IPE 4716 Material Handling & Maintenance Management Lab PDF

Islamic University of Technology (IUT) The Organization of Islamic Cooperation (OIC) IPE 4716 Material Handling and Maintenance Management Lab Programme: B.Sc in IPE Credit: 0.75 Semester: 7th...

Islamic University of Technology (IUT) The Organization of Islamic Cooperation (OIC) IPE 4716 Material Handling and Maintenance Management Lab Programme: B.Sc in IPE Credit: 0.75 Semester: 7th Lab: Applied Mechanics Lab  IPE 4716 : Material Handling and Maintenance Management Lab 1 Laboratory Policy 1. Philosophy: To present a physical significance to the analytical material covered in the sessional course taken prior or concurrently and to familiarize the student with realistic testing techniques and laboratory practices. A second, but still extremely important objective is the development of sound attitudes and procedures in conducting and reporting experimental work. 2. Reports: Reports are a vital part of good engineering practice. They permit the organization, condensation, analysis, interpretation, and transmission of meaningful results. For more details, see the lab Report Structure. 3. Preparation and Procedures: The experiments are conducted by groups of students under the guidance of the instructor. The reports are to be handed in at the beginning of the next class unless otherwise directed by the instructor. 4. Grading: To obtain credit for each laboratory period, a student must: (a) Work effectively as part of a team to obtain accurate data and (b) Submit an acceptable report. These two requirements imply that each student must come to the lab on time and be fully prepared. Tardy students, who do not do their best in being efficient and careful in experimenting will receive a zero, failing, or incomplete grade for that experiment. There will be no opportunity to make up work, which has been missed because of an unexcused absence or tardiness. If conditions develop that cause you to miss laboratory work, please contact your lab instructor as soon as possible in advance of the scheduled laboratory. 5. Laboratory Grades: The grade for each experiment will be based on the following: (a). Data processing, (b). Written reports, (c). Practical Test, (d). Peer Evaluation 6. Plagiarism: Students must not adopt or reproduce ideas works or statements of another person without an appropriate acknowledgment. Copying someone else’s work or facilitating academic dishonesty constitutes plagiarism. Plagiarism will be heavily penalized. © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 2 Lab Report Structure I. Title page This page must include: a. Title of experiment b. Course and course code c. Day and date experiments were performed and submission date d. Student name, student number e. Section, and group number II. Statement of Purpose/Introduction/Objective This should be a brief description of what the experiment is demonstrating. Be specific. It should be consistent with the statement of the experiment instructions. Some experiments have one or more parts, and each part demonstrates a different aspect. Be sure to include all objectives of the experiment in this section. III. Equipment/Description of Experimental Apparatus A list of equipment and specimens used should be included. This may be the same as the list in the experiment instructions. A sketch of the equipment should also be included where necessary. IV. Data and Observations The data and observations obtained in the experiments should be presented in an orderly form – in a data table if possible. A spreadsheet would be ideal, especially if there are many repetitive calculations in data analysis. Each table, figure, and graph should be labeled and numbered. V. Analysis and Results The data obtained will be analyzed to fulfill the purpose stated at the beginning of the report. Part of the analysis may be combined with the data table in a spreadsheet when possible. If there is an accepted or expected value for a quantity to be obtained by the experiment, the percentage difference between the expected and experimental value should be calculated. In many cases, another part of the analysis will be the construction of the graph, which is often a very helpful way of showing the relationship between two quantities. The graph must have a title, each exist will show scale, units, and a label. All data points must have a marking to show that it is an observed data point, and all data points must be connected showing the trend of the data. If the student uses a computer software package to generate graphs, then this package must convey the same information as a hand-generated graph. VI. Discussions This section should tie the results of the experiments to the purpose. Sources of error, deviations, and uncertainty should be discussed and how they might affect the results. Any points that are specifically asked for in experiment instructions should be discussed in this section. © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 3 Expt. Truth Table of Basic Logic Gates Operation using 01 Ladder Logic Diagram Objectives i. To study the Programmable Logic Controller (PLC), logic diagrams, ladder logic diagrams, and their functions. ii. To demonstrate the truth table of basic logic gates operation using a ladder logic diagram and hardware connection. iii. To understand and justify the truth table using a ladder logic diagram. Apparatus i. Automation Learning Kit ii. Programmable Logic Controller (PLC) iii. Wire (Connecting) Cable iv. Monitor/Desktop v. Panel PC Communicating Port Theory What is Programmable Logic Controller (PLC): A Programmable Logic Controller (PLC) is defined as a digitally operating programmable memory that is capable of generating output signals according to logic operations and other functions performed on input signals. The program for a PLC determines the sequence of operations and generation of input and output signals. A PLC is programmed by specifying some kind of logic diagrams called ladder diagrams. PLCs were introduced around 1969 and are available today in a wide variety of styles. Other programming methods are also possible on many PLCs including the use of symbolic notions similar to computer programming. The functions that can be accomplished on a PLC include: Control relay functions for the generation of an output signal based on logic rules applied to one or more input signals. Timing functions for the generation of an output signal for a specified period. For example, there is a delay. Counting functions for summing the number of contact closures and generating an output signal when the sum reaches a certain level. Arithmetic functions for performing addition, subtraction, etc. © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 4 Analog function capable of simulating analog functions such as proportional, integral, and derivative control. Advantages of PLC over an ordinary computer is that PLC, when provided with input/output ports, can be directly wired to the plant equipment like transfer machines, flow line conveyor systems, injection molding, grinding, welding, etc. The basic components of a PLC are the following: Input/output interfaces Central Processing Unit (CPU) Memory Programming devices and Power supply as shown in Figure 1. Figure 1: PLC block diagram (Khalid et. al., 2021) Features of PLC: Rugged design; suitable for harsh industrial environments against high-temperature variations, dust and vibrations. Industry-standard I/O interfaces; capable of communicating with other PLCs, computers and intelligent devices. Industry-standard programming languages; easily learned and understood. Programming is primarily concerned with logic, timing, counting and switching operations. Field programmable. Reduces hard wiring and wiring cost. Monitoring, error checking and diagnostics capability. Competitive in both cost and space requirements. Applications of PLC: i. Manufacturing/Machining Assembly machines Boring Cranes Energy demand Grinding © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 5 Injection/blow moulding Material conveyors Metal casting Milling Painting Plating Tracer lathe Welding iv. Metals Blast furnace control Continuous casting Rolling mills Soaking pit v. Mining Bulk material conveyors Loading/unloading Ore processing Water/waste management vi. Pumber/Pulp/Paper Batch digesters Chip handling Principles of Operation: Figure 2 shows an input that accepts a variety of digital or analogue signals from various field devices or sensors and converts them into a logic signal that the CPU can use. These field devices may be discrete or analogue input devices, such as: Limit switches Pressure transducers Push buttons Motor starters Solenoids, etc. The CPU makes decisions and executes control instructions based on program instructions in memory. During its operation, the CPU completes three processes: It reads, or accepts, the input data from the field devices via the input interfaces It executes, or performs, the control program stored in the memory system, and It writes, or updates, the output devices via the output interfaces. This process of sequentially reading the inputs, executing the program in memory, and updating the outputs is known as scanning. © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 6 Output modules convert control instructions from the CPU into a digital or analogue signal that can be used to control various field devices or actuators. A programming device (programmer), usually a personal computer or a manufacturer’s miniprogrammer unit, must enter the control program or instructions into memory. These instructions determine what the PLC will do for a specific input. An operator interface device allows process information to be displayed and new control parameters to be entered. The system power supply provides all the voltages required to operate the various central processing properly. Figure 2: PLC principal operation PLC Programming Languages There are five PLC programming languages: i. Ladder Diagram (LAD): Graphic language derived from a circuit diagram of directly wired relay controls ii. Function Block Diagram (FBD): Functions & functions blocks are represented graphically and interconnected into networks. iii. Instruction List (IL): Textual assembler-type language consisting of an operator and an operand. iv. Structured Text (ST): High-level language based on Pascal. v. Sequential Function Chart (SFC): A language resource for structuring sequence-oriented control programs. © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 7 Ladder Diagram: A ladder diagram is a type of graphic language for automatic control systems it has been used for a long period and user user-friendly. Using ladder programming involves writing a program to draw a switching circuit. Originally, only a few basic elements were available such as Normally Open or contact, Normally Closed or contact, output coil, timers, and counters. Ladder Programming Conventions: When a ladder diagram contains a functional