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
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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.

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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.

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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.

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• 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

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➢ 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.

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➢ 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.

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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

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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

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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

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Application of Boolean Algebra Laws:

Table 1: Boolean Algebra Identities

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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

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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.

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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