Lab 3 Integrated PLC Pneumatics Circuits 2015

FAKULTI KEJURUTERAAN ELEKTRIK
SUBJECT:
MECHATRONIC
LABORATORY II
SYSTEM
ENGINEERING
BEKM 3631
LEARNING OUTCOMES
Students should be able to:1. Design the appropriate solution to actuate a mechatronic system by using
PLC, pneumatic and hydraulic circuits. (PO4,PO5,LO2)
2. Design a controller for mechatronics system using PLC. (PO4,LO1)

3. Analyze and evaluate the accuracy of the integrated mechatronics
system performance by using statictical method. (PO5,LO3)
TASK 1: PROCESS CONTROL & TROUBLESHOOTING
Figure 1: Pressing-in device for sleeves with ejector

Initially, the electro-pneumatics assembly for the application in Figure 1 will be
presented to you in the lab. You need to identify the electro-pneumatics
components associated with the process from the assembly. Take pictures of the
assembly and label them accordingly. The lab instructor will run the system and
upon inspection, you have to draw the appropriate pneumatics and electric circuit
diagram for the assembly. Explain the process by drawing a flowchart and draw the
corresponding functional diagram. After that, the instructor will produce a faulty
connection and you need to figure out the mishaps and rewired the correct
connection. Explain the error and how you overcome that.
For this application as well, you are required to propose a PLC control solution. You
need to define the I/O assignment, draw the corresponding PLC connection diagram
(hardware) and also the ladder diagram to control the process. You are expected to
provide necessary results and observations for the assembly with the appropriate
analysis and discussions.
Lab 3
Integrated PLC & Pneumatics Circuits
Page 1 of 5

SUBJECT:
MECHATRONIC
LABORATORY II
SYSTEM
ENGINEERING
BEKM 3631
TASK 2: STAMPING PROCESS CONTROL
Figure 1: Miniature Stamping Device

In this laboratory, you have to design the control program using CX-One
programming software and integrate it to the miniature stamping device to perform
the stamping process. The device as seen in Figure 1 comprises of two double
acting cylinders equipped with four (4) reed sensors and I/O slots which are predeveloped and labelled on the black box.
The process will start by pressing the START button. Cylinder 2 will extend to push
the bottommost plastic part from the stack until Cylinder 1 extends to stamp the
part. After that, Cylinder 1 will return to the original position. You must manually
remove the stamped part before starting on another process. The stop button must
act as an emergency switch. Please use the indicators to signify the completion of
each step.
You should also design the method to analyze the repeatability and accuracy of the
stamping itself. You are expected to provide necessary results and observations for
the design with the appropriate analysis and discussions.
Lab 3
Page 2 of 5

SUBJECT:
MECHATRONIC
LABORATORY II
SYSTEM
ENGINEERING
BEKM 3631
Instruction before starting experiment

1. Connect the air-pressure tube to the miniature stamping device to test the
solenoid & double acting cylinders.
2. Based on the TASK 2: Stamping Process Control labsheet, draw/write the:
a) The input/output assignments into a table.
b) Flow-chart of the process.
c) The ladder diagram of the process using CX-Programmer.
d) Mnemonic codes equivalent of the ladder diagram.
e) Simulate the program using CX-Programmer.
f) After simulation is succesfull, connect the PLC to the hardware
of the stamping process. Make sure all wiring connections are
done correctly.
3. Before running the experiments, place a masking tape on top of each
magazines (Fig. 1a) & make a grid line as shown in Fig. 1b. Fig. 1c shows the
magazine after the stamping process. The arrow indicates the direction of the
magazines being pushed by the double acting cylinder.
(a) Glass magazine
(b) Glass magazine with masking tape & grid line (Before stamping process)
(a) Glass magazine with masking tape & grid line (After stamping process)
Lab 3
Page 3 of 5

SUBJECT:
MECHATRONIC
LABORATORY II
SYSTEM
ENGINEERING
BEKM 3631
Fig. 1 Magazine for stamping process
4. For experimental results, each stamping process for 2 magazines should be

repeated 10 times to check the repeatability & accuracy of the process and
fill them into Table 1 (example).
5. Based on Table 1, calculate the average & standard deviation of the center
point on each magazine. Complete the calculation into a table & plot the
data.
6. Make a conclusion based on your analysis & finding.
7. Submit a HARDCOPY of the full report of TASK 2 by 10 May, 12pm to
the technition & sign the submission form for confirmation.
Table 1 Sample of repeatability test
Repeatabi
lity
1
Magazines
1
2
3
4
5
6
7
8
9
10
DOCUMENTATION & FULL REPORT

Lab Report
1. Describe in details your lab experiment in a report by following UTeMs thesis writing
format. Maximum number of pages is EIGHT (8) pages only, front, references &
appendixes pages not included.
2. Your report should contain information below:
a. Background of study covers the integration of electro-pneumatic with PLC concept.
b. Explanation in experimental setup/ procedure
c. Describe the statistical method that been used in measuring the performance of the
robot. (Part B only)
3. Send a softcopy (only one student as representative) of your lab report for each group it via
ELearning Portal UTeM (Ulearn). Multiple copies for one group will be automatically given
zero marks.
Lab 3
Page 4 of 5

SUBJECT:
MECHATRONIC
SYSTEM
ENGINEERING BEKM 3631
LABORATORY II
4. Use standard file title as mention in Lab briefing: BEKM3631_S2_L3_C1
Indicates : BEKM3631_section_lab3_groupC1
PLAGIARISM & LATE SUBMISSION WILL BE TAKEN SERIOUSLY.
Lab 3
Page 5 of 5

Lab 3 Integrated PLC Pneumatics Circuits 2015

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FAKULTI KEJURUTERAAN ELEKTRIK

2. Design a controller for mechatronics system using PLC. (PO4,LO1)

TASK 1: PROCESS CONTROL & TROUBLESHOOTING

Figure 1: Pressing-in device for sleeves with ejector

Integrated PLC & Pneumatics Circuits

FAKULTI KEJURUTERAAN ELEKTRIK

TASK 2: STAMPING PROCESS CONTROL

Figure 1: Miniature Stamping Device

Integrated PLC & Pneumatics Circuits

FAKULTI KEJURUTERAAN ELEKTRIK

Instruction before starting experiment

(a) Glass magazine

Integrated PLC & Pneumatics Circuits

FAKULTI KEJURUTERAAN ELEKTRIK

Fig. 1 Magazine for stamping process

4. For experimental results, each stamping process for 2 magazines should be

DOCUMENTATION & FULL REPORT

Integrated PLC & Pneumatics Circuits

FAKULTI KEJURUTERAAN ELEKTRIK

Integrated PLC & Pneumatics Circuits

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