block, contact instructions are used to represent the input conditions that drive the block’s logic. A functional block can have one or more enabled inputs that control its operation. In addition, it can have one or more output coils, which signify the status of the function being performed (refer to Figure 3). Input & Logic Conditions Functional Blocks & Outputs enable reset enable time reset Figure 3: Input conditions, a functional block, and outputs ladder programming Fundamental Logical Functions: AND gate: “All one makes a one” It executes the AND operation (multiplication). When both of the two inputs are high, the output will be high; otherwise, at times, the output will be low. AND Truth Table Input Output A B AB A B AB A 0 0 0 AB 0 1 0 B 1 0 0 1 1 1 Equivalent Circuit © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 8 OR gate: “Anyone makes a one” It executes the OR operation (Summation). When both of the two inputs are low, the output will be low; otherwise, at all times, the output will be high. OR Truth Table A A+B Input Output A A B A+B A+B B 0 0 0 B 0 1 1 1 0 1 1 1 1 Equivalent Circuit NOT gate (Inverter): The output is complementary to the input. This means that when the input is low (0), the output will be high (1), and when the input is high (1), the output will be low (0). NOT Truth Table Input Output A A A A 0 1 1 0 Exclusive OR / XOR gate: “either or but not both makes a one” It is also known as EX-OR gate or XOR gate. When both of the two inputs are low or high, the output will be low, and when both inputs are different (a combination of high and low), the output will be high. XOR Truth Table A B A Input Output A B AB B 0 0 0 0 1 1 1 0 1 1 1 0 Equivalent Circuit NAND gate: “Any zero makes a one” It is the combination of AND gate and NOT gate. When both of the two inputs are high, the output will be low; otherwise, all-time, the output will be high. NAND Truth Table A AB A Input Output AB A B AB B 0 0 1 0 1 1 1 0 1 1 1 0 Equivalent Circuit © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 9 NOR gate: “Any one makes a zero” It is the combination of OR gate and NOT gate. When both of the two inputs are low, the output will be high; otherwise, all-time, the output will be low. NOR Truth Table A B A Input Output A B A+B B 0 0 1 0 1 0 1 0 0 1 1 0 Equivalent Circuit XNOR gate: “either or but not both makes a zero” Commonly only have two inputs. It will only give out a HIGH or logic “1” if both inputs are equal. So, the inputs must be high (1) or low (0) for the output to become high (1). A XNOR Truth Table Input Output B A B AB 0 0 1 0 1 0 1 0 0 1 1 1 © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 10 Application of Boolean Algebra Laws: Table 1: Boolean Algebra Identities © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 11 Procedure: 1. Complete all hardware connections for logic gates. Connect all the connections according to the hardware connection section given below. Hardware Connection: i. +24V (DC Power Source) with +24V (Buzzer) ii. +24V (Buzzer) with P (PLC Digital Output) iii. P (PLC Digital Output) with PLC COM (PLC Digital Input) iv. 24VG (DC Power Source) with COM 0 (PLC Digital Output) v. COM 0 (PLC Digital Output) with SWITCH COM (PLC Digital Input) vi. 24VG (Buzzer) with P40/P41/P42/P43/P44/P45 (PLC Digital Output) 2. Open the software XG5000 – New project – File Directory – CPU Series – CPU Type – Program Name – Press OK – New Program – Draw the ladder logic gates (AND, OR, NOT, XOR, NAND, NOR, XNOR) by following the figure given below. Software connection i. AND, OR, NOT and XOR © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 12 i. NAND, NOR and XNOR 3. Click on the Online of the software screen. 4. Click on Connect 5. Click on the Write 6. Click on the Sets link enable with parameters of the dialog box shown in the computer screen. 7. Click on the OK button of the same dialog box. 8. Click on Yes shown another dialog box on the PC Screen 9. Wait for a few seconds for the program to your PLC 10. Click on Yes 11. Click on Monitor 12. Click on Start Monitoring 13. Now test your operation theory with PLC according to your theory Discussion Discuss what you have learned in theory and practice. Pre-Work Questions: 1. What is PLC? 2. What is the principle of operation of PLC and its application used in industry engineering? 3. What are the differences between logic diagrams and ladder logic diagrams. © Department of Mechanical and Production Engineering, IUT  IPE 4716 : Material Handling and Maintenance Management Lab 13 Assignment Questions: 1. Convert the following logic gate circuit into a Boolean expression, writing Boolean sub-expressions next to each gate output in Figure 1 below: Figure 1: Logic gate circuit 2. Boolean Algebra Properties: Prove that A+B=B+A and AB=BA, and draw the ladder diagram of these properties. 4. Switches Logic Fundamental: If both switches, X1 and X2, in the circuit, are closed, the buzzer is ON (beeping). Draw and discuss the circuit illustrating the operation, logical gate, and truth table. 5. Switches Logic Fundamental: X1 and X2 are arranged in a parallel circuit, if either of the switches is closed, the buzzer will be ON (beeping). Draw and discuss the circuit illustrating the operation, logical gate, and truth table. References: 1. Automation, Production Systems, and Computer-Integrated Manufacturing- Mikell P. Groover. 2. Materials Handling Equipment - Edward J. Tournier, McGraw-Hill Book Company © Department of Mechanical and Production Engineering, IUT