13. EGR 450 Manufacturing Controls

13.1 Overview

• This course addresses a need for a comprehensive examination of modern control techniques found in manufacturing environments. The course will begin with evaluation of PLC’s for discrete logic control. The course will then examine PLC usage for more complex control tasks. By the time the course is complete, students will comprehend how these work, and how they can be applied.

13.1.1 Resources

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• A large collection of manuals for ALL of the equipment will be stored either in the lab room, KEB 209, or can be found at “www.ab.com”. This will include manuals for,


PLC/5 processors, I/O card, etc (bulletin 1771)

RSLogix software

13.2 Project

Objective: Students will learn how to synthesize a control system by selecting and building a complete control system from beginning to end.

Method: The basic steps are outlined below,

1. Course begins.

2. Students (individuals or groups) will submit a proposal for a project within the first three weeks.

3. The instructor will review the proposal, and suggest changes as necessary.

4. During the term students will design, build and test their proposed projects.

5. In the last week of classes the final project will be demonstrated and formally presented. Reports are to be posted to the students web page before this presentation.


previous project reports can be seen via the course web pages.

projects will involve construction and testing, except in unusual cases.

NOTE: projects must work to receive a passing grade.

13.2.1 Previous Topics

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• Brief descriptions of student projects follow.

• Previous topics for this or similar courses were,

Adams: Wheelchair Pressure Measurement: A system will be designed and built to measure the pressure on a wheelchair seat pad over time, and log these values to a file. The data will be used to design a system that will apply and release pressure.

Afrik, T., Hedman, M., Howe, M., Jousma, T., Muckey, L., Postema, J., Thelen, J.: ASME Student Design Competition: An entry for the competition will be conceived, designs and built with the intention of entering (and winning) the 2000 ASME Student Design competition.

Agnello: Customer Counter: A counter will be designed to detect the number of visitors to an archery range. This will be done with sensors arranged to count visitors. A system will be used to count visitors during variable periods. A PLC has been proposed, but other options are worth considering.

Andrevska: Fuzzy Logic Controller: A fuzzy logic controller will be designed and implemented using a Basic Stamp II chip. The controller will position a DC motor.

Baksik & Vinch: SoftLogix For Control of Material Handling Via Devicenet: A Devicenet based control system for a material handling system will be designed, purchased and built. The main system will be based around an AB SoftLogix controller.

Beard: Car Alarm: A car alarm will be designed and constructed using basic logic ICs and other circuitry to drive the actuators and sensors.

Bennett, Dunklin, Workman & Williams: Gumball Machine: A gumball will drop into a merry go round, go up an elevator, roll down a spiral track, be lifted in a bucket, bounce off a trampoline, and bounce out to be delivered.

Bernreuter: Water Heater Test System: A control system will be designed for testing water heaters. The focus of this project will be to use the alternate programming methods in the IEC-61131-3 PLC programming standard.

Beute: An Automated Drill: a fully automated drill press will be designed and constructed. Air cylinders and contact switches will be used.

Bialk: Control of Conveyor: A conveyor system that was designed and build for EGR 409/367 will have controls added so that it may be controlled from a PLC. This will include the use of a divertor that may be used to sort packages based on size.

Bleeker, Deemter, Elzinga: Oven Temperature Control: Controls hardware and software will be designed and implemented for an oven with different temperature zones.

Bouwhuis: Industrial PLC Training Materials: A PLC trainer board will be developed and built. Training materials will also be developed. These will be used by a local manufacturer to train hourly employees in the use and debugging of PLCs.

Brinkman: Audio Amp Cooler: A temperature sensor will be used to detect the temperature of a car audio amplifier. Circuitry will be designed and constructed to drive a cooling fan.

Brinks: Automatic Back Gage Setting: This project will involve the evaluation of a back gage system that exists on a shearing machine. An automatic control system will be selected and implemented to allow users to control the depth setting with a keypad entry.

Brogdan: Automated House: An X-10 modem with modular units will be used to allow a central PC to control devices in a house. A user interface will be designed, along with interface software to control the devices.

Bronkema: Automated House: A unit will be designed and built to allow control of an automated house using an embedded controller. This will monitor external lights, control lights, and allow house status reporting.

Brown, Miersen, Timmer: Basketball Arcade Game: An arcade version of a basketball game will be designed to store balls, and release them for a limited game time. Within the allowed time the user will have to make as many baskets as possible, and the count will be displayed with a status light.

