Machine Control Systems

 

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Main Description show detail >>
 
 
 
Department: Manufacturing Engineering Module Code: CENG81000
Level: Level 8 Contact Hours: 36
Duration: 1 Semester Directed Study Hours: 20
Effective Term: 2015/16 Indep. Study Hours: 44
Credits: 5

Prerequisite Knowledge:

  Must have completed sucessfully, 'PLC's and Pneumatics' , 'Automation and Robotics' and 'Control Engineering and Robotics' or equivalent.

Module Description/Aims:

  To introduce the student to more advanced Control Engineering and Automation concepts theoretically and practically so as to prepare the student for further study in the area of 'Machine Control Systems' and / or for work in real world engineering industrial applications.  


 
Contact Hours show detail >>
   
 
Contact Type Hours
Lecture1 Per Week
Practical/Workshop2 Per Week


 
Learning Outcomes show detail >>
   
 
On successful completion of the module, the learner will be able to:
No. Description/Learning Outcomes
1Program PLC's (Omron & Pneu-Alpha) to simulate the automation of industrial process situations. 'Trouble shoot' the control logic when problems occur.
2Appreciate all the steps involved in the automation of a process, i.e. process description, specification, process instrument diagram (PID), flow chart & ladder logic solution, signal wiring to PLC & power wiring from PLC, fault finding, pre-commissioning checks, installation & documentation, and safety.
3Understand various forms of control i.e. mechanical, Boolean Logic, pneumatic, hydraulic, PLC, & computer control and learn the importance of process management & monitoring via computer.
4Program a Staubli Robot to perform basic pick and place movements and appreciate interfacing a Computer Vision System (Cognex DVT 515 Camera) and / or other islands of automation with the Robot to check and sort components into different machines and fault catagories.
5Build and test the simulation of an automatic machine on the computer using automation software 'AutoSim' proving its control systems operate correctly before releasing the machine to production.
6Ability to analyse Control Systems using Proportional Valves (Pulse Width Modulation), Hydraulic Servo Valves and Servo Motors.


 
Learning Strategies show detail >>
   
 
Learning Strategies
This module involves both development of competence in both theory and practical skills and requires particular attention to Laboratory Health & Safety and real world factory or work location Health and Safety.


 
Indicative Syllabus Content show detail >>
   
 
Content Detail
PLC controlled Electro-Pneumatic circuits with Real Time Simulation i.e. AutoSim'AutoSim' simulation of the Machine Control Circuit e.g. Roof Vent Control, Fatigue Test Machine, Pneumatic Sequencer and / or Two Handed Safety Control Circuit. Pure Pneumatic Drilling Machine including Safety Circuit.
PLC controlled Electro-Hydraulic circuits with Real Time Simulation i.e. AutoSim'AutoSim' simulation of the Machine Control Circuit e.g. Electro-Hydraulic Cylinder Sequence control circuit, single speed control of cylinder, two speed control of cylinder, Clamp and Drill machine, Bearing Insertion Machine for Interference Fit bearings.
PLC Programming and Steps involved in automating a process.Automation of a Machine or Process, Process Description, Specification, Process Instrument Diagram (PID), Ladder Logic control Solution (Inputs & Outputs, Timers & Counters, Auxillary Relays and Master Protective Circuit (Safety Circuit); Pneumatic, Hydraulic and Electrical Control Schematics, Signal Wiring to the PLC and Power Wiring from the PLC, Fault Finding, Pre-commissioning Checks, Installation, Safety and Commissioning, Documentation and Troubleshooting. Supervisory Control And Data Acquisition (SCADA).
Programming Robots to communicate with 'Islands of Automation'.Programming Robots to communicate with a Camera and / or PLC controlled Machines and / or Sensors and / or other Robots i.e. other Islands of Automation.
Introduction to Computer Vision (Cognex DVT 515 Camera)Vision Fundamentals, Image Acquisition, Pixel Resolution, Lighting Techniques, Vision Tools, Application Specific Tools and Communications. Case study in Computer Vision.
Proportional Valves (PWM), Hydraulic Servo Valves and Servo MotorsProportional Valve Control with PWM (Pulse Width Modulation). Control System for Modern Injection Moulding Machines changing from Hydraulic to Servo Motors. Universal Testing Machine with Hydraulic Servo Valve Control. Electric Robots with AC Servo Motor Control of all Axes. Evolution of the Modern Single Spindle Automatic Machines from Mechanical Cam Control to Servo Motor Control. CAN Bus System.


