K. J.

Somaiya College of Engineering, Mumbai-77

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

Introduction to Automation and

Course Name: Semester: VI
Mechatronics
Date of Performance: 15/1/2024 Batch No: A3
Faculty Name: Sandeep Hanumante Roll No: 16010222804
Faculty Sign & Date: Grade/Marks:

Experiment No: 2
Title: Real Time Flow monitoring of Automation system using S7-1200 PLC

Aim and Objective of the Experiment:

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

COs to be achieved:

CO2. Design PLC based Mechatronics systems

Theory:

Circuit Diagram/ Ladder diagram:

Real-time monitoring of flow using electro pneumatics and PLC (Programmable Logic Controller)
involves the integration of flow sensors, pneumatic components, and a PLC system to continuously
measure and control the flow of gases or fluids in an industrial or automation environment. Here's a
general overview of the steps involved in such a system:

Pressure Sensors:

Install flow sensors at relevant points in the pneumatic system. These sensors can be based on various
technologies, such as ultrasonic, thermal, or electromagnetic, and they generate electrical signals
proportional to the flow rate.

Sensor Interface:

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

PLC Programming:

IAM Semester: VI Academic Year: 2023-24

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

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

Pneumatic Diagram

IAM Semester: VI Academic Year: 2023-24

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

Sensor symbols

Stepwise-Procedure:

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

2) Test the pneumatic connection

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

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

5) Test the cyclic operation of cylinder using PLC

6) Connect the flow sensor to measure the flow in the pneumatic setup

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

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

IAM Semester: VI Academic Year: 2023-24

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

Observation Table:

PLC output : Paste the screenshot of the program, photo of the pneumatic setup

IAM Semester: VI Academic Year: 2023-24

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

IAM Semester: VI Academic Year: 2023-24

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

Post Lab Subjective/Objective type Questions:

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

ANS: -
The specification of the flow sensor used in an experiment to monitor the flow of pneumatic supply
using IW64 of PLC (Programmable Logic Controller) will depend on the specific requirements of the
experiment and the characteristics of the pneumatic system. Here are some general specifications you
might consider:

● Flow Range: The range of pneumatic flow rates the sensor can effectively measure.
● Pressure Rating: The maximum pressure that the flow sensor can handle within the
pneumatic system.
● Accuracy: The precision of the flow sensor in providing measurements, which is crucial for
accurate monitoring.
● Response Time: The time it takes for the sensor to respond to changes in pneumatic flow.
● Output Signal: The type of output signal compatible with the PLC (e.g., analog signal, digital
signal, current loop, voltage signal).
● Connection Type: The method of connecting the flow sensor to the pneumatic system.
● Environmental Conditions: Operating temperature range, humidity, and other environmental
factors that may affect sensor performance.
● Calibration: Information on calibration procedures and requirements.
2. What are the different types of flow sensors available? Explain based on its construction and
principle
ANS: -
1)Mechanical Flow Sensors:
● Rotameters: Consist of a tapered tube and a float. The position of the float within the tube
corresponds to the flow rate.
● Paddlewheel Sensors: Include a rotating paddlewheel turned by the fluid flow, producing a
signal proportional to the flow rate.

2)Differential Pressure Flow Sensors:

● Orifice Plate: Introduces a restriction in the flow path, creating a pressure drop. Flow is
determined by measuring the pressure difference across the restriction.
● Venturi Tube: Similar to an orifice plate but with a gradually converging and diverging
section. Measures the pressure difference to determine flow.

3)Thermal Flow Sensors:

● Thermal Mass Flow Meters: Include a heated element and temperature sensors. The heat
dissipation is used to determine the mass flow rate.
● Thermal Dispersion Flow Meters: Measure the cooling effect of a fluid on a heated sensor,
providing information about the flow rate.

4)Vortex Shedding Flow Sensors:

IAM Semester: VI Academic Year: 2023-24

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

Include a bluff body (vane) in the flow. Vortices are shed alternately on either side of the bluff body,
and the frequency of shedding is proportional to the flow rate.

5)Ultrasonic Flow Sensors:

● Transit-Time Flow Meters: Emit ultrasonic pulses upstream and downstream, measuring the
time of flight to calculate the flow rate.
● Doppler Flow Meters: Use the Doppler effect to measure changes in frequency of ultrasonic
waves scattered by particles in the fluid.

6)Magnetic Flow Sensors:

Utilize a magnetic field and electrodes in the flow pipe. As a conductive fluid passes through the
field, a voltage is induced, which is proportional to the flow rate.

7)Coriolis Flow Sensors:

Feature a vibrating tube through which the fluid flows. The Coriolis effect causes a phase shift, and
the degree of shift is used to measure mass flow.

8)Positive Displacement Flow Sensors:

● Gear Flow Meters: Measure the volume of fluid displaced by rotating gears.
● Piston Flow Meters: Use a piston or a rotating reciprocating piston to displace fluid and
measure the volume.

9)Turbine Flow Sensors:

Contain a rotor with blades placed in the flow. As the fluid moves the blades, the rotor spins at a rate
proportional to the flow rate.

Conclusion: Hence, we have Obtained the Real Time Flow monitoring of Automation system
using S7-1200 PLC

Signature of faculty in-charge with Date:

IAM Semester: VI Academic Year: 2023-24

Roll No: