Industrial Automation (20MC44P)

Industrial
Automation
20MC44P
N Akshaykumar
B.E. M.Tech.
INDUSTRIAL AUTOMATION
[20MC44P]
BY
N AKSHAYKUMAR
B.E. [Mechanical Engg.]
M.Tech. [Thermal Power Engg.]
INDUSTRIAL AUTOMATION
[20MC44P]
Course Overview
Program Mechatronics CIE Marks Time Week Marks
Course Code 20MC44P WT 1 30 80 5 Avg. 30
Course Name Industrial Automation WT 2 30 80 9
Scheme L:T:P::3:1:4 WT 3 30 80 13
CIE Marks 60 ST 1 100 180 6 Avg. 20
Semester 4 ST 2 100 180 12
Type of Course Core – Integrated Port Folio 10 1 – 13 10
Contact Hours 8 hrs/wk, 104 hrs/sem CIE 60
Credits 6 SEE 100 180 SEE 40
SEE Marks 40 Total Marks 100
Course Outcomes
Understand concept on Automation in material identification & Material handling
CO1
techniques
CO2 Perform specified control functions using a Programmable Logic Controller [PLC]
CO3 Explain the concepts of SCADA, HMI and DCS and list their various applications
CO4 List various applications of embedded systems
CIE & SEE Scheme of Evaluation

Sl. No. Particulars/Dimensions Marks
1 Writing application on CO-4 20
2 Drawing ladder diagram for a given problem 15
3 Construction & Conduction 35
4 Printout 10
5 Demonstration & Viva-Voce 20
Total Marks 100
L: Lecture, T: Tutorial, P: Practice, CIE: Continuous Internal Evaluation, SEE: Semester End Examination, WT: Written Test, ST:
Skill Test, CO: Course Outcomes, PO: Program Outcomes.
Course Rationale:
In present scenario, Manufacturing industries are moving towards complete automation. Small
and medium industries are in a phase of switching to PLC and SCADA technology for data acquisition
and control. Industrial automation systems are used to control and monitor a process, machine or device
in a computerized manner that usually fulfills repetitive functions or tasks. They are intended to operate
automatically in order to reduce and improve human work in the industry. Advantages of this technology
is commonly attributed to higher production rates and increased productivity, more efficient use of
materials, better product quality, improved safety, shorter worksheets for labor, and reduced factory lead
times.
The Automation Engineer will design, program, simulate and commission automated machines
and plant wide processes to perform many job functions. Depending on the size of the organization, the
engineer will perform some or all of these responsibilities. Therefore, it is necessary for diploma
engineers to have knowledge of both PLC and SCADA technology. This course attempts to provide basic
theoretical and practical aspects of automation technologies to develop operational competency. Hence
this course is the foundation for diploma engineers who want to further specialize in the field of industrial
automation.
Reference Books
1. Programmable Logic Controllers – W Bolton
2. Digital Fundamentals – Thomas L. Floyd
3. Automation, Production Systems, and Computer-Integrated Manufacturing – Mikell P.
Groover.
4. Electric Motors and Drives – Fundamentals, Types and Applications – Austin Hughes & Bill
Drury.
5. Programmable Logic Controllers – Frank Petruzella.
Week 1
Lecture 1
Introduction
Production Systems
A production system is a collection of people, equipment, and procedures organized to
perform the manufacturing operations of a company [organization, firm, factory, shop floor, etc.]
Production systems are classified as:
1. Facilities: Facilities consists of the factory, the equipment and
the organization of equipment.
2. Manufacturing support systems: This is the set of
procedures used by the company to manage production and to
solve technical and logistics problems encountered in ordering
materials, moving work through factory, and ensuring that
products meet quality standards. Product design and certain
business functions are included among manufacturing support
systems.
Automation
Automation can be defined as the technology by virtue of which all the processes of
manufacturing systems are performed by machines without the direct involvement of human
worker.
Automation in Production Systems

Some components of
the firm’s production are likely
to be automated, whereas
others will be operated
manually or electrically.
Automated manufacturing
systems operating on the
factory are implemented by
computer systems and
connected to computerized manufacturing support systems and management information system
operating at plant and enterprise level.
Automation in production systems can be classified as:
1. Automation of manufacturing systems
2. Computerization of manufacturing support systems.
Needs and Benefits of Industrial Automation

1. To increase labor productivity. Automating a manufacturing operation usually increases
production rate & labor productivity. This means greater output per hour of labor input.
2. To reduce labor cost. Machines are increasingly being substituted for human labor to reduce
unit product cost.
3. To mitigate the effects of labor shortages. There is a general shortage of labor in many
advanced nations, & this has made the development of automated operations as a substitute for
labor.
4. To reduce or eliminate routine manual & clerical tasks. Automating the routine, boring,
fatiguing & possibly irksome tasks serves the purpose of improving the general level of working
conditions.
5. To improve worker safety. By automating a given operation and transferring the worker
from active participation in the process to supervisory role, the work is made safer.
6. To improve product quality. Automation not only results in higher production rates than
manual operations; it also performs the manufacturing process with greater uniformity &,
conformity to quality specifications. It also reduces fraction defect rate.
7. To reduce manufacturing lead time. Automation helps to reduce the elapsed time between
order & delivery. It also reduces work-in-process inventory.
8. To accomplish processes that cannot be done manually. Certain operations cannot be done
without a machine. They require precision, miniaturization or they have complex geometry.
Example: IC fabrication, CAD models & machining of complex surfaces using CNC Machines.
9. To avoid high cost of not automating. The benefits of automation often show up in
unexpected and intangible ways, such as, improved quality, higher sales, better labor relation &
better company image.
Automation Hierarchy
The concept of automated systems
can be applied to various levels of factory
operations. We can have five possible
levels of automation in a production plant.
1. Device Level: This is the lowest level.
It includes the actuators, sensors & other
hardware that comprise the machine level.
The devices are combined into the
individual control loops of machine. For
example, the feedback control loops for
one axis of CNC machine or a joint of a
robot.
2. Machine Level: Hardware at device
level is assembled into machines.
Functions at this level include performing
sequence of steps in a program in an
orderly and accurate manner. For example,
CNC machine tools, industrial robots,
powered conveyors & automated guided vehicles.
3. Cell or System Level: This level operates under the instructions from plant level. It is a group
of machines or workstations connected by a material handling system, computer & other
equipment. Production lines are included in this level. Functions include: part dispatching &
machine loading, coordination among machines & material handling system & collecting &
evaluating inspection data.
4. Plant Level: Plant or factory level receives instructions from the corporate information system
& implements them in production. Functions include: order processing, process planning,
inventory control, purchasing, material requirements planning, shop floor control & quality
control.
5. Enterprise Level: This is the highest level, consisting of corporate information system. It is
concerned with management of the company. Functions include: marketing & sales, accounting,
design, research, aggregate planning & master production scheduling.
Basic Components of Automation System

An automated system consists of three basic
elements:
1. Power to accomplish the automated process.
2. Program of instructions to direct the process.
3. Control system to actuate the instructions.
Power
Any automated system requires power to drive the process as well as controls. The
principal source of power used here is electricity. Electric power can be converted to other forms
of energy like, mechanical, thermal, pneumatic, etc. easily. It can also be stored in long-life
batteries for use in any locations. Other sources of power include: fossil fuels, solar energy,
water & wind.
Power for the Process: In addition to driving the manufacturing process itself, power is also
required for loading & unloading the work unit & also for the material transport between
operations.
Power for Automation: Modern industrial controllers are based on digital computers, which
require electrical power to read the program & execute it by sending commands to actuators.
Controller commands need electromechanical devices such as switches and motors called
actuators. Power is also needed to amplify the low power command signals.
Process Power Forms

Casting, Heat Treating Thermal
Electric Discharge Machining [EDM] Electrical
Forging, Machining, Sheet Metal Punching & Blanking Mechanical
Injection Molding, Welding Thermal & Mechanical
Laser Beam Cutting Light & Thermal
Program of Instructions
The actions performed by automated process are defined by a program of instructions.
Part or product developed during the operation is completed during a work cycle in various steps.
The processing steps for work cycle are specified in a work cycle program. Work cycle programs
are also called numerical control [NC]. Common steps of program include: loading of part,
performing the operation & unloading the part.
Control System
The control element of the automated system executes the program of instructions to get
the desired product. The controls in an automated system can be either closed loop or open loop.
Closed-loop Control system:

A closed loop control system also known as feedback control system is one in which the
output is compared with input. The input given to the system actuates the process and the output
is compared with input by a feedback sensor. Controller receives the error signal makes the
corrections and sends the signal as output.
Open-loop Control system:

An open loop control system operates without feedback loop; hence no comparison
is made between the actual & desired value.
Week 1
Lecture 2
Introduction to Shop Floor Control
Shop floor control deals with managing the work-in-process. This consists of the release
of production orders to the factory, controlling the progress of the orders through the various
work stations, and getting the current information of the status of the orders.
Relationship between Shop Floor Control and Factory Information Control

System
The relationship between shop floor and
factory information control system is shown in the
form of a factory information system. The input to
the shop floor control system is the collection of
production plans. These can be in the form of
master schedule, manufacturing capacity planning
and ERP data. The factory production operations are
the processes to be controlled.
Shop Floor Control

A typical shop floor control system consists of three phases: 1. Order release, 2. Order
scheduling, and 3. Order progress.
Week 1
Lecture 3
Phases of Shop Floor Control
1. Order Release
The order release phase of shop floor control provides the documentation needed to
process a production order through the factory. The collection of documents is sometimes called
the shop packet. In a modern factory, automated identification and data capture technologies are
used to monitor the status of production orders
Order release consists of:
1. Route sheet, which documents the process plan for the item to be produced.
2. Material requisitions, to draw the necessary raw materials from inventory.
3. Job cards to report direct labor time for the order and to indicate progress of the order.
4. Move tickets to authorize the material handling man to move parts between work centers.
5. Parts list, if required for assembly jobs.
2. Order Scheduling
The order scheduling module prepares a dispatch list, which indicates which production
orders should be accomplished at the various work centers. It also provides information about
relative priorities of different jobs
The order scheduling module in shop floor control is intended to solve two problems in
production control:
1. Machine loading: Allocating orders to work centers is referred to as machine loading. The
term shop loading is also used, which refers to the loading of all machines in the plant.
2. Job sequencing: Job sequencing involves determining the sequence in which the jobs will be
processed through a given work center.
Some of the dispatching rules used to establish priorities for production orders are,
• First-come-first-serve. Jobs are processed in the order in which they arrive at the machine.
• Earliest due date. Orders with earlier due dates are given higher priorities.
• Shortest processing time. Orders with shorter processing times are given higher priorities.
• Least slack time. Slack lime is defined as the difference between the time remaining until due
date and the process time remaining. Orders with the least slack in their schedule are given
higher priorities.
• Critical ratio. The critical ratio is defined as the ratio of the time remaining until due date
divided by the process time remaining. Orders with the lowest critical ratio are given higher
priorities.
When an order is completed at one work center, it enters the queue at the next machine in
its process routing. The relative priorities of the different orders may change over time. Reasons
behind these changes include, demand for certain products, equipment breakdowns,
cancellation of an order by a customer, and defective raw materials.
3. Order Progress
The order progress module in shop floor control monitors the status of the various orders
in the plant, WIP, and other characteristics that indicate the progress and performance of
production. The information presented to production management is often summarized in the
form of reports, such as
• Work order status reports. These reports indicate the status of production orders, like the
current work center, processing hours remaining, whether the job is on-time or behind schedule,
and priority level.
• Progress reports. A progress report is used to report performance of the shop during a certain
time period (e.g., week or month in the master schedule). It provides information on how many
orders were completed, how many orders should have been completed and so on.
• Exception reports. An exception report indicates the deviations from the production schedule
(e.g. overdue jobs) and similar exception information.
Factory Data Collection System
The factory data collection system (FDC
system) consists of the various paper documents,
terminals, and automated devices located throughout
the plant for collecting data on shop floor operations.
The ultimate purpose of the factory data collection
system is 1. To supply status and performance data to
the shop floor control system and 2. To provide
current information to production foremen, plant
management and production control personnel.
To accomplish this purpose, the factory data
collection system must input data to the plant
computer system. In current CIM technology, this is
done using an on-line mode, in which the data are
entered directly into the plant computer system and
are immediately available to the order progress
module, the advantage of on-line data collection is
that the data file representing the status of the shop
can be kept current at all times. As changes in order
progress are reported, these changes are immediately
incorporated into the shop status file.
Week 1
Tutorial
Multimedia / Industrial Visit expose on automatic Shop Floor Control &

Material Handling
1. Inside the Robotic Palletizing System at Molnlycke Health Care
2. Advanced Automation with AutoStore Warehouse Robots
3. New Robotic Shuttle Technology Provides Goods-to-Person Fulfillment

4. Sensors and Sensor Solutions for Automated Guided Vehicles AGVs FTS
5. Lean Management Systems: Visual Management at Hayes Manufacturing

Week 1
Practical
Exercise 1
Identification of Automation Systems in Day-to-day Use

Automatic Electric Iron
The automatic
electric iron uses
thermostat to control
the heating process.
The thermostat gives
control signal to the
heating element, which
is actuator, which in
turn increases the
temperature of the sole plate of the iron. The thermostat compares feedback signal of the actual
temperature and input temperature to generate signal proportional to the preset temperature.
Automatic Temperature Control System