Bultman: Automated Spot Light: A controller for a remote spotlight will be designed and constructed to allow adjustment via remote control, or adjustment via remote control. (Note: as proposed this project is too simple)

Buter: Defect Detection System: A system will be devised to detect a non-critical screw on an automotive floor console. If a missing screw is detected, an operator console will warn an operator to take corrective actions.

Burgess, S., DeBoer, M.: PLC Control of a Welding Station: A PLC will be integrated and programmed to control all aspects of a welding station. Issues to be considered include cycle times, safety, and manual/automatic modes.

Campeau: Hanging Tab Machine: A PLC with appropriate sensors and actuators will be used to add hanging tags to medical pouches. A machine for adding the pouches had been purchased and will be used to add the tags.

Chan, Sedine: Automated Bartender: A PLC will be used to prepare mixed drinks. The user will be able to select the proportions or drink type and the final product will be delivered.

Clark, Dohm, Dyer, Steinke, Valenzuela: ASME Design Competition: An entry will be developed for the ASME 2002 Student Design Competition. This will be developed within the given rules, and be working at the completion of the course

Conner: Controls for a Stretching and Stapling Machine: The controls for a material stretching and stapling machine will be designed and implemented using a Micrologix 1500 and RS-Logix software.

Cooke, Humphrey: Timer System for Pinewood Derby Track: A timer system will be developed with a 6811 processors for a pinewood derby track.

Cowan: PLC Retrofit of Taping Machine: A PLC will be selected to replace an existing controller on a machine that creates a tape of screws. This will also require some redesign of the machine.

Cummings: Automatic Fishing Pole: An ice fishing pole will be fitted with control system that will watch to see when a fish has hit. When the fish has been detected the line will be slowly reeled in.

Curtis: Expansion Unit for Automatic Sprinkler Controller: A system will be designed that will ‘piggy back’ onto an existing sprinkler system. This will use the last set state to then switch on a supplemental state for the additional zones.

Davis: Screw Machine Control: A set of limit gages will be designed for a screw machine. The gages will test completed parts, and allow out of tolerance parts to be diverted. Visual basic and a PLC will be used for control.

Dejager, Friskey, Fugate: Instrumentation for Sports Medicine Research: A piece of sports equipment will be instrumented so that researchers in Physiotherapy can evaluate repeatability of motions. This will include devices for ball trajectory and club

Dejong, McKervey: A Really Fancy Pencil Dispenser: A pencil dispenser with a few Rube Goldberg twists.

DeJonge: Control of a Heat Stake Machine: Controls for a heat stake machine will be designed and built for a local company. This will involve the design of all electrical components, working with trades to get electrical and mechanical work done, and final programming of the machine.

DeVos, Karlesky, Kuieck: A Ground Breaking Robot: A hydraulically controlled robot will be designed and built for the ground breaking for the Keller Engineering Building. The robot will be controlled by a VR glove to allow a dignitary to guide the robot to break ground.

DeVries: Train Set Controller: An automatic train set controller will be designed so that a train set will run automatically, including switch track, lights, etc.

Dodge, Eddy, Oostdyk, Spikes: Art for New Building: This project will use equipment that is already owned by the school to develop an artistic display for the Keller Engineering building.

Dood, Fleischman, Sanford, Kozikoski: “Sip-and-Puff” Fishing System: An entry will be designed and built for the 2001 ASME design competition.

Duncan, Nicola, Vergas, “PLC Control of an AGV”, The chassis of an Automated Guided Vehicle has been constructed in the past. It has since been superseded by another vehicle. But, with the addition of some mechanical and electrical components, this AGV was restored to working order.

Eissa: PLC Control of Assembly Fixture: An assembly fixture that will be used by a local company to assemble machine that will uses a number of slides, pins and other actuators to assemble a panel. This project will involve the design and construction/implementation of all wiring and programming.

Emery: Stereo Amplifier Overheat Control: A basic controller will be used to monitor the temperature of a car audio amplifier. When the amplifier temperature rises too much the amplifier will be shut off, or the power output decreased. A PLC may be too expensive for this application.

Endres: FMEA for Chlorine Scrubber Control: A control system was previously constructed that will scrub chlorine gas in the event of a leak. There are numerous sensors and actuators to be considered.