 
Assessment Strategies show detail >>
   
Assessment Strategies
Knowledge and comprehension of module concepts will be assessed by written examination at the end of the semester.
Laboratory Practical learning outcomes will be assessed weekly by written laboratory reports.
A minimum attendance at practicals of 80% and achievement of 40% in laboratory assessment is required.


 
Indicative Assessments show detail >>
   
Learning Outcome Assessment Category Assessment Method Additional Information % alloc
1, 2, 3, 5Continuous AssessmentPracticalPLC programming e.g. Linear Feeder, Silo Project, Boiler project, Roof Vent Control, Fatigue Test Machine.10
1, 2, 3, 5Continuous AssessmentPracticalPLC programming and simulation of the control features of the Automatic Machine using 'AutoSim' e.g. Two Handed Safety Circuit, Pneumatic Sequencer Control change to PLC Control using the Step Sequence Function. Change the Pure Pneumatic Drilling Machine from Pneumatic Control to Programmable Electro-Pneumatic Control.10
3, 6Continuous AssessmentPracticalHydraulic Servo Valve e.g. Universal Test Machine, Sheet Steel Manufacture.5
4Continuous AssessmentPracticalConditional 'pick and place' Robot programming and Communication with other Automatic Machines e.g. Computer Vision System and / or PLC controlled machines, in order to sort components into different machines and different fault catagories.5
1, 2, 3, 4, 5, 6Final Exam (Scheduled)Final Written Exam70


 
Reading List show detail >>
   
 
Type ISBN Title Author Publisher Year Edition Library Link
Essential0077090179Programmable Controllers - A Practical Guide
Denis Collins and Eamonn Lane
McGraw Hill		19972nd-
Recommended0750681128Programmable Logic Controllers...e-book
W. Bolton
Elsevier Newnes		20064th-
Recommended075066276xPractical Hydraulic Systems - Operation and Troubleshooting for Engineers and Technicians...e-book
Ravi Doddannavar Andries Barnard
McGraw Hill		19983rd-
Recommended1111111111Staubli Robot Training and Operation Manuals
Staubli
Staubli		19974th-
Recommended1111111111Cognex DVT 515 Camera
Cognex
Cognex		20062nd-
Recommended1111111111Omron PLC Training and Operation Manuals for models CPM2A and C20H.
Omron
Omron		20041st-
Recommended1111111111Pneu-Alpha Training and Operation Manuals.
SMC
SMC		20061st-
Recommended0582357055Mechatronics
W Bolton
Addision Wesley Longman Publishing, New York		20002nd-
Recommended9780340662199Practical Pneumatics
Chris Stacey
Butterworth		19972nd-
Recommended9780890891193Basic Pneumatics
Jay F. Hooper
Carolina Academic Pr.		2003-
Recommended9780750644198Hydraulics and Pneumatics: A Technician's and Engineers Guide
Andrew Parr
Butterworth - Heinemann		1999-
Recommended9780640625262Engineering Applications of Pneumatics and Hydraulics
Ian Turner
Butterworth - Heinemann		1995-
Recommended0134898400The PLC Workbook - Programmable Logic Controllers
K. Clements-Jewery W. Jeffcoat
McGraw Hill		19983rd-


 
Journals and Websites show detail >>
   
 
Type Description
Course MaterialOmron Training and Operation manuals for PLC models CPM2A, C20H and C200H.
Course MaterialPneu-Alpha PLC Training and Operation manuals.
Course MaterialSMC Pneumatic Training manual.
Course Material'AutoSim' Software Instruction Sheets.
Course MaterialPneumatic Components Software 'Pneumat'
Websitewww.cognex.com Computer Vision
Websitewww.staubli.com Robotics
Websitewww.moog.com Servo Valves and Proportional Controllers
Websitewww.aerotech.com Servo Motors
Websitewww.analog.com Servo Motor Controllers
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Curricular information is subject to change