PROCESS AUTOMATION

PRACTICAL MANUAL
(N – SCHEME)

MECHANICAL ENGINEERING
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Name:___________________________

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 Contents
INTRODUCTION Page No.
1. Pneumatic system …….............................................................................. 1
2. Hydraulic system ……................................................................................ 7

EXERCISES PART – A
PNEUMATICS
1. a) Direct operation of single acting cylinder ...................................................
b) Direct operation of double acting cylinder ..................................................
2. Operation of double acting cylinder with quick exhaust valve ............................. 33
3. a) Speed control of double acting cylinder using metering in circuit .................... 35
b) Speed control of double acting cylinder using metering out circuit .................. 37
4. Automatic operation of double acting cylinder in single cycle-using limit switch ........... 39
HYDRAULICS
5. Direct operation of double acting cylinder ...................................................... 41
6. Direct operation of hydraulic motor ............................................................... 43
7. a) Speed control of double acting cylinder using metering in circuit .................... 45
b) Speed control of double acting cylinder using metering out circuit .................. 47
PART – B
PLC
1. Direct operation of motor using latching circuit ............................................... 49
2. Operation of motor using ‘AND’ logic control ................................................... 53
3. Operation of motor using ‘OR’ logic control ..................................................... 57
4. a) On-delay control of motor ......................................................................... 61
b) Off-delay control of motor ........................................................................ 65
5. Automatic operation of double acting cylinder – single cycle with time delay ......... 69
6. Automatic operation of double acting cylinder – multi cycle ............................... 73
7. Sequential operation of double acting cylinder and a motor ............................... 77
Viva – Voce Questions & Answers ................................................................... 80
 1. PNEUMATIC SYSTEM
1.1 Introduction
A pneumatic system is a system that uses compressed air to transmit and
control energy. Pneumatic systems are used in many industrial applications such as:
Material handling
Clamping
Shifting
Positioning
Branching of material flow
Packaging
Filling
Transfer of materials
Sorting of parts
Stamping and embossing of components, etc.

Pneumatic systems are also used in carrying out machining and some industrial
processes such as:
Drilling
Turning
Milling
Sawing
Finishing
Forming, etc.

1.2 Components of pneumatic system

A simple pneumatic system consists of the following components :
1) Air compressor
2) Air reservoir
3) Air service unit (FRL unit)
4) Direction control valves
5) Control valves
6) Actuators

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1) Air Compressor
Air compressor is used to produce the compressed air for the system by the
required volume and pressure. A single central compressor can supply various
pneumatic components with compressed air. Reciprocatory and rotary compressors
can be used.

2) Air reservoir (tank)

An air reservoir should be fitted to store and stabilizes the compressed air. It
also compensates the pressure fluctuation and cools the air.

3) Air service unit (FRL unit)

It consists of the following :
i) Filter : To remove impurities from compressed air before it is fed to the
pneumatic components.
ii) Pressure regulator: To stabilise the pressure and regulate the operation of
pneumatic components

iii) Lubricator : To provide lubrication for pneumatic components.

4)Directional control valves (DCV)

Directional control valves ensure the flow of air between air ports by opening,
closing and switching their internal connections. Their classification is determined by
the number of ports, the number of switching positions, the normal position of the
valve and its method of operation. Common types of directional control valves include
2/2, 3/2, 4/2, 4/3, 5/2, etc. The first number represents the number of ports; the
second number represents the number of positions.

i) 2/2 Directional Control Valve (2/2 DCV) : It has 2 ports and can be
operated with 2 positions, open and close. It uses the thrust force from the
spring to open and close the valve. When a force is applied the valve will be
pushed open. It connects the air inlet to the working tube.

ii) 3/2 Directional Control Valve (3/2 DCV) : It has 3 ports and can be
operated in 2 positions. This valve can be used to control a single acting
cylinder. When the spool of a three-way valve is in one extreme position, the
pressure passage is connected with the actuator passage. When in the other

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 extreme position, the spool connects the actuator passage with the exhaust
passage. The valves can be driven manually, mechanically, electrically or
pneumatically. 3/2 directional control valves can be Normally open type (NO)
or Normally closed type (NC)

iii) 4/2 Directional Control Valve (4/2 DCV) : It has 4 ports and can be
operated in 2 positions. A common application of four-ported four-way
directional valve is to cause reversible motion of a cylinder or motor. To perform
this function, spool connects the pressure port with one actuator port. At the
same time, the spool connects the other actuator port with the exhaust port.

iv) 4/3 Directional Control Valve (4/3 DCV) : It has 4 ports and can be
operated in 3 positions. The ports include one pressure port, two actuator
ports, and one exhaust ports. When it is operated in the left and right position,
spool connects the pressure port with one actuator port. At the same time, the
spool connects the other actuator port with the exhaust port. In the middle
position, it disconnects all the inlet and outlet ports.

v) 5/2 Directional Control Valve (5/2 DCV) : It has 5 ports and can be
operated in 2 positions. The ports include one pressure port, two actuator
ports, and two exhaust ports. Such valves provide the same basic control of
flow paths as the four-ported version, but have individual exhaust ports. Each
exhaust port serves an actuator port. This directional valve will remain in
operational position until another signal is received. Therefore, this type of
DCV is known as ‘memory valve’.

5) Control valves
A control valve is a valve that controls the flow of air. Examples include non-
return valves, flow control valves, shuttle valves, etc.
i) Non-return valve : A non-return valve allows air to flow in one direction only.
When air flows in the opposite direction, the valve will close. Another name
for non-return valve is poppet valve or check valve.

ii) Flow control valve : A flow control valve is formed by a non-return valve and
a variable throttle.

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 iii) Shuttle valve : It is also known as double control or single control non-return
valve. A shuttle valve has two air inlets and one air outlet. When compressed
air enters through one inlet port, the sphere inside the valve passage will seal
and block the other inlet port. Air can then flow from one inlet port to outlet.

iv) Quick exhaust valve : It is used for the quick exhaust of air to cause rapid
forward or return movement of actuator.