The automatic
temperature control
system uses tank
temperature as the
feedback signal, which
will be sensed by a
pressure thermometer,
and compares it with
reference input and the
new control signal is
sent the valve which
actuates and allows controlled steam to flow and alter the temperature of tank. The valve closes
the tank temperature reaches desired value.
Automatic Liquid Level Controller

In an automatic
liquid level controller,
the position of the float
determines the control
signal needed to actuate
the valve to maintain the
liquid level. As the
liquid level comes down
float sends signal to
valve which allows the
liquid to fill the tank to maintain the required liquid level.
Other common automation systems in everyday use are, automatic washing machine,
air conditioning system, refrigeration system, automatic coffee dispenser, etc. the modern-
day developments in Artificial Intelligence [AI] has paved way for automation of home,
industry, office/workplace, farming, smart city, etc. which use IoT [Internet of Things] to
achieve automation.
Alexa: Virtual Assistant
Home Automation
Week 2
Lecture 1
Data Input Techniques
Manua1 (Clerical) Data Input Techniques.
Manually oriented techniques of factory data collection are those in which the production
workers must read from and fill out paper forms indicating order progress data. The paper forms
include:
• Job traveler: This is a log sheet that travels with the shop packet through the factory. Workers
who spend time on the order are required to record their times on the log sheet along with other
data such as the date, piece counts, defects, and so on.
• Employee time sheets: In this method, a daily time sheet is prepared for each worker, and the
worker must fill out the form to indicate work that he/she accomplished during the day. Data
entered on the form include order number, operation number on the route sheet, number of
pieces completed during the day, and time spent.
• Operation tear strip: With this technique, the traveling documents include a set of preprinted
tear strips that can be easily separated from the shop packet. The preprinted data on each tear
strip includes order number and route sheet details. At the end of the shift, one of the tear strips
is torn off.
• Prepunched cards. This is essentially the same technique as the tear strips method, except that
prepunched computer cards are included with the shop packet instead of tear strips.
Automated and Semi-Automated Data Collection Systems

Because of the human errors and time delay associated with the manual/clerical
procedures techniques have been developed that use data collection terminals located in the
factory. Data collection terminals require workers to input data relative to order progress using
simple keypads or conventional alphanumeric keyboards. The data entry methods also include
more automated input technologies such as optical bar code readers or magnetic card readers
Using either PCs or terminals that combine keypad entry with bar code technology, there are
various configurations of data collection terminals that can be installed in the factory. These
configurations include:
• One centralized terminal: In this arrangement there is a single terminal located centrally in the
plant. This requires all workers to walk from their workstations to the central location when they
must enter the data. If the plant is large, this becomes inconvenient.
• Satellite terminals: In this configuration, there is multiple data collection terminals located
throughout the plant.
• Workstation terminals: The most convenient arrangement for workers is to have a data
collection terminal available at each workstation. The investment cost of this configuration is
high, it may be used when the number of data transactions is relatively large and the terminals
are also designed to collect certain data automatically.
Automated Identification Methods

Automatic identification & data capture [ADC] refers to the technologies that provide
direct entry of data into a computer or other microprocessor-controlled system without using a
keyboard. Many of these technologies require no human involvement in the data capture process.
Automatic identification systems are being used increasingly to collect data in material handling
& manufacturing applications.
Automatic identification technologies consist of three principal components:
1. Encoded Data: A code is a set of symbols or signals representing alphanumeric characters.
When data are encoded, the characters are translated into machine-readable code [not readable
by humans]. A label or tag containing the encoded data is attached to the item that is to be later
identified.
2. Machine Reader or Scanner: This device reads the encoded data, converting them to
alternative form, usually an electrical analog signal.
3. Decoder: This component transforms the electrical signal into digital data & finally back into
the alphanumeric characters.
The most widely used ADC methods in the factory are: 1. Bar Codes, 2. Radio Frequency
Methods, 3. Magnetic Stripes, 4. Optical Character Recognition & 5. Machine vision.
Bar Code Technology

Bar codes divide into two basic types:
1. Linear or One-dimensional, in which the encoded data are read using a linear sweep of
scanner. There are two forms of linear bar codes:
1. Width-modulated: consists of bars & spaces of varying width
2. Height-modulated: consists of evenly spaced bars of varying height.
2. Two-dimensional, in which the encoded data must be read in both directions.
Linear Width-Modulated Bar Code

In linear width-modulated
bar code technology, the symbol
consists of a sequence of wide &
narrow colored bars separated by
wide & narrow spaces [the colored
bars are usually black & the spaces
are white for high contrast]. The
pattern of bars & spaces is coded to
represent numeric or alphanumeric
characters.
Bar code readers intercept
the code by scanning & decoding
the sequence of bars. The reader
consists of the scanner & decoder.
The scanner emits a beam of light that is swept past the bar code & senses light reflections to
distinguish between the bars & spaces. The light reflections are sensed by a photo detector,
which converts the spaces into an electrical signal & the bars into absence of an electrical signal.
The width is indicated by the duration of the corresponding signals.
Bar Code Readers

Bar code readers come in a variety of configurations; some require a human to operate
them & others are standalone automatic units. They are usually classified as contact or non-
contact readers.
1. Contact bar code readers are hand-held wands or light pens operated by moving the tip of
the wand quickly across the bar code on the object or product. The wand tip must be in contact
with or nearer to the bar code surface while reading the bar code. They are battery powered &
include a solid-state memory device to store data. The data can then be transferred to computer.
2. Non-contact bar code readers focus a light beam on a bar code & a photo detector reads the
reflected signal to interpret the code. The reader probe is located a certain distance from the bar
code [inches to feet] during read procedure. Non-contact readers are classified as fixed beam &
moving beam scanners.
1. Fixed beam scanners are stationary units that use a fixed beam of light. They are
usually mounted beside a conveyor and depend on the movement of the bar code past the light
beam for their operation.
2. Moving beam scanners use a highly focused beam of light, actuated by a rotating
mirror to traverse an angular sweep in search of the bar code on the object. Lasers are often used
to achieve the highly focused beam of light.
Bar Code Printers

Bar code printers are used to print the bar code labels on the product. The labels are
printed in either identical or sequenced symbols. Printing technologies include traditional
techniques such as, letter press, offset lithography & flexographic printing. Advanced techniques
used for printing involves following: Dot matrix, Ink-jet, direct thermal, thermal transfer,
laser printing & laser etching.
Week 2
Lecture 2
Radio Frequency Identification [RFID]
In radio frequency
identification, an identification tag
containing electronically coded
data is attached to the subject item
& communicates these data by
radio frequency to a reader as the
item passes. The reader decodes &
validates the RF signal before
transmitting the data to computer
system. The identification tag is a
transponder, which is a device
capable of emitting a signal. To
activate the tag, the reader
transmits a low-level RF magnetic
field that serves as a power source
for transponder when it is nearer.
Advantages of RFID include: Independent of physical contact or line of observation,
identification tags can hold more data than other ADC techniques & the tags can be reused. The
disadvantage of RFID is that the hardware required is more expensive.
Magnetic Stripe Technology

Magnetic stripes attached
to the product or containers are
used for item identification in
factory & warehouse applications.
A magnetic stripe is a thin plastic
film containing small magnetic
particles whose pole orientations
can be used to encode bits of data
into the film. The film can be
encased in or attached to a plastic
card for automatic identification.
These are same kinds of magnetic
stripes used to encode data onto
plastic credit cards & bank access
cards.
Disadvantages of this technology are unavailability of proper coding, decoding and
reading methods in shop floor & high cost of magnetic stripes. Two advantages of magnetic
stripes are their large data storage capacity & the ability to alter data contained in them.
Optical Character Recognition [OCR]
Optical character recognition refers to the use of specially designed alphanumeric
characters that are machine-readable by an optical reading device. OCR is a 2-D symbology
& scanning involves interpretation of both vertical & horizontal features of each character during
decoding. Accordingly, when manually operated scanners are used, a certain level of skill is
required by operator. The great benefit of OCR technology is that the characters & texts can be
read by humans as well as by machines.
The disadvantages of OCR in factory applications include: the requirement of near-
contact scanning, lower scanning rates & higher error rates compared to bar code scanning.
Week 2
Lecture 3
Automated Material Handling
Types of Material Handling Equipment

The material handling equipment may be classified into following four categories:
1. Material Transport Equipment
a. Industrial Trucks, b. Automated Guided Vehicles [AGVs], c. Monorails & other Rail
Guided Vehicles [RGVs], d. Conveyors, e. Cranes & Hoists.
2. Storage Systems
a. Conventional Storage Systems
i. Bulk Storage, ii. Rack Systems, iii. Shelving & Bins, iv. Drawer Storage.
b. Automated Storage Systems
i. Automated Storage/Retrieval Systems [ASRS], ii. Carousel Systems.
3. Unitizing Equipment
4. Identification & Tracking Systems
Introduction to Automated Guided Vehicles [AGVs]

The first automated guided vehicle was developed in 1954 by A M Barrett, Jr. who used
an overhead wire to guide a towing truck pulling a trailer in a grocery warehouse.
“An automated guided vehicle is a material handling equipment that uses
independently operated, self-propelled vehicles guided along defined pathways.” The vehicles
are powered by on-board batteries that allow many hours of operations [8-16 hr] between
recharging. The advantage of AGVs compared to RGVs is that the pathways can be altered.
AGVs are used where different materials are moved from various load points to unload points.
AGV is therefore suitable for automating material handling in batch production & mixed model
production.
Types of Automated Guided Vehicles
1. Driver-less Trains
A driver-less train consists of a towing
vehicle [AGV] that pulls one or more trailers to form
a train. It was the first type of AGV System to be
introduced & is still widely used. A common
application is moving heavy payloads over large
distances in warehouses or factories. For trains
consisting of 5-10 trailers, this is an efficient
transport system.
2. Pallet Trucks
Automated guided pallet trucks are used to
move palletized loads along pre-determined routes. In
the typical application the vehicle is backed into the
loaded pallet by a human worker who steers the truck
& uses its forks to elevate the load slightly. Then the
worker drives the pallet truck to the guide path,
programs its destination & the vehicle proceeds
automatically to the destination for unloading. The
capacity of a pallet truck ranges up to several thousand
kilograms & some trucks are capable of handling two
pallets. A recent introduction in pallet trucks is the
Fork Lift AGV. This can reach greater heights to reach loads on racks & shelves.
3. Unit Load Carriers
AGV unit load carriers are used to move
unit loads from one station to another. They are
often equipped for automatic loading & unloading
of pallets by means of powered rollers, moving
belts, mechanized lift platforms. Unit load carriers
are of two types, light load AGVs & assembly line
AGVs. The light load AGV is a small vehicle with
a load capacity of 250 kg or less. They are
designed to move small loads like, single parts, small baskets or pans. Assembly line AGV is
used to carry partially completed subassembly through a sequence of assembly workstations to
finish the product.
Guidance & Routing of Automated Guided Vehicles

The guidance system is the method by which AGV pathways are defined & vehicles are
controlled to follow the pathways. The three technologies used in commercial systems for
vehicle guidance are: 1. Imbedded Guide Wires, 2. Paint Strips & 3. Self-guided Vehicles.
Imbedded Guide Wires

In the imbedded guide wire method,
electrical wires are placed in a small channel
cut into the surface of the floor. The channel
is typically 3-12 mm wide & 13-26 mm deep.
After the guide wire is installed, the channel
is filled with cement to eliminate the
discontinuity in the floor surface. The guide
wire is connected to frequency generator,
which emits a low voltage, low current signal
with a frequency in the range 1-15 kHz. This
induces a magnetic field along the pathway
that can be followed by sensors on the
vehicles. Two coils are mounted on the vehicles which act as sensors. The difference in the
magnetic intensity sensed by each coil drives the vehicle by tracking the guide wire.
When a vehicle approaches a
branching point where the guide path forks
into two (or more) pathways, a means of
deciding which path to take must be provided.
The two principal methods of making this
decision in commercial wire guided systems
are: 1. The frequency select method and 2.
The path switch select method.
In the frequency select method, the
guide wires leading into the two separate
paths at the switch have different frequencies. As the vehicle enters the switch, it reads an
identification code on the floor to determine its location. Depending on its programmed
destination, the vehicle selects the correct guide path by following only one of the frequencies;
this method requires a separate frequency generator for each different frequency used in the
guide path layout.
The path switch select method operates with a single frequency throughout the guide
path layout. To control the path of a vehicle at a switch, the power is turned off in all other
branches except the one that the vehicle is to travel on. To accomplish routing by the path switch
select method the guide path layout is divided into blocks that are electrically insulated from
each other. The blocks can he turned on and off either by the vehicles themselves or by a central
control computer
Paint Strips
When paint strips are used to define
the pathways, the vehicle uses an optical
sensor system capable of tracking the paint.
The strips can be taped, sprayed or painted on
the floor. One system uses a 1-inch wide paint
strip containing fluorescent particles that
reflect an ultraviolet [UV] light source from
the vehicle. An on-board sensor detects the
reflected light in the strip & controls the
steering mechanism to follow it. Paint strip
guidance is useful in environments where
electrical noise renders problems & where installation of guide wires on the floor is impractical.
The paint strips deteriorate with time, it must be kept clean & periodically repainted.
Self-guided Vehicles
Self-guided vehicles
[SGVs] represent the latest
AGVs guidance technology.
SGVs operate without
continuously defined
pathways. They use a
combination of dead reckoning
& beacons located throughout
the plant, which can be
identified by on-board sensors.
Dead reckoning refers to the
capability of a vehicle to
follow a given route without a
defined pathway in the floor.
Movement is accomplished by computing the required number of wheel rotation in a sequence of
steering angles. These calculations are done by the vehicles on-board computer. Based on the
beacon positions in the plant, the on-board navigation computer uses triangulation to update
positions calculated by dead reckoning. Dead reckoning is used to move the vehicle between
beacons, & the actual locations of beacons provide data to update computer’s dead reckoning
map.
The advantage of SGV is its flexibility. The SGV pathways are defined in software. The
path can be changed by altering the data in navigation computer. The pathways can be expanded
by installing new beacons. All these changes can be made quickly & without much alteration to
plant facility.
Week 2
Tutorial
Multimedia / Industrial Visit to PLC Based Automated Machines
1. What is a PLC?
2. Industrial Automation & Control
3. Industry 5.0 with IoT and Robotics

