Version 1.0, August 31, 2001, Copyright, Hugh Jack 1993-2001

9.5 LABORATORY EXPERIMENT GUIDELINES

 

General Objective of Laboratories:

  1. The laboratory experiments will allow the student to apply the theoretical techniques learned during this and previous controls courses. While implementing the theoretical controls techniques, the students will also learn the practical aspects of modern controls technologies. The first labs will introduce the student to Programmable Logic Controllers. The final labs will focus on advanced applications and control of a small scale industrial process.

 

· Notes:

  1. 1. Prelabs are essential, and must be done before every lab session when required.
  2. 2. Prelabs require that some assumptions be made.
  3. 3. The lab period should be used for debugging prelab work.
  4. 4. Labs are to be handed in before leaving.
  5. 5. Prelabs for individual labs are to be done individually. Prelabs for group labs are to be done in groups.

 

· The projects sheets that are in the lab notes are to be filled out as follows,

  1. PLC Project sheet - identifies the project, packet contents and contact person.
  2. Project Notes:
    1. System Description - a succinct paragraph stating how the system will behave
    2. I/O Notes - description of all inputs and oututs.
  3. Design Notes - A detailed description f the control system. This description must be in the form of a state diagram, flow cart, sequential function chart, Boolean equations or ruth table.
  4. Application Notes - For our use this page will usually contain a test plan. A test plan lists the test cases needed to verify correct operation of the system. Each test case consists of a set of inputs and the corresponding outputs. A complete test plan ensures proper operation of the system in all states.
  5. Input/Output Card - Detailed plan for attaching the inputs and outputs to the PLC.
  6. Program Listing - A list of ladder logic to implement the system.

 

· NOTE: IN ORDER TO COMPLETE LABS IN THE TIME ALLOTED THE PRELAB WORK MUST BE COMPLETED BEFORE ATTEMPTING THE LAB EXERCISE

 

 

Course Number: EGR 450

Course Name: Manufacturing Control Systems

Academic Unit: Padnos School of Engineering

Semester: Summer 2001

 

Class Times: 12-2 pm - Mon, Wed, Thurs, first half of semester

Lab Times: Sec. 1, Fri., 12-3pm (Prof. Blauch)

Sec. 2, Fri., 8-11am (Prof. Blauch)

Sec. 3, Wed., 3-6pm (Prof. Jack)

Instructor: Dr. Hugh Jack

office: EC 716

office hours: 2-3pm - Mon, Thurs

phone: (616) 771-6755

fax: (616) 771-6642

email: jackh@gvsu.edu

web: http://claymore.engineer.gvsu.edu

 

Description: An introduction to the control of machines and processes widely used in

manufacturing. Topics include programmable logic controllers, actuators and

sensor for discrete and continuous systems, structured design techniques,

memory structures, data handling functions, A/D and D/A converters, data

communications, and hierarchical control. The technical issues involved in

implementing control schemes are presented. (3-0-3). Four credits.

Offered spring-summer semester.

Prerequisites: EGR 345

Textbooks: Jack, H. Automated Manufacturing Systems; PLCs, 2001.

Software: Netscape Communicator

PLC programming software

FTP/Telnet

Objective: When done the student should be able to design and implement control

systems for typical industrial problems.

Instruction Methods: Lectures, labs, projects and discussions.

Tentative Schedule:

Week Topic

1 PLC Introduction

PLC Logic and Connection

Sensors and Actuators

2 Combinatorial Logic

3 Sequential Logic

4 Advanced Data Functions

5 Analog I/O and controls

6 Data Communications

Design Issues

Tentative Laboratory Projects:

1. Introduction to micro PLCs

2. Basic ladder logic design and PLC interfacing - combinatorial press control

3. Intermediate ladder logic design and PLC interfacing - encoder controlled motor

4. Advanced ladder logic design and PLC interfacing - sequential traffic lights

5. Introduction to PLC-5s

6. Analog I/O and PID Control

7. PLC Networking and Serial Communications - with DH+ and RS-232C

8. Control of a multistation keytag maker

9. Control of a multistation keytag maker (cont'd)

10. Introduction to embedded controllers

11. Programming embedded controllers

 

Grading: Laboratories 25%

Project 40%

Tests and Assignments 35%

Tests will be given at natural points during the term as new material is covered.

A major final project, involving design, construction and testing, will be

proposed early in the term, and be completed later in the term. Marks will be

some combination of performance and report. A final examination will be

given to conclude the work and test the students global comprehension of the

material.

 

Grading Scale: A 100 - 90

A- 89-80

B+ 79-77

B 76-73

B- 72-70

C+ 69-67

C 66-63

C- 62-60

D+ 59-57

D 56-50