6) Actuators
Pneumatic actuator components provide rectilinear or rotary movement.
Examples include cylinder pistons, pneumatic motors, etc.

i) Single acting cylinder : It has only one entrance that allows compressed air
to flow through. Therefore, it can only produce thrust in one direction The
piston rod is propelled in the opposite direction by an internal spring, or by the
external force provided by mechanical movement or weight of a load.

ii) Double acting cylinder : In a double acting cylinder, air pressure is applied
alternatively to both the side of the piston, producing a propelling force and a
retracting force.

iii) Pneumatic motors : Motors with one direction or two direction rotation are
available. In a two direction rotation motors, air pressure is applied alternately
to both the side, producing a rotary movement.

Valve actuators
The directional control valves can be operated using a number of actuating
mechanisms. The following are the important valve actuators :

Spring Manual Push button Lever

Mechanical Solenoid Air pilot

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1.3 ISO symbols of pneumatic components

Symbol Description Symbol Description

Air source Flow direction

External port not

Exhaust to atmosphere
connected

Air compressor Air reservoir

Air dryer FRL unit

Air filter Regulator

Lubricator 2/2 DCV

3/2 DCV – Normally Closed

3/2 DCV – Normally Open
(Inline slide valve)

5/2 DCV
4/2 DCV
(Memory Valve)

Non return valve

Flow Control valve
(Check valve)

Shuttle valve Quick exhaust valve

Fixed restriction Adjustable restriction

Single acting cylinder Double acting cylinder

Pneumatic motor
(One direction & Two
direction)

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 2. HYDRAULIC SYSTEM
2.1 Introduction
An hydraulic system is an enclosed fluid based system that uses pressurized
incompressible liquids to transmit and control energy. The hydraulic system works
on the principle of Pascal’s law which says that the pressure in an enclosed fluid is
uniform in all the directions.

The hydraulic systems are mainly used for precise control of larger forces. The
main applications of hydraulic system include the following :

Industrial : Plastic processing machineries, steel making and primary metal

extraction applications, automated production lines, machine tool industries,
paper industries, loaders, crushes, textile machineries, R & D equipment and
robotic systems etc.

Mobile hydraulics : Tractors, irrigation system, earthmoving equipment,

material handling equipment, commercial vehicles, tunnel boring equipment,
rail equipment, building and construction machineries and drilling rigs etc.

Automobiles : It is used in the systems like breaks, shock absorbers, steering

system, wind shield, lift and cleaning etc.

Marine applications : It mostly covers ocean going vessels, fishing boats

and navel equipment.

Aerospace equipment : There are equipment and systems used for rudder
control, landing gear, breaks, flight control and transmission etc. which are
used in airplanes, rockets and spaceships.

2.2 Components of hydraulic system

The hydraulic system is also called as hydraulic power pack or power unit. It
consists of the following components :
1) Storage tank
2) Filter
3) Pump
4) Pressure regulator
5) Control valves
6) Actuator

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1) Storage tank
The storage tank is a reservoir for the liquid used as a transmission media.
The liquid used is generally high density incompressible oil.

2) Filter
Filter removes dust or any other unwanted particles from the oil before it is
pumped to pipeline. It helps to keep the fluid system clean and efficient, as well as
avoid damage to the actuator and valves.

3) Pump
The hydraulic pump converts mechanical energy into hydraulic energy by
moving, or transmitting, the hydraulic fluid. The capacity of pump depends on the
hydraulic system design. These pumps generally deliver constant volume in each
revolution of the pump shaft. There are several types of hydraulic pumps including
gear, vane and piston pump.

4) Pressure regulator
Pressure regulators maintain the required level of pressure in the hydraulic
fluid by redirecting the excess fluid back to the storage tank.

5) Control valves
Valves are used to control the direction, pressure and flow rate of a fluid
flowing through the circuit.

Directional Control Valves : These valves are used to control the start, stop
and change in direction of the fluid flow. Examples include check valve, 2/2 DCV,
3/2 DCV, 4/2 DCV, 5/2 DCV, etc.

Flow Control Valves : A flow control valve can regulate the flow or pressure of
the fluid. The fluid flow is controlled by varying area of the valve opening through
which fluid passes. Examples include glove valve, butterfly valve, ball valve,
balanced valve, etc.

Pressure relief valves : The pressure relief valves are used to protect the
hydraulic components from excessive pressure. This is one of the most important
components of a hydraulic system and is essentially required for safe operation
of the system. Examples include direct relief valve, unloading valve, sequence
valve, counterbalance valve, pressure reducing valve, etc.

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6) Actuator
The hydraulic actuator is a device used to convert the fluid power into
mechanical power to do useful work. The actuator may be of the linear type (hydraulic
cylinder) or rotary type(hydraulic motor) to provide linear or rotary motion
respectively.

The leak proof piping is also important due to safety, environmental hazards
and economical aspects. Some accessories such as flow control system, travel limit
control, electric motor starter and overload protection may also be used in the
hydraulic systems.

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Process Automation Trainer
PROCESS AUTOMATION TRAINER

START STOP Regulator Solenoid Valve Limit Switches

A-
LS-1 A-
Air LS-1 LS-2
LS-2

LS-3 A+ A+
DAC
LS-4 DC
Motor
A+

A- B+ B+

B+ Filter
Lubricator LS-3 LS-4
B- B-
B-
DC
Motor Limit Switches

Fig.3.4 A typical PAT

A basic Process Automation Trainer (PAT) consists of the following devices :

 FRL Unit with Pressure Indicator
 Double Acting Solenoid Valves
 Double Acting Cylinders
 Limit Switches
 DC Motor
 Input / Output Terminals with Indicators.

FRL UNIT
FRL stands for Filter, Regulator, and Lubricator. The correct functioning of a
pneumatic system is maintained through the use of FRL units, comprising a filter, a
pressure regulator and a lubricator positioned before the pneumatic equipment.

Filter: This component is used to eliminate vapour particles, dust, solid

particles, corrosive gases, oil vapours etc from the air. As air flows, especially under

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the high pressure, it carries particles called contaminants. These particles will cause
damage to component in the pneumatic system. Filters are used to remove
contaminants. The filtration is achieved at various locations on the Pneumatic system.
 At the intake of the Compressor that take in outside air
 At the outlet of the Compressor tank that air feed to pneumatic system
 At the input of some Pneumatic driven machine to remove contaminants
that are picked when the air flows to distribution network.

Regulator: Regulator enables the regulation, reduction and stabilization of the

air pressure in the pneumatic circuit and adapting it to the requirements of the
equipment to be supplied. A pressure regulator has two functions,
 To adjust the supply pressure to a desired level
 To maintain a constant air pressure

Lubricator: A pneumatic lubricator injects an aerosolized stream of oil into an

air line to provide lubrication to the internal working parts of pneumatic tools, and to
other devices such as actuating cylinders, valves and motors. A lubricator should
always be the last element in an unit. Lubrication can be done in two ways,
 Permanent lubrication can be provided by the manufacturer during
production
 A lubricator can be used to spray a fine mist of oil into the air that is carried
downstream to the components.

Solenoid valves
The term "solenoid valve" generally refers to a valve that is opened or closed
by energizing a solenoid. The solenoid converts electrical energy into mechanical
energy which, in turn, opens or closes the valve mechanically. In the usual
configuration, if the valve is opened by energizing a solenoid, it is closed by the action
of a spring when the solenoid is de-energized.

Double acting cylinders

Double-acting cylinders use the force of air to move in both extends and retracts
strokes. They have two ports to allow air in, one for outstroke and one for in stroke.
It is a type of linear actuator. It uses pressurized air to create motion in a straight

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line. Double acting cylinders can create controlled motion for a certain distance in
either of two opposite directions. The cylinder does this by moving a piston in and
out.

Limit Switches
Limit switch is a switch operated by the motion of a machine part or presence
of an object. They are used for control of a machine, as safety interlocks, or to count
objects passing a point. A limit switch is an electromechanical device that consists of
an actuator mechanically linked to a set of contacts. When an object comes into
contact with the actuator, the device operates the contacts to make or break an
electrical connection.

➤ ➤ RockWell Software➤ RSLogix

Micro.
2) Create a New Project. Click FILE Menu ➤ New .
3) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
4) Verify and compile the program. Click Edit Menu ➤ Verify File.
During compilation, software translates the program code block into
machine language for execution by the CPU in PLC. A program cannot be
downloaded to the CPU until it is compiled. If there is any error in the program,
the software will give warning about the errors in result window. After correcting
errors, the program should be compiled again.
5) Save the compiled program with suitable file name. Click File Menu ➤ Save.
6) Connect the PLC with PC using RS232 cable.
7) Switch ON the PLC and set the status to STOP mode.

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14
 E X ERC ISE S – P NE UMAT IC S LAB
Ex. No. : 1(a) DIRECT OPERATION OF SINGLE
ACTING CYLINDER
Aim :
To design a pneumatic circuit for direct operation of single acting cylinder and
verify its operation using pneumatic system.

Apparatus required :
1) Air compressor 2) Inline slide valve 3) FRL unit 4) 3/2 DCV
5) Single acting cylinder 6) Connecting pipes 7) Mounting board

Connection procedure :

1) Inline slide valve, FRL unit, DCV and single acting cylinder are fixed on the board.
2) Air compressor outlet is connected to the inlet port of inline slide valve.
3) The outlet of inline slide valve is connected to the inlet port of FRL unit.
4) The outlet from FRL unit is connected to the inlet pressure port (P) of 3/2 DCV.
5) The outlet port (A) of DCV is connected to the piston side in single acting cylinder.

Process description :
The inline slide valve is closed and compressed air is admitted to enter DCV
through FRL unit. The lever of the DCV is activated to bring the left position into
action. Now the pressure port P is connected with cylinder port A. It enables the air
to enter in piston side of the Single Acting Cylinder and moves the piston forward.
When the lever of DCV is released, the exhaust port E is connected to the cylinder
port A. It enables the air inside the cylinder to exit to atmosphere. The piston moves
backward due to the thrust in the spring.

Result :
The pneumatic circuit for direct operation of single acting cylinder is designed
and its operation is verified using pneumatic system.

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16
Ex. No. : 1(b) DIRECT OPERATION OF DOUBLE
ACTING CYLINDER
Aim :
To design a pneumatic circuit for direct operation of double acting cylinder and
verify its operation using pneumatic system.

Apparatus required :
1) Air compressor 2) Inline slide valve 3) FRL unit 4) 5/2 DCV
5) Double acting cylinder 6) Connecting pipes 7) Mounting board

Connection procedure :
1) Inline slide valve, FRL unit, DCV and double acting cylinder are fixed on the board.
2) Air compressor outlet is connected to the inlet port of inline slide valve.
3) The outlet of inline slide valve is connected to the inlet port of FRL unit.
4) The outlet from FRL unit is connected to the inlet pressure port (P) of 5/2 DCV.
5) The outlet port A of DCV is connected to the piston side in double acting cylinder.
6) The outlet port B of DCV is connected to the rod side in double acting cylinder.

Process description :
The inline slide valve is closed and compressed air is admitted to enter DCV
through FRL unit. The lever of the DCV is activated to bring the left position into
action. Now the pressure port P is connected with cylinder port A and the exhaust
port E2 is connected with cylinder port B. It enables the air to enter in piston side of
the cylinder and moves the piston forward. At the same time, air in the rod side of
the cylinder exits to atmosphere through port E2.

Then the lever of the DCV is activated to bring the right position into action.
Now the pressure port P is connected with cylinder port B and the exhaust port E1 is
connected with cylinder port A. It enables the air to enter in the rod side of the
cylinder and moves the piston backward. At the same time, air in the piston side of
the cylinder exits to atmosphere through port E1.

Result :
The pneumatic circuit for direct operation of double acting cylinder is designed
and its operation is verified using pneumatic system.

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18
Ex. No. : 2. OPERATION OF DOUBLE ACTING
CYLINDER WITH QUICK EXHAUST VALVE
Aim :
To design a pneumatic circuit for the operation of double acting cylinder with
quick exhaust valve and verify its operation using pneumatic system.