Essenburg, McDaniel, Thompson, Vandenbrink: Pinball Machine Controller Retrofit: A pinbal machine will be retrofit with a PLC for control. The score display unit will also be replaced. The project involves all electrical work, programming, and an aesthetically pleasing finish.

Evans, W., VanEss, J.: Material Handling System Project: Various components for a mini manufacturing system will be designed and constructed. These functions will probably include a wood metering and cutting station, and a marble feeding station. This will complement the activities of the students in EGR 474.

Farley, T., Groeneweg, L.: Slot Car Lap Counter: A lap counter/timer will be constructed for a 1/64th scale car race track. The counter will use optical sensors to determine lap times and counter, and the results will be displayed on large LED displays.

Feenstra: Electric/Pneumatic Fire Cycle:

Fett: Shifter Test Apparatus: A Labview controlled test machine will be developed that will cycle an automotive shifter. Labview will be used to make some adaptations to the test strategy and analyze the results. Final data values will be output to database files.

Frazee: SPC Testing in a Screw Machine: A screw machine has had a gauge added, but requires a diverter system for bad parts. The project involves designing and building a diverter system, and developing a control program to detect and eradicate unacceptable parts.

Frei, Meneses: Injector Control System: The system will inflate an artificial lung through a process that involves partial inflation, with pauses. A variable position valve will be used to change the flowrate as the lung fills. The system will be PLC based. More details are required soon.

Gallatin, Jousma, Karabelski: A Small Work Cell: Equipment that was originally developed in EGR 409/367 will be refit and used to construct a small workcell. The task of the cell will be to handle cans and drill holes in them.

Gehrke: Paint Line Model: A small model of a dip paint line with an overhead conveyor. There will be three stops on the line.

Glass & Werdon: Corner Cutter: A device will be designed that automatically rounds the corners on lexan keytags.

Goosen, Hills: Carnival Game Controller: A system will be devised to watch targets that have been set up. When balls are thrown the targets will be knocked down. A score display will be used, and a winner siren will be enabled. A PLC may be too expensive an option for this project.

Grimshaw, Hupcik: Upgrade of The Keytag Maker: The keytag maker will be updated including refitting it with new sensors to detect the holes in the plastic strip, replacing the current servo control system with an Ultra 100 unit. The project will also consider the feasibility of changes to the keytag rounder.

Gutierez, Williams: Redesign and Control of Sketching Device: An existing device for doing simple sketches will be redesigned mechanically and electrically so that it may be controlled with a PLC. The final unit will use optical sensors so that it may be operated behind a window.

Hansen: Servo Driven Bumper Cutoff: An existing system uses hydraulics to cut automobile bumpers. This system will be retrofit with a servo drive cutter so that the cutting blade stroke can be adjusted as the cutting blade wears. The operator will be able to control the blade stroke using an HMI.

Hart, J., Kern, E., Maas, C.: Automatic Hose Cutter: A machine will be design and built to allow hoses to be fed variable lengths and cut automatically. A keypad will be used to set the length, and a blade will be used to cut the hose.

Hitchcock: A Table Height Cycling Test Stand: A control system will be developed and built that can cycle table height adjusters for a fixed number of cycles. The system may drive either pneumatic cylinders or motors to drive the tables. A proximity sensor will be used to mark the end of the travel. Adjustments will be included to allow the height settings to be changed without reprogramming the PLC.

Hornacek & Tietz: RC Car Controlled by 68HC11 and Sensors

Hubbard: Fermentation Control System: A control system will be devised that will observe the density in a primary fermenter using a hydrometer. When the density drops below a set point the secondary fermentation vessel will be cleansed with a bleach solution, rinsed, and then the wort in the primary will be pumped across. Floats will be used for fluid levels. A micro PLC will be used for control.

Hultman: Drag Racing Timer System: A drag racing timer system will be designed with the ‘christmas tree’ and a digital display to indicate time and speed. The system will involve the design an construction of required circuitry and software development. The system will be based on a 68HC11 microcontroller.

Ivanov: PLC Demonstration Unit: A SLC-500 demonstration board will be designed and constructed. The board will include analog inputs, and motor.

Jamison: Animatronics: Anthropomorphic robotics will be designed and built. Through control they will exhibit lifelike features. This project may be too ambitious.

Johnson: PLC control of weld data quality: A system will be designed to watch signals coming from a welding station. These signals will indicate when a weld is good or bad. The PLC will use experimental parameters to determine the weld quality. An external display will be used to display information about weld quality.

Johnson: Satellite Dish Positioning System: A model of a satellite dish will be constructed. A motor will be controlled to reposition the dish via a user interface.

Kaye: Drag Racing Christmas Tree: A simulator unit for drag racing start lights will be constructed to allow drivers to improve reaction start of a run. A mini PLC will serve as the heart of this system, and will vary the light times in accordance with the national regulations.

Klein, J.: Temperature Control Unit: A unit will be designed an built to monitor temperature and switch a fan on/off when upper/lower temperature limits are reached. The unit will be based on basic discrete electronics.

Klynstra: Crash Test Calibration and Control: A hydraulically driven crash test unit will use a Labtech program to calibrate and control the unit to ensure a precise impact velocity.

Knibbe, R.: Home Timing Unit: A clock module will be purchased and used as the core of system that will turn on room lights, fan, etc. External circuitry will be designed and built to allow the user to turn on the light independent of the clock.

Koperski, C., Powell, M., Schutter, N.: Skee Ball Machine: A machine will be designed for Skee Ball. When balls are rolled they will fall into one of four holes. While the game is active balls will be returned. Points will be totaled and displayed with an LED display. A light and siren will be turned on for a winning score.

Kunzi, B., Thomas, J.: Parts feeder for the EGR474 material handling system.

Lamfers, A.: A PLC Based Home Security System: An Allen Bradley SLC-1504 will be used for a home security system. This will include sensors on various doors and windows, and a light and alarm that will be triggered when there is an intrusion. The alarm will have arm/disarm functions and zone control.

Langendoen, Vermaire: Golf Game: A golf game will be designed that will allow balls to hit into cups. Scores will be tabulated and output on an LED display. A switch setting will allow the user to select various game option.

Langston, S.: Programming Package for Ladder Logic Simulation: A package will be written in C to simulate ladder logic. The program could be entered in a number of forms, and it will allow the user to change inputs and observe the results.

Lewis, Miller: Baseball Scoring System: A system will be designed and built that will automatically detect balls and strikes. The system will score the game and display the results on a display.

Likic: Automated Model Home: A model home will be built and controlled with a PLC. One major feature will be a security system that uses various sensors.

Ljubic, Ngui, “Control of a Rhino Robot with an Allen-Bradley PLC-5”, A rhino robot was in working condition, but lacked controls. Control via a PLC and a new keypad was added to allow direct control, and program execution of movements.

Lubbers, J., Scholten, J.: Container Changer for Production Equipment: An automated tote changer will be added to a production machine (makes elbows?). This will use pneumatics to drive a new mechanism to load and unload totes from the machine.

Magee, M.: Constant Volume Reheat System: A small model with 3 rooms will be controlled for temperature, pressure and humidity. The system will use heating elements, and various control elements to adapt system behavior to compensate for different room settings and seasonal variations.

Mathews: Retrofit of a Dumpster Testing Station: An existing system is used by a local manufacturers to test dumpsters by filling them with a load, and then dumping the contents out repeatedly. The machine needs to be updated to meet new test standards. This will involve redesign of some of the mechanical and electrical systems. The program in the PLC will be updated to reflect the changes to the system.

Maschewske: Extrusion Monitoring Station: A system will be designed and build for a company to monitor an extrusion station. This will monitor process variables (how?) and then display messages on a scrolling LED screen. The project will involve the design, partial wiring and programming of the system.

McInally, Wood: Automatic Camera Platform: A camera positioning system will be designed and built. This system will use a Basic Stamp chip to interface to a PC computer through a serial port.

McJones: Control of Automatic Tool Changer: A CNC machine tool has been fitted with an open architecture controller. This controller does not control the automatic tool changer. To get this functionality a PLC will be added to the system to control the tool changer. This will involve control of the magazine, and loading arm. The PLC will communicate with the CNC controller (via RS232?) to determine when a tool is to be changed.

McMullan, A., Mose, D.: Sprinter Timer: A timing system will be designed and built. The basic function will be to be tripped at the start line for a sprint, and stopped at the end of the distance. The elapsed time will be displayed on an LED readout.

Mead: Use of PLC to Control Indexing Table: An existing indexing table uses hard wired controls. A PLC will be used to control the table, and allow the user to program parameters.

Miller: Starship: An actuated model of the starship Voyager.

Moelker, N.: Travelling Sprinkler Stop -A system will be designed, built and installed to monitor a moving sprinkler. When it passes a certain distance a sensor will detect this limit and close a valve on the water main. This system should include appropriate start/stop/reset buttons, along with an optical sensor to determine when the sprinkler has reached the end of travel.

Mollema & Welch: Voice Controlled Robot: A microcontroller with a voice recognition IC will be used to control a mobile robot.

Moore: Electric Wheelchair: An existing wheelchair will be refurbished and tested. Additional work will be done to add a pressure switch to ensure a rider is in the chair, and a battery low indicator.

Morgan, Uken: Drag Tank Retrofit: A drag controller will be designed and built for the drag tank in EC713. This unit will allow a target speed to be specified, and also read the actual drag speed.

Morrell: Vision Directed Control of a Robot: A DVT vision system will be configured and setup to control a Fanuc RJ-2 robot. The vision system will compare scenes to determine part offset. Offset and orientation vectors will be sent to the robot via an RS-232. The robot will then adapt to the location and orientation of the part. This will be a prototype system, so statistical tests of performance will be done.

Munster: Vision Control System: A proof of concept system will be developed around a vision system. The vision system will locate an object in a field of view. The location will be sent over a serial cable to direct an x-y positioning axis. An HMI will be added to allow limited user interaction, and simple reporting.

Muthucumarasamy, Porter, “PLC Programming for a Material Handling System”, A system was donated to Ryerson. The system was previously assembled, and basic programing of the PLC was done. This project completed the programming.

Nahin: Design and Construction of NC: This multi part project will begin with the design of mechanical and control system for a small NC lathe. In future course projects this will be outfitted with a control computer.

Nink & Seco: An External Keypad Based Car Door Lock: A Car door locking/unlocking system will be designed and built around an Altera based controller. This system will have a keypad mounted outside the car with a keycode to lock and unlock the driver door. When an incorrect code is entered a horn and lights will be activated.

Olthof: Train Set Controller: An automated train set controller will be designed and built. This will allow switching of tracks, coordination of lights, power switching to tracks, etc. The type of controller must be determined.

Palmbos, E.: Retrofit of House Electrical Control System: The current house uses 24Vdc to drive relays at the lights to switch 115Vac. The relays are starting to fail, and a redesign is needed. Replacement relays will be found and a rectified voltage will be used to control them.

Peterson: Bedroom Security System: An alarm system for a single room will be developed to monitor motion. Knocks will be required before entry is permitted. The system will be controlled with a Mitsubishi PLC.

Phoa, “A PLC controlled Box Orientation Device”, The existing system was put in working order, and the PLC was programmed to ensure complete functionality of the device.

Remelts: Automatic Guitar Tuner

Rollenhagen: Home Security System: A home security system based on the Basic Stamp chip will monitor various inputs. In the event of an alarm, it will turn on a siren for a set time and then reset.

Rutgers: Automatic Guitar Tuner

Schmitt: Remote Control of Car With PC

Schulz: Design of a PWM Motor Controller: A high current pulse width modulated (PWM) motor controller will be designed, built and tested. This will be used in the future by the electric race team.

Scott: Hatchback Unlatch Mechanism: A hatchback controller for a small car will be designed so that it will latch/unlatch automatically. A remote control will also be considered.

Seaver: Thermoforming Process Controller: An existing thermoforming machine will be retrofit with a system to load and unload a blank from the oven with variable cycle times.

Semeyn: A Carpet Cutting Machine: A controller will be added to a machine, and programmed, to pull the correct carpet length from a roll, cut it, then place the carpet on the part to be molded together.

Serebryakov: Speaker Directivity Index Measurement: A turntable arrangement will be developed to support hardware and software for measuring speaker loudness at various angles. This apparatus will use a PLC to position the table as requested.

Sham, Sutander, “PLC Control of an Automated House”, A house was developed with a number of automated systems. These allowed windows, doors etc to be opened/closed to meet changing environmental conditions. The system will also include other useful features such as a burglar alarm.

Sietsema: Car Alarm: A car alarm will be designed and constructed.

Silcox: Cat Feeder: An automate cat feeder will dispense food at regular intervals as controlled by an electromechanical timer. A sensor will stop the feeding cycle if food remains in the dish. Another sensors will be used to indicate when the food hopper is empty.

Singhal, M.: Computer Controlled Model Railroad- A three part system will be design and implemented. There will be a Visual Basic program at the front end that will allow the user to specify actions and monitor status. An RS232 connection to a Basic Stamp chip will communicate commands, and the Basic stamp chip will control the train set. Functions will include train speed, switch tracks, etc.

Smith, Tang, “Traffic Light Control for Optimal Flow”, Multiple sets of traffic lights were constructed, and controlled via a PLC. The Control programs in the PLC were such that the traffic lights adapt to nonuniform traffic flow.

Springer, T.: Table Lifting Machine: Controls for a machine will be designed and implemented to clamp and raise a work surface. There will actually be two independent work surfaces.

Turner: PLC Control of Waterjet Machine: A waterjet machine controlled by PLC will be reprogrammed. The goal will be to allow cutting of one or more parts in foam.

Tuttle: PLC: A 6811 will be used to implement a simple PLC

Ulbikas, Chetcuti, “Upgrade of PLC controlled robot”, An existing robot that is connected to a PLC was put back in working order, and a keypad was added for direct, and programmed control of the robot.

Vanderkolk: LabVIEW Interface To Dynamometer: LabVIEW will be interfaced to a cutting force dynamometer. The cutting forces will be displayed for easy reading, and graphs of values may be written to files.

Vidinlic: Upgrade of Assembly Station: An assembly station will be upgraded for a local company to include two new sensors, a manual switch and an updated program to ????.

Wan, Lim, “Automated Car Wash”, A carwash model was built, and outfitted with sensors and actuators. A PLC was used to control various function such as a security keypad, driers, belt, wax, etc.

Wiersma, Stehouwer: Keytag Corner Rounder: Retrofitting for a keytag rounder will be completed so that it is fully automated. This will include a chute for incoming parts, an automate clamping mechanism, etc.

Wong, Kan, “Design and Control of a Conveyor Offloading Robot”, A robot was designed, built and controlled by a PLC for sweeping objects off a conveyor belt.

Woodard: Flooding Alarm: An alarm will be developed to detect flooding in a house in the event of power failure. This device will need to detect when the house power is off, and when water is present.

13.2.2 Possible Topics

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• Some projects available are,

Golf data collection system (sponsor: Prof. John Stevenson, Physical Therapy, GVSU): A method will be designed and implemented to measure the motion pattern of a golf swing. The resulting system will be used by Physiotherapy for research into sports performance.

Electrical Part Testing System (sponsor: Faith Koski, Invensys): An existing testing system for electrical components will be upgraded from a pascal based control system, to a Labview based system.

Timer System (sponsor: Lisa Wezeman, Physical Therapy student): A timer will be developed using a sensor and display so that the agility of basketball players can be analyzed.

MAT PLC (sponsor: Prof. Hugh Jack): students will work on a project to apply or develop Linux based control software. More details on the project are available at http://mat.sf.net.

• Other topic sources include (in priority),

1. do a project for a local company or somebody in GVSU

2. select a project based on personal interest

13.2.3 Final Project Requirements

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• The final requirements for the projects are list below. Unless you have been specifically and deliberately told to otherwise, use these as requirements.

1. A demonstration of your working project.

This will be on the same day as the senior project presentations.

Some students may use videos of their projects by prior arrangements with the instructor.

The projects are to be set up in EC 713. Other spaces are available on request.

Those requiring air supplies, or 220Vac will be in EC713 only. If you have these need, speak to Bob beforehand to make sure you will have them.

Have the demonstrations set up BEFORE 11am. They can be taken down after the Ring ceremony.

Have the demonstrations taken down, and all parts returned by Monday.

You are expected to be at your display between 2pm and 3:30pm.

2. You will need to present a poster for your project.

This will be similar to the poster for your senior project. See an example in the EC718 conference room if necessary. These should be neatly done. I suggest that you use “foam core” board that will support itself.

Use a table available in one of the class rooms.

3. A report that is posted to the web.

For teams, the report can be posted to one homepage, and links added by other students on the team.

A project without a report will not be accepted.

The report should be posted before the demonstration.

The report should contain technical details. Keep in mind that when you are gone another student may want to use your report. The more questions they need to ask, the lower your grade.

Add digital photographs, schematics, etc. to illustrate what you have done.

Examples of previous reports can be found at,





13.2.4 Proposed Topics Summer 2004

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Name(s): Baker and Slater

Title: Rolling Mill Prototype

