

To design the circuit with logical sequence AND Gate using electro pneumatic trainer
kits.

Apparatus required:-

!. Single acting cylinder

2. Solenoid actuated DCV
3. Sliding valve
4. Switches

Procedure:-

OR GATE

1. An OR gate with inputs A and B gives an outplf{t f

2. An OR gate is an electrical circuits involve o ches in parallel.

A+B=Q

The inp u t an d output are tabulated in truth table.

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 ..

I '

....

\.i s
CQ -
13 ,,
,cit Q
l ,;:!
--J

-
U

C-5
,j >.. () C)

-'=
- ')( C) C> -</)

Result:-
Thus the design of circu its with logic se qu ence (OR Gate) has been drawn and
performed.

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EX.N0.8

DESIGN AND CIRCUIT OF SINGLE ACTING CYLINDER USING ELECTRO

PNEUMATIC WITH PLC (LADDER LOGIC)

Aim:
To perform the operation of PLC using electro pneumatic with ladder logic.

Apparatus required:
Electro pneumatic trainer kit
Wires
PLC
Single acting cylinder
Computer

PROCEDURE:
I.Open the file and select option and save it.
2.Then draw the ladder diagram as given.
3. Press fit and select the required diagram and give the inpµ value.
4.Press F6 and select the requirement diagram and give the out t
value.
5. Then take the connecting impless and give the conn'e . ltms s given in the circuit.
6. Then the select the download options and downloa at hen the operations of SAC is
performed. ,.
t to DCV to single cylinder.
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D iagra m
SINGLE ACTI
J NG CYLINDER
_

DCV
'
FRLUNIT
0

PLC
.------+---+. J VE ,VE[.,.........- - - --- - - ---;
-VE SMPS

LADDER DIAGRAM

iH H )
10.01 10.02 QO.1

Res ul t:
T hus the operat ion of SAC using electropneumatic with PLC ladder logic has been performed.
EX.NO.9

DESIGN AND CIRCUIT OF DOUBLE ACTING CYLINDER USING ELECTRO

PNEUMATIC WITH PLC (LADDER LOGIC)

Aim:
To perfom1 the operation of PLC using electro pneumatic with ladd er logic.

Apparatus required:
Electro pneumat ic trainer
kit Wires
PLC
Double acting cylinder

Procedure:

I. Open the file and select option and save ir.

2.Then draw the ladder diagram as given.

•
3. Press fit and select the required diagram and give t tt,a lue.

4. Press F6 and select the requirement diagram an ive"the out put value.

5. Then take the connecting impless and g 'lil,nnectionsas given in the circuit.

6. Thcn the se lect the downol: on an ·downloadat then the operations o f DAC is

performed.

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Diagr am

oI[•3WITC XUl lE b [ TIIIGCYLNDER

=w; H

SO. : NODSWID

0 l
02
1) 1 102 Q )
P_; KIT 10) FU3HBLTm

_.
'- 'vf , VE
.VE ; \IEG

Sl,IPS

L adder Diagram

Result:
T hus the operation of DAC usin g e lect rop neumat ic w ith PLC ladd e r log ic ha s bee n p erform ed.
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EX.N0.10

ACTUATION OF HYDRAULIC CYLINDER AND TO FIND OUT PRESSURE VS

FORCE

Aim:
To actuate the hydraulic cylinder and find out the Pressure VS Force.

Apparatus required:

1. Oil Tank
2. Three - Phase Motor
3. Gear Pump
4. Pressure Relief Valve
5. Solenoid Valve
6. Double Acting Cylinder
7. Load Cell

Formula:

P = F/A
A= ( n / 4) * D2 P
Pressure Kg/cm2
F Force Kg
2
A Area cm
D Diameter of Cylinder cm
TABULATION:

Pres.sure Calculated Force

s. o % of Error
Kg/cm2 Kg
1)

2)

3)
4)

5)
6)
7)

8)
9)
10)

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Model calculation:

Error= Displayed Force - Calculated Force / Displayed Force

%1 of Error = Error * 100

Procedure:

1. Switch on the electrical power supply with motor.

2. Switch on the power supply to the control unit. .
3. Inter face hydraulic trainer with system using REF-13
4. Open the force. Go to operate, click the run. Than power on (below).
5. Now extend the system by pressing the up button.
6. Load cell indicate the force value in the monitor.
7. Now adjust the pressure regulator and set the maximum pressure.
8. Retract the cylinder. •

,
9. Once again forward the cylinder; you have adjusted ti<e))re s re in pressure regulato r.
l 0. You have seen the force value in monitoring.

f!
11. Repeat the force value for different pressu e.

GRAPH:

Pressure VS Force

MODEL GRAPH:

".I
Pressure in Kg/en!'

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HYD RAULIC CIRC UIT

.I IIL5"'1
, -==::,

u
7

T .s

-'

Result:
The actuation of double acting cylinder was carried out and the curve between pressure
and force is been obtained.

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EX.N0.11

STEPPER MOTOR INTERFACING CLOCK WISE DIRECTION IN 8051

MICROPROCESSOR

Aim:

To write and complete the program of stepper motor interfacing full step resolution using
8051 microprocessor.

Apparatus required:
► 805 1 Microprocessor
► Stepper motor
► Power supply
Program:

ORO 410 0

START:MOY DPTR,#4500 H

MOY RO,#04

TO:MOVX A,@ DPTR

PUSH DPH

PUSH
DPL
•
MOV DPTR,#FFCOH

MOV R2,#04

MOV Rl ,#04

OLY:MOV R3,#OF

DJNZ R3,41 I3

DJNZ Rl ,411 l

DJNZ R2,4 l 1

I MOYX @ DPT R,A

POP DPL

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 POP DPH

INC DPTR

DJNZ RO,4102

SJMP 4100

END

RUN

SP 4500

OA-06-05-09

-
GO 4100

ult:
Res
Thus the program is executed by using 8051 kit
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EX.N0.12

STEPPER MOTOR INTERFACEING ANTI CLOCKWISE DIRECTION USING 8051

MICROPROCESSOR

Aim:

To write and complete the program of stepper motor interfacing full step resolution using
8051 microprocessor and micro controller.

Apparatus required:
► 8051 Microcontroller
► Stepper motor
► Power supply
Program:

ORG 4100

START:MOV DPTR,#4500 H

MOY RO,#04

TO:MOVX A,@DPTR

PUSH DPH

PUSH DPL

MOY DPTR,#FFCOH

MOY R2,#04

MOY Rl ,#0F

OLY:MOV R3,#O F

OLY:D.INZ R3,4113

DJNZ R1,4111

DJNZ R2,4 111

MOVX @DPTR,A

POP DPL

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 POP DPH

INC DPTR

DJNZ RO,4102

SJMP 4100

END

RUN SP 4500

09-05-06-OA

GO 4100

Result: •
Thus the stepper motor full step resolution has been writtep' . a <:.uted using
8051 microcontroller

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EX.N0.13

SIMULATION OF SINGLE ACTING CYLINDER BY USING AUTOMATION

SOFTWARE

Aim:

To perform the simulation of single acting cylinder with use of automation software

Apparatus requried:

I.Automation software

2.Computer

Procedure:

1.0pen the file automation software and open a new file.

2. Then the select the requried circuit using the library tool bar

3.Then pick the requried cylinder and valves requried.

4. Then drag it and place it is the file

5. Then give the connections as given in the circu it

,.
-
6. Then save the circuit and then select the simula option.

Diagram: 4 S........·,-A=--.--'<--,- ---=-F= O

f RL IUN IT
r - - - - - --- - _- -1
I•

16. _ _ _ _ _ _ _ _ _ I
Co m p r e s s o r

Result:

Thus the simulation operation of a single acting cylinder was done.

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EX.N0.14

SIMULATION OF DOUBLE ACTING CYLINDER BY USING SOFTWARE

Aim:

To perform the simulation of Double acting cylinder with use of automation software

Apparatus requried:

I .Automation software

2.Computer

Procedure:

I .Open the file automation software and open a new file.

2. Then the select the requried circuit using the library tool bar

3.Then pick the requried cylinder and valves requried.

4. Then drag it and place it is the file

5. Then give the connections as given in the circuit

6. Then save the circuit and then select the simulati-d'"n 0g :on.

Diagram: '?J-"-
4 ...,, • ,

F=O
DA C

t
r- - -1

. L _ _ _ _ _ _ _ _ , _ 1

C o n n p re s s o r

Result:

Thus the simulation operation of a Double acting cylinder was done.

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EX.N0.15

STUDY OF IMAGE PROCESSING USING LABVIEW SOFTWARE

Aim:

To imaging system, acquire and display an image, analyze the image, and prepare the image for
additional processing.

Apparatus requried:

I . Labview software

2.Smart camera

3. Power supply

Procedure:

1. Determine the type of equipment you need given space const in md the size of the
object you need to inspect. System Setup and Calibration, of the:,N I I ion Concepts Manual
for more infonnation.

a. Make sure your camera sensor is large enough to s

.
atis requirement.
,.:
'-
.
b. Make sure your lens has a depth of field lli ough to keep all of your objects in focus

regardless of their distance from the le s. Jls make sure your lens has a focal length that meets
your needs. '\-

c. Make sure your lighting p 11:)l s e¥o'ugh contrast between the object under inspection and
the background for you to extract the infonnation you need from the image.

2. Position your camera so that it is perpendicular to the object tmder inspection. If your camera
acquires images of the object from an angle, perspective errors occur. Even though you can
compensate for these errors with software, NI recom mends that you use a perpendicular
inspectio n angle to obta in the most accurate results.

Create an image

Use the IMAQ Create VI (Vision Utilities»Image Management) to create

an image reference. When you create an image, specify one of the

following image data types:

• Grayscale (U8, default)- 8-bit unsigned

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• Grayscale (I16)-16-bit signed

• Grayscale (SGL)-Floating point

• Complex (CSG)

RGB (U32}-32-bit RGB

• HSL (U32)-32-bit HSL

• RGB (U64}-64-bit RGB

You can create multiple images by executing IMAQ Create as many times as you want, but each
image you create requires a unique name. Detennine the number of required images gh an
analysis of your intended application. Base your decision on different processing ltl ses and

s-;
whether you need to keep the original image after each processing
phase.
?'
Analyze an Image
When you acquire and display an image, you may want to analYze t c◊ntents of the image for
the following reasons:

• To obtain the values of parameters that you want t0J1S n,.,process ing

functions during the inspection process.The histo "dnd line profile tools can help you analyze
the quaIity of your images.

Results:

Thus the image processing using labview was studied.

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 Viva questions:
1. Define Mechatronics.
Mechatronics is defined as the integration of precision mechanical & electro nic control for the
development of smart products & process.
2. What is a system? Give an example.
A system can be considered as a box, which has an input, and an output and where it is not
concerned with what goes on inside the box but only the relationship between the output and the
input. Example: A motor may be thought of as a system, which has as its input electric power
and as output the rotation of a shaft.
3. What is a measurement system?
A measurement system can be considered as a black box, which is used for makin
measurements. It has as its input the quantity being measured and its output the a ue f that
q -
4. Write about the sensor and give an example. •
A sensor, which responds to the quantity being measured by giving a s µtput a signal which is
related to the quantity. Example: A thermocouple is a temperattfre se so r. The input to the
sensor is a temperature and the output is an e.m.f. which is related t e teµrperature value.
5. Write about the signal conditioner?
A signal conditioner takes the signal from the sensor4in manjpulates it in to a condition, which
is suitable for either display, or in the case of a control sy m, for use to exercise control.
6. What are the two basic forms of the control ·stent'?
The two basic forms of the control systems atr
a. Open loop control system. -1,,"""
b. Closed loop con_tro l system.
Type Advantage i '
Disadvantage

W
a. It is being ic4ltively simple
b. Low cost
Open Loop c. Good reliability inaccurate since there is no correction of error

a. More complex
b. More costly
c. Greater chance of breakdown as a
Accurate in matching the consequence of the greater number of
Closed Loop actual to the required values. components.
7. What are the elements of the closed loop control system?
The various elements of a closed loop control system are,
a. Comparison element
b. Control element
c. Correction element
d. Process element

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 e. Measurement element
8. What are the two types of feedback loop?
The two types of feed back loop are,
a. Positive feed back loop
b. Negative feed back loop.
"The feedback is said to be negative/ positive feedback when the signal; which is feed
back, subtracts/adds from the input value. It is required to control a system. The control
elements decide what action to take when it receives an error signa l"
9. What are the types of control elements?
There are two types of control elements. They are
a. Hard - wired systems
b. Programmable systems.
9. What are the various elements of a closed loop system for a person contr
temperature?
The various elements of a closed loop system are,
1. Controlled variable
2. Comparison element
3. Error signal
4. Control unit
5. Measuring device

10. Write about the Mechatronics approach in a m·c a-processor- controlled washing
machine?
In the microprocessor-controlled washing m.{Q. ij e, a mechanical system has become integrated
with electro nic controls. As a conseq nc a:b&fky mechanical system is replac ed by a much

programs. 6
more compact microprocessor sys em w ich# readily adjustable to give a greater variety of
"\:
11. What is the larger scal ,t Jicatfon of Mechatronics?
A larger scale application of Mec t ronics is a Flexible Manufacturing engineering System
(FMS) involving computer - controlled machines, robots, automatic material conveying and
overall supervisory control.

12. List some of the applications of Mechatronics?

1. Home Appliances: Washing machine, Bread machines etc
2. Automobile: Electrical fuel injection , Antilock brake system
3. Aircraft: Flight contro l, Navigation system
4. Automated Manufacturing
13. What are the components of Mechatronics System?
'I. Actuators
2. Sensors
3. Signal Condition ing units
4. Digital control devices
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5. Graphical Displays
14. What is meant by a system in Mechatronics?
The System is the group of physical component combined to perform a specific function. Any
mechatronics devices consists of systems
15. What are the main applications of mechatronics?
Washing machines, dish washers, micro ovens, cameras, camcorders, robots, automatic
conveyors, computer-controlled machines
16. Obtain the basic functions of control systems.
I. To minimize the error between the actual and desired output
2. To minimize the time response to load changes in the system
17. What are the types of control system?
· Open loop system
· Closed loop system
18. List down the requirements of control systems.
· Stability
· Accuracy
· Response
19. Give an example for open loop system and closed looQ
I. Closed loop system - Automatic water leve l controller
2. open loop system - Electric fire
20. Compare open loop control system and closed lo
Open loop systems

The feedback signal controls the table position

accurately
Is used almost in all automation process
Its not suitable for rough works
Error is currently checked and rectified
21. What are the basic elements of feedback system'?
· Forward path
· Feedback path
· Error detecting device
· Amplifier
· Compensating networ k
22. What is meant by sequential control what are the two modes in it?
A system operating with sequential control is one where a set of prescribed operations are
performed in sequence. The modes are,
· Event - based mode
· Time - based mode
23. Give an example for event-based and time-based sequential control.
· Time-based Water Heater
· Event-based Domestic washing machine

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 24. What is the purpose of a sensor'?
Sensor is used for an element which produces a signal relating to the quantity being measured.
I.e., an electrical resistance temperature element, the quantity being measured is temperature and
the sensor transfonns an input of temperature into a change in resistance.
25. Define transducer?
The tenn transducer is often used in place of the term sensor. Transducer is defined as elements
that when subject to some physical change experience a related change. Thus, sensors are
transducers.
26. What are the terms that define the performance of the transducers?
1. Range and span
2. Eiror
3. Accuracy
4. Sensitivity
5. ysteresis error

27. Define static characteristics? •

The static characteristics are the values given when the steady tate ions occur. i.e., the
values given when the transducer has settled down after havin received some input.
28. Define dynamic characteristics?
The dynamic characteristics refer to the behavior between •th:s,ip{e that the input value changes
and the times that the value given by the transducer set KI wn to the steady - state value.
Dynamic characteristics are stated in tenns of the res onse of the transducer to inputs in
particular forms.
29. What are the terms that you can fin m e dynamic characteristics?
1. Response time.
2. T ime constant. •
3. Rise time L '\- "'-.,

4S.ettling time.
30. What is a displacement sensor?
Displacement sensors are concerned with the measurement of the amount by which some object
has been moved.
31. What is a position sensor?
Position sensors are concerned with the determination of the position of some object with
reference to some reference point.
32. What is a proximity sensor?
Proximity sensors are a form of position sensor and are used to determine when an object has
moved to within some particular critical distance of the sensor.
33. What are the two basic types of the displacement and the
position transducers?
The two basic types are,
1. Contact sensors
2. Non contact sensors.

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34. Write about the strain - gauged element?
The electrical resistance strain gauge is a metal wire, metal foil strip, or a strip of semiconductor
material, which is wafer - like and can be stuck onto surfaces like a postage stamp.
35. Define gauge factor.
The gauge factor is defined as the ratio of per unit change in resista nce to per unit change in
length.
Gauge factor Gf= R/R
UL
36. Write about the gauge factors for different types of strain gauges?
The gauge factor of metal wire or foil strain gauges with the metals generally used is about 2.0.
Silicon p - and n - type semiconductor strain gauges have gauge factors of about + 100 or more
for p- type silicon and - 100 or more for n - type silicon.
37. What is the capacitance of a parallel plate capacitor?
The capacitance of a parallel plate capacitor is given by,

C = EA/d = ErE0 A/d

s
;:;r:rmitivity of the medium/m •
Er= Re lative pem1itivity
Eo= Pem1itiv ity of the free space= 8.85x I o-12 F/m P
A = Area of plates
D = Distance between two plates
38. Define LVDT'? ,. ,,..
The Linear Variable Differential Trans fonner consi s of three coils symmetrically spaced
along an insu lated tube. The central coil is the prim r( and the other two are identical
secondary
coils, which are connected in ser iesi:S,u a waythat their outputs oppose each other.
39. Determine the working Principle of LV T?
When there is an alternating volt ge in u to the primary coil, alternating e.m.f.s are induced in
the secondary coils. With the@iagt:!eti t' core central, the amount of magnetic material in each
of the secondary coil is the same.
40. What are the uses of LVDT?
The uses are as follows.
a. Widely used as primary transducers for monitoring displacements.
b. Also used as secondary transducers in the measurement of force, weight and pressure.
41. Write about inductive proximity switch?
Inductive proximity switch consists of a coil wound round a core. When the end of the coil is
close to a metal object is inductance changes.
42. What is an encoder?
An encoder is a device that provides a digital output as a result of a lin ear or angular
displaceme nt.
43. What are the two types of position encoders'?
The two types of position encoders are,
a. Incremen tal encoders
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b. Absolute encoders.
44. What is an incremental encoder?
An incremental encoder is used for the measurement of angular displacement. A beam of light
passes through slots in a disc and is detected by a suitable light sensor..
45. Write about absolute encoder?
An absolute encoder is used for the measurement of angular displacement. This gives an output
in the fonn of a binary number of several digits, each such number representing a particular
angular position.
46. What are the uses of photosensitive devices?
Photosensitive devices can be used to detect the presence of an opaque object by it breaking a
beam of light or infrared radiation, falling on such a device or by detecting the light reflected
back by the object.
47. Write about Hall effect sensors?
When a beam of charged paiticles passes through a magnetic field, forces act op paii icles and
the beam is deflected from its straight line path. A current flowing in a condu to.IJ is like a beam of
moving charges and thus can be deflected by a magnetic field. •

49. What are digital signals?

Digital signals are discrete time signals in t t are not continuous functions of time but exist
at only discrete times.
50. Why the signal conditioning ·s re-quire «g
Signal conditioning of analogueAigtialsrnquires components such as amplifiers filter circuits and
digital signal microprocessor.
51. Define Actuator.
An actuator is an output device which performs useful works
52. Classify actuator based on motion.
1. Linear motion
· Single acting cylinde r
· Double acting cylinder
2. Rotary Motion
· Air motors
· Rotary actuators
3. Flow Control valve
53. When is cascade control Needed?
The need for cascade control will occur when a final control element experiences signal overlap
i.e. when a trip valve mechanism is still held down, but the output signal has to been used and
requires removal

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 54. Write down the principles of cascade control.
· A simple design procedure to detem1ine the minimum number of groups in the circuit
· Evolve separate supply bus for each group
· Arrange selector valves to divert the supply to whichever is the active group
55. Mention the various components of a hydraulic system.
· Motor
· Filter
· Pump
· Pressure Regulator
· Control Valve
· Piston and cylinder
56. What is called a pneumatic system?
System using gas for power transmission are called pneumatic systems and indu, tr1{1
usually based on air.
57. List down the components of pneumatic system.
• Motor driven compressor •
• Air receiver :-::;,
• Directional control
• Pneumatic cylinder
58. What is the purpose of using filters in the hydrauli
Filters are used to prevent dirt or dust entering importa e n ents of hydraulic system like

S, ""
valves, seals, etc. Filters are used to remove verywf e 1cles.
59. What are the types of pumps used as energ source in a hydraulic system?
· Centrifugal Pump(Hydrodynamic Pumps)
· Positive displacement pump .,
I. Gear Pumps •
2. Vane Pumps
3. Piston pumps
00. What are the factors to be co sidered for selecting compressors?
The type of air compressor is selected dependent on quality of air, pressure and cleanliness
61. What are the uses of air receive r?
An air receiver is used to store high pressure air and provide constant supply of air pressure in
the pneumatic system regardless of varying and fluctuating consumption. It is used for the
emergency supply of air to the system in case of power failure.
62. State the purpose of providing air dryers.
The aim is to reduce the temperature of the air to a dew point which ensures that the water in the
air condenses and drops out easily.
63. State the function of a control valve.
The primary function of the control valve is to direct and regulate the flow of fluid from an
energy source to various loadin g devices. Nonnally the control valves are used for the purpose of
sensing, processing ,and controlling. They are used for:
· Allowing the passage of air/fluid and directing it to a loading line

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· Cancel the signal by blocking its passage
· Alert or generate the signal
· Release the air to atmosphere or rettu-n the fluid to tank
64. List the different control valves.
· Directional control valve
· Non return valves
· Flow control valves
· Pressure control valves
· Combinational valves
· Solenoid valves
65. Define the term degrees of freedom.
The minimum number of independent displacement required to specify the system c
called degrees of freedom
66. Define kinematic pair. (!:
The two links or elements are joined together to form a pair. If the relative motioh between them
is completely or successfully constrained, the pair is known as kinemati pair_
67. When is cascade control needed?
The need for cascade control will occur when a final contr ment',e perie nces signal overlap
ie; when a trip valve mechanism is still held down, but the o tP. t signal has been use and

69. What is a stepper motor? •

A stepper motor is a rotating machine w \O nverts a DC voltage pulse into a series of discrete
rotational steps. Each step positioi is n ilw riu m position without further excitat ion, this
makes it ideally suitable for the-dse<w" it digital control
70. What is stepper motor'?6....\
A stepper motor is a device w ansforms electrical pulses into equal increments of
rotary shaft motion called steps.
71. What is servo motor?
The motors used in auto matic control systems or in servomechanism are called servomotors.
They are used to convert electrical signal into angular motion.
72. What is synchro?
A synchro is a device used to convert an angular motion to an electrical signal or vice versa.
73. At what conditions SPOT, DPST an DPDT switches are used?
a. SPOT (Single Pole, Double Throw): When we require ON and OFF operation as the circuit is
actuated, SPOT is used.
b. DPST (Double Pole, Single Throw): When we need to tum two separate circuits ON and OFF
simultaneously with a single switch, DPST is used.
c. DPDT (Double Pole, Double Throw): When a switch is turned ON and OFF between N and 0
with double pole switches , DPDT is used.

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74. What are the factors to be considered for selecting solenoids?
a. The size of the mechanical load.
b. The movement distance of plunger.
c. The type of electrical connections.
d. The type of value of current and voltage.

75. What is the principle of relay?

Relay is used for many control functions and essentially an electro-mechanical switch. It uses
basic switching principles and solenoid actuation.
76. What is zener voltage?
In the reverse direction, the diode conducts very little when the voltage is below the breakdown
value. This critical limiting value of reverse voltage is known as zener voltage.
77. Name three output characteristics of transistor configuration.
a. Saturation region
b. Active region
c. Cut-off region.
78. What is a microprocessor?
A microprocessor is a multipurpose, programmable, clock driven, eg1s ers - based elec tro nic
device that reads binary instructions from a storage device fa11eomet 10ry, accepts binary data
as
input and processes data according to those instructions, al'icl. P.r des results as output.
79. What are the four components of a programma le ma hine'?
A typical programmable machine can be represe2 d witl our components. a. Microprocesso r
b. Memo ry c. Input d. Output. '-
80. Deline the terms. a) Bus b) RAM c) R .
BUS
- A group of lines used to transfe., bit e wefj the microprocessor and other components of the
computer system.
RAM
-Random Access Memory. Data 1 stored in a read / write memory.
ROM
- Read only Memory. A memory that stores binary info1mation permanently. The information
can be read from this memory but cannot be altered.
81. W hat the types of languages used?
The types of languages used are,
a. Machine language
b. Assembly language
c. Low - leve l lan guage
d. High - lev el language.
82. What is a machine language'?
The binary medium of communication with a computer through a designed set of instructions
spec ific to each computer.
83. What is a assembly language'?
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A medium of communication with a computer in which programs are written in mnemonics. An
assembly language is specific to a given computer.
84. What is ]ow - 1eve11anguage?
A medium of communication that is machine - dependent or specific to a given computer. The
machine and the assembly language of a computer are considered low - level languages.
Programs written in these languages are not transferable to different types of machines.
85. What is a high - level language?
A medium of communication that is independent of a given computer. Programs are written in
English - lie words, and they can be executed on a machine using a translator (a compiler or an
interpreter).
86. Differentiate a compiler and an interpreter?
Compiler -A program that translates English- like words of a high level language _.Uf ,,
machine language of a computer. A compiler reads a given program, called a so}4;c ) ¥e , in its
entirety and then translated the program into the machine language, which is lied n object

s
code. Interpreter -A program that translates the English- like statements of hit h - level
language in to the machine language of a computer. An interpreter tran ne statement at a
time from a source code to an object code.
87. What are the two parts of an instruction'?
An instruction has two parts. P
Opcode
- Operation to be perfonned.
Operand ,,..
- The operand can be data (8 - or 16- bit), addr r register, or it can be impIicit. The
O>l
method of specifying and operand (directiy, indir is called the addressing mode.
88. What are the types of bus'?
The types of bus are, •
a. Address bus ,L '\- ""-,

Data bus
c. Control bus.
89. Define the term , Data Bus, Address bus, Control Bus
a. Address Bus
A group of lines that are used to send a memory address or a device address from the MPU to the
memory location or the peripheral and is unidirectional. The 8085 microprocessor has 16
address lines.
b. Data bus
A group of bi-directional lines used to transfer data between the MPU and peripherals and is bi
directional. The 8085 microprocessor has eight data lines.
c. Control bus
Single lines that are generated by the MPU to provide timing of various operations.
90. Write about the 16 - bit register of a 8085 microprocessor?
The 8085 has two 16 - bit register.
a. The program counter

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b. Stack pointer The program counter is used to sequence the execution of a program. The
stack pointer is used as a memory pointer for the stack memory.
91. What are the two types of memories?
The two types of memories are ,
a. Static memory (SRAM)
b. Dynamic memory (DRAM)
92. Write about the SRAM'?
a. This memory is made up of flip - flops, and it sores the bit as a voltage.
b. Each memory cell requires six transistors.
c. The memory chip has low density, but high speed.
d. More expensive, and consumes more power.
e. Also known as cache memory.
93. What are the advantages of DRAM?
The advantages of DRAM are, (!
a. This memory is made up of MOS transistor gates and it stores the bit as a eharge.
b. It has high density. •
c. Low power consumption :-::;,
d. Cheaper than static memory
e. Economic to use when the system memory size is atleast'SKXor sriiall systems.
94. What are the disadvantages of DRAM?
The disadvantages of DRAM are,
a. The charge (bit information) leaks. #) ..,,.
b. Stored information needs to be read and writt ain every few milliseconds this is
called refreshing the memory. •
c. Requ ires extra circuitry, adding to e g,g_{s\ o ft he system.
95. What is tlash memory'? • ,
The flash memory must be eraseif @ith lb n its entirely or at the sector level. The memory chips
can be erased and programm cl at1-eas6t million times. The power supply requirement for
programming these chips 2wa d 12V, but now chips are available that can be programmed
using a power supply as low as 1.8 V. Hence, this memory is ideally suited for low - power
systems.
96. What are the interfacing devices?
The bus drivers increase the current driving capacity of the buses, the decoder decodes the
address to identify the output port, and the latch holds data output for display. These devices are
called interfacing devices. The int erfacing devices are semiconductor chips that are needed to
connect periphera ls to the bus system.
97. Write about buffer?
The buffer is a logic circuit that amplifies the current or power. It has one input line and one
output line. The logic level of the output is the same as that of the input , logic l input provides 1
output. The buffer is used primarily to increase the driving capability of a logic circuit. It is also
known as driver.
98. Define looping'?

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The programming technique used to instruct the microprocessor to repeat tasks is called looping.
A loop is set up by instructing the microprocessor to change the sequence of execution and
perform the task again. This process is accomplished by using Jump instructions.
99. What are the types of loops'?
Loops can be classified in to two groups. They are,
a. Continuous loop
b. Conditional loop.
100. Write about the continuous loop'?
A continuous loop is a set up by using the unconditional jump instruction. A program with a
continuous loop does not stop repeating the tasks until the system is reset.
101. Write about the conditional loop?
A conditional loop is set up by the conditional jump instructions. The instructions cll k gs
(Zero, C.ury etc.,) and repeat the specified tasks if the conditions are satisfied. T,p e ps
usually include counting and indexing. '1
102. \\ 'hat are the instructions of a 8085 instruction set for data transfer roin memory
to the microprocessor? •
The 8085 instruction set includes three memory transfer instructif)ns"\.'.L. re, a.MOY R,M :
Move from Memory to Register ¥
b.LDAX B/ D : Load Accumulator Indirect
c.LDA 16 - bit : Load Accumulator Direct
103. What are the instructions of a 8085 instruction et for data transfer from
microprocessor to the memory? f
The 8085 instruction set includes three memory m sfer instruction. They are, a. MOY. R,M :
Move from Memory to Regis te r b. STAX tore Accumulator Ind irect c. STA 16 - bit :
Store Accumulator Direct d. V
MVI M, 8 - bit : Load 8 - bit data n tn ory
104 . What are the opcodes relaied to rotating the accumulator bits?
The opcodes related to rotati \ ,aceumulator bits are,
a. RLC - Rotate Accunmlator Lefrt hroughCarry
b. RAL - Rotate Accumulator Left
c. RRC - Rotate Accumulator Right through Carry
d. RAR - Rotate Accumulator Right
105. What is dynamic debugging?
After the steps have been completed in the process of static debugging, and if the program still
does not produce the expected output, attempt is made to debug the program by observing the
execution of instructions. This is called dynamic debugging.

106. What are the tools used for dynamic debugging'?

The tools used for dynamic debugging are,
a. Single step
b. Reg is ter exa mine
c. Break point.
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107. Write about single step'?
Th e single step key on a keyboard allows to execute one instruction at a time, and to observe the
results following each instruction. Generally, a single-step facility is built with a hard-wired
log ic circuit. When the single step key is pushed, addresses and codes are observed as they are
executed.
108. What are the advantages of single step?
With the single step technique, it is able to spot,
a. Incorrect addresses
b. Inco rrect jump locations for loops
c. Incorrect data or missing codes.
109. Write about register examine?
The register examine key allows to examine the contents of the microprocessor regis r
110. Write about the break point?
In a single - board computer, the break point facility is a software routine th l w executing a
program in sections. The break point can be set in a program by using RST iae1 ctionsll l.
What are the advantages of the break point? •
With the break point facility, :-::;,
a. Iso lat e the segment of the program with errors.
b. Iso lat ed seg ment can be debugged with the single - ste a i(l ty.
c. Check out the timing loop. ..._'yr
d. Check the 1/0 section
e. Check the interrupts. \;.,.,...,,
112. How will you interface the 1/0 devices?
1/0 devices can be interfaced using two te h 1 es.. hey are,
a. Periphera l - mapped 1/0
b. Memo ry - mapped 1/0. •

113. Write about peripherat m peKT/0 ?

In peripheral - mapped , a dev e is identified with an 8 - bit address and enabled by 1/0
10/ related control
signals.
114 . Write abo ut memory - mapped T/O?
In memory mapped 1/0, a device is identified with a 16-bit address and enabled by
memory - related control signals.
115. What is A/D and D/A converter?
The electronic signal that translates the analog signal into digital signal is called analog to digital
(A/D) converter. The electron ic s ignal that translates the digital signal into analog signal is
called digital to analog (D/A) converter.
116. What are the types of DIA converters?
Digital to analog converters can be broadly classified in three categories. They are,
a. Current output
b. Voltage output
c. Multiplying type
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117. Write about the three types of D/A converters?
Current output - It provides current as the output signal. Voltage output - Internally converts the
current signal into the voltage signal. It is slower than the current output DAC because the delays
in converting the current signal in to the voltage signal. Multiplying type - Its output represents
the product of the input signal and the reference source and the product is linear over a broad
range.
118. What are the elements required for D/A converter?
A DI A converter circuit requires three elements. They are
a. Resistor network with appropriate weighting
b. Switches
c. Reference source.

e l
119. What are the two techniques involved in AID conversion?
The techniques involved in AID conversion are,
a. Comparing a given analog signal with the internally generated
equivalent includes successive approximation, counter, and flash - type
converters.
b. Changing an analog signal into time or frequency and comparing the e new, parameters to
known values. This group includes integrator conve1ters and vo ag uency conve1iers.
120. What are the applications of A/D converters? ' ¥
The AI D converters are used in applications such as data <o, ig ePS a n/ instrumentation, where
conversion speed is important. The integrating type converters reused in applications such as
digital meters, panel meters and monitoring systems, w e he conversion accuracy is critical.
121. What are the functions of a microprocesso ·o be mterfaced with an AID converter?
To interface an A/D converter with the microproc s r, the microprocessor should,
a. Send a pulse to the '.START' pin. This.ca 1tl nved from a control signal such as
write (WR)
b. Wait until the end of the convei io . his v, riod can be verified either by status checking
(polling) or by using the interrup .
c. Read the digital signal at a inp· t pefrt.
122. What is a PLC?
A programmable Logic Controller (PLC) is defined as a digital electronic device that uses a
programmable memory to store instructions and to implement functions such as logic,
sequencing, timing, counting and arithmetic in order to control machines and processes.
123. What is main advantage of PLC?
PLC's have great advantage that it is possible to modify a control system without having to
rewire the connections to the input and output devices.
124. What are the features of PLC as a controller'?
The features of PLC as a controller are,
a. They are rugged and designed to withstand vibrations, temperature, humidity and noise.
b. The interfacing for inputs and outputs is inside the controller.
c. They are easily programmed and have an easily understood programming language.
125. Write about the architecture of a PLC'?
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It co nsis ts essentially of a central processing unit (CPU), memory and input/output circuitry.
The CPU controls and processes all the operat ions within the PLC. It is supplied with a cloc k
with a frequency between 1 and 8 MHz. It also has a bus system, memory and input/output units,
a system ROM for permanent storage, RAM for the users program and temporary buffers.
126. What is ladder programming?
The ladder programming involves each program task being specified as though a rung of a
ladd e r. Thus such a rung could specify that the state of switches A and B, the inputs, be
examined and if A and Bare both closed then a so lenoid, the output is energize d.
127. How are programs entered'?
Programs are entered into the input / output unit from a panel, which can vary from small
keyboards with liquid crystals to those using a visual display unit (VDU) with keyboar d
screen display. Alternatively, the programs can be entered into the system by means a lµik to
a PC.
128 Write about the input / output channels?
The input/output channels provide signal conditioning and isolation function so that sensors and
actuators can be generally directly connected to them without the need lier circuitry.
Common input voltages are 5 V and 24V. Common output volt es a1e 2 and 240 V.
129. Write about the relay?
With the relay type, the signal from the PLC output is use d''t erai a relay and so is able to
switch currents of the order of a few amperes in an external oircpft. The relay isolates the PLC
from the external circuit and can be used for both D. . n .C. switching. Re lays are,
however, relat ive ly slo w to operate.
130. What are opto isolators'? . ,,
Opto isolators are used with transistor switche 6.P vide iso lat ion between the external
circuit and the PLC. They are also used to p vi "\ plation.
131. What are the methods usedJ or inputl) mtput processing?
There are two methods used for;tb put r otitput processing. They are
a. Continuous updating
b. Mass input/output copying.
132. \\ 'hat is continuous \lpdating ?
This invol ves the CPU scanning the input channels as they occur in the program instructions.
Each input point is examined individually and its effect on the program dete1mined. Each input is
scanned with a 3 ms delay, before the program has the instruction for a logic operation to be
executed and an output to occur. This process is called continuous updating.
133. What is the disadvantage of continuous updating?
Because of the 3 ms delay in the continuous updating on each input , the time taken to examine
several hundred input/output points can become comparatively long.
134. Write about the mass input/output copying?
To allow a more rapid e xecution of a program, a specific area of RAM is used as a buffer
store between the control logic and the input/output unit. At the start of each program cycle
the CPU scans all the inp uts and copies the ir status into the input/output address in RAM. At
the end of
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each program cycle all the outputs are transferred from RAM to the output channels. The outputs
are latch ed so that they reta in the ir status until the next updating
135. What is a LATCH circuit?
The tenn latch circuit is used for the circu it used to carry out such an operation. It is a self -
maintaining circu it in that , after being energized , it maintains that state until another input
is rece ived. It remembers its last state.
136. Define the term point and delay-<m?
T he tenn point is used for a data point and so is a timing, marker (internal r e lay) or counter
element. Thus, the 16 points for timers means that there are 16 timer circuits. The term delay
on is used to indicate that this type of timer waits for a fixed delay period before turning on.
137. Write about timer circuit?
A timer circuit is specified by stating the interval to be times and the conditions or nts • at
are to stait and / or stop the timer.They are commonly regarded as delays with coils w!ii hen
energized, res ult in the closing or opening of input contacts after some preset,
138. \\ 'rite about internal relays?
The term internal relay, auxiliary relay or marker is used for what can b "sidered as an
internal relay in the PLC. These behave like relays with their associa a co tacts, but in reality
o-:t1;: LC. fi temal relays are often
are not actual relay s w ith th eir associated by the software
used when there are programs with multiple input conditio

139. Write about counters?

Counters are used when there is a need to count a :W.e e · number of contact operations.
Example - where items pass along a conveyor i xes, and when the specifi ed number of
items has passed into a box the next item ed into another box.
140. What is an up counter?
An up coun ter would count up to e Jf eset v ue i.e., events are added until the number reaches
the set value. When the set valu ·welchecl the co unters contact changes state.
141. What is a down count ?
Down counter means that the comp ter counts down from the preset value to zero i.e., events are
s ubtracted from the set value. When zero is reached the counters contact changes state.
142 . Write abo ut shift register?
The term shift register is used because the bits can be shifted along by one bit when there is a
s uitable input to the register.
143. What are the inputs of shift register?
There are three inputs of sh ift reg ister . T hey are,
a. One to load data into the first element of the register (OUT).
b. One as the sh ift comma nd (SFT).
c. One for resetting (RST).
144. What the operations that are carried out with a PLC on data words?
The opera tions that are carried out with a PLC on data words are,
a. Moving data
b. Comparison of magnitudes of data

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c. Arithmetic operations such as addition and subtraction
d. Conversions between binary coded decimal (BCD), binary and octal.
145 . What is the criteria need for the selection of a PLC?
The criteria needed for the selection of a PLC are the following.
a. Input /output capacity is required.
b. Types of inp uts/outputs are required.
c. Size of memo1yrequired.
d. Speed and power is required for the CPU.
146. What are the numbers of stages in the design process'?
The design process can be considered as a number of stages. They are,
a. The need
b. Analysis of the problem
c. Preparation of a specification
d. Generation of possible solutions
e. Selections of a suitable solution
f Production of a detailed design
g. Production of working drawings.

147. What are the advantages of the microprocessor co trol ed system?

The microprocessor controlled system can cope easily wit]('gti iJlg precision and programmed
control. The system is much more flexible. Th is im ( in flexibility is a
common characterist ic of Mechatronics systems when comgar 'i-fh traditional
systems.
148. What is the advantage of using PLC solutf n over mechanical solution?
A PLC solution could involve the arrangem J\t the given ladd er program. Th is would
have the advantage over the rotating cam okh off and on times which can be adjusted by purely
changing the timer preset values ii th ogr whereas a different cam is needed if the times
have to be changed with the mee,.a.nica so ution.
149. What are the axes of a ic and place robot?
The robot has three axes about h motion can occur.
a. Rotation in a clockwise or counter clockwise direction of the unit on its base.
b. Arm extension or contraction and arm up or down.
c. Gripper can open or close.
150. How do the movements of robot take place?
Clockwise rotation of the unit might result from the piston in a cylinder being extended and the
counter clockwise direction by its retraction. Likewise th e upward movement of the arm might
result from the pisto n in a linear cylinder being extended and the downward motion from it
retracting, the extension of the arm by the piston in another cylinder extending and its return
movement by the piston retracting.
151. What is the use of PLC in automatic car park system?
An illustrat io n of the use of a PLC in the coin operated barriers for a car park. The in-barrier is to
open when the correct money is inserted in the collection box and the out - barrier is to open
when a car is detected at the ca r park side of the barrier.
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152. How does a car park barrier works?
When a current flows through the solenoid of valve, the piston in a cylinder moves upwards and
causes the baiTier to rotate about its pivot and rise to let a car through.
153. Write about the engine speed sensor'?
The engine speed sensor is an induct ive senso r and consists of a coil for which the inductance
changes as the teeth of the sensor wheel pass it and so results in an oscillating voltage.
154. How is the voltage produced by the oxygen sensor'?
The oxygen sensor is generally a closed- end tube made of zirconium oxide with porous
platinum elect rodes on the inner and outer surfaces. Above about 300°C, the sensor becomes
permeable to oxygen ions with the result that a voltage is produced between the electrodes.
155. Give some applications of microprocessor.
The examples of the microprocessor are,
a. Microprocessor Controlled Temperature System (MCTS)
b. Stepper motor control
c. Traffic light controller.

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