Apparatus required :
1) Air compressor 2) Inline slide valve 3) FRL unit 4) 5/2 DCV
5) Double acting cylinder 6) Quick exhaust valve 7) Connecting pipes

Connection procedure :
1) Inline slide valve, FRL unit, DCV, QEV and cylinder are fixed on the board.
2) Air compressor outlet is connected to the inlet port of inline slide valve.
3) The outlet of inline slide valve is connected to the inlet port of FRL unit.
4) The outlet from FRL unit is connected to the inlet pressure port (P) of 5/2 DCV.
5) The outlet port A of DCV is connected to the piston side through and exhaust valve.
6) The outlet port B of DCV is directly connected to the rod side.

Process description :
The inline slide valve is closed and compressed air is admitted to enter DCV
through FRL unit. The lever of the DCV is activated to bring the left position into
action. Now the pressure port P is connected with cylinder port A through exhaust
valve and the exhaust port E2 is connected with cylinder port B. It enables the air to
enter in piston side of the cylinder and moves the piston forward. At the same time,
air in the rod side of the cylinder exits to atmosphere through port E2.

Then the lever of the DCV is activated to bring the right position into action.
Now the pressure port P is connected with cylinder port B and the piston side is
connected to the quick exhaust valve. It enables the air to enter in the rod side of
the cylinder and moves the piston backward. At the same time, air in the piston side
quickly exhausted to atmosphere. Thus the quick return of piston is achieved.

Result :
The pneumatic circuit for the operation of double acting cylinder with quick
exhaust valve is designed and its operation is verified using pneumatic system.

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20
 Ex. No. : 3(a) SPEED CONTROL OF DOUBLE ACTING
CYLINDER USING METERING-IN CIRCUIT
Aim :
To design a pneumatic circuit for the speed control of double acting cylinder using
metering in circuit and verify its operation using pneumatic system.

Apparatus required :
1) Air compressor 2) Inline slide valve 3) FRL unit 4) 4/3 DCV
5) Double acting cylinder 6) Metering-in circuit 7) Connecting pipes

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) Air compressor outlet is connected to the inlet port of inline slide valve.
3) The outlet of inline slide valve is connected to the inlet port of FRL unit.
4) The outlet from FRL unit is connected to the inlet pressure port (P) of 4/3 DCV.
5) The outlet port A of DCV is connected to the piston side through metering-in circuit.
6) The outlet port B of DCV is directly connected to the rod side.

Process description :
The metering circuit consists of non-return check valve and a flow control valve.
When the lever of the DCV is activated to bring the left position into action, the
pressure port P is connected with cylinder port A through flow control valve and the
exhaust port E is connected with cylinder port B. It enables the air to enter in piston
side of the cylinder and moves the piston forward. At the same time, air in the rod
side of the cylinder exits to atmosphere through port E. The piston speed in forward
stroke can be controlled by adjusting the flow control valve.

When the lever of the DCV is activated to bring the right position into action, the
pressure port P is connected with cylinder port B and the piston side is connected to
the check valve. It enables the air to enter in the rod side of the cylinder and moves
the piston backward. At the same time, air in the piston side exits through check valve.

Result :
The pneumatic circuit for the speed control of double acting cylinder using
metering-in circuit is designed and its operation is verified using pneumatic system.

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33
22
Ex. No. : 3(b) SPEED CONTROL OF DOUBLE ACTING
CYLINDER USING METERING-OUT CIRCUIT
Aim :
To design a pneumatic circuit for the speed control of double acting cylinder using
metering out circuit and verify its operation using pneumatic system.

Apparatus required :
1) Air compressor 2) Inline slide valve 3) FRL unit 4) 4/3 DCV
5) Double acting cylinder 6) Metering-out circuit 7) Connecting pipes

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) Air compressor outlet is connected to the inlet port of inline slide valve.
3) The outlet of inline slide valve is connected to the inlet port of FRL unit.
4) The outlet from FRL unit is connected to the inlet pressure port (P) of 4/3 DCV.
5) The outlet port A of DCV is directly connected to the piston side.
6) The outlet port B of DCV is connected to the rod side through metering-out circuit.

Process description :
When the lever of the DCV is activated to bring the left position into action, the
pressure port P is connected with cylinder port A and the rod side is connected to the
check valve. It enables the air to enter in piston side of the cylinder and moves the
piston forward. At the same time, air in the rod side of the cylinder exits to
atmosphere through check valve.

When the lever of the DCV is activated to bring the right position into action, the
pressure port P is connected with cylinder port B through flow control valve and the
exhaust port E is connected to cylinder port A. It enables the air to enter in the rod
side of the cylinder and moves the piston backward. At the same time, air in the piston
side exits to atmosphere through port E. The piston speed in return stroke can be
controlled by adjusting the flow control valve.

Result :
The pneumatic circuit for the speed control of double acting cylinder using
metering-out circuit is designed and its operation is verified using pneumatic system.

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24
Ex. No. : 4. AUTOMATIC OPERATION OF DOUBLE ACTING
CYLINDER IN SINGLE CYCLE USING LIMIT SWITCH
Aim :
To design a pneumatic circuit for automatic operation of double acting cylinder
operates in single cycle using limit switch.

Apparatus required :
1) Air compressor 2) 3/2 Lever operated DCV 3) 5/2 Pilot operated DCV
4) 3/2 Roller operated DCV 5) Double acting cylinder 6) Connecting pipes

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) Air compressor outlet is connected to the inlet port of signal valve, memory
valve (5/2 DCV) and limit switch.
3) The outlet port A of DCV is connected to the piston side and port B is connected to
rod side in double acting cylinder.
4) Outlet of signal valve is connected to left side of memory valve.
5) Outlet of limit switch is connected to right side of memory valve.

Process description :
The initial signal air is admitted at the left side of memory valve by operating
signal valve. Now the pressure port P is connected with cylinder port A and moves
the piston forward. At the same time, air in the rod side of the cylinder exits to
atmosphere through port E2.

When the piston rod reaches its final position, a cam activates the limit switch.
The signal air is admitted at the right side of memory valve. Now the pressure port
P is connected with cylinder port B and moves the piston backward. At the same
time, air in the piston side of the cylinder exits to atmosphere through port E1.

Result :
The pneumatic circuit for automatic operation of double acting cylinder operates
in single cycle using limit switch is designed and its operation is verified using
pneumatic system.

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26
 H Y DRA UL ICS LA B
Ex. No. : 5. DIRECT OPERATION OF DOUBLE
ACTING CYLINDER
Aim :
To design a hydraulic circuit for direct operation of double acting cylinder and
verify its operation using hydraulic system.

Apparatus required :
1) Hydraulic power pack 2) Check valve 3) 4/3 DCV
4) Double acting cylinder 5) Connecting pipes 6) Mounting board

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) The outlet of the pump is connected to the check valve.
3) The outlet of check valve is connected to the inlet pressure port (P) of 4/3 DCV.
4) The outlet port A of DCV is connected to the piston side in double acting cylinder.
5) The outlet port B of DCV is connected to the rod side in double acting cylinder.

Process description :
The pump is switched ON and the lever of the DCV is activated to bring the left
position into action. Now the pressure port P is connected with cylinder port A and
the return port R is connected with cylinder port B. It enables oil to enter in piston
side of the cylinder and moves the piston forward. At the same time, oil in the rod
side of the cylinder returns to the tank through port R.

Then the lever of the DCV is activated to bring the right position into action.
Now the pressure port P is connected with cylinder port B and the return port R is
connected with cylinder port A. It enables oil to enter in the rod side of the cylinder
and moves the piston backward. At the same time, oil in the piston side of the cylinder
returns to the tank through port R.

Result :
The hydraulic circuit for direct operation of double acting cylinder is designed and
its operation is verified using hydraulic system.

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28
Ex. No. : 6. DIRECT OPERATION OF
HYDRAULIC MOTOR
Aim :
To design a hydraulic circuit for direct operation of hydraulic motor and verify its
operation using hydraulic system.

Apparatus required :
1) Hydraulic power pack 2) Check valve 3) 4/3 DCV
4) hydraulic motor 5) Connecting pipes 6) Mounting board

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) The outlet of the pump is connected to the check valve.
3) The outlet of check valve is connected to the inlet pressure port (P) of 4/3 DCV.
4) The outlet port A of DCV is connected to one side of the hydraulic motor.
5) The outlet port B of DCV is connected to another side of the hydraulic motor.

Process description :
The pump is switched ON and the lever of the DCV is activated to bring the left
position into action. Now the pressure port P is connected with port A and the return
port R is connected with port B. It enables oil to enter in the left side of the motor
and rotates the motor in forward direction. At the same time, oil in the right side of
the motor returns to the tank through port R.

Then the lever of the DCV is activated to bring the right position into action.
Now the pressure port P is connected with port B and the return port R is connected
with port A. It enables oil to enter in the right side of the motor and rotates the motor
in reverse direction. At the same time, oil in the left side of the motor returns to the
tank through port R.

Result :
The hydraulic circuit for direct operation of hydraulic motor is designed and its
operation is verified using hydraulic system.

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30
Ex. No. : 7(a) SPEED CONTROL OF DOUBLE ACTING
CYLINDER USING METERING-IN CIRCUIT
Aim :
To design a pneumatic circuit for the speed control of double acting cylinder using
metering in circuit and verify its operation using hydraulic system.

Apparatus required :
1) Hydraulic power pack 2) 4/3 DCV 3) Check Valve 4) Flow control valve
5) hydraulic motor 6) Connecting pipes 7) Mounting board

Connection procedure :

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) The outlet of pump is connected to the inlet pressure port (P) of 4/3 DCV.
3) The outlet port A of DCV is connected to the piston side through metering-in circuit.
4) The outlet port B of DCV is directly connected to the rod side.

Process description :
The metering circuit consists of non-return check valve and a flow control valve.
When the lever of the DCV is activated to bring the left position into action, the
pressure port P is connected with cylinder port A through flow control valve and the
return port T is connected with cylinder port B. It enables oil to enter in piston side
of the cylinder and moves the piston forward. At the same time, oil in the rod side of
the cylinder returns to tank through port R. The piston speed in forward stroke can
be controlled by adjusting the flow control valve.

When the lever of the DCV is activated to bring the right position into action, the
pressure port P is connected with cylinder port B and the piston side is connected to
the check valve. It enables oil to enter in the rod side of the cylinder and moves the
piston backward. At the same time, air in the piston side returns to tank through check
valve.

Result :
The hydraulic circuit for the speed control of double acting cylinder using
metering-in circuit is designed and its operation is verified using hydraulic system.

31
32
Ex. No. : 7(b) SPEED CONTROL OF DOUBLE ACTING
CYLINDER USING METERING-OUT CIRCUIT
Aim :
To design a pneumatic circuit for the speed control of double acting cylinder using
metering out circuit and verify its operation using hydraulic system.

Apparatus required :
1) Hydraulic power pack 2) 4/3 DCV 3) Check Valve 4) Flow control valve
5) hydraulic motor 6) Connecting pipes 7) Mounting board

Connection procedure :

Connection procedure :
1) The components are properly fixed on the board at suitable places as per the circuit.
2) The outlet of pump is connected to the inlet pressure port (P) of 4/3 DCV.
3) The outlet port A of DCV is directly connected to the piston side.
4) The outlet port B of DCV is connected to the rod side through metering-out circuit.

Process description :
When the lever of the DCV is activated to bring the left position into action, the
pressure port P is connected with cylinder port A and the rod side is connected to the
check valve. It enables oil to enter in piston side of the cylinder and moves the piston
forward. At the same time, oil in the rod side of the cylinder returns to tank through
check valve.

When the lever of the DCV is activated to bring the right position into action, the
pressure port P is connected with cylinder port B through flow control valve and the
return port R is connected to cylinder port A. It enables oil to enter in the rod side of
the cylinder and moves the piston backward. At the same time, oil in the piston side
returns to tank port R. The piston speed in return stroke can be controlled by
adjusting the flow control valve.

