Industrial Electronics Lab Manual

Department of Electrical Engineering
Industrial Electronics
Lab Manual
B.E-VII Electronics
Instructor: Engr. Ghulam Abbas Lashari

Department of Electrical Engineering
Certificate
It is certified that …………..........................................................student
of
BE………… has carried out the necessary work of
Industrial Electronics
Lab as per course of studies prevailed in the department of
Electrical Engineering
Sukkur IBA University for Fall 2017.
____________________
Instructor’s Signature
Date: _______________

1
Designed By: Zeeshan Ahmed Lodro
1. Differentiate between Ladder Programming and Functional Block Programming?
LAD: Ladder logic is a visual programming language based on the concept of representing
each individual network as it would be shown in a circuit diagram for relay logic. This
language is best for people who come from an electrical (as opposed to electronic or
computer science) background.
FBD: Function Block Diagram is better for people coming from an electronic or computer
science background as it is a visual representation based on logic gates. It depends on
your network, FBD representation may take up more or less screen space than LAD.
2.Draw Ladder diagram of XOR logic gates using different addressing schemes?
3. List down different manufactures of PLC systems?
▪ Siemens
▪ ABB
▪ Schneider (Modicon)
▪ Rockwell (Allen-Bradley)
▪ Mitsubishi
▪ GE
▪ Omron
▪ Bosch Rexroth
▪ Beckhoff
▪ Fuji
▪ Toshiba
Lab Experiment No# 01
PLC Programming

2
4.Simulate following Logic Gates and Flip-Flops?
A] NAND
A] NOR

3
A] XOR and XNOR

4
B) RS Flip-Flop

5
B) JK Flip-Flop

6
B) D Flip-Flop

1
1. Design a two-way traffic control system using timers?
Timer Programming

2

3
2. Simulate S_PEXT, S_ODT, S_ODTS, S_OFFDT?
S_PEXT
S_ODT
S_ODTS
S_OFFDT

4
3. Simulate Timer Coils.
All of the Timer Coil are Simulated.

5

6

1
1. Design a Simple program for automatic Parking using Ladder Programming?
Counter Programming

2
2. Simulate different types of counter instructions?
Up Counter
Down Counter

3
Up-Down Counter

1
1.Explain Classification of Ultrasonic Waves?
Sound waves can be classified into following three classes:
1. Audible waves
2. Infrasonic waves
3. Ultrasonic waves
Audible waves:
The waves which can be heard by human ears are called audible waves. Their frequency
range extends from 20 Hz to 20 KHz but it may vary from person to person in accordance to
his age. Children and youth can hear sounds of up to 20 KHz frequency whereas the audible
range of old persons is lesser than 20 KHz.
Infrasonic waves:
Waves having a frequency of less than 20 Hz are called infrasonic waves. These waves cannot
be heard by human ears. These waves are produced by the vibration of huge bodies like the
earth.
Ultrasonic waves:
Waves having frequency of more than 20 KHz are called ultrasonic waves. These waves also
cannot be heard by human ears, but can be heard by bats. The bat can hear waves of
frequencies up to 50 to 60 KHz and can produce such waves even.
2. List the speed of ultrasonic waves in various types of media?
Speed of ultrasonic waves in various medium.
Ultrasonic Transducer

2
3. List and briefly explain the ultrasonic applications?
Applications of Ultrasonic Waves
▪ Ultrasonic flaw detection
▪ Cutting and matching of hard materials
▪ Ultrasonic soldering and welding
▪ Applications in medicine
▪ Ultrasonic as means of communication
Ultrasonic flaw detection
Of all the applications of industrial ultrasonic testing, flaw detection is the oldest and the
most common. Since the 1940s, the laws of physics that govern the propagation of sound
waves through solid materials have been used to detect hidden cracks, voids, porosity, and
other internal discontinuities in metals, composites, plastics, and ceramics. High frequency
sound waves reflect from flaws in predictable ways, producing distinctive echo patterns that
can be displayed and recorded by portable instruments
Cutting and matching of hard materials
Ultrasonic machining is a metal cutting process that is facilitated by ultrasonic technology.
The process, developed by Sauer & Company which uses a diamond coated milling, boring
or grinding tool, actuated by ultrasonic technology that can impact a workpiece with a
frequency of 20 kHz or 20,000 times per second.
Ultrasonic soldering and welding
Ultrasonic soldering is a flux-less soldering process that uses ultrasonic energy, without the
need for chemicals to solder materials, such as glass, ceramics, and composites, hard to
solder metals and other sensitive components which cannot be soldered using conventional
means. Ultrasonic (U/S) soldering, as a flux-less soldering process, is finding growing
application in soldering of metals and ceramics from solar photovoltaic and medical shape
memory alloys to specialize electronic and sensor packages.
Applications in medicine
Medical ultrasound is a diagnostic imaging technique based on the application of ultrasound.
It is used to see internal body structures such as muscles, joints, vessels and internal organs.
Its aim is to find a source of a disease. The practice of examining pregnant women using
ultrasound is called obstetric ultrasound, and is widely used.
Ultrasonic as means of communication
Quietnet is a chat program coded in Python that operates using near ultrasonic frequencies.
Ultrasound itself is sound with a frequency greater than 20 kHz which makes it inaudible for
humans. The application itself works with ~19 kHz frequencies.

1
1.What is Optical encoder? List down its Various types?
Optical Encoder: An optical encoder is an electromechanical device which has an electrical
output in digital form proportional to the angular position of the input shaft. Optical
encoders enable an angular displacement to be converted directly into a digital form. It has
a shaft mechanically coupled to an input driver which rotates a disc rigidly fixed to it. A
succession of opaque and clear segments is marked on the surface of the disc.
Light from infrared emitting diodes reaches the infrared receivers through the transparent
slits of the rotating disc. An analogue signal is created. Then electronically, the signal is
amplified and converted into digital form. This signal is then transmitted to the data
processor.
Figure 1. Optical Encoder
Various Types of Optical Encoder
▪ Incremental Optical Encoder
▪ Absolute Optical Encoder
▪ Single turn absolute optical encoder
▪ Multiturn absolute encoder
Linear Scale

1
1.Explain different types of Photovoltaic Cells?
Photovoltaic cells or PV cells can be manufactured from a variety of different materials.
Despite this difference, they all perform the same task of harvesting solar energy and
converting it to useful electricity. The most common material for solar panel construction is
crystalline silicon which has semiconducting properties. Hundreds of these solar cells are
required to make up a full photovoltaic array.
There are four main types of solar panels that are commercially available, and they include
monocrystalline silicon PV, polycrystalline silicon PV, amorphous silicon PV, and hybrid PV.
Monocrystalline Silicon Cell: These cells are composed primarily of silicon crystals. To
produce these, a cylindrical crystal of silicon is "grown" from molten silicon. This crystal is
then cut into thin slices and shaped into a hexagon so that they fit together well on the solar
panel. These cells are smooth in appearance and are rigid, thus they must be mounted in a
sturdy frame to prevent them from breaking. Generally speaking, these cells
have efficiencies of 13-16% and are the most efficient of the silicon-type cells.
Figure 1. Monocrystalline silicon cell
Photovoltaic Transducer

2
Polycrystalline Silicon Cell: These cells are also composed primarily of silicon, but instead
high purity molten silicon is shaped using a cast and cooled under controlled conditions in a
mould. It sets somewhat irregularly into multi-crystal form, giving the final product a
speckled appearance, shown in Figure 2. This square block is then cut into thin slices and the
slices are arranged on the panel. The cell is then coated with an anti-reflective coating (which
gives the cell its blue colour) to ensure maximum absorption of light. These cells generally
have efficiencies of 12-16%, and are less expensive than monocrystalline varieties.
Figure 2. Polycrystalline Cell

