R 2008 Mtrs Lab

KITE
MECHATRONICS LABORATORY MANUAL
KITE
EXPT NO: 1
STUDY OF BASICS OF MECHATRONICS SYSTEM
DATE:
AIM:
To study about the important features, about Mechatronics system.
INTRODUCTION TO MECHATRONICS SYSTEM:

Mechatronics is one of the new and existing fields on the engineering landscape, subsuming
parts of traditional engineering fields and requiring a broader approach to the design of system that we
can formally call as Mechatronics system.
Many industries improving their works through automation which is based on the inter
connection between the electronic control systems and mechanical engineering.
Such control systems generally use microprocessors as controllers and have electrical sensors
extracting information from mechanical inputs through electrical actuators to mechanical systems.
This can be considered to be application of computer based digital control techniques through
electronic and electric interfaces to mechanical engineering problems. Successful design of
Mechatronics can lead to products that are extremely attractive to customer in quality costeffectiveness.
MECHATRONICS DEFINITION:
Mechatronics may be defined as a multi-disciplinary field of study that implies the synergistic
integration of electronic engineering, electric engineering, control engineering
computer technology with mechanical engineering for the design, manufacture, analysis and
maintenance of a wide range of engineering products and processes.
Mechatronics brings together areas of technology involving sensors and measurement
systems, drive and actuation systems, analysis of the behavior of systems microprocessor systems.
The integration across the traditional boundaries of mechanical engineering, electrical
engineering, electronics and control engineering has to occur at the earliest stages of the design
process if cheaper, more reliable; more flexible systems are to be developed.
APPLICATIONS OF MECHATRONICS ENGINEERING:

Mechatronics engineering finds application in the following fields.
Electronic home appliances
Electronic entertainment products
Engine systems (cars)
Large scale application
Schematic Layout of Hydraulic System
BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Reservoir (or air tank):
A reservoir is an oil supply tank. It is provided to hold the hydraulic liquid (usually
oil).
Pump:
The pump is used to force the liquid into the system.
Prime mover:
A Prime mover, usually an electric motor, is used to drive the pump.
Valves:
Valves are refitted in the system to control liquid direction, pressure, and flow rate.
Actuator:
An actuator is provided to convert the liquid energy into mechanical force or torque to do
useful work. The actuator is the actual working element of the system. The actuators can be either
cylinders (to provide linear motion) or hydro motors (to provide rotary motion).
Fluid-transfer piping:
The hydraulic Piping is provided to carry the compressed liquid from one place to
another.
Schematic Layout of Pneumatic System
BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

Reservoir (or air tank):
An air tank is provided to store the compressed air required for the operations.
Compressor:
The compressor is used to compress the atmospheric air so as to increase the pressure of the
air.
Prime mover:
A Prime mover, usually an electric motor, is used to drive the compressor.
Valves:
Valves are refitted in the system to control air direction, pressure, and flow rate.
Actuator:
An actuator is provided to convert the air energy into mechanical force or torque to do
useful work.
Fluid-transfer piping:
Piping is provided to carry the compressed air from one place to another.
BASIC SYMBOLS USED IN HYDRAULIS AND PNEUMATIC

SYSTEM:
KITE
Symbols
Description
DIRECTIONAL CONTROL VALVES

Directional Control Valve (2 Ports / 2 Positions)
-Normally closed directional control valve
with 2 ports and 2 finite positions.
-Normally open directional control valve
-Normally closed directional control valve
-Normally open directional control valve
-directional control valve with 4 ports and 2
finite positions

finite positions
*-(center position can have various flow paths)
Directional Control Valve (5 Ports / 2 Positions) Normally A Pneumatic Valve
finite positions
Directional Control Valve (5 Ports / 3 Positions) Normally A Pneumatic Valve
finite positions
CONTROL METHODS
Manual Control
-general symbol (without showing the control type)
-pushbutton
-lever
-foot pedal
Mechanical Control
-plunger or tracer
-spring
Symbols
Description
-roller
-roller(one direction only)
Electrical Control
-Solenoid (the one winding)
Pilot Operation
-pneumatic
-hydraulic
Pilot Operated Two-Stage Valve

-Pneumatic: Sol first stage
-Pneumatic: Air pilot second stage
-Hydraulic: Sol first stage
-Hydraulic: Hyd pilot second stage
CHECK VALVES, SHUTTLE VALVES, RAPID EXHAUST VALVES
-check valve -free flow one direction,
blocked flow in other direction
-pilot operated check valve, pilot to close
-pilot operated check valve, pilot to open
Shuttle Valve
-to isolate one part of a system from an
alternate part of circuit
Rapid Exhaust Valve/Pneumatic

-installed close to an actuator for rapid
movement of the actuator
PRESSURE CONTROL VALVES
Pressure Relief Valve(Safety Valve) Normally Closed
- Line pressure is limited to the setting of the
valve, secondary part is directed to tank
Symbols
Description
Proportional Pressure Relief
- line pressure is limited to and proportional
to an electronic signal
Sequence Valve
- When the line pressure reaches the setting of the
valve, valve opens permitting flow to the secondary
port. The pilot must be externally drained to tank.
Pressure Reducing Valve

- pressure downstream of valve is limited
to the setting of the valve
FLOW CONTROL VALVES
Throttle valve
-adjustable output flow

Flow Control Valve
-with fixed output (variations in inlet
pressure do not affect rate of flow)
-with fixed output and relief port to reservoir
with relief for excess flow (variations in inlet
pressure do not affect rate of flow)
-with variable output
-fixed orifice
-metered flow toward right free flow to left
-pressure compensated flow control fixed
output flow regardless of load
-pressure and temperature compensated
-with variable output and relief port to reservoir
Flow Dividing Valve
-flow is divided equally to two outputs
SHUT-OFF VALVE
-Simplified symbol
Symbols
Description
FILTERS, WATER TRAPS, LUBRICATORS AND MISCELLANEOUS
APPARATUS
Filter or Strainer
-filter
Water Trap
-with manual drain

-with automatic drained
Filter With Water Trap

-with manual drain
-automatic drain
Air Dryer
- refrigerant, or chemical removal of water from

compressed air line
Lubricator
-oil vapor is indected into air line
Conditioning unit
-compound symbol of filter, regulator, lubricator unit
-Simplified Symbol
RESULT:
Thus the important feature Mechatronics system was studied.
MAX
MARKS
PREPARATION
INTEREST & INVOLVEMENT
SKILLS IN COMPLETING
THE EXPERIMENTS &
RESULTS
VIVA VOICE
TOTAL
DATE
SIGNATURE
OBTAINED
MARKS
CIRCUIT DIAGRAM:
SINGLE ACTING CYLINDER WITH ONE WAY PRESSURE VALVE
EXPT. NO.:2)a) DESIGN AND TESTING OF SINGLE ACTING CYLINDERS

USING PRESSURE VALVES
DATE :
AIM:
To actuate single acting cylinders in a pneumatic circuit using pressure valves.
APPARATUS REQUIRED:
1. Single acting cylinder
2. FRL unit
3. 3/2 single pilot valve
4. OR gate/one way pressure valve
5. AND gate/two way pressure valve
6. Air service unit
7. Connecting tubes
PROCEDURE:
1. The connection is made as shown in figure.
2. The pilot pressure are fed into the 3/2 direction control valve.
3. When the button is pushed the air is sent into single acting cylinder.
4. The cylinder moves in forward position.
5. When the push button is released, it retracts because of the spring.
6. Feed the air through different valves and make the cylinder to actuate.
SINGLE ACTING CYLINDER WITH TWO WAY PRESSURE VALV
KITE
RESULT:
Thus the cylinders are actuated by the air pressure in the pneumatic circuit.
16
CIRCUIT DIAGRAM
DOUBLE ACTING CYLINDER WITH ONE 3/2 SINGLE PILOT VALVE
17
EXPT.NO.:2)b)
DATE :
DESIGN AND TESTING OF DOUBLE ACTING

CYLINDERS USING PILOT VALVES
AIM:
To actuate double acting cylinders in a pneumatic circuit using pilot valves.
APPARATUS REQUIRED:
1. Double acting cylinder
2. 3/2 push button spring return DCV
3. 3/2 single pilot valve
4. 5/2 single, double pilot DCV
5. Air service unit
6. Connecting tubes
7. Compressor
PROCEDURE:
1. The connection is made as shown in figure.
2. The pilot pressure are fed into the 3/2 direction control valve.
3. When the button is pushed the air is sent into single acting cylinder.
4. The cylinder moves in forward position.
5. When the push button is released, it retracts because of the spring.
6. Feed the air through different valves and make the cylinder to actuate.
18
DOUBLE ACTING CYLINDER WITH TWO 3/2 SINGLE PILOT VALVE
RESULT:
Thus the cylinders are actuated by the air pressure in the pneumatic circuit.
CIRCUIT DIAGRAM-SINGLE ACTING CYLINDER:
EXPT.NO.:2)c)
DATE:
DESIGN & TESTING OF CONTINUOUS

RECIPROCATINGOF SINGLE ACTING AND DOUBLE
ACTING CYLINDER USING PILOT VALVES
AIM:
To actuate a single and double acting cylinders using pilot valves.
APPARATUS REQUIRED:
2. 3/2 single pilot DCV
3. 5/2 single pilot DCV
4. 5/2 double pilot DCV
5. 3/2 roller lever valves
6. FRL unit
7. Connecting tubes
PROCEDURE:
SINGLE ACTING CYLINDER:
1. The circuit is given as shown in figure.
2. Connect the compressed air supply to FRL unit
3. Check the all circuit
4. Open the hand slide valve
5. Observe the working of continuous running single acting cylinder
CIRCUIT DIAGRAM:
DOUBLE ACTING CYLINDER USING 5/2 PILOT VALVE
DOUBLE ACTING:
1. Draw the circuit diagram
2. connect compressor air supply to FRL unit
3. Connect any one of the outputs of FRL unit to 5/2 direction control unit port 1
4. Connect port 4 of DCV to blank end of the double acting cylinder
5. Connect the output of FRL unit to the input of two 3/2 roller lever valves to give
pilot pressure for 5/2 double pilot valve
6. The output of the two roller valves are connected to the either side of the 5/2
double pilot valve properly.
7. When the FRL valve is opened the higher pressure air enters the blank end of
the cylinder through DCT and the piston moves forward.
8. At the end of the forward stroke the piston rod pressures the roller valve. The
output of roller valve is sent to double acting cylinder to change the position.
9. Now the high pressure air from FRL unit is sent to rod end of the double
acting cylinder through the second position of the DCV the piston retracts.
10.At the end of return stroke the roller valve is pressed.
The output of the roller valve is sent to dc change the piston. This is repeated until
the FRL valve is cl
RESULT:
Thus
of single
and double acting cylinders are
actuated
by the
the continuous
air pressurereciprocating
in the pneumatic
circuit
CIRCUIT DIAGRAM-SPDT SWITCH
EXPT.NO.:3)a)
DATE:
DESIGN OF CIRCUITS WITH LOGIC SEQUENCE

USING ELECTRO PNEUMATIC TRAINER KIT
AIM:
To develop a electro-pneumatic circuit for extension and retraction of double acting
cylinder
APPARATUS REQUIRED:
2. 3/2 solenoid valve
3. 5/2 single and double solenoid valve
4. FRL unit
5. Relay
6. SMPS
7. Pushbutton switch
8. Connecting tubes & wires
PROCEDURE:
SPDT SWITCH
1. Provide power supply to the pneumatic trainer from control trainer by interfacing
24+vand-v
2. Using the SPDT switch energize the corresponding solenoid valve to get the desired
movement in the cylinder.
3. Supply the Air to FRL unit.
4. Assemble all the components.
5. Check all the connections carefully.
6. Test the circuit. Observe the working of the cylinder using the 3/2 and 5/2 solenoid valve.
CIRCUIT DIAGRAM-PUSH BUTTON
PUSHBUTTON SWITCH:
1. Draw the circuit diagram and connect the air supply to FRL unit.
2. Connect the electrical circuit from 24 dc source to ON/OFF switch.
3. Solenoids are connected to the pushbutton switch.
4. Draw the circuit diagram and connect the air supply to FRL unit.
5. Connect the electrical circuit from 24 dc source to ON/OFF switch.
6. Solenoids are connected to the pushbutton switch.
RESULT:
Thus the movement of double acting cylinder was carried out using switches.
CIRCUIT DIAGRAM-ON TIMER
EXPT.No.: 3)b) ACTUATION OF SINGLE ACTING CYLINDER USING

DATE:
ON AND OFF DELAY TIMER
AIM:
To develop an electro-pneumatic circuit for the activation of single acting cylinder using
timer.
APPARATUS REQUIRED
1. single acting cylinder
2. 3/2 single solenoid valve
3. Slide valve
4. FRL unit
5. Connecting tubes & wires
PROCEDURE:
ON DELAY TIMER
1. Provide power supply to electrical controller by interfacing the +ve to ve and
ve to -ve
2. Provide power supply to pneumatic trainer for electrical controller by interfacing
24+ve to +ve and ve to ve.
3. Using the SPDT switch energize the corresponding solenoid to get the desired
movement of the cylinder
4. Actual the time delay circuit.
5. From time delay, give connection to single acting cylinder to actuate the cylinder
according to time set.
6. Design and draw the pneumatic circuit.
7. Connect the air supply.
8. Test the circuit
9. Observe the working of the cylinder.
31
OFF DELAY TIMER

1. Provide Power supply to pneumatic trainer from electrical
Controller by interfacing +24V and -24V
2. Provide 24V power supply to timer
3. Any one of the outputs of FRL unit is directly connected to 3/2 single solenoid
valve.
4. Single solenoid valve output is connected to single acting cylinder.
5. Give +24V and -24V in timer
6. Output of Timer is connected to solenoid coil.
7. Check the all circuit
8. Observe the working of cylinder
9. Observe the working circuit.
RESULT:
Thus the movement of single acting cylinder was carried out using time delay
EXPT.NO:4
DATE :
STUDY OF 8051 MICROCONTROLLER AND STEPPER
AIM:
The study the fundamentals of 8051 microcontrollers and stepper motor.
MICROCONTROLLER:
A microcontroller is an integration of a microprocessor with memory and input, output
interfaces and other peripherals such as timers on a single chip.
A microcontroller may take an input from the device it is controlling and control the
device by sending signals to different components in the device.
A microcontroller is often small and low cost. The components may be chosen to
minimize size and to be as inexperience as possible.
Another name for a microcontroller is embedded controller. They can control features or
action of the product.
Register in microcontroller:
A microcontroller contains a group of registers each type of register having a different
functions.
Accumulator:
The accumulator (A) is an 8 bit register where data for an input to the arithmetic and
logic unit is temporarily stored. So the accumulator register is a temporary handling register for
data to be operated on by the arithmetic and logic unit also after the operation the register for
holding the result.
B Register:
In addition to accumulator an 8 bit B-register is available as a general purpose register
when it is not used for the hardware multiply/divide operation
Data pointer (DPTR):

The data pointer consists of a high byte (DPH) and a low byte (DPL). Its function is to
hold a 16 bit address. It may be manipulated as a 16 bit data register. It serves as a base register
in direct jumps, lookup table instructions and external data transfer.
Stack pointer:
The stack refers to an area of internal RAM that is used in conjunction with certain
opcode data to store and retrieve data quickly. The stack pointer register is used, by the 8051 to
hold as internal RAM that is called top of stock. The stack pointer register is 8 bit wide. It is
increased before data is stored during PUSH and CALL instructions and decremented after data
is restored during POP and RET instruction. The stack pointer is initialized to 07H after a reset.
This causes the stack to begin at location 08H.
Program counter:
The 8051 has 16 bit program counter. It is used to hold the address of memory location
from which the instruction to be fetched. 8051 is a 16 bit hence it can be address up to 216 byte
i.e. 64k of memory. The PC is the only register that does not have an internal address.
Internal RAM:
The 8051 has 128 bytes internal RAM. It is addressed using RAM address register
First thirty two bytes from address 00H to 1FH of internal RAM constitute 32
working registers. They organized into four banks of eight registers each. The
four register banks are numbered 0 to 3 and consist of eight registers named R0 to
R7. Each register can be addressed by name or by its RAM address.
Only one register bank is in use at a time. Bits Rs0 and Rs1 in the PSW determine
which bank of register is currently in use.
Register banks when not selected can be used as general purpose RAM.
PIN diagram of microcontroller:

The 8051 microcontroller is available in a 40 pin dual in-line (DIL) package
arrangement. It is important to note that many pins of 8051 are used for more than one function.
The function of each of the pins is as follows.
PORT 0 (pins 32-39):
Port 0 pins can be used as I/O pins. The output drives and input buffers of port 0 are
used to access external memory address, time multiplexed with the data being written or read.
Thus port 0 can be used as multiplexed address data bus.
PORT 1 (pins 1-8):
Port 1 pins can be used only as I/O pins.
The output drives of port 2 are used to access external memory. Port 2 outputs the high
order byte of the external memory address when the address is 16 bits wide otherwise port 2 is
used as I/O ports.
All ports pins of port-3 are multifunctional. They have special functions including two
external interrupts two counter two special data lines and two timing control strobes.
Power supply pins Vcc and ground to pin Vcc with rated power supply current of 125mA.
Oscillator Pins XTA2 (pin 18) and XTA1 (pin 19):

For generating an internal clock signal the external oscillator is connected at these two
pins.
ALE (address latch enable) Pin 30:
AD0 to AD7 lines are multiplexed. To determine these lines and for obtaining lower half
of an address, an external latch and ALE of 8051 is used.
RST (Reset pin 9):
This pin is used to reset 8051. For proper reset operation, reset signal must be held high
at least for two machine cycles, while oscillator is running.
PSEN (Program Store Enable pin29):
It is the active low output control signal used to activate the enable signal if the external
ROM/EPROM. It is activated every six oscillator periods while reading the external memory.
Thus this signal acts as the read store to external program memory.
STEPPER MOTOR
A motor in which the rotor is able to assume only discrete stationary angular position is
a stepper motor. The rotary motion occurs in a stepwise manner from one equilibrium position
to the next.
Construction features:
A stepper motor could be either of the reluctance type of or permanent magnet type. A
PM motor consists of multiphase stator and two part permanent magnet rotor variable
reluctance motor has magnetized rotor. PM stepper motor is the most commonly used type. The
basic two phase stepper motor consists of two pairs of stator poles. Each of four poles has its
own winding. The excitation of any one winding generates a north pole and a South Pole gets
attracted and the torque induced at the diametrically opposite side. The rotor magnetic system
has two end faces. The left face is permanently magnetized as south and the right face as North
Pole faces.
The north pole structure is twisted with respect to the south pole structure so that south
pole precisely between two north poles. In an arrangement where there are four stator poles and
three pairs of rotor poles, there exist 12 possible stable position in which a south pole if the
rotor can lock with a north pole of the stator. From this is can be noted that the step size is
= 360 (Ns*Nr)
Ns number of stator pole
Nr number of pairs of rotor poles
Generally step size of the stepper motor depends up on rotor poles. There are three
different schemes available for stepping a motor. They are
1.
2.
3.
wave scheme
2 phase scheme
half stepping or missed scheme
WAVE SWITCHING SCHEME:

Anticlock Wise
Clock wise
Step
A1
A2
B1
B2
Step
A1
A2
B1
B2
TWO PHASE SWITCHING SCHEME:

Anticlock
wise
Clock wise
Step
A1
A2
B1
B2
Step
A1
A2
B1
B2
Operational features of stepper motor:
There are many kinds of stepper motor like unipolar type, bipolar type, single phase
type, multiphase type; single phase stepper motor is often used for quartz watch. In PM type
stepper motor, a permanent magnet is used for motor and coils are put on stator. The stepper
motor model which has 4 poles at top and bottom and at either sides. X coil, X coil, r coil and
r coil are put to the upper side and the lower pole. r coil and r coil are rolled up for the
direction of the pole becomes opposite when applying an electric current to the r coil. It is
similar about X and X too. The turn of the motor is controlled by the electric current which
pairs into X, X, r, r. The rotor rotational speed and the direction of turn can be controlled by
this control.
Speed control of a stepper motor:
The requirement is to use a microcontroller to drive a stepper motor in both forward and
reverse directions of shaft rotation and to implement a two speed arrangement switches are to
be used to produce the two speeds and a reversal of shaft rotation.
Generally a stepper motor has four sets of coils; one end of each coil may be connected
together and then connected to DC supply. The remaining four ends may be driven through
transistors either separately or in integrated circuit form. A four bit code sequence continuously
applied to the drive circuit from the microcontroller port causes the motor shaft to rotate in
angular steps. Stepper motor have step angles of 1.8 degree step revolution and turning force
may be improved by using a step down gear box.
The stepping code sequence may be obtained from the motor manufacturer or distributor.
The program in this example was a common four step sequence of A,9,5,6 that it sent
continuously would cause the motor shaft to rotate.
RESULT:
Thus the fundamentals of microcontroller and stepper motor were studied.
PROGRAM:
FULL STEP REVOLUTION
ADDRESS
OP CODE
LABEL
SD 4100
INSTRUCTION
ORG 4100H
4100
90 45 00
4103
78 08
4105
E0
4106
10 83
PUSH DPH
4108
10 82
PUSH DPL
410A
90 FF 00
MOV DPTR, #FFCOH
410D
7A 04
MOV R2, #04H
410F
79 0F
MOV R1, #FFH
4111
7B 0F
DLY 1
MOV R3, #FFH
4113
DB FE
DLY
DJNZ R3, DLY
4115
D9 FA
DJNZ R1, DLY1
4117
DA F8
DJNZ R2, DLY1
4119
F0
MOV @DPTR, A
411A
D0
82
POP DPL
411C
D0
83
POP DPH
411E
A3
411F
D8
E4
DJNC R0 ,J0
4121
80
DD
SJMP START
START
MOV R0, #04

J0
MOVX A, @DPTR
INC DPTR
4123
SD_4500
MOV DPTR, 4500H
END
09
05 06 0A.
TABLE
DB 09, 05, 06, 0A
GO_4500
EXPT.NO.:5)a)
DATE:
STEPPER MOTOR INTERFACING WITH 8051 MICRO

CONTROLLER AT FULL & HALF STEP REVOLUTION
AIM:
To run a stepper motor at full step and Half step revolution by using 8051 assemble
language
APPARATUS REQUIRED:
1. Stepper Motor
2. Interface Board
PROCEDURE:
1. Switch ON the micro controller
2. Initialize the starting address
3. Enter the mnemonics code in the microcontroller
4. Reset the microcontroller
5. Execute the program
PROGRAM 2
HALF STEP REVOLUTION
ADDRESS
OP CODE
LABEL
SD 4100
ORG 4100H
4100
90 45 00
4103
78 04
4105
E0
4106
10 83
PUSH DPH
4108
10 82
PUSH DPL
410A
90 FF 00
MOV DPTR, #FFCOH
410D
7A 04
MOV R2, #04H
410F
79 0F
MOV R1, #FFH
4111
7B 0F
DLY 1
MOV R3, #FFH
4113
DB FE
DLY
DJNZ R3, DLY
4115
D9 FA
DJNZ R1, DLY1
4117
DA F8
DJNZ R2, DLY1
4119
F0
MOV @DPTR, A
411A
D0
82
POP DPL
411C
D0
83
POP DPH
411E
A3
411F
D8
E4
DJNC R0 ,J0
4121
80
DD
SJMP START
START
SD_4500
GO_4500
MOV DPTR, 4500H

MOV R0, #04
J0
MOVX A, @DPTR
INC DPTR
4123
LT:
INSTRUCTION
END
09
05 06 0A.
TABLE
DB 09, 05, 06, 0A
R
E
S
U
Thus the program to run the stepper motor at different speed and different
direction was derived using 8051 assemble language and was verified.
PROGRAM-1 :
CLOCKWISE ROTATION
ADDRESS
OP CODE
LABEL
E000
INSTRUCTION
ORG E000H
E000
74 80
MOV
E002
90 20 23
MOV DPTR,#2023H
E005
F0
MOVX @DPTR,A
E006
74 0D
E008
90 20 22
MOV DPTR,#2022 H
E00B
F0
MOVX @DPTR,A
E00C
12 E0 2C
LCALL
E00F
74 0E
MOV
E011
90 20 22
MOV DPTR,#2022 H
E014
F0
MOVX @DPTR,A
E015
12 E0 2C
LCALL
E018
74 07
MOV
E01A
90 20 22
MOV DPTR,#2022 H
E01D
F0
MOVX @DPTR,A
E01E
12 E0 2C
LCALL
E021
74 0B
MOV
E023
90 20 22
MOV DPTR,#2022 H
E026
F0
MOVX @DPTR,A
E027
12 E0 2C
LCALL
START:
A,#80H
MOV A,#0DH
DELAY
A,#0EH
DELAY
A,#07H
DELAY
A,#
DELAY
E02A
E02C
80 DA
SJMP
DELAY:
START
EXPT.NO.:5)b)
DATE:
STEPPER MOTOR INTERFACING WITH 8051 MICRO

CONTROLLER AT CLOCKWISE & ANTICLOCKWISE
ROTATION
AIM:
To run a stepper motor at clockwise & anticlockwise rotation by using 8051 assemble
language.
APPARATUS REQUIRED:
1. Stepper Motor
2. Interface Board
PROCEDURE:
1. Switch ON the micro controller
4. Initialize the starting address
5. Enter the mnemonics code in the microcontroller
4. Reset the microcontroller
5. Execute the program
`
E02C
78
F7
MOV
R0,#F7H
E02E
79
FF
OLOOP:
MOV
R1,#FFH
E030
D9 FE
ILOOP:
DJNZ
R1,ILOOP
E032
D8 FA
DJNZ
R0,OLOOP
E034
22
RET
E035
E035
END
PROGRAM-2 :
ANTICLOCKWISE ROTATION
ADDRESS
OP CODE
LABEL
E000
INSTRUCTION
ORG E000H
E000
74 80
MOV
E002
90 20 23
MOV DPTR,#2023H
E005
F0
MOVX @DPTR,A
E006
A,#80H
START:
E006
74 0D
MOV A,#0DH
E008
90 20 22
MOV DPTR,#2022 H
E00B
F0
MOVX @DPTR,A
E00C
12 E0 2C
LCALL
E00F
74 0B
MOV
E011
90 20 22
MOV DPTR,#2022 H
E014
F0
MOVX @DPTR,A
E015
12 E0 2C
LCALL
E018
74 07
MOV
E01A
90 20 22
MOV DPTR,#2022 H
E01D
F0
MOVX @DPTR,A
E01E
12 E0 2C
LCALL
E021
74 0E
MOV
E023
90 20 22
MOV DPTR,#2022 H
E026
F0
MOVX @DPTR,A
E027
12 E0 2C
LCALL
QE02A
80 DA
SJMP
START
MOV
R0,#F7H
E02C
DELAY
A,#0BH
DELAY
A,#07H
DELAY
A,# 0EH
DELAY
DELAY:
E02C
78
F7
E02E
79
FF
OLOOP:
MOV
R1,#FFH
E030
D9 FE
ILOOP:
DJNZ
R1,ILOOP
E032
D8 FA
DJNZ
R0,OLOOP
E034
22
RET
E035
END
E035
END
46
47
RESULT:
Thus the program to run the stepper motor in clockwise and
anticlockwise direction was derived using 8051 assemble language and was verified.
48
CIRCUIT DIAGRAM
49
EXPT.NO.:6
DATE:
PID CONTROLLER INTERFACE REAL TIME

TEMPERATURE CONTROLLER
AIM:
The Objective of the experiment is to control the temperature process.
APPARATUS REQUIRED:
1. VRTTC- 01 Unit
2. Microcontroller / PC
3. Heater Setup
4. RTD
5. PC Power chord & cable
PROCEDURE:
1. Heater Power plug , Blower, RTD are connected in Back panel (VRTC 01)
connecters named as Heater, Blower, Sensor respectively
2. Switch 1 is provided to control the heater supply voltage either by manually or by auto
mode.
3. If switch 1 is selected as int mode potentiometer provided to control heater supply
voltage (0-230V AC) manually.
4. If switch 1 selected as ext mode, potentiometer provided to control the Heater supply
Voltage (0-230V AC) manually.
5. Interfacing should be followed as 1st pin Gnd, 2nd pin ADC (Negative), 3rd pin ADC
(Positive) ,DAC output fed at 4th &5th pin of 9 pin D connector.
6. Switch on the VRTTC 01 Unit.
7. Select any one of the control action (ON/OFF, PID) and enter the controller parameters
(Kp, Ki, Kd, DB)
8. Based on the optimum parameters, temperature reaches to designed level (30 C 100o
C)
9. For various set point, controller parameters, Observe the process response.
Note:
Run the Blower for at-least 5 minutes after the experiment to cool the heater. Temperature
is a slow and smooth process.
.
50
TABULATION
S.NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
TIME(sec)
TEMPERATURE(C)
RESULT:
Thus the controlling of real time temperature is done.
CIRCUIT DIAGRAM:
ON DELAY TIMER
EXPT.NO:7)a)
DATE:
PLC CONTROL OF SINGLE ACTING CYLINDERS

USING ON AND OFF DELAY TIMER
AIM:
To design a circuit to extend and retract the single acting cylinder with the help of
delay timer controlled by PLC.
APPARATUS REQUIRED:
1. Single acting cylinder
2. RS 232 cable
3. Versa pro software
4. 3/2 single solenoid valve
5. FRL unit
6. PLC
7. Connecting wires and tube
PROCEDURE:
ON DELAY TIMER:
2. Provide +24V and 24V from PLC trainer to panel.
3. Open the versa pro software in desktop
4. Interface PLC with PC using RS 232 cable.

5. Write a ladder diagram.
6. Output of PLC (q1) is directly connected to input of solenoid coil.
7. Following the opening procedure of versa pro software.
8. Check the ladder diagram.
9. Connect the air supply to FRL unit.
10. Run the PLC. After some delay the cylinder will be activated.
CIRCUIT DIAGRAM:
OFF DELAY TIMER
PROCEDURE:
OFF DELAY TIMER
4. Interface PLC with PC using RS 232 cable.
6. Output of PLC (q1) is directly connected to input of solenoid coil.
10. Run the PLC and observe the working of single acting cylinder.
RESULT:
Thus the actuation of single acting cylinder with ON and OFF delay timer
was done using PLC.
CIRCUIT DIAGRAM
EXPT.NO.:7)b) CIRCUITS WITH MULTIPLE CYCLINDER SEQUENCE

DATE:
IN ELECTRO PNEUMATIC USING PLC
AIM
PLC.
To simulate the circuits with multiple cyclinder sequence in electro pneumatic using
APPARATUS REQUIRED
2. Compressor
3. Versa pro software
4. 5/2 double solenoid valve
5. FRL unit
6. PLC
7. Connecting wires and tube.
PROCEDURE:
4. Interface PLC with PC using Siemens cable.
6. Both outputs of PLC (q1 and q2) are directly connected to inputs of solenoid coils.
CIRCUIT DIAGRAM
RESULT:
Thus the ladder diagram for the automatic running of double acting cylinders is
designed and executed.
EXPT.NO.:7)c)
DATE:
PLC CONTROL OF SEQUENCING CIRCUIT USING

PLC LADDER DIAGRAM
AIM
To design a circuit for the sequence A+B+A-B using PLC
APPARATUS REQUIRED:
2. Siemens cable
3. Siemens software
4. 5/2 double solenoid valve
5. FRL unit
6. PLC
7. Connecting wires and tube
PROCEDURE:
4. Interface PLC with PC using Siemens cable.
6. Outputs of PLC (q1, q2, q3 and q4) are directly connected to the inputs of solenoid coil.
10. Run the PLC and observe the working of double acting cylinder.
RESULT:
Thus the ladder diagram for the automatic running of double acting cylinders is designed and
executed
EXPT.NO.:8)a)
DATE:
COMPUTERIZED DATA LOGGING SYSTEM WITH

CONTROL FOR PRESSURE VARIABLE LIKE
PRESSURE VALVE
AIM
To study the performane of ON/OFF/PID controller on pressure process.
APPARATUS REQUIRED
1. RS 232 close loop case
2. VMPA 62A
3. VDPID 03
4. PC with process and labview software
5. Patch chords
6. Multimeter
HAND VALUE SETTING

HV1 Fully open
HV2 Fully close
HV3 Fully open
HV4 Partially open
PRESSURE RANGE
I/P (0-250mm) of WC
O/P (4-20) mA
PROCEDURE
1. Ensure availability of water.
2. Interface the Digital controller with process and PC.
3. Make connections as per circuit diagram.
4. Ensure hand value settings are correct.
5. Invoke labview.
TABULATION 1:
PRESSURE PROCESS PID CONTROLLER
SP
KP
Ki
Kd
=
S.NO
PRESSURE(mm of wc)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
TIME(sec)
6. Heater/Pump ON switch should be in pump mode.

7. Enter the parameter and observe response of various controller set point.
8. Heater Pump ON switch should be in pump mode.
9. Step the process.
10. Save the response and conclude the behaviour of pressure process
TABULATION 2
PRESSURE PROCESS ON/OFF CONTROLLER
SP
Diff gap
ON POSITION (mm of wc)
OFF POSITION (mm of wc)
RESULT:
Thus the Performance of ON/OFF/PID controller on pressure process was studied.
CIRCUIT DIAGRAM:
EXPT.NO.: 8)b)
DATE:

CONTROL FOR PRESSURE VARIABLE LIKE FLOW
PROCESS
AIM
To study the performane of ON/OFF/PID controller on flow process.
APPARATUS REQUIRED
1. RS 232 close loop case
2. VMPA 62A
3. VDPID 03
5. Patch chords
6. Multimedia
HAND VALUE SETTING

HV1 Fully open
HV2 Fully close
HV3 Fully open

HV4 Partially open
PRESSURE RANGE
I/P (50-500) LPH
O/P (4-20) mA
PROCEDURE
3. Make connections as per circuit diagram.
5. Invoke labview.
TABULATION 1:
FLOW PROCESS PID CONTROLLER
SP
KP
Ki
Kd
=
S.NO
FLOW RATE
1.
2.
3.
4.
5.
6.
7.
8.
9.
TIME(sec)
6. Heater/Pump ON switch should be in pump mode.

8. Heater Pump ON switch should be in pump mode.
9. Step the process.
10. Save the response and conclude the behaviour of pressure process
TABULATION 2:
FLOW PROCESS ON/OFF CONTROLLER
SP
=
KP
Ki
Kd
ON POSITION (sec)
OFF POSITION (sec)
RESULT:
Thus the Performance of ON/OFF/PID controller on flow process was studied.
CIRCUIT DIAGRAM:
EXPT.NO.: 8)c)
DATE:

CONTROL FOR PRESSURE VARIABLE LIKE
TEMPERATURE
AIM
To study the performane of ON/OFF/PID controller on temperature.
APPARATUS REQUIRED
1. VMPA 62A
2. VDPID 03
4. Patch chords
5. Multimedia
HAND VALUE SETTING

HV1 Fully open
HV2 Fully close
HV3 Fully open
PRESSURE RANGE
I/P (0-100 C)
O/P (4-20) mA
PROCEDURE

4. Switch ON VMPA 62A unit digital controller with PC.
5. Select Temperature << control << ON/OFF/PID .
6. Set rotameter at some minimum flow rate
7. Start the process.
TABULATION :
TEMPERATURE PID CONTROLLER
SP
KP
Ki
Kd
=
S.NO
TEMPERATURE(C)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
TIME(sec)
RESULT:
Thus the Performance of ON/OFF/PID controller on temperature was studied.
TABULATION:
S.NO
1.
2.
PRESSURE(bar)
FORCE (kg)
EXPT.NO.: 9)a)
DATE:
DESIGN AND TESTING OF FLUID POWER CIRCUITS

TO CONTROL FORCE OF DOUBLE ACTING
CYLINDER
AIM
To test and design the fluid power circuits by controlling the force of Double acting
cyclinders.
APPARATUS REQUIRED
1. Data Acquistion System
2. Cyclinder setup
3. Load cell
4. Solenoid valve
5. Patch chords
PROCEDURE
1. Connect the Patch chords to the Data acquisition System as mentioned above.
2. Connect the USB cable to the Data Acquisition System.
3. Now switch ON the unit and the hydraulic motor.
4. Follow the instruction as mentioned in the chapter 2 by opening the INSTACAL
Software.
5. Open the application software for the fluid power circuits.
6. In that open the force window.
7. After opening the force window click ON and enter the load cell capacity as cell.
8. Now give forward and analyse that the cylinder moves forward and hits the load
cell.
9. Now note the reading in the Display gauge.
10. Similarly take the Reading for various pressure.
CALCULATION
F=PXA
Where,
F force in Nm
P pressure in kg/cm2.
A cylinder area in cm2.
Area = (Pi/4) X D2
D = 50 mm cylinder bore dia
RESULT:
Thus the designing and testing of the fluid power circuits by controlling the force of
double acting cylinder was done and readings were taken.
.
TABULATION:
S.NO
1.
2.
3.
PRESSURE(bar)
VELOCITY
(m/sec)
DISTANCE Cm
(constant)
EXPT.NO.: 9)b)
DATE:

TO CONTROL VELOCITY OF DOUBLE
ACTING CYCLINDER
AIM
To test and design the fluid power circuits by controlling the velocity of Double acting
cyclinders.
APPARATUS REQUIRED
2. Cyclinder setup
3. Proximity sensor
4. Solenoid valve
5. Patch chords
PROCEDURE
Software.
6. In that open the velocity window.
7. After opening the velocity window click ON and enter the distance between the
sensors.
8. Now give forward and analyse that the cylinder moves forward.
9. Now note the velocity reading in the Display gauge.
CALCULATION
Velocity = Distance / Time.
RESULT:
Thus the designing and testing of the fluid power circuits by controlling the velocity of
double acting cylinder was done and readings were taken.
.
EXPT.NO.:9)c)
DATE:

TO CONTROL DIRECTION OF DOUBLE ACTING
CYCLINDER
AIM
To test and design the fluid power circuits by controlling the direction of Double acting
cyclinders.
APPARATUS REQUIRED
2. Cyclinder setup
3. Proximity sensor
4. Solenoid valve
5. Patch chords
PROCEDURE
Software.
6. In that open the direction window.
7. After opening the direction window click ON and enter the load cell capacity as cell.
8. Now give forward and analyse that the cylinder moves forward and hits the load cell.
RESULT:
Thus the designing and testing of the fluid power circuits by controlling the direction of double
acting cylinder was done and readings were taken
CIRCUIT DIAGRAM:
EXPT.NO.:10)a)
DATE:
SPEED CONTROL OF AC MOTOR USING PI

CONTROLLER
AIM
To control the speed of AC motor using PID controller.
APPARATUS REQUIRED
1. AC motor
2. AC controller unit
3. PID controller unit
4. Patch chords
5. Power chords
PRECAUTION
1. Dont exceed the speed limit of the motor beyond 1500 rpm.
2. Dont hold the motor teeth with the hand while the motor in running.
PROCEDURE
1. Connections are given as per the circuits diagram.
2. Switch ON the PID unit and AC controller unit and give supply 230 V to the motor.
3. Give the set point as 500 rpm by controlling the PID switch unit.
4. Now press enter the motor was settled at 500 rpm.
5. Again follow the same procedure to vary the motor speed as mentioned above.
TABULATION:
KP
Ki
Kd
S.NO
1.
2.
3.
4.
5.
SPEED(rpm)
PROCESS
VARIABLE(rpm)
CONTROL
VARIABLE
ERROR
RESULT:
Thus the AC motor speed was controlled using PID for the closed loop condition and the
parameters were noted.
.
CIRCIUT DIAGRAM
MODEL GRAPH
EXPT.NO.:10)b)
DATE:
SPEED CONTROL OF DC MOTOR USING PID

CONTROLLER
AIM
To control the speed of DC motor using PID controller.
APPARATUS REQUIRED
1. DC motor
2. DC controller unit
3. PID controller unit
4. Patch chords
5. Power chords
PRECAUTION
1. Dont exceed the speed limit of the motor beyond 1500 rpm.
2. Dont hold the motor teeth with the hand while the motor in running.
PROCEDURE
1. Connections are given as per the circuits diagram.
2. Switch ON the PID unit and DC controller unit and give supply 230 V to the motor.
3. Give the set point as 500 rpm by controlling the PID switch unit.
4. Now press enter the motor was settled at 500 rpm.
5. Again follow the same procedure to vary the motor speed as mentioned above.
TABULATION:
KP
Ki
Kd
S.NO
1.
2.
3.
4.
5.
SPEED(rpm)
PROCESS
VARIABLE(rpm)
CONTROL
VARIABLE
ERROR
RESULT:
Thus the DC motor speed was controlled using PID for the closed loop condition and the
parameters were noted.
.
TABULATION
S.NO SET ACTUAL

VOLTAGE ERROR CONTROLLER
(mV)
SPEED SPEED SPV(mV) Pv (mV) (mV)
(rpm) (rpm)
1.
2.
3.
4.
FEED
BACK
(mV)
5.
EXPT.NO.:11)a)
DATE:
SERVO CONTROLLER INTERFACING FOR

OPEN LOOP
AIM
To control the speed and study the performance of the DC servo motor in open loop.
APPARATUS REQUIRED
1. DC servo motor
2. Controller mode
3. Special sensing unit Digital multimeter.

PROCEDURE
1. Before switch ON the unit.
i) Interface the motor supply sensor.
1. Initially pulse ON/OFF switch should be in OFF module.
2. Switch ON the unit and keep the pulse ON/OFF to ON mode.
3. Set Vref = 1 volt, slowly increase the gain Vp volts by means of proportional gain
adjustments.
4. Vary the response voltage in steps and for each steps.
5. Determine
i) Speed in radians per second = 2 PN/S
ii) % error
= [ (n s)/d] X 100
iii)
6. Taking actual speed in Y axis and armature voltage a in X axis and plot the graph.
7. Taking actual speed in X axis and % error in Z axis.
Note
1. In open loop system, the system is controlled activated by a signal at input.
2. The system is case in the permanent DC motor.
3. The DC motor is choosen at the system because it can be modelled as a simple first
order line system.
4. For a DC motor the torque is directly proportional to the armature.
5. Even load the motor takes certain amount of current to produce torque to rotate the
armature against its own interia.
RESULT:
Thus the sequential circuit is performed.
TABULATION
S.NO SET ACTUAL

VOLTAGE ERROR CONTROLLER
(mV)
SPEED SPEED SPV(mV) Pv (mV) (mV)
(rpm) (rpm)
1.
2.
3.
4.
FEED
BACK
(mV)
5.
EXPT.NO.:11) b)
DATE:
SERVO CONTROLLER INTERFACING FOR

CLOSED LOOP
AIM
To control the speed and study the performance of the DC servo motor in closed loop
mode.
APPARATUS REQUIRED
1. DC servo motor
2. Controller module
3. Special sensing unit Digital multimeter.
PROCEDURE
1. Before switch ON the unit.
ii) EXT/INT switch should be in INT mode.
iii) Close switches in open mode signal.
2. Initially pulse ON/OFF switch should be in OFF module.
3. By adjusting Kp make the motor to run without any oscillation and measure the
following quantities.
Vref
Vc
Verror
Nc
Note
= Reference speed voltage

= Control voltage
= Error voltage
= Speed in rpm
4. Vary the Proportional given Kp in step.

Note down the readings in table.
5. Reduce the speed and switch OFF power supply calculate the various gains.
1. A closed loop system is driven by two signals one at the input signal and other speed
back signal which is derived from output of the system.
2. The reference speed is compared with actual speed of motor speed.
3. Controller sets the required voltage to be applied to the motor.
4. However during the transient, there is mistake between the applied voltages.
FORMULA USED
Calculate steady state error
Qss = Vref /(1+ Km Ka Kw)
KA = Kp X G
Where G is given power
Amplitude = Vg/VE
Ka
Kp
= Kp (a/ c)
= Vc /error
Where Kp is proportional gain.

Km = 1/ Kb
Kb = W/ Eb
Eb = Va - Ia Ra volts
Where
Km is motor gain
Kb is back emf
Eb is back emf of DC motor
Kw = Vf / W A
Actual Speed = 2PNA/60
RESULT:
Thus the given sequential circuit is performed.
CIRCUIT DIAGRAM
SINGLE ACTING CYCLINDER
EXPT.NO.: 12)a)
DATE:
DESIGN OF PNEUMATIC CIRCUIT USING

AUTOMATION STUDIO SOFTWARE
AIM:
To simulate the pneumatic circuit with single acting, double acting cylinders by manual
and automatic mode using pneumatic simulation software
REQUIREMENTS:
1. Personal Computer
2. Automation Software
PROCEDURE:
1. Open the software in the personal computer.
2. Select the new file in it.
3. Click on the supply elements and then select, copy, paste the compressor.
4. Click the attenuator and then select copy, paste the single and double acting cylinder.
5. Then select, copy, paste the 3/2, 5/2 single and double solenoid valve.
6. Select the air supply unit.
7. Connect all the components.
8. Start and operate the single, double acting cylinders.
CIRCUIT DIAGRAM
DOUBLE ACTING DIAGRAM
RESULT:
Thus the Pneumatic circuit for single acting, double acting cylinder was simulated
using AUTOMATION STUDIO software.
EXPT.NO.: 12)b)
DATE:
DESIGN OF HYDRAULIC CIRCUIT USING

AUTOMATION STUDIO SOFTWARE
AIM:
To simulate the hydraulic circuit with single acting, double acting cylinders by manual
and automatic mode using Automation Studio software
REQUIREMENTS:
1. Personal Computer
2. AUTOMATION STUDIO Software
PROCEDURE:
1. Open the software in the personal computer.
2. Select the new file in it.
3. Click on the supply elements and then select, copy, paste the pump and tanks.
4. Click the attenuator and then select, copy, paste the single and double
acting cylinder.
5. Then select, copy, paste the 3/2, 5/2 single and double solenoid valve.
6. Connect all the components
7. Start and operate the single, double acting cylinders.
RESULT:
Thus the Hydraulic circuit for single acting, double acting cylinder was simulated using
AUTOMATION STUDIO software.
KITE

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KITE

MECHATRONICS LABORATORY MANUAL

MECHATRONICS LABORATORY MANUAL

STUDY OF BASICS OF MECHATRONICS SYSTEM

INTRODUCTION TO MECHATRONICS SYSTEM:

APPLICATIONS OF MECHATRONICS ENGINEERING:

Electronic entertainment products

Engine systems (cars)

Large scale application

Schematic Layout of Hydraulic System

BASIC COMPONENTS OF A HYDRAULIC SYSTEM:

Schematic Layout of Pneumatic System

BASIC COMPONENTS OF A PNEUMATIC SYSTEM:

BASIC SYMBOLS USED IN HYDRAULIS AND PNEUMATIC

MECHATRONICS LABORATORY MANUAL

DIRECTIONAL CONTROL VALVES

-directional control valve with 4 ports and 3

Pilot Operated Two-Stage Valve

-to isolate one part of a system from an

alternate part of circuit

Rapid Exhaust Valve/Pneumatic

Pressure Reducing Valve

-adjustable output flow

-with manual drain

Filter With Water Trap

- refrigerant, or chemical removal of water from

EXPT. NO.:2)a) DESIGN AND TESTING OF SINGLE ACTING CYLINDERS

SINGLE ACTING CYLINDER WITH TWO WAY PRESSURE VALV

MECHATRONICS LABORATORY MANUAL

DESIGN AND TESTING OF DOUBLE ACTING

DOUBLE ACTING CYLINDER WITH TWO 3/2 SINGLE PILOT VALVE

CIRCUIT DIAGRAM-SINGLE ACTING CYLINDER:

DESIGN & TESTING OF CONTINUOUS

CIRCUIT DIAGRAM-SPDT SWITCH

DESIGN OF CIRCUITS WITH LOGIC SEQUENCE

CIRCUIT DIAGRAM-PUSH BUTTON

CIRCUIT DIAGRAM-ON TIMER

EXPT.No.: 3)b) ACTUATION OF SINGLE ACTING CYLINDER USING

9. Observe the working of the cylinder.

OFF DELAY TIMER

STUDY OF 8051 MICROCONTROLLER AND STEPPER

Data pointer (DPTR):

PIN diagram of microcontroller:

PORT 0 (pins 32-39):

PORT 1 (pins 1-8):

Port 1 pins can be used only as I/O pins.

PORT 2 (pins 21-28):

PORT 3 (pins 10-17):

Oscillator Pins XTA2 (pin 18) and XTA1 (pin 19):

ALE (address latch enable) Pin 30:

RST (Reset pin 9):

PSEN (Program Store Enable pin29):

WAVE SWITCHING SCHEME:

TWO PHASE SWITCHING SCHEME:

Operational features of stepper motor:

Speed control of a stepper motor:

MOV DPTR, #FFCOH

MOV R2, #04H

MOV R1, #FFH

MOV R3, #FFH

DJNZ R3, DLY

DJNZ R1, DLY1

DJNZ R2, DLY1

MOV R0, #04