Result :
The hydraulic circuit for the speed control of double acting cylinder using
metering-out circuit is designed and its operation is verified using hydraulic system.

33
34
 PLC
Ex. No. : 1 Date :

DIRECT OPERATION OF MOTOR

USING LATCHING CIRCUIT

Aim :
To create a ladder logic diagram for direct operation of motor using latching
circuit and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Stop push switch
5) Start push switch
6) 24 V DC motor
7) Mounting board
8) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.

35
36
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.
8) Set the PLC status to RUN mode and execute the program.
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
There are often situations where it is necessary to hold an output energized,
even when the input stops. A simple example of such a situation is a motor, which is
started by pressing a push button switch. Though the switch contacts do not remain
closed, the motor is required to continue running until a stop push button switch is
pressed. The term latch circuit is used for the circuit used to carry out such an
operation. It is a self-maintaining circuit in that, after being energized, it maintains
that state until another input is received.

From the ladder diagram, the STOP Push Switch is a normally closed contact.
When the START Push Switch is pressed, it closes the circuit and energizes the output
(DC Motor). It also closes the parallel circuit consists of output (DC Motor) contacts.
Even, after releasing the Start Push Switch, the circuit maintain the output (DC
Motor) energized. The only way to stop the output is by pressing the STOP Push
Switch. It breaks the circuit and stops the output (DC Motor).

Result :
The ladder logic diagram for direct operation of motor using latching circuit is
created using application software. The program is executed and verified using PLC.

37
38
Ex. No. : 2 Date :

OPERATION OF MOTOR
USING ÂANDÊ LOGIC CONTROL

Aim :
To create a ladder logic diagram for operation of motor using ‘AND’ logic control
and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Stop push switch
5) Start push switch
6) 24 V DC motor
7) Mounting board
8) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.

39
40
8) Set the PLC status to RUN mode and execute the program.
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
In an AND logic control two or more inputs are connected in series with the
output. The output will be energized only if all the inputs are in closed condition. The
output will be de-energized when any one of the inputs is open.

From the ladder diagram, Push Switch-1 and Push Switch-2 are connected in
series with the Motor(Output). If both the switches are in ON condition, the motor
will run. If any one of the switches is in OFF condition, the motor will not run.

Result :
The ladder logic diagram for direct operation of motor using ‘AND’ logic control is
created using application software. The program is executed and verified using PLC.

41
42
Ex. No. : 3 Date :

OPERATION OF MOTOR
USING ÂORÊ LOGIC CONTROL

Aim :
To create a ladder logic diagram for operation of motor using ‘OR’ logic control
and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Stop push switch
5) Start push switch
6) 24 V DC motor
7) Mounting board
8) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.

43
44
8) Set the PLC status to RUN mode and execute the program.
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
In an OR logic control two or more inputs are connected in parallel with each
other and the output is connected in series with the switch assembly. The output will
be energized when any one of the the inputs or all the inputs are in closed condition.
The output will be de-energized when all the inputs are open.

From the ladder diagram, Push Switch-1 and Push Switch-2 are connected in
parallel with each other. The Motor(Output) is connected in series with the switch
assembly. When any one of the switches OR all the switches are in ON condition, the
motor will run. When all the switches are in OFF condition, the motor will not run.

Result :
The ladder logic diagram for direct operation of motor using ‘OR’ logic control is
created using application software. The program is executed and verified using PLC.

45
46
Ex. No. : 4(a) Date :

OPERATION OF MOTOR
USING ON-DELAY CONTROL

Aim :
To create a ladder logic diagram for operation of motor using ON-DELAY control
and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Start push switch
5) 24 V DC motor
6) Mounting board
7) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.
8) Set the PLC status to RUN mode and execute the program.

47
48
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
The timers in PLC are operated by an internally generated clock embedded in
the processor module. The ON-Delay Timer (TON) turns an output ON after the timer
has been ON for a preset time interval. This output instruction begins timing when
its rung goes "true." The timer adjusts its accumulated value (ACC) until it reaches
the preset value (PRE). Then it sets the done (DN) bit ON and changes the state in
output. The accumulated value is reset when rung conditions go false.

TON instruction consists of the following :

Enable (EN) bit : It is true whenever the timer instruction is true.
Done (DN) bit : It changes state whenever the accumulated value reaches the
preset value.
Timer : It is the timer number in the processor.
Time base : It is the duration of each time base interval.
Preset Value (Preset) : It is timer preset value rangers from 0 to 32,767.
Accumulated Value (Accum) : It is the number of time base intervals the
instruction has counted.

From the ladder diagram, START Push Switch, STOP Push Switch and a Timer
(T4:0) are connected in series with a Motor (Output). The timer Time base is set as
1 sec. and the Preset value is set as 10 sec. When the START Push switch is pressed,
it enables the timer to begins timing. After the Accumulated value reaches 10 sec.,
it enables the done bit ON and the Motor will run. The motor can be stopped by
pressing STOP Push Switch.

Result :
The ladder logic diagram for operation of motor using ON-DELAY control is
created using application software. The program is executed and verified using PLC.

49
50
Ex. No. : 4(b) Date :

OPERATION OF MOTOR
USING OFF-DELAY CONTROL
Aim :
To create a ladder logic diagram for operation of motor using OFF-DELAY control
and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Start push switch
5) 24 V DC motor
6) Mounting board
7) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.
8) Set the PLC status to RUN mode and execute the program.

51
52
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
The OFF-Delay Timer (TOF) turns an output ON or OFF after its rung has been
OFF for a preset time interval. The TOF instruction begins timing when its rung makes
a true-to-false transition. The timer adjusts its accumulated value (ACC) until it
reaches the preset value (PRE). Then it sets the done (DN) bit ON and changes the
state in output. The accumulated value is reset when rung conditions go false.

TOF instruction consists of the following :

Enable (EN) bit : It is true when the rung conditions are true and remains same
when the rung conditions are false.
Done (DN) bit : It changes state whenever the accumulated value reaches the
preset value.
Timer : It is the timer number in the processor.
Time base : It is the duration of each time base interval.
Preset Value (Preset) : It is timer preset value rangers from 0 to 32,767.
Accumulated Value (Accum) : It is the number of time base intervals the
instruction has counted.

From the ladder diagram, START Push Switch and a Timer (T4:1) are connected
in series with a Motor (Output). The timer Time base is set as 1 sec. and the Preset
value is set as 10 sec. When the START Push switch is pressed, it enables the timer
and the Motor will run. After releasing the Switch, the rung condition goes false and
the timer begins timing. After the Accumulated value reaches 10 sec., it enables the
done bit ON and the Motor will stop.

Result :
The ladder logic diagram for operation of motor using OFF-DELAY control is
created using application software. The program is executed and verified using PLC.

53
54
Ex. No. : 5 Date :

AUTOMATIC OPERATION OF A DOUBLE ACTING

CYLINDER – SINGLE CYCLE WITH TIME DELAY
Aim :
To create a ladder logic diagram for automatic operation of a double acting
cylinder operates in single cycle with time delay and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Start Push Switch
5) Limit Switches – 2 Nos.
6) Double acting cylinder
7) Mounting board
8) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.
8) Set the PLC status to RUN mode and execute the program.

55
56
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
From the ladder diagram, when the Start Push Switch is pressed, it energizes
the A+ side of the solenoid valve. It enables the air to enter in A+ side of the Double
Acting Cylinder and moves the piston forward. After it reaches the extreme right end,
it activates the Limit Switch-2. It cuts off the A+ side of the solenoid valve and turns
ON the timer. After the Accumulated value reaches 10 sec., it enables the done bit
ON and energizes the A- side of the solenoid valve. It enables the air to enter in A-
side of the Double Acting Cylinder and moves the piston backward. After it reaches
the extreme left end, it activates the Limit Switch-1. It cuts off the A- side of the
solenoid valve and the piston stops.

Result :
The ladder logic diagram for operation of double acting cylinder operates in a
single cycle with time delay is created using application software. The program is
executed and verified using PLC.

57
58
Ex. No. : 6 Date :

AUTOMATIC OPERATION OF A DOUBLE

ACTING CYLINDER – MULTI CYCLE
Aim :
To create a ladder logic diagram for automatic operation of a double acting
cylinder operates in multi cycle and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Start Push Switch
5) Stop Push Switch
6) Limit Switches – 2 Nos.
7) Double acting cylinder
8) Mounting board
9) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.

59
60
8) Set the PLC status to RUN mode and execute the program.
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
From the ladder diagram, when the Start Push Switch is pressed, it energizes
the Normally Open Contact B. It enables the Timer T4:0 ON. When the Accumulated
value reaches 2 sec.(Lower limit of Limit Test), it energizes A+ side of the solenoid
valve. It enables the air to enter in A+ side of the Double Acting Cylinder and moves
the piston forward. After the Accumulated value reaches 4 sec. (High Limit of Limit
Test), it de-energizes the A+ side and closes the Normally Open Contact B. It
energizes the A- side of the solenoid valve. It enables the air to enter in A- side of
the Double Acting Cylinder and moves the piston backward. When the Accumulated
value becomes 5 (when A>B), it resets the Timer T4:0. When the Accumulated value
reaches 2 sec.(Lower limit of Limit Test), it again energizes A+ side of the solenoid
valve and the cycle repeats. When the Stop Push Switch is pressed, it disconnects
the continuity and the operation of the cylinder stops.

Result :
The ladder logic diagram for operation of double acting cylinder operates in multi
cycle is created using application software. The program is executed and verified using
PLC.

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Ex. No. : 7 Date :

SEQUENTIAL OPERATION OF A DOUBLE

ACTING CYLINDER AND A MOTOR
Aim :
To create a ladder logic diagram for sequential operation of a double acting
cylinder and a motor, and verify its operation using PLC.

Apparatus required :

1) PC with Ladder Programming Software

2) PLC Trainer
3) RS232 Cable
4) Start Push Switch
5) Limit Switches – 2 Nos.
6) Double acting cylinder
7) DC Motor
8) Mounting board
9) Patching chords

Procedure :

1) Open the application software and create a new project.

2) Create the ladder logic diagram by suitably inserting the input, output, and
other instructions rung by rung in between the rails.
3) Verify and compile the program. After correcting errors, compile the program
again and save the program with suitable file name.
4) Connect the PLC with PC using RS232 cable.
5) Switch ON the PLC and set the status to STOP mode.
6) Download the program to PLC. During this operation, the compiled program is
transferred to PLC memory.
7) Connect the input and output devices to PLC according to the connection
diagram using patching chords.

63
64
8) Set the PLC status to RUN mode and execute the program.
9) Now the devices connected with the PLC are actuated according to the ladder
program. The functioning of these external devices are also simulated in the
application software.

Process description :
From the ladder diagram, when the Start Push Switch is pressed, it energizes
the A+ side of the solenoid valve. It enables the air to enter in A+ side of the Double
Acting Cylinder and moves the piston forward. After it reaches the extreme right end,
it activates the Limit Switch-2. It cuts off the A+ side of the solenoid valve and turns
ON the timer T4:0. After the Accumulated value reaches 15 sec., it enables the done
bit ON and energizes the DC Motor. It also turns ON the timer T4:1. After the
Accumulated value of T4:1 reaches 60, it energizes the A- side of the solenoid valve.
It enables the air to enter in A- side of the Double Acting Cylinder and moves the
piston backward. After it reaches the extreme left end, it activates the Limit Switch-
1. It cuts off the A- side of the solenoid valve and the piston stops. It also disconnects
the continuity and the motor stops.

Result :
The ladder logic diagram for sequential operation of a double acting cylinder and
a motor is created using application software. The program is executed and verified
using PLC.

65
 1 . PNEUMATICS
1. Define pneumatic system.
A pneumatic system is a system that uses compressed air to transmit and
control energy.
2. List out the industrial applications of pneumatics.
Material handling, Clamping, Shifting, Positioning, Branching of material flow,
Packaging, Filling, Transfer of materials, Sorting of parts, Stamping and
embossing of components, etc.
3. List out the uses of pneumatic system in machining processes.
Drilling, Turning, Milling, Sawing, Finishing, Forming, etc.
4. Name the important components in pneumatic system.
1) Air compressor 2) Air reservoir 3) Air service unit
4) Direction control valves 5) Control valves 6) Actuators
5. What is FRL unit?
FRL unit is the service unit in pneumatic system. It consists of a Filter, a
Regulator and a Lubricator.
6. What is Directional Control Valve?
Directional control valves ensure the flow of air between air ports by opening,
closing and switching their internal connections.
7. How DCVs are classified?
DCVs are classified by the number of ports, the number of switching positions,
the normal position of the valve and its method of operation.
8. List out common DCVs.
1) 2/2 DCV 2) 3/2 DCV 3) 4/2 DCV 4)4/3 DCV 5) 5/2 DCV

78
66
9. Describe 5/2 DCV.
It indicates 5/2 Directional Control Valve. It has 5 ports and can be operated
with 2 positions.
10. What is control valve?
A control valve is a valve that controls the flow of air.
11. Name the important control valves.
1) Non-return valve 2) Flow control valve
3) Shuttle valve 4) Quick exhaust valve
12. What is the use of non-return valve?
A non-return valve allows air to flow in one direction only. When air flows in
the opposite direction, the valve will close.
13. Describe shuttle valve.
A shuttle valve has two air inlets and one air outlet. When compressed air
enters through one inlet port, the sphere inside the valve passage will seal
and block the other inlet port. Air can then flow from one inlet port to outlet.
14. Give the use of quick exhaust valve.
It is used for the quick exhaust of air to cause rapid forward or return
movement of actuator.
15. Name some actuators in pneumatic system.
1) Single acting cylinder 2) Double acting cylinder 3) Pneumatic motor
16. List out the actuating mechanism used in pneumatic system.
1) Spring 2) Manual 3) Push button 4) Lever
5) Mechanical 6) Solenoid 7) Air pilot
17. Draw the ISO symbols for valve actuators.
Ref: Page No.5
18. Draw the ISO symbols for important pneumatic components.
Ref : Page No.6

6779
 2 . HYDRAULICS
19. Define hydraulics.
An hydraulic system is an enclosed fluid based system that uses pressurized
incompressible liquids to transmit and control energy.
20. List out the industrial applications of hydraulic system.
Plastic processing machineries, steel making and primary metal extraction
applications, automated production lines, machine tool industries, paper
industries, loaders, crushes, textile machineries, robotic systems etc.
21. What are the uses of mobile hydraulics.
Tractors, irrigation system, earthmoving equipment, material handling
equipment, commercial vehicles, tunnel boring equipment, rail equipment,
building and construction machineries and drilling rigs etc.
22. Mention the uses of hydraulics in automobiles.
It is used in the systems like breaks, shock absorbers, steering system, wind
shield, lift and cleaning etc.
23. List out the components of hydraulic system.
1) Storage tank 2)Filter 3) Pump
4) Pressure regulator 5) Control valves 6)Actuator
24. What is the use of filter in hydraulic system?
Filter removes dust or any other unwanted particles from the oil before it is
pumped to pipeline. It helps to keep the fluid system clean and efficient, as
well as avoid damage to the actuator and valves.
25. Give examples of hydraulic pumps.
1) Gear pump 2) Vane pump 3) Piston pump
26. Give examples of flow control valves used in hydraulic system.
Glove valve, butterfly valve, ball valve, balanced valve, etc.
27. What is pressure relief valve? Give examples.
The pressure relief valves are used to protect the hydraulic components
from excessive pressure.
Direct relief valve, unloading valve, sequence valve, counterbalance valve,
pressure reducing valve, etc.

68
 3 . PLC
28. Define PLC.
PLC stands for Programmable Logic Controller.
29. Give the uses of PLC.
It is universally applied for factory automation, process control and
manufacturing systems.
30. How PLC works?
The PLC works by looking at its inputs and depending upon their state, turning
on/off its outputs.
31. List out the components of PLC.
a) Central Processing Unit (CPU) b) Input modules c) Output modules

32. What is the standard used for PLC programming languages?

IEC 1131-3 is the international standard for PLC programming languages.
33. List out the PLC programming languages.
1) Ladder Logic Diagram (LD) 2) Function Block Diagram (FBD)

3) Sequential Function Charts (SFC) 4) Structured Text (ST)

34. What is Ladder Logic Diagram?

The ladder diagram consists of two vertical lines representing the power rails.
Circuits are connected as horizontal lines, i.e., the rungs of the ladder,
between these two verticals.
35. Mention the uses of LLD.
Ladder Logic Diagram is best used for
 Boolean operations
 Complex logical operations
 Message and communication processing
 Interlocks
 Troubleshoot a machine or process

69
36. What is FBD?
Function Block Diagram is a graphical language. In FBD, program elements
appear as blocks, which are connected together with lines that represent
wires in a way, that look much like a circuit diagram.
37. What is SFC?
Sequential Function Chart is a graphical language used to organize the flow
and control of complex, simultaneous operations. It graphically shows the
state and the transition used in a process.
38. What is Structured Text?
Structured Text is a high-level language that resembles to Pascal or Basic.
ST allows easy modeling and performs loops and conditional branching.
39. What are instructions in LLD?
Ladder logic instructions are commands which use inputs and counter relays
to determine the status of outputs and other counter relays.
40. Draw the symbols for LLD instructions.
Ref: Page Nos.16,17 & 18
41. List out the important PLC manufacturers.
Allen-Bradley, Siemens, Divelbiss, Schneider, Mitsubishi, Velocio, Panasonic,
Keyence, GE, etc.
42. Mention the widely used PLC Programming softwares.
RSLogix Micro, Step 7, EZ Ladder, TwidoSuite, AL-PCS/WIN, GX Developer
iQ Works, vBuilder, FPWIN PRO, KV Ladder Builder, Zelio Soft, Durus, etc.

70