3
Amorphous Silicon Cell: This type of cell is made from non-crystalline or amorphous silicon
and is one type of thin film cell. The film of amorphous silicon is sprayed as a gas onto some
surface, such as glass or flexible rubber material. After this a conducting grid and electrical
contacts are attached. This cell is especially thin so less raw material is needed as compared
to crystalline silicon cells. These are fairly inefficient cells, only about 6-8% efficient, and are
thus not suitable for use on residential developments as they require large amounts of space.
However, they are still used in a number of solar devices.
Figure 3. Amorphous Silicon Cell
Hybrid Cell: These types of cells are simply PV cells that use two different types of PV
technology. For example, a hybrid cell could be composed of a monocrystalline PV cell
covered by a layer of amorphous silicon. These cells generally perform well at
high temperatures and have efficiencies exceeding 18%. However, these cells can be very
expensive.
Figure 4. Hybrid Cell

1
1. Differentiate between AD590, Thermocouple, RTD and Thermistor.
Criteria AD590 Thermocouple RTD Thermistor
Temp Range -55°C to 155°C -267°C to 2316°C -240°C to 649°C -100°C to 500°C
Accuracy ±0.5°C Good Best Good
Linearity Most Linear Better Best Good
Sensitivity Low Good Better Best
Cost Moderately expensive Best Good Better
2. Explain the working principle of AD590.
AD590 is a type of temperature sensor output current, power supply voltage range of 3 ~ 30
v, output power 223 mu to 423 mu, sensitivity to 1 mu A / ℃. When the sampling resistance
R is connected in the circuit, the voltage at both ends of the R can be used as the output
voltage. The resistance of R is not too large to ensure that the voltage of the AD590 is not less
than 3V.
AD590 output current signal transmission distance can reach more than 1km. As a kind of
high impedance current source, up to 20 m Ω, so it need not consider choosing switch or
introduced by CMOS multiplexer additional resistance caused by the error. It is suitable for
multi-point temperature measurement and remote temperature measurement.
Temperature Transducer [AD590]

1
1. Design [ RS, JK, T and D Flip Flops] using Ladder Programming and attach the
solutions.
T Flip-Flop
SIMATIC S7-1200 and STEP7

3
JK flip-flop

4

5
D Flip-Flop

6
RS Flip-Flop

7
2. Design two direction motor control circuit using ladder programming and attach the
solutions.
Clock Wise Counter Clock Wise
When both are ON [motor is not running]

1
1. What is HMI? What are advantages of HMI in Industrial Control?
HMI stands for Human Machine Interface and is the means by which a human operator will
interact with a process controller. The Human Machine Interface is the process controller’s
input/output mechanism for humans.
A human will depend on the output of the HMI to provide feedback about the current state
of a particular industrial process. This may be as simple as reassuring the human that an
automated process is running or has completed correctly, or that specific parameters are
operating inside required limits. The HMI output is usually a visual display but it can also
include audible feedback and alarms.
The HMI will also allow a range of inputs by providing interaction controls such as dials, push
buttons or, in a more advanced HMI, a touch screen display. These controls allow processes
to be started, stopped, adjusted or programmed as necessary.
Process controllers are available with or without a built-in HMI. A built-in HMI means that
the HMI is physically integrated with the process controller: the controller’s outputs will
already be connected to the display and the input controls will be integrated into a single
casing.
Advantages of HMI in Industrial Control?
There are several advantages of HMI in industrial control. some are given below.
▪ Ability
▪ Durability
▪ Touch Capabilities
▪ Viewing Area
▪ Design
▪ Improved Productivity
▪ Improved Worker Satisfaction
▪ Internet of Things
▪ Data Recording
HMI For Simple Motor Control

2
2. Design two Direction Motor control HMI and attach the Solution.
WinCC Flexible GUI
Ladder Program

3
3. Design a water tank level Monitoring HMI and attach the Solution.
Wincc Flexible GUI
Ladder Program

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