Week 2
Practical
Exercise 1
Case Study: Radio Frequency used in Identification of Objects

RFID is a technology that uses radio waves to transfer data from an electronic tag, called
an RFID tag or label, through a reader attached to an object for the purpose of identifying and
tracking the object. Some RFID tags can be read from several meters away and beyond the line
of sight of the reader.
There are three main types of RFID systems: low frequency (LF), high frequency (HF)
and ultra-high frequency (UHF). Microwave RFID is also available. Frequencies vary greatly by
country and region.
• Low-frequency RFID systems: These range from 30 kHz to 500 kHz, though the typical
frequency is 125 kHz. LF RFID has short transmission ranges, generally anywhere from
a few inches to less than six feet.
• High-frequency RFID system: These ranges from 3 MHz to 30 MHz, with the typical
HF frequency being 13.56 MHz the standard range is anywhere from a few inches to
several feet.
• UHF RFID systems: These range from 300 MHz to 960 MHz, with the typical
frequency of 433 MHz and can generally be read from 25-plus feet away.
• Microwave RFID systems. These run at 2.45 GHz and can be read from 30-plus feet
away.
The frequency used will depend on the RFID application, with actual obtained distances
sometimes varying from what is expected.
Week 2
Practical
Exercise 2
Case Study: Magnetic Strip used in Identification of Objects

A magnetic stripe is made up of three ‘tracks’ which
allows you to encode and store three pieces of information. What
you need to know is that tracks 1 and 3 can store up to 85
characters while track 2 can only store up to 30 characters. When
the card is swiped, the data is read and passed to the system, which
then performs a defined action based on the data collected.
The data that can be stored on the magnetic stripe are your
methods of payment, things like account number and bank routing
number are encoded. For other use cases like college students,
student ID number and pre-paid cafeteria account number are
encoded. When these pieces of data are swiped into a computer
that can understand the data, a defined action will occur. That’s
why no one can take a student ID and use it to pay at their favorite
clothing store. The system will not understand a student ID
number.
Here is an example of what the card data looks like when it’s swiped!
%SULFAPENNICILLIN?@103020181222?&49512?
Week 3
Lecture 1
Traffic Control and Safety
Vehicle Management
For AGVs to operate efficiently the vehicle must be well managed. There are two aspects
of vehicle management, 1. Traffic Control & 2. Vehicle Safety.
1. Traffic Control
The purpose of traffic control in an AGVS is to minimize interference between vehicles
& to prevent collisions. Two methods of traffic control used in AGVS are, 1. On-board Vehicle
Sensing & 2. Zone Control. The two techniques are often used in combination.
On-board Vehicle Sensing

On-board vehicle sensing, also called forward sensing, involves the use of one or more
sensors on each vehicle to detect the presence of other vehicles & obstacles ahead on the guide
path. Sensor technologies include optical & ultrasonic devices. When an on-board sensor detects
an obstacle in front of it; the vehicle stops. When the obstacle is removed, the vehicle proceeds.
These systems are less effective at turns where obstacles are not directly in front of the vehicle.
Zone Blocking
In zone control,
AGVS layout is divided
into separate zones, &
the operating rule is
that no vehicle is
permitted to enter a
zone if that zone is already occupied by another vehicle. The length of the zone is at least
sufficient to hold one vehicle plus allowances for safety & other considerations.
2. Vehicle Safety
• An important safety feature
of an AGV is that its
travelling speed is slower
than the normal walking
pace of a human. This
reduces the danger of
overtaking a human walking
along the guide path in front
of the vehicle.
• In addition to this a safety
feature included in most
guided systems is automatic
stopping of the vehicle if it moves in wrong path away from the defined path by a short
distance of 50-150 mm.
• Another safety device is an obstacle sensor located on each vehicle. This is the same on-
board sensor used for traffic control. The sensor can detect obstacles along forward path,
including humans.
• A safety device included on all AGVs is an emergency bumper. The bumper surrounds the
front of the vehicle & protrudes ahead of it by 300 mm or more. When bumper contacts an
object, the vehicle is programmed to brake immediately.
• Other safety devices on a typical vehicle include warning lights [blinking or rotating
lights] & warning bells, which alert humans that the vehicle is present.
Week 3
Lecture 2
System Management of Automated Guided Vehicles
On-board Control Panel
Each guided vehicle is equipped with
some form of On-board control panel for the
purpose of manual vehicle control, vehicle
programming, and other functions. Most
commercial vehicles can be dispatched by means
of this control panel to a given station in the
AGVS layout. It provides the AGVS with
flexibility and timeliness in coping with changes
and variations in delivery requirements.
Remote Call Stations

Remote call stations represent another method for an AGVS to satisfy delivery
requirements, the simplest call station is a press button mounted at the load/unload station This
transmits a signal for any available vehicle in the neighborhood to dock at the station and either
pick up or drop off a load. The on-board control panel might then be used to dispatch the vehicle
to the desired destination point.
Central Computer Control

Central computer control is used to accomplish automatic dispatching of vehicles
according to a preplanned schedule of pickups & deliveries in the layout & in response to calls
from various load/unload stations. In this dispatching method, the central computer issues
commands to the vehicle in the system concerning their destinations & the operations they must
perform. Radio frequency [RF] is commonly used to achieve the required communication links.
A useful tool in system management is a performance report for each shift of AGVS operation.
Periodic reports of system performance provide summary of number of deliveries made during a
shift, & other data about each station & each vehicle in the system.
Industrial Applications of Automated Guided Vehicles

• AGVs are used in drive train operations, which involve the movement of large quantities
of material over relatively large distances.
• AGVs are used in storage & distribution. Unit load carriers & pallet trucks are typically
used, which involve the movement of material in unit loads. The application often interfaces
the AGVs with some other automated handling & storage system, such as automated
storage/retrieval system [AS/RS].
• AGVS is used in assembly line applications, where unit load carriers & light load guided
vehicles are used to transfer components between different stations in an assembly line. The
assembly tasks are usually performed on-board the vehicle to reduce loading & unloading
time.
• AGVS technology is also used in Flexible Manufacturing System [FMS] where work
parts are placed on pallet fixtures & are delivered to individual work stations. While
processing the work part, vehicle returns to pick up the new work parts.
• Other applications of AGVS include office mail delivery & hospital material transport.
These transports have the ability to achieve the movement between different floors using
elevators.
• A robotic manipulator mounted on an AGV provides a mobile robot for performing
complex handling tasks at various locations of plant.
Automated Storage/Retrieval System
An automated storage/retrieval system [AS/RS] can be defined as a storage system that
performs storage & retrieval operations with speed & accuracy under a defined degree of
automation. The basic AS/RS consists of a rack structure for storing loads & a storage/retrieval
mechanism whose motions are linear [x-y-z motions].
Basic Components of AS/RS

An AS/RS consists of one or more storage aisles that are each serviced by a
storage/retrieval machine. The aisles have storage racks for holding the stored materials. The
S/R machines are used to deliver materials to storage racks & to retrieve materials from the
racks. Each AS/RS aisle has one or more input/output stations where materials are delivered into
storage system or moved out of the system. These stations are called pickup-&-deposit [P/D]
stations. P/D stations can be manually operated or interfaced to a conveyor or AGVS.
Week 3
Lecture 3
Types of Automation System
1. Relay-controlled Systems
At the outset of industrial revolution, especially during 60’s and 70’s, relays were used to
operate automated machines, and these were interconnected using wires inside the control panel.
• In some cases, a control panel covered an entire wall.

• To discover an error in the complex control system much time was needed.
• A lifetime of relay contacts was limited, so some relays had to be replaced.
• If replacement was required, machine had to be stopped and production too.
• Often there would not be enough room for necessary changes.
• Control panel wasn’t easy to adapt to the requirements of a new system.
• As far as maintenance, electricians had to be very skillful in finding errors.
In short, conventional relay control panels proved to be very inflexible.
2. The Programmable Logic Controller [PLC]
A programmable logic controller (PLC) is a special form of microprocessor-based
controller that uses programmable memory to store instructions and to implement functions such
as logic, sequencing, timing, counting, and arithmetic in order to control machines and processes.
Difference between Relay-Control panel and PLC Control panel

When compared with relay systems, PLCs:
• Can easily implement changes since changes are made in software
• Can be readily expanded by adding new modules to the PLC.
• Are more robust and reliable than relay systems
• Are more compact than relay systems
• Require less maintenance than relay systems
• Can operate faster than relay systems.
Relay Logic vs. PLC Ladder Diagram

[Process control circuit for mixing operation
Week 3
Tutorial
Write a PLC Ladder Program to Switching on/off the Lamp whether they are
at the bottom or the top of the staircase.
As shown in figure consider a house with staircase. Here we will set lighting system for
the users to switch ON/OFF the light whether they are on bottom of the stair or at top. We will
provide separate switch for each floor as shown in figure.
Working
• Add two NO contacts of SW 1 (X0) and SW 2 (X1) in series and NC contacts of SW1
(X0) and SW2 (X1) in series, in parallel to NO Contacts.
• If the status of the bottom switch (SW1) and status of the top switch (SW2) are same then
lamp will be ON.
• And if either status of the bottom or top switch is different from other then lamp (Y0)
will be OFF.
• When lamp (Y0) is OFF then user can ON the lamp by changing status of any switch.
Two-Way Switch Input/Output Logic
Inputs Outputs Physical Elements

X0 = 1 & X1 = 1 Y0 = 1 Lamp ON
X0 = 0 & X1 = 0 Y0 = 1 Lamp ON
X0 = 0 & X1 = 1 Y0 = 0 Lamp OFF
X0 = 1 & X1 = 0 Y0 = 0 Lamp OFF
PLC Ladder Diagram for Two-Way Switch Logic
Working of PLC Ladder Diagram for Two-Way Switch Logic
Sl. No. Inputs Outputs Physical Elements

01 X0 = 1 & X1 = 1 Y0 = 1 Lamp ON
02 X0 = 0 & X1 = 0 Y0 = 1 Lamp ON
03 X0 = 0 & X1 = 1 Y0 = 0 Lamp OFF
04 X0 = 1 & X1 = 0 Y0 = 0 Lamp OFF

Week 3
Practical
Exercise 1
Case Study: Automated Material Handling Equipment

Material Handling Equipment
Category Equipment
Industrial Trucks, Automated Guided Vehicles, Rail-Guided Vehicles,
Transport Equipment
Conveyors, Hoists & Cranes
Positioning Equipment Industrial Robots
Containers: Pallets, Tote Pans, Boxes, Baskets, Barrels, Drums,
Unit Load Formation
Cartons
Equipment
Unitizing Equipment: Palletizers, Depalletizers
Conventional: Bulk Storage, Racks, Shelving & Bins, Drawers
Storage Equipment
Automated: AS/RS
Identification and
Barcodes, RFID, Magnetic Stripe, OCR, Machine Vision
Control Equipment
Industrial Robot [Robotic Arm, Industrial Material Handling Robot]

Conveyors
Automated Material Handling Using Conveyors & Robots

Week 4
Lecture 1
Programmable Logic Controller [PLC]
A programmable logic controller (PLC) can be defined as a microcomputer-based
controller that uses stored instructions in programmable memory to implement logic, sequencing,
timing, counting, and arithmetic functions through digital or analog input/ output (I/O) modules,
for controlling machines and processes.
Block Diagram of PLC Systems

a) Fixed PLC System
Fixed I/O is typical of small PLCs that come in one package with no separate, removable
units. The processor and I/O are packaged together, and the I/O terminals will have a fixed
number of connections. The main advantage of this type of packaging is lower cost.
One disadvantage of fixed I/O is its lack of flexibility; you are limited in what you can
get in the quantities and types dictated by the packaging. For some models, if any part in the unit
fails, the whole unit has to be replaced.
b) Modular PLC System
Modular I/O is divided by compartments into which separate modules can be plugged.
This feature greatly increases your options and the unit’s flexibility. The basic modular controller
consists of a rack, power supply, processor module (CPU), input/output (I/O modules), and an
operator interface for programming and monitoring. The modules plug into a rack. When a
module is slid into the rack, it makes an electrical connection with a series of contacts called the
backplane, located at the rear of the rack. The PLC processor is also connected to the backplane
and can communicate with all the modules in the rack.
• The power supply supplies DC power to other modules that plug into the rack.
• The processor (CPU) is the “brain” of the PLC. A processor consists of a

microprocessor for implementing the logic and controlling the communications among
the modules. The processor requires memory for storing user program instructions,
numerical values, and I/O devices status. The CPU controls all PLC activity. A typical
PLC scan starts with the CPU reading inputs. Then, the application program is executed
and output is updated.
• The I/O system forms the interface to condition the various signals received from or sent
to external field devices. Input devices such as pushbuttons, limit switches, and sensors
are hardwired to the input terminals. Output devices such as small motors, motor starters,
solenoid valves, and indicator lights are hardwired to the output terminals. To electrically
isolate the internal components from the input and output terminals, PLCs commonly
employ an optical isolator, which uses light to couple the circuits together.
• A programming device is used to enter the desired program into the memory of the
processor. A personal computer (PC) is the most commonly used programming device.
Most brands of PLCs have software available so that a PC can be used as the
programming device.
• A program is a user-developed series of instructions that directs the PLC to execute

actions. Relay ladder logic (RLL) is the standard programming language used with
PLCs. The relay ladder logic program graphically represents rungs of contacts, coils, and
special instruction blocks.
Internal Architecture of PLC
The CPU controls and processes all the operations within the PLC. It is supplied with a
clock with a frequency, 1 – 8 MHz. This frequency determines the operating speed of the PLC
and provides the timing and synchronization for all elements in the system. A bus system carries
information and data to and from the CPU, memory and input/ output units. There are several
memory elements: a system ROM to give permanent storage for the operating system and fixed
data, RAM for the user’s program and temporary buffer stores for the input/output channels.
Week 4
Lecture 2
I/O Modules [Interfaces]
The Input/Output (I/O) section of a PLC is the section to which all field devices are
connected and provides the interface between them and the CPU.
1. Discrete I/O Modules

The discrete
type of interface
connects field input
devices of the ON/OFF
nature such as selector
switches, pushbuttons,
and limit switches.
Likewise, output control

is limited to devices such as
lights, relays, solenoids, and
motor starters that require simple
ON/OFF switching.
Discrete Input Interface Module
Operation
• The input noise filter consisting of the capacitor and resistors R1 and R2 removes false
signals due to contact bounce or electrical interference.
• When the pushbutton is closed, 120 VACS is applied to the bridge rectifier input.
• This results in a low-level DC output voltage across the LED of the optical isolator. The
Zener diode (ZD) rating sets the minimum threshold voltage that can be detected.
• When light from the LED strikes the phototransistor, it conducts the status of the
pushbutton logic to the processor.
• The optical isolator separates the higher AC input voltage from the logic circuits and
prevents damage to the processor due to line voltage transients. This isolation also
reduces electrical noise.
• An AC/DC type of input module is used for both AC and DC inputs as the input polarity
does not matter.
Discrete Output Interface Module
Operation
• The digital
logic circuits
of the
processor set
the output
status
according to
the program.
• When the
processor
calls for an
output load to
be energized,
a voltage is
applied
across the LED of the opto-isolator.
• The LED then emits light, which switches the phototransistor into conduction which
triggers the triac AC semiconductor switch into conduction, allowing current to flow to
the output load.
• The triac conducts in either direction, the output to the load is alternating current.
• Fuses are normally required for the output module for each circuit to be protected
• The triac cannot be used to switch a DC load.
2. Analog I/O Modules

Analog devices
represent physical quantities
that can have an infinite
number of values. Typical
analog inputs and outputs
vary from 0 to 20 mA, 4 to 20
mA, or 0 to 10 V.
The analog input
interface module accepts an
analog voltage or current signal from the field device. This input is converted from an analog to a
digital value for use by the processor. The circuitry of the analog output module accepts the
digital value from the processor and converts it back to an analog signal.
Analog input interface module

The transition of an analog signal to digital values is accomplished by an analog-to-
digital (A/D) converter which is the main element of the analog input module. A transducer
converts a field device’s variable (e.g., pressure, temperature etc.) into a very low-level electric
signal (current or voltage) that can be amplified by a transmitter and then input into the analog
module.
Analog output interface module
The transition of a digital signal to analog values is accomplished by a digital-to-analog
(D/A) converter which is the main element of the analog output module. An analog output signal
is a continuous and changing signal according to PLC program. Common devices controlled by a
PLC analog output module include instruments, control valves, chart recorder, electronic drives,
etc.
Week 4
Lecture 3
Memory Organization
The user memory of a PLC includes space for the
user program as well as addressable memory locations for
storage of data. Memory elements store individual pieces of
information called bits (for binary digits).
Memory can be placed into two general categories: Memory Conversion

volatile and nonvolatile. Volatile memory will lose its stored 1 Bit 0 or 1
information if all operating power is lost or removed. Volatile 8 Bit 1 Byte
memory is easily altered and is quite suitable for most 16 Bit [2 Byte] 1 Word
applications when supported by battery backup. Nonvolatile 1 K [1024 Byte] 1000 Word
memory has the ability to retain stored information when power is removed accidentally or
intentionally.
Programmable logic controllers have programmable memory that allows users to develop
and modify control programs. This memory is made nonvolatile so that if power is lost, the PLC
holds its programming.
Memory Abb. Type Features

Random Access
RAM Volatile CMOSRAM for extended memory [2-5 years]
Memory
Non- OS is burned Into ROM [Programmable ROM
Read Only Memory ROM
volatile (PROM) – one time programmable]
Erasable Partially Erasable with special equipment [E.g.: UV
EPROM
Programmable ROM Volatile light]
Electrically Erasable Non-
EEPROM Can be electrically overwritten
Programmable ROM volatile
Non-
Flash EEPROM Used for backup [Fast saving & retrieving]
volatile
PLC Input/Output [I/O] Devices
Input Device Examples

Mechanical Switches SPST, SPDT, Limit Switch, Liquid-level switch, etc.
Proximity Switches Eddy current PS, reed switch, capacitive PS, Inductive PS
Photoelectric Sensors & Transmissive PS, Reflective PS, LED, Phototransistor,
Switches Photodiode, Photoconductive cell
Encoders Incremental & Absolute Rotary Encoders
Resistive temperature detector [RTD], Thermometer,
Temperature Sensors
Thermistor, Thermodiode, Thermotransistor, Thermocouple
Position/Displacement Resistive linear & angular position sensors, linear & rotary
Sensors potentiometers, LVDT, capacitive displacement sensors
Metal foil SG, Wheatstone Bridge, SG with temperature, force
Strain Gauges
and pressure sensors
Pressure Sensors Diaphragm & Bellow types, Piezoelectric Crystal
Liquid–Level Detectors Float switch
Fluid Flow Measurement Orifice Flow Meter
Ultrasonic Proximity Sensors Sound sensors
Data convertors, processor with buffering & conditioning,
Smart Sensors
EEPROM
Output Device Examples
Relay NO, NC, solenoid and latching relay
Directional Control Valve Hydraulic, Pneumatic, solenoid, spool type DCV, 2/2, 3/2, 4/2,
[DCV] 5/2, 4/3, 5/3 DCV
Motors AC Motor, DC Motor, Brushless DC Motor
Permanent Magnet & Variable Reluctance type and Hybrid
Stepper Motors
stepper motor
Week 4
Tutorial
Output is to be ON only when either inputs 7 and 8 are ON or if Inputs 17 and

18 are ON. Output can be ON when all the four Inputs are ON. Construct the
above conditions in the Boolean expression and write the Logic diagram using
gates and PLC Ladder diagram.
Boolean Expression: (7 ∙ 8) + (17 ∙ 18) = O
Logic Diagram:
Truth Table:
(7 ∙ 8) +
7 8 (7 ∙ 8) 17 18 (17 ∙ 18) Output
(17 ∙ 18)
1 1 1 1 1 1 1 7, 8, 17, 18 ON
1 1 1 1 0 0 1 7, 8 ON
1 1 1 0 1 0 1 7, 8 ON
1 1 1 0 0 0 1 7, 8 ON
1 0 0 1 1 1 1 17, 18 ON
1 0 0 1 0 0 0 OFF
1 0 0 0 1 0 0 OFF
1 0 0 0 0 0 0 OFF
0 1 0 1 1 1 1 17, 18 ON
0 1 0 1 0 0 0 OFF
0 1 0 0 1 0 0 OFF
0 1 0 0 0 0 0 OFF
0 0 0 1 1 1 1 17, 18 ON
0 0 0 1 0 0 0 OFF
0 0 0 0 1 0 0 OFF
0 0 0 0 0 0 0 OFF
Ladder Diagram:
Working of PLC Ladder Diagram for Boolean Logic: (7 ∙ 8) + (17 ∙ 18)
Sl. No. Inputs Outputs Remark

01 X7 = 0, X8 = 0, X17 = 0, X18 = 0 Y0 = 0 All inputs OFF – Output OFF
02 X7 = 1, X8 = 1, X17 = 0, X18 = 0 Y0 = 1 Input 7 & 8 ON – Output ON
03 X7 = 0, X8 = 0, X17 = 1, X18 = 1 Y0 = 1 Input 17 & 18 ON – Output ON
04 X7 = 1, X8 = 1, X17 = 1, X18 = 1 Y0 = 1 Input 7, 8, 17 & 18 ON – Output ON

Week 4
Practical
Exercise 1
Execute energized motor or bulb using switches in series or parallel
Ladder Diagram:
Working:
Rung N0000 shows ladder diagram for bulb energized through series switches X0 & X1.
The bulb will be energized or ON only when both the switches are ON [Realization of AND
logic].
Rung N0001 shows ladder diagram for bulb energized through parallel switches X2 &
X3. The bulb will be energized or ON only when either of the two switches or both switches are
ON [Realization of OR logic].
Truth Table: Series Switch Parallel Switch

X0 X1 Y0 X2 X3 Y1
1 1 1 1 1 1
1 0 0 1 0 1
0 1 0 0 1 1
0 0 0 0 0 0
Working of PLC Ladder Diagram for Series Switches: [Rung N0000]

01 X0 = 0, X1 = 0 Y0 = 0 All inputs OFF – Bulb OFF
02 X0 = 1, X1 = 0 Y0 = 0 Input X0 ON – Bulb OFF
03 X0 = 0, X1 = 1 Y0 = 0 Input X1 ON – Bulb OFF
04 X0 = 1, X1 = 1 Y0 = 1 All Inputs ON – Bulb ON

Working of PLC Ladder Diagram for Parallel Switches: [Rung N0001]

01 X2 = 0, X3 = 0 Y0 = 0 All inputs OFF – Bulb OFF
02 X2 = 1, X3 = 0 Y0 = 1 Input X2 ON – Bulb ON
03 X2 = 0, X3 = 1 Y0 = 1 Input X3 ON – Bulb ON
04 X2 = 1, X3 = 1 Y0 = 1 All Inputs ON – Bulb ON
Observations:
1. Series Switches act as AND logic.
2. Parallel Switches act as OR logic.
Week 5
Lecture 1
Ladder Diagram Symbols
PLC programming based on the use of
ladder diagrams involves writing a program in a
similar manner to drawing a switching circuit.
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.
Contact and Coil Input/Output

Given below is the ladder diagram for a simple single-
contact single coil circuit. The coil will be ON or OFF as and
when the Contact switch is closed or opened [energized or de-
energized] respectively.
Output:
Programming Examples
1. Two limit switches connected in series and used to control a solenoid valve.
2. Two limit switches connected in parallel and used to control a solenoid valve.
3. Two limit switches connected in parallel with each other and in series with a
pressure switch.
4. Two limit switches connected in parallel with each other and in series with two sets
of flow switches (that are connected in parallel with each other), and used to control
a pilot light.
5. Two limit switches connected in series with each other and in parallel with a third
limit switch, and used to control a warning horn.
Week 5
Lecture 2
Relation of Digital Gate Logic to Contact/Coil Logic
AND Gate
An AND gate is a device with two or more
inputs and one output. The AND gate output is 1
only if all inputs are 1
OR Gate
An OR gate can have any number of
inputs but only one output. The OR gate output is
1 if one or more inputs are 1.
NOT Gate
Unlike the AND and OR functions, the
NOT function can have only one input. The NOT
output is 1 if the input is 0. The output is 0 if the
input is 1. The result of the NOT operation is
always the inverse of the input, and the NOT
function is, therefore, called an inverter.
NAND Gate: An AND gate with an inverted output is called a NAND gate.
NOR Gate: An OR gate with output an inverted output is called a NOR gate.
XOR Gate: An often-used combination of gates is the exclusive-OR (XOR) function. The
output of this circuit is HIGH only when one input or the other is HIGH, but not both. The
exclusive-OR gate is commonly used for the comparison of two binary numbers.
Week 5
Lecture 3
Conversion from word description to ladder diagram and vice-versa.
It is possible to prepare a ladder logic program directly from the narrative description of a
control process. Some of the steps in planning a program are as follows:
• Define the process to be controlled.
• Draw a sketch of the process, including all sensors and manual controls needed to carry
out the control sequence.
• List the sequence of operational steps in as much detail as possible.
• Write the ladder logic program to be used as a basis for the PLC program.
• Consider different scenarios where the process sequence may go astray and adjust as
needed.
• Consider the safety of operating personnel and adjust as needed.
Example:
Figure shows the sketch of a drilling process that
requires the drill press to turn on only if there is a part
present and the operator has one hand on each of the start
switches. This precaution will ensure that the operator’s
hands are not in the way of the drill.
The sequence of operation requires that switches 1
and 2 and the part sensor all be activated to make the drill
motor operate.
Week 5
Tutorial
The Process Fan is to run only when all of the following conditions are met,
a. Input 1 is OFF.
b. Input 2 is ON or Input 3 is ON, or both 2 and 3 are ON.
c. Inputs 5 and 6 are both ON.
d. One or more of the inputs 7, 8 or 9 is ON.
Develop the above conditions in the Boolean expression and write the
Logic diagram using gates and PLC Ladder diagram.
̅) ∙ (2 + 3) ∙ (5 ∙ 𝟔) ∙ (7 + 8 + 9) = F
Boolean Expression: (𝟏
Logic Diagram:
Ladder Diagram:
̅) ∙ (2 + 3) ∙ (5 ∙ 𝟔) ∙ (7 + 8 + 9) = F
Working of PLC Ladder Diagram for Boolean Logic: (𝟏
Week 5
Practical
Exercise 1
Develop PLC ladder diagram to realize the following logic gates:

AND, OR, NOT, NAND, NOR, EX-OR.
Ladder Diagram:
Working of Logic Gates:

The above ladder diagram explains the working of all Logic gates: AND, OR, NOT,
NAND, NOR, XOR.
N0000: AND Logic – Output Y0 is ON when both inputs X0 & X1 are ON.
N0001: OR Logic – Output Y1 is ON when either of inputs, X2 and X3 or both are ON.
N0002: NOT Logic – Output Y2 is ON when input X4 is OFF.
N0003: NAND Logic – Output Y3 is ON when either of inputs, X5 and X6 or both are OFF.
N0004: NOR Logic – Output Y4 is ON when both inputs X7 & X8 are OFF.
N0005: XOR Logic – Output Y5 is ON only either input X9 or input X10 is ON.
Truth Table:
Input Output
A B AND OR NOT [A] NAND NOR XOR
0 0 0 0 1 1 1 0
0 1 0 1 1 1 0 1
1 0 0 1 0 1 0 1
1 1 1 1 0 0 0 0
Working of PLC Ladder Diagram for AND
Logic: [Rung N0000]

01 X0 = 0, X1 = 0 Y0 = 0 All inputs OFF – Output OFF
02 X0 = 0, X1 = 1 Y0 = 0 Input X1 ON – Output OFF
04 X0 = 1, X1 = 1 Y0 = 1 All Inputs ON – Output ON
Working of PLC Ladder Diagram for OR

Logic: [Rung N0001]

02 X2 = 0, X3 = 1 Y1 = 1 Input X3 ON – Output ON
04 X2 = 1, X3 = 1 Y1 = 1 All Inputs ON – Output ON

Working of PLC Ladder Diagram for NOT
Logic: [Rung N0002]

01 X4 = 0 Y2 = 1 Input OFF – Output ON
02 X4 = 1 Y2 = 0 Input ON – Output OFF
Working of PLC Ladder Diagram for NAND

Logic: [Rung N0003]

01 X5 = 0, X6 = 0 Y3 = 1 All inputs OFF – Output ON
04 X5 = 1, X6 = 1 Y3 = 0 All Inputs ON – Output OFF

Working of PLC Ladder Diagram for NOR
Logic: [Rung N0004]

01 X7 = 0, X8 = 0 Y4 = 1 All inputs OFF – Output ON
Working of PLC Ladder Diagram for XOR

Logic: [Rung N0005]


Week 6
Lecture 1
PLC Arithmetic Functions
The basic math instructions are ADD, SUB, MUL, and DIV. Each of these instructions
has three parameter fields namely, Source A, Source B and Destination fields.
The Source A and Source B fields can be an input rack location, file address, instruction
field, or a fixed value. The Destination fields can be an output location, file address, or an
instruction field.
Function Description Ladder Diagram
The value at source A is added to the value

ADD at source B, and the result (answer) is stored
at destination address
The value stored at the source B address is

subtracted from the value stored at the
SUB
source A address, the answer is stored at the
destination address
The value stored in source A is multiplied by

MUL the value stored in source B, the product is
placed into destination word
The data in source is divided by the data in

DIV source B The result is placed in the
destination
Program to convert temperature in Celsius scale to Fahrenheit scale
Week 6
Lecture 2
PLC Basic Comparison Functions
Data compare instructions are used to compare numerical values. These instructions
compare the data stored in two or more words (or registers) and make decisions based on the
program instructions. Comparison instructions are used to test pairs of values to determine if a
rung is true.
Instruction Name Function

Tests whether one value is within the limit range of two
LIM Limit Test
other values
Masked Comparison Tests portions of two values to see whether they are
MEQ
for Equal equal
Tests whether the value of Source A is equal to the value
EQU Equal
of Source B
Tests whether the value of Source A is not equal to the
NEQ Not Equal
value of Source B
Tests whether the value of Source A is less than the value
LES Less Than
of Source B
Tests whether the value of Source A is greater than the
GRT Greater Than
value of Source B
Tests whether the value of Source A is less than or equal to the
LEQ Less Than or Equal value of Source B
Tests whether the value of Source A is greater than or
GEQ Greater Than or equal
equal to the value of Source B
Automatic Heater [Illustration]

Week 6
Lecture 3
Introduction to Timer Functions
Mechanical timing relays are used to delay the opening or closing of contacts for circuit
control. Timers allow a multitude of operations in a control circuit to be automatically started
and stopped at different time intervals. Mechanical timing relays provide time delay through two
arrangements. The on delay, provides time delay when the relay coil is energized. The off
delay, provides time delay when the relay coil is de-energized.
On-delay timer circuit with normally open, timed closed (NOTC) & normally closed, timed
open (NCTO) contact
Off-delay timer circuit with normally open, timed open (NOTO) & normally closed, timed
closed (NCTC) contact
Timer Instructions
Instruction Function
TON [Timer On Delay] Counts time-based intervals when the instruction is true.
Counts time-based intervals when the instruction transitions
TOF [Timer Off Delay]
from a true to false condition.
Counts time-based intervals when the instruction is true and
RTO [Retentive Timer On] retains the accumulated value when the instruction goes false or
when power cycle occurs.
RES [Reset] Resets a retentive timer’s accumulated value to zero.
Coil & Block formatted Timer Instruction
Timer Instruction Information and Control Bits
Control Bits
The enable bit is true (has a status of 1) whenever the timer instruction
Enable Bit [EN] is true. When the timer instruction is false, the enable bit is false (has
a status of 0).
The timer-timing bit is true whenever the accumulated value of the
Timer-Timing Bit timer is changing, which means the timer is timing. When the timer is
[TT] not timing, the accumulated value is not changing, so the timer-timing
bit is false.
The done bit changes state whenever the accumulated value reaches
Done Bit [DN]
the preset value. Its state depends on the type of timer being used.
Instruction Information [T4:0]
This number must come from the timer file. In the example shown,
Timer Number the timer number is T4:0, which represents timer file 4, timer 0 in that
file.
The time base (which is always expressed in seconds) may be either
Time Base
1.0 or 0.01 s. In the example shown, the time base is 1.0 s.
In the example shown, the preset value is 15. The timer preset value
Preset Value
can range from 0 through 32,767.
In the example shown, the accumulated value is 0. The timer’s
accumulated value normally is entered as 0, although it is possible to
Accumulated Value
enter a value from 0 through 32,767. Regardless of the value that is
preloaded, the timer value will become 0 whenever the timer is reset.
Example: Conveyor warning signal circuit

Week 6
Tutorial
Write a PLC Ladder Program Providing lubricant for the gear box before the
lathe spindle starts to run which aims to ensure that the oil pump motor starts
first and the main motor starts subsequently.
Timers are often used as part of automatic sequential control systems. The operation of
the circuit can be summarized as follows:
• Lube-oil pump motor starter coil M1 is energized when the start pushbutton PB1 is
momentarily actuated.
• As a result, the lube-oil pump motor starts. When the lube-oil pump builds up sufficient oil
pressure, the lube-oil pressure switch closes.
• This in turn energizes TD to begin the time-delay period.
• After the preset time-delay period of 25, TD contact closes to energize coil M2 and start the
main feed motor.
Ladder Diagram:
Output:
01 Lube Oil ON Y0 = 1 Process Starts
02 After 10s Y1 = 1 Motor M2 is ON

Week 6
Practical
Exercise 1
Develop the Boolean expressions in to ladder diagram

̅
1. O = A + 𝐁
̅ (BC) + D
2. O = 𝐀
3. ̅̅̅̅̅̅̅̅
𝐀+𝐁=𝐀 ̅. 𝐁
̅ [De-Morgan’s Theorem]
̅ C + D𝐄̅F
4. S = A + 𝐁
5. Z = A.B.C.D
Week 6
Practical
Exercise 2
There are 3 mixing devices on a processing line A, B, C. After the process

begin mixer-A is to start after 7 seconds elapse, next mixer-B is to start 3.6
second after A. Mixer-C is to start 5 seconds after B. All of then remain ON
until a master enable switch is turned off. Develop PLC ladder diagram,
timing diagram and realize the same.
Ladder Diagram:
Working:
[N0000] When the Master Switch X0 is ON the process starts which is indicated by the Status
indicator Y0. Soon after the process starts the timer switch T100 starts timing and after its preset
delay time of 7s, it actuates Mixer A [Y1].
[N0001] When the timer T100 is up the timer T101 starts timing and after its preset delay time of
3.6s, it actuates Mixer B [Y2].
[N0002] When the timer T101 is up the timer T102 starts timing and after its preset delay time of
5s, it actuates Mixer C [Y3].
[N0000] The process continues and all the mixers will be ON until the Master switch is turned
OFF.
Timing Diagram &Function:
T100: Timer Number

70: Preset Value
.1s: Type of timer
Timer Number Type of Timer
T0 – T49 0.01s Timer
T50 – T199 0.1s Timer
T200 – T255 1s Timer
Output:

01 Soon After Master Switch is ON Y0 = 1 Process Starts
02 After 10s Y1 = 1 Mixer A is ON
03 After 3.6s, since T100 Y2 = 1 Mixer B is ON
04 After 5s, since T101 Y3 = 1 Mixer C is ON

Week 6
Practical
Exercise 3
Write a Ladder Program to count the number of Items moving on a conveyor

Belt
Ladder Diagram:
Working:
[N0000] The X0 acts as sensor which conducts [ON] when the item is detected. The X0 sends
signal in pulses to the counter which counts each time until it reaches the Preset value. The Y0
indicates the status of completion of counting operation.
The switch X1 is the reset switch to reset the counter.
Counter Function: Counter Type of

Number Counter
C0: Counter Number
5: Preset Value C0 – C199 16 Bit
PLS: Pulse input for C200 – C255 32 Bit
counting
Output:

01 Item Sensor, X0 = 1 Y0 = 1 Counter Operation
02 Counter Reset, X1 = 1 Y1 = 0 Counter Reset

Week 7
Lecture 1
PLC Counter Functions
Counters accumulate (count) the changes in state of an external trigger signal. There are
two basic counter types: count-up (CTU) and count-down (CTD). Count-up (CTU) counters
will cause the accumulated count to increase by 1 every time there is a false-to-true transition of
the counter ladder rung. Count-down (CTD) counter will cause the accumulated count to
decrease by 1 every time there is a false-to-true transition of the counter ladder rung.
Coil-formatted & Block-formatted Counters
Timer Instruction Information and Control Bits
Control Bits
Count-Up Enable Bit The count-up enable bit is used with the count-up counter and is true
[CU] whenever the count-up counter instruction is true.
Count-Down Enable The count-down enable bit is used with the count-down counter and is
Bit [CD] true whenever the count-down counter instruction is true.
The done bit is true whenever the accumulated value is equal to or
Done Bit [DN] greater than the pre-set value of the counter, for either the count-up or
the count-down counter.
The overflow bit is true whenever the counter counts past its
Overflow Bit [OV] maximum value, which is 32,767. On the next count, the counter will
wrap around to –32,768 and will continue counting till 0
The underflow bit will go true when the counter counts below –
Underflow Bit [UN] 32,768. The counter will wrap around to +32,767 and continue
counting down toward 0
Update Accumulator The update accumulator bit is used only in conjunction with an
Bit [UA] external HSC (high-speed counter).
Instruction Information [C5:0]
This number must come from the counter file. In the example shown,
Counter Number the counter number is C5:0, which represents counter file 5, counter 0
in that file.
The preset value can range from – 32,768 to +32,767. In the example
Preset Value
shown, the preset value is 10.
The accumulated value can also range from –32,768 to +32,767.
Typically, as in this example, the value entered in the accumulated
Accumulated Value
word is 0. Regardless of what value is entered, the reset instruction
will reset the accumulated value to 0.
Counter Instructions
Instruction Function
Increments the accumulated value at each false-to-true transition
CTU [Count-Up] and retains the accumulated value when an off/on power cycle
occurs.
Decrements the accumulated value at each false-to-true
CTD [Count-Down] transition and retains the accumulated value when an on/off
power cycle occurs.
HSC [High-Speed Counter] Counts high-speed pulses from a high-speed input.
RES [Reset] Resets a counter’s accumulated value to zero.
PLC counter function in process control:

PLC counter program used to stop a motor from running after 10 operations.
Week 7
Lecture 2
Counter and Timer Program
Many PLC applications use both the counter function and the timer function.
Paint spray process control that requires both a timer and counter.
Working:
When X0 sends 5 signals, counter counts and after 5 counts which is its preset value it
energizes Y0 & Y1. Also, after 5 counts the Y0 starts timer with a preset value of 25 [2.5 s] after
which Y1 is turned OFF.
Delay of the start of the counting process
Working:
When X0 is ON it starts timer with a preset value of 30s. After 30s delay X0 energizes
Y0, when Y0 is ON we can start counting process by counting signals at X1. Y1 will be ON after
5 counts and X2 is reset button.
Rate per Time Period Program Sequencer Function
Working:
This program is designed to indicate how many parts pass a given process point per
minute. When the X0 is closed, both the timer and counter are enabled. The counter is pulsed for
each part that passes the parts sensor [X1]. The counting begins and the timer starts timing
through its 1-minute time interval. At the end of 1 minute, the timer done bit causes the counter
rung to go false. The number of parts for the past minute is represented by the accumulated value
of the counter. The sequence is reset by momentarily opening and closing
the X2 switch.
Week 7
Lecture 3
Simple Real Time Examples
1. Counting parts on a conveyor
2. Stacking Problem
Week 7
Tutorial
The production line may be powered off accidentally or turned off for noon
break. The program is to control the counter to retain the counted number
and resume counting after the power is turned ON again. When the daily
production reaches 500, the target completed indicator will be ON to remind
the operator for keeping a record. Press the Clear button to clear the history
records. The counter will start counting from 0 again. Write a PLC Ladder
Program to perform this operation.
Retentive Counters are often used for retaining the count even after the line is
accidentally turned OFF. The retentive counters are available from C0 to C199.
• Sensor X0 detects the product on production line and the Counter C0 counts it. [N0000]
• Once the counter preset valve or Production target for the day is reached, the target indicator
Y0 will be ON. [N0001]
• X1 is the reset switch which deletes the counter data and starts from 0 the next day.
Ladder Diagram:
Output:
01 Production Line OFF Y0 = 0 Process Starts
02 After 500 Products Y0 = 1 Target Indicator ON

Week 7
Practical
Exercise 1
Develop Ladder Program for relay-based motor control automation such that
the motor reverses its direction when the limit switches are activated
Ladder Diagram:
Working:
[N0000] Latching rung to

operate the system through
Master Start and Stop Push
Button.
[N0001] When the workpiece

is near Limit Switch 1, it will
enable forward motor,
for latching forward Motor is
connected in parallel with
limit switch 1. Forward
Pushbutton (PB) is also
connected in parallel to manually operate forward motor.
[N0002] When the workpiece is near Limit switch 2, it will enable reverse motor, for latching
reverse Motor is connected in parallel with limit switch 2. Reverse Pushbutton (PB) is also
connected in parallel to manually operate Reverse motor.
Output:

01 X0 = 1, X2 = 1, X3 0 Y1 = 1 Forward Motor Active
02 X0 = 1, X3 = 1, X2 = 0 Y2 = 1 Reverse Motor Active

Week 7
Practical
Exercise 2
Build PLC ladder program for the real time application: Traffic light
controlling
Ladder Diagram:
Working:
[N0000] Start/Stop switch and timed switch T52 and T50

actuate Y0 [RED Signal] and also enables timer T50 with a
preset value of 50 [5 s].
[N0001] When the timer T50 completes 5 s it enables T50 in

rung N0001, turns the YELLOW light on, and also starts timer
T51, it also enables T50 in rung N0000 and turns the RED
light off.
[N0002] When the timer T51 completes 5 s it enables T51 in

rung N0002, turns the GREEN light on, and also starts timer
T52, it also enables T51 in rung N0001 and turns the
YELLOW light off and.
When the timer T52 completes 5 s it enables RED light in rung N0000 and starts timer
T50, it also enables T52 in rung N0002 and turns the GREEN light off and the cycle repeats.
Output:

01 X0 = 1, T52 = 0 Y0 = 1 RED ON
02 X0 = 1, T50 = 1 Y1 = 1 YELLOW ON
03 X0 = 1, T51 = 1 Y2 = 1 GREEN ON
Week 7
Practical
Exercise 3
Build PLC ladder program for the real time application: Water level
controlling
Ladder Diagram:
Working:
[N0000] The water in the tank can

be filled by starting the X2 Push
button momentarily which enables
memory bit M1
[N0001] The memory bit and low-

level indicator, the memory and the
high-level indicator are connected
in parallel.
Both the level sensors
remain OFF before filling, when
filling starts, when the water level
reaches low-level sensor, X1 is
enabled and filling continues.
When the water level reaches high-level sensor, X0 is enabled and the inlet valve is turned OFF.
Now the tank can be emptied by discharging the fluid, the fluid level now decreases.
When it goes past high-level sensor, X0 is disabled and when the water level falls below low-
level sensor, X1 is disabled and the inlet valve is turned back ON. The cycle repeats and the
water levels are thus maintained.
Output:
01 X0 = 0, X1 = 0, M = 0 Y0 = 0 Inlet Valve OFF
02 X0 = 0, X1 = 0, M = 1 Y0 = 1 Inlet Valve ON [Tank Filling]
03 X0 = 0, X1 = 1, M = 1 Y0 = 1 Low-Level Sensor ON
04 X0 = 1, X1 = 1, M1 = 1 Y0 = 0 High-Level Sensor ON, Inlet Valve OFF
[The discharging process yields reverse set of above outputs]

Week 8
Lecture 1
1. Develop automatic door system using optical sensor and linear actuator
Working:
When someone enters the optical sensor sensing field, opening motor starts working to
open the door automatically till the door touches the opening limit switch. If the door touches
the opening limit switch for 8 s and nobody enters the sensing field, the closing motor starts
working to close the door automatically till the closing limit switch touched together. Stop the
closing action immediately if someone enters the sensing field during the door closing process.
Below are the sensor and actuator used in this system:
Optical Sensor: An optical sensor can detect the presence of human and their movement
towards the door.
Servo Motor: Motor is a rotary actuator or linear actuator that is capable of carrying out precise
control of angular or linear position, velocity, and acceleration. It uses a suitable motor coupled
to a sensor for position feedback. The motor drives the door when the input is given.
Ladder Diagram:
Week 8
Lecture 2
2. Develop automatic elevator control

Assumptions:
1. Lift door is manual sliding type.
2. A door switch is provided to ensure the door is properly closed.
3. In first Floor there is only Down Call Button
4. Inside Lift, there are Both up and down button
5. In Ground Floor there is only Up Call Button
Working:
The following ladder diagram explains the basic control for
upward and downward movement of lift either operated from inside
elevator or from outside elevator. Also, the door opening and closing
indication is available as and when they are opened and closed. The
limit switches status indicates whether the lift is making an upward or
downward movement henceforth. The ladder diagram consists four inputs for up and down
movement, two inputs for limit switch status and one for door status. Two outputs for the motor
direction.
Ladder Diagram:
Week 8
Lecture 3
3. Design ladder diagram for car parking. (Hint: car is to be detected and
enter the parking space to a particular location if space is available. If there is
no space, a lamp should indicate that parking is full)
Working:
The entry/exit
sensor [X0] senses the
car when it passes in
close proximity to
sensor. The exit sensor
[X1] senses the car
leaving the parking area.
The signal from exit
sensor is given to the
U/D input of Up-Down
Counter C0 there by
decreasing the count
whenever the car leaves the parking area. The Counter preset value is set as 10. When the
number of cars in the parking area is 10 the ‘Parking Full’ status indicator will be ON. It will go
OFF when one or more car leaves the parking area. The X3 switch acts as emergency reset
button for counter.
Ladder Diagram:
Output:
Week 8
Tutorial
Write a PLC Ladder Program such that Once the photoelectric sensor detects
10 products, the robotic arm will begin to pack up. When the action is
completed, the robotic arm and the counter will be reset.
Ladder Diagram:
Working:
[N0000]: Item sensor senses the products on the conveyor and counts them. When the count
reaches 10 [preset value] the robotic arm gets actuated [Y0].
[N0001]: Now the robotic arm carries out packing process, and the packed item is sensed by
another sensor [Y1]. When the count of packed product reaches 10 [preset value] the process is
completed the robotic arm and counter is reset.
Output:
Week 8
Practical
Exercise 1
Develop automatic door system using optical sensor and linear actuator
Working:
When someone enters the optical sensor sensing field, opening motor starts working to
open the door automatically till the door touches the opening limit switch. If the door touches
the opening limit switch for 8 s and nobody enters the sensing field, the closing motor starts
working to close the door automatically till the closing limit switch touched together. Stop the
closing action immediately if someone enters the sensing field during the door closing process.
Below are the sensor and actuator used in this system:
Optical Sensor: An optical sensor can detect the presence of human and their movement
towards the door.
Servo Motor: Motor is a rotary actuator or linear actuator that is capable of carrying out precise
control of angular or linear position, velocity, and acceleration. It uses a suitable motor coupled
to a sensor for position feedback. The motor drives the door when the input is given.
Ladder Diagram:
[N0000]: Optical sensor [X0] detects the human being and the door is opened through motor
[Y0].
[N0001]: When the opening door reaches extreme end it is indicated by open limit switch [X2].
It starts the customary 8 s delay using a timer [T200]
[N0002]: When the timer time is up it actuates the door close motor [Y1]
Output:

01 X0 = 1, X2 = 0 Y0 = 1 Door Opens
02 X0 = 0, X2 = 1 Y1 = 1 Door Closes after Time Delay of 8 s

Week 8
Practical
Exercise 2
Develop automatic elevator control

Working:
The following ladder diagram explains the basic control for
upward and downward movement of lift either operated from inside
elevator or from outside elevator. Also, the door opening and closing
indication is available as and when they are opened and closed. The limit
switches status indicates whether the lift is making an upward or
downward movement henceforth. The ladder diagram consists four inputs
for up and down movement, two inputs for limit switch status and one for
door status. Two outputs for the motor direction.
Ladder Diagram:
[N0000]: This rung shows if the elevator call is made from 1st floor or from inside elevator from
ground floor, the elevator moves up through motor Y0 until it reaches 1st floor and actuates up
limit switch X6
[N0002]: This rung shows if the elevator call is made from ground floor or from inside elevator
from 1st floor, the elevator moves down through motor Y1 until it reaches ground floor and
actuates down limit switch X5
[N0003, N0004, N0005]: Indicates the door status of the elevator.
Output:

01 X5 = 1, X1 =1 Y0 = 1 Motor Up is ON
02 X6 = 1, X3 = 1 Y1 = 1 Motor Down is ON
Week 8
Practical
Exercise 3
Design ladder diagram for car parking. (Hint: car is to be detected and enter
the parking space to a particular location if space is available. If there is no
space, a lamp should indicate that parking is full)
Working:
The entry/exit sensor [X0]
senses the car when it passes in close
proximity to sensor. The exit sensor
[X1] senses the car leaving the
parking area. The signal from exit
sensor is given to the U/D input of
Up-Down Counter C0 thereby
decreasing the count whenever the car
leaves the parking area. The Counter
preset value is set as 10. When the number of cars in the parking area is 10 the ‘Parking Full’
status indicator will be ON. It will go OFF when one or more car leaves the parking area. The X3
switch acts as emergency reset button for counter.
Ladder Diagram:
Output:
Week 9
Lecture 1
1. Write a PLC ladder diagram for detecting the standing bottles on the
conveyor and pushing falling bottles in tray.
Working:
When conveyor is running, all bottles transfer form one station to other station for next
process. There are two sensors used, for standing and fallen bottles detection, one pneumatic
cylinder for pushing the fallen bottle from the conveyor onto tray.
[N0000]: When the start push-button is actuated, process cycle starts and the conveyor starts
[N0001]: When Bottles are transferring on the conveyor, the sensors X2 and X3 sense the
orientation of the bottle. Sensor X2 sense down position of the bottle & Sensor X3 sense top
position of the bottle. If sensor X2 sense the bottle & sensor X3 does not sense the bottle then
the pneumatic actuator Y2 will come in action & it will reject the bottle from the conveyor. After
this, the perfect bottles will go in the soda filling station & whole cycle will be completed.
Ladder Diagram:
Output:
Week 9
Lecture 2
2. Write a PLC ladder diagram for enabling the indicator to be ON

immediately when switch pressed and OFF after a 5 sec delay by the switch.
Working:
[N0000]: When switch is actuated the indicator will be ON.
[N0001]: When the switch is turned OFF it will turn on the timer T0 and after 5 s time delay the
indicator will turn OFF.
Ladder Diagram:
Output:

01 X0 = 0 Y0 = 1 Before 5 s
02 X0 = 0 Y0 = 0 After 5 s
Week 9
Lecture 3
3. Write a PLC ladder diagram to simulate a 24-hour clock.

Working:
[N0000]: M1922 is a 1 s pulse generator and the counter,
C0 connected to it is preset a value 60 which acts as
seconds counter and it is reset for each 60 counts by C0.
[N0001]: The C0 is in turn connected to counter C1 with a
preset value of 60, which counts the minutes.
[N0002]: The C1 is in turn connected to counter C2 with a preset value of 24, which counts the
hours.
Ladder Diagram:
Output:
Week 9
Tutorial
Develop PLC Programming Examples on Industrial Automation according to

the logic given below:
• A Saw, Fan and oil pump all go ON when a start button is pressed.
• If the saw has operated less than 20s, the oil pump should go off when the
saw is turned off and the fan is to run for an additional 5s after the shutdown
of the saw.
• If the saw has operated for more than 20s, the fan should remain on until
reset by a separate fan reset button and the oil pump should remain on for an
additional 10 s after the saw is turned off.
Ladder Diagram:
Working:
[N0000]: X0 is the main start button to turn on saw, fan and oil pump, Y0 is the start memory.
[N0001]: X1 is the stop button for sawing process.
[N0002]: X2 is the fan reset button, also the T0 switch gets actuated when saw is stopped within
20 s, T0 is actuated after 5 s when the saw is turned OFF within 20 s of its operation.
[N0003]: T2 has a preset value of 10 s. Oil pump will be off when saw is turned OFF within 20 s
of its operation. If the saw is turned OFF after 20 s of operation, oil pump remains ON for 10 s
after the saw is turned OFF.
[N0004]: This rung actuates the timer T0 when the saw is turned OFF within 20 s of its
operation.
[N0005]: This rung actuates the timer T1, which times the sawing operation.
[N0006]: This rung actuates the timer T2, when the saw is stopped after 20 s.
[N0007]: This rung generates the OFF signal for oil pump [Y4] when the saw is stopped before
operating for 20 s.
Output:

01 X1 = 1 [Before 20 s] Y2 = 1 Fan OFF delayed by 5 s
02 X1 = 1 [After 20 s] Y2 & Y3 = 1 Oil Pump OFF delayed by 10 s, Y2 = 1

Week 9
Practical
Exercise 1
An output Indicator is to go on when six of Part C and eight of Part D are on a

conveyor. This Circuit should monitor the proper counts. X1 and X2 are
proximity devices that pulse on when a part goes by them. Note that the
circuit should not indicate more than six or eight parts, it would only indicate
when there are enough parts. Construct a PLC Ladder diagram to illustrate
the above scenario (Dual Counter Operation).
Ladder Diagram:
Working:
[N0000]: X0 is the Start/Reset button.
[N0001]: X1 is the Sensor 1 which senses Part C and the items are counted by counter C0.
[N0002]: X2 is the Sensor 2 which senses Part D and the items are counted by counter C1.
[N0003]: The indicator Y1 will be ON only when 6 of Part C & 8 of Part D are on conveyor.
The counters are reset when indicator is ON. And the counting begins again.
Output:

01 C0 = 6 & C1 = 8 Y1 = 1 Indicator ON
02 C0 = 0 & C1 = 0 Y1 = 0 Both Counters Reset

Week 9
Practical
Exercise 2
The Counter has to keep track of net number or parts on a conveyor. The
number of parts going on the conveyor is counted by one proximity device’s
count. The number leaving the conveyor is counted by a second proximity
devices count. Each Proximity device feeds information into its own counter
function. Construct a PLC diagram using Counters Used for a Net Count
Ladder Diagram:
Working:
[N0000]: Entry sensor X1 senses the object at entry and the counter C0 counts them.
[N0001]: Exit sensor X2 senses the object at exit and the counter C1 counts them.
[N0002]: The (-) function subtracts the value of C1 from C0 and displays at D0 [net count].
Output:
Week 10
Lecture 1
Program Control
Program control instructions are used to enable or disable a block of logic program or to
move execution of a program from one place to another place. The program control commands
can be summarized as follows:
Program Control Commands

JMP [Jump to Label] Jump forward/backward to corresponding label instruction.
LBL [Label] Specifies label location.
JSR [Jump to Subroutine] Jump to a designated subroutine instruction.
RET [Return from Subroutine] Exits current subroutine and returns to previous condition.
SBR [Subroutine] Identifies the subroutine program.
TND [Temporary End] Makes a temporary end that halts program execution.
MCR [Master Control Reset] Clears all output rungs between paired MCR instructions.
SUS [Suspend] Identifies conditions for debugging and troubleshooting.
Master Control Rely Function

Hardwired master control relays are used in relay control circuitry to provide
Input/Output power shutdown of an entire circuit. The equivalent PLC instruction to a Master
Control Relay is the Master Control Reset (MCR) instruction. This instruction functions in a
similar manner to the hardwired master control relay; that is, when the instruction is true, the
circuit functions normally, and when the instruction is false, non-retentive outputs are switched
off.
Jump Instruction
The jump (JMP) instruction
is an output instruction used to jump
over certain program instructions
when certain conditions exist. When
the jump instruction is used, the PLC
will not execute the instructions of a
rung that is jumped. The jump
instruction is often used to jump
over instructions not pertinent to the
machine’s operation at that instant.
Some manufacturers provide
a Skip instruction, which is
essentially the same as the jump
instruction.
The Forward jump
function permits an input logic condition to skip over a block of PLC ladder logic. The Reverse
jump is also possible where the instruction travels backwards to a specific block.
Subroutine Function
In addition to the main ladder logic program, PLC programs may also contain additional
program files known as subroutines. A subroutine is a short program that is used by the main
program to perform a specific function. Large programs are often broken into subroutine
program files, which are called and executed from the main program.
The jump to subroutine (JSR), subroutine (SBR), and return (RET) instructions are used
to direct the controller to execute a subroutine file.
Week 10
Lecture 2
Data Manipulation
Data manipulation instructions allow numerical data stored in the controller’s memory to
be operated on within the control program. It includes operations involving moving or
transferring numeric information stored in one memory word location to another word in a
different location, and carrying out simple operations such as converting from one data format to
another. The commands can be summarized as follows:
Data Manipulation Commands

MOV [Move] Moves the source value to the destination.
MVM [Masked Move] Moves data from source location to a selected destination.
AND [And] Performs a bitwise AND operation.
OR [Or] Performs a bitwise OR operation.
XOR [Exclusive Or] Performs a bitwise XOR operation.
NOT [Not] Performs a bitwise NOT operation.
CLR [Clear] Sets all bits of a word to zero.
Block-Formatted MOV Instruction
Ladder Diagram to change the preset time of a timer

Week 10
Lecture 3
Bit Patterns in a Register
The words of data memory in
singular form may be referred to either
as registers or as words, depending on
the manufacturer. The terms table or file
are generally used when a consecutive
group of related data memory words is
referenced. The data contained in files and words will be in the form of binary bits represented as
series of 1s and 0s.
Changing Register Bit Status

BS [Bit Set] Sets the bit value as 1
BC [Bit Clear] Clears the bit value to 0
BF [Bit Follow] Follows the bit value 1 if 0 or 0 if 1
Shift Register Functions

The bit shift register shifts bits serially
(from bit to bit) through an array in an orderly
fashion. A shift register can be used to
simulate the movement, or track the flow, of
parts and information. There are two-bit shift
instructions: bit shift left (BSL), which shifts
bit status from a lower address number to a
higher address number through a data file, and
bit shift right (BSR), which shifts data from a
higher address number to a lower address
number through a data file. Some PLCs
provide a circulating shift register function, which allows you to repeat a pattern again and
again.
FIFO Functions
The First In, First Out (FIFO)
instructions are word shift operations that are
similar to bit shift operations. Word shifting
provides a simpler method of loading and
unloading data into a file, usually called the
stack. This ensures that the oldest part in the
inventory is used first, as the first part entered is the first part removed. The opposite principle—
where the last data to be stored are the first to be retrieved—is known as LIFO (Last In, First
Out).
The FFL loads logic words into a user-created file called a FIFO stack. The FFU
instruction is used to unload the words from the FIFO stack.
The parameters that are required to be entered in the instruction block are summarized as
follows:
FFL & FFU Instruction Parameters
Source Word address from which the data are entered into the FIFO file
FIFO Address of the file in which the data are entered [starts with #]
Control The status bits, stack length, and position are stored here
Length File length in words
Position The next available location where instruction loads data to stack
Week 10
Tutorial
Develop and Simulate a PLC Ladder Diagram for Bottle Filling Plant
Working:
[N0000]: Master Start and Stop PB.
[N0001]: Conveyor is turned ON.
[N0002]: Sensor senses the bottle.
[N0003]: The bottle indicator turns conveyor OFF and turns the solenoid valve ON for filling
operation. Which is stopped after 10 s [T1 Preset]. The Conveyor starts again.
[N0004]: A counter to count daily target [500 Preset]
Ladder Diagram:
Output:

01 X2 = 1 M0 = 0, M1 = 1 Bottle Filling [10 s]
02 X2 = 0 M0 = 1, M1 = 0 Bottle Filled, Conveyor ON

Week 10
Practical
Exercise 1
Applying the Concept of shift Registers, Explain Flashing Arrow Pattern and
Registers.
Working:
The figure shows the
arrangement of lights to give a
flashing, moving arrow pattern that
moves to right. Bit Shift Right
register moves the bit one at a time
to the right. The starting 7 1’s in the registers is progressively moved to right and then up to next
register. As the bits move the lights signal move progressively to consecutive lights.
Initial Condition:
Unused Bits
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0
Initial Load [1st Arrow]
Second Condition:
Unused Bits
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 1 1 1 1 1 1 1 0 0
2nd Arrow
Third Condition:
3rd Arrow Unused Bits
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1
3rd Arrow
Fourth Condition:
4th Arrow Unused Bits
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
0 0 0 0 0 1 1 1 1 1 1 1 0 0 0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Week 10
Practical
Exercise 2
Applying the Concept of Shift Registers, Explain Morse code SR Patterns.
The Morse Code data can be

stored in the registers and the ladder
diagram to send Morse Code
signal/horn can be constructed used
following code logic:
Horn on for X time.

Horn off for fixed time (1 s)
Horn on for Y time.
Horn on for Z time.
The message data stored in the

registers can be altered according to the
signal, whether long or short, by
altering the preset values of timers used.
Week 11
Lecture 1
PID Module
PID control is a feedback control method that combines proportional, integral, and
derivative actions. The proportional action provides smooth control without hunting. The
integral action automatically corrects offset. The derivative action responds quickly to large
external disturbances.
The PID controller is the most widely used type of process controller. When combined
into a single control loop the proportional, integral, and derivative modes complement each other
to reduce the system error to zero faster than any other controller.
Either programmable controllers can be fitted with Input/Output modules that produce
PID control, or they will already have sufficient mathematical functions to allow PID control to
be carried out.
The operation of the
PID loop can be summarized as
follows:
• The process variable
(pressure) is measured and
feedback is generated.
• The PLC program compares
the feedback to the setpoint and
generates an error signal.
• The error is examined by the
PID loop calculation in three ways: with proportional, integral, and derivative methodology.
• The controller then issues an output to correct for any measured error by adjustment of the
position of the variable flow outlet valve.
Basically, PID controller tuning consists of determining the appropriate values for the
gain (proportional band), rate (derivative), and reset time (integral) tuning parameters (control
constants) that will give the control required.
Week 11
Lecture 2
Concept Of HMI [Human Machine Interface]
Human machine interfaces give the ability to the operator and to management to view the
operation in real time. Through personal computer–based setup software, you can configure
display screens to:
• Replace hardwired pushbuttons and pilot lights with realistic-looking icons. The machine
operator need only touch the display panel to activate the pushbuttons.
• Show operations in graphic format for easier viewing.
• Allow the operator to change timer and counter presets by touching the numeric keypad graphic
on the touch screen.
• Show alarms, complete with time of occurrence and location.
• Display variables as they change over time.
Human Machine Interfaces (HMIs), are also referred to as User Interface, Operator Panel,
or Terminal and provide a means of controlling, monitoring, managing, and/or visualizing
device processes. They can be located on the machine or in centralized control rooms.
Week 11
Lecture 3
Introduction to DCS [Distributive Control System]
A distributive control system (DCS) is a network-based system. Distributive control
involves two or more PLCs communicating with each other to accomplish the complete control
task. Each PLC controls different processes locally and the PLCs are constantly exchanging
information through the communications link and reporting on the status of the process.
The main features of a distributive control system can be summarized as follows:

• Distributive control permits the distribution of the processing tasks among several controllers.
• Each PLC controls its associated machine or process.
• High-speed communication among
the computers is done through CAT-5
or CAT-6 twisted pair wires, single
coaxial cables, fiber optics, or the
Ethernet.
• Distributive control drastically
reduces field wiring and heightens
performance because it places the
controller and I/O close to the
machine process being controlled.
• Depending on the process, one PLC failure would not necessarily halt the complete process.
• DCS is supervised by a host computer that may perform monitoring/supervising functions such
as report generation and storage of data.
Week 11
Tutorial
We are banding dowels into bundles of 40. Counter function keeps track of
the count of number of dowels in the bundle as they are added. The dowel
counter’s count number is kept in register. Running Count is compared to 40.
When the counter reaches 40, the output goes ON. The same output is
connected to a bander that operates when 40 is reached. Construct a ladder
diagram using Equal - to Compare Function.
Ladder Diagram:
Working:
[N0000]: X0 is the start button which starts the process and the counter C0 with a preset value of
40 which is kept in a register R5. Y0 also resets counter. Y0 is actuated when counter/register
accumulated value equals 40.
[N0001]: When the counter reaches 40 it is then compared to 40 in an EQUAL TO comparator
function, when it is true it actuates the bander machine which bands and packs 40 dowels
together [Y1].
Output:
Week 11
Practical
Exercise 1
Simulate / Interface Electro-Pneumatic Kit to control SAC [Single-Acting
Cylinder].
SAC Control Module: [Automation Studio®]
Working:
The input module consists of a push button switch. The output module has a 3/2 Solenoid
DCV which, when actuated, allows fluid to piston side of Spring-returned, single-acting
cylinder. When the pushbuttin is released the piston in the cylinder returns to its original position
by the action of spring.
Output:
Retracted Position:
Extended Position:
Week 11
Practical
Exercise 2
Simulate / Interface Electro-Pneumatic Kit to control DAC [Double-Acting
Cylinder].
DAC Control Module: [Automation Studio®]
Working:
The input module consists of two solenoid push button switches X1 & X2 which
actuates the solenoid Directional Control Valve. The output module is a 5/2 Solenoid DCV
which, when actuated, allows fluid to double-acting cylinder. X3 is the solenoid which when
actuated extends the cylinder, and the X4 solenoid retracts the cylinder back.
Output:
Extended Position:
Retracted Position:
Week 12
Lecture 1
SCADA [Supervisory Control And Data Acquisition]
Data collection is simplified by using a SCADA (supervisory control and data
acquisition) system. Exchanging data from the plant floor to a supervisory computer allows data
logging, data display, trending, downloading of recipes, setting of selected parameters, and
availability of general production data.
In general, a SCADA system usually refers to a system that coordinates but does not
control processes in real time. In a typical SCADA system, independent PLCs perform I/O
control functions on field devices while being supervised by a SCADA/HMI software package
running on a host computer. An important part of most SCADA implementations is alarm
handling. The announcement includes audible sounds, visual indications, and messages.
Typical SCADA System

Week 12
Lecture 2
Benefits of SCADA
1. Increased life of the equipment being used, through knowledge of system performance.
2. Reduced labor costs required for troubleshooting or service.
3. Increased compliance with regulatory agencies through automated report generating.
4. No requirement of large capital investment.
5. Many automation companies are using the SCADA to provide access to real-time data display,
alarming, trending, and reporting from remote equipment.
6. It gives the flexibility to choose equipment and systems based on performance rather than
compatibility with installed base.
Week 12
Lecture 3
Applications of SCADA
1. Oil and Gas
a. Pipeline monitoring and control
b. Remote equipment and asset monitoring and control of production, pumping, and storage
locations
c. Offshore platforms and onshore wells
d. Refineries, Petro-chemical stations
e. Plant/factory automation
2. Water and Wastewater

a. Water treatment centers and distribution
b. Wastewater collection and treatment facilities
3. Utilities
a. Electrical power distribution from gas-fired, coal, nuclear
b. Electrical power transmission and distribution
4. Agriculture / Irrigation
5. Manufacturing
6. Food and Beverage
7. Pharmaceutical
8. Telecommunications
9. Transportation
Week 12
Tutorial
Output is to be ON except when an input count is exactly 87. Input count is

tracked in IR0062. Operand 2 can be programmed as the number 0087.
Develop the ladder diagram using, i. Not- Equal - to Function, ii. Equal - to
Function.
Ladder Diagram:
Working:
[N0000]: The pulse input is sent to incrementor which increments the value stored in register
R62.
[N0001 & N0002]: These rung compares the value of register R62 with 87, Y0 & Y1 will be ON
except when R62 is 87. [N0001 is NOT EQUAL TO comparator and N0002 has EQUAL TO
comparator.
Output:

01 R62 <> 87 Y0 = 1 “Not Equal to”
02 R62 = 87 Y1 = 0 “Equal to”

Week 12
Practical
Exercise 1
Simulation/ Interface Electro-Pneumatic Kit to control 1. Gripper movement
Count 2. Rotary movements of clockwise and anti-clockwise
Gripper Control Module: [Automation Studio®]
Working:
The gripper rotary motion can be controlled by the two different circuits and switches
which when operated exclusively makes the gripper motor to rotate clockwise or anti-clockwise.
The gripper can be controlled through a ladder diagram with two input switches and two outputs
for clockwise and anti-clockwise motion. The ladder diagram also counts the number of motion
or switching ON off switches X1 and X2 through a count up counter.
Output:
Week 13
Lecture 1
Embedded System
The term embedded system is used for a microprocessor-
based system that is designed to control a function or range of
functions and is not designed to be programmed by the system user.
The programming has been done by the manufacturer and has been
‘burnt’ into the memory system and cannot be changed by the system
user.
An embedded system is nearly any computing system other
than a desktop computer. An embedded system is a dedicated system which performs the desired
function upon power up, repeatedly.
Architecture of Embedded System

Week 13
Lecture 2
Applications of Embedded System
Embedded systems are found in a variety of common electronic devices such as
consumer electronics like Cell phones, pagers, digital cameras, VCD players, portable Video
games, calculators, etc.,
Embedded systems are found in a variety of common electronic devices, such as:
(a) Consumer electronics: cell phones, pagers, digital cameras, camcorders, videocassette
recorders, portable video games, calculators, and personal digital assistants;
(b) Home appliances: microwave ovens, air conditioning, refrigeration system, answering
machines, thermostat, home security, washing machines, and lighting systems;
(c) Office automation: fax machines, copiers, printers, and scanners;
(d) Business equipment: cash registers, curbside check-in, alarm systems, card readers, product
scanners, and automated teller machines;
(e) Automobiles: transmission control, cruise control, fuel injection, anti-lock brakes, and active
suspension, engine control system, keyless entry in automobiles
(f) Manufacturing: industrial robots, robotic arms, automation jigs and fixtures, machine tools
(g) Defense: drones, surveillance equipment, satellites, missiles.
Week 13
Lecture 3
Robotic Drones
An unmanned aerial
vehicle (UAV), or a drone, is
an aircraft without any human pilot,
crew, or passengers on board. UAVs are
a component of an unmanned aircraft
system (UAS), which includes adding a
ground-based controller and a system of
communications with the UAV. The
flight of UAVs may operate under remote
control by a human operator, as remotely-
piloted aircraft (RPA), or with various
degrees of autonomy, such
as autopilot assistance, up to fully
autonomous aircraft.
Braking System
Anti-lock brake system is used in
automobiles to avoid skidding especially in
a slippery road. This system allows the
wheels to have better contact with the road.
This system consists of sensors to track the
speed, valves, pump and a controller. There
is an electronic control unit in the system
which monitors the movement of the wheel.
If a wheel in the automobiles goes slow, the
speed sensors will tell the valves to reduce
pressure to the brake and thereby the wheel
turns faster. On the other hand, if the wheel
goes faster, the pressure to the wheel is
increased thereby slowing down the wheel.
Air-conditioning
The main job of an air conditioner is to cool the indoor air. Air conditioners monitor and
regulate the air temperature via a thermostat. Air conditioners function also acts as
dehumidifiers. On-chip analog to digital converters (ADCs) will keep on monitoring the
temperature via various temperature sensors. If at all the room temperature changes due to
variation in external temperature, controller will take a counter acting signal to the compressor
and temperature will be brought to required range. PWM could be used to control the compressor
motor frequency and fan speed. ADCs could monitor the varying compressor motor frequency
and signal the on-chip multi-channel Timers (via CPU) to create most efficient PWM waveforms
for the motor speed, resulting in better efficiency and low power consumption.
Refrigerator
The temperature measurement requires one or more sensors, and then whatever signal
conditioning and data acquisition circuitry that is needed. Some sort of data processing is
required to compare the signal representing the measured temperature to that representing the
required temperature and deduce an output. Controlling the compressor requires some form
of electronic interface, which accepts a low-level input control signal and then converts this to
the electrical drive necessary to switch the compressor power. This process of control can be
done by a conventional electronic circuit or it can be done by a small embedded computer.
Engine Control System
This new ECU, or ECM (engine control module), shares the information from all of the sensors
fitted to the engine to provide very precise control of the fuel and ignition systems. This integration also
allows both systems to work together in providing improved fuel economy, performance, emissions and
reliability.
Automatic Washing Machine

Controlling the motor is very
crucial part of the design. PWM controls
motor speed. To rotate the motor in two
different directions ‘forward’ and
‘reverse’ direction control blocks are
used. Motor speed sensor is interfaced to
microcontroller. Microcontroller reads
the speed of the motor and appropriately
controls the speed of the motor in
different phases of washing using PWM
output. Door sensor, pressure sensor,
keypad is also interfaced to
microcontroller. The system should
provide all basic features of a washing
machine like washing, rinsing, spinning,
drying, cold wash, hot wash etc. Keypad
provides automatic and manual wash
options to the user. LCD display is
convenient to convey machine
information to user.
Microwave Owen
In a microwave oven,
food is cooked by exposing it
to microwave radiation.
Microwaves are a form of
radiofrequency (RF)
electromagnetic energy.
When this energy comes in
contact with food, the
absorbed energy causes the
water molecules in the food
to rotate. This movement
causes friction between the
molecules and produces a
rapid rise in temperature.
Microwave energy generated by the magnetron is transferred to the oven cavity through a
waveguide section (2450 MHz (megahertz) for most conventional ovens). A mode stirrer spreads
the microwave energy more or less evenly throughout the oven. A control circuit with a
microcontroller is integrated on a circuit board. The microcontroller controls the waveguide and
the entire unit so the microwaves are emitted at a constant rate.
Keyless Entry in Automobiles

A remote keyless
system is a device that
allows the operation from a
distance of vehicle functions
by using a unit that sends
signals to the car from a
wireless transmitter. The
device works via a control
unit in the vehicle and a
transmitter commonly
known as a fob or a key fob
that has buttons to activate
the functions of the system.
One common type is a remote keyless entry system to unlock car doors This type of remote
keyless system is usually able to unlock car doors and open the trunk or cargo area with the
touch of a few buttons, thereby allowing for easy entrance, loading, and unloading.
Week 13
Tutorial
Week 13
Practical
Exercise 1
Embedded Systems
Drone
Week 13
Practical
Exercise 2
Case Study: Drone Construction [DIY]
Components:
1. Quadcopter Frame
2. Brushless Motor,
A2212 1000KV
Propeller Brushless
ESC, 30A
3. Lipo battery, 3S /
11,1V / 2200mAh /
30C
4. 3S lipo battery
charger, AC
100~240v
5. Funduino UNO R3
ATMEGA328
Development Board
6. GY-521 MPU6050
3-Axis Acceleration Gyroscope 6DOF Module
7. Transmitter, 2.4GHz 6-CH TX Receiver, RX
Wiring:
Code: http://www.brokking.net/ymfc-al_downloads.html

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Industrial

CIE & SEE Scheme of Evaluation

Automation in Production Systems

Needs and Benefits of Industrial Automation

Basic Components of Automation System

Process Power Forms

Closed-loop Control system:

Open-loop Control system:

Relationship between Shop Floor Control and Factory Information Control

Shop Floor Control

Multimedia / Industrial Visit expose on automatic Shop Floor Control &

2. Advanced Automation with AutoStore Warehouse Robots

3. New Robotic Shuttle Technology Provides Goods-to-Person Fulfillment

5. Lean Management Systems: Visual Management at Hayes Manufacturing

Identification of Automation Systems in Day-to-day Use

Automatic Temperature Control System

Automatic Liquid Level Controller

Automated and Semi-Automated Data Collection Systems

Automated Identification Methods

Bar Code Technology

Linear Width-Modulated Bar Code

Bar Code Readers

Bar Code Printers

Magnetic Stripe Technology

Types of Material Handling Equipment

Introduction to Automated Guided Vehicles [AGVs]

Types of Automated Guided Vehicles

Guidance & Routing of Automated Guided Vehicles

Imbedded Guide Wires

2. Industrial Automation & Control

3. Industry 5.0 with IoT and Robotics

Case Study: Radio Frequency used in Identification of Objects

Case Study: Magnetic Strip used in Identification of Objects

On-board Vehicle Sensing

Remote Call Stations

Central Computer Control

Industrial Applications of Automated Guided Vehicles

Basic Components of AS/RS

• In some cases, a control panel covered an entire wall.

Difference between Relay-Control panel and PLC Control panel

Relay Logic vs. PLC Ladder Diagram

Two-Way Switch Input/Output Logic

Inputs Outputs Physical Elements

Working of PLC Ladder Diagram for Two-Way Switch Logic

Sl. No. Inputs Outputs Physical Elements

03 X0 = 0 & X1 = 1 Y0 = 0 Lamp OFF

04 X0 = 1 & X1 = 0 Y0 = 0 Lamp OFF

Case Study: Automated Material Handling Equipment

Industrial Robot [Robotic Arm, Industrial Material Handling Robot]

Automated Material Handling Using Conveyors & Robots

Block Diagram of PLC Systems

b) Modular PLC System

• The processor (CPU) is the “brain” of the PLC. A processor consists of a

• A program is a user-developed series of instructions that directs the PLC to execute

Internal Architecture of PLC

1. Discrete I/O Modules

Likewise, output control

Discrete Input Interface Module

2. Analog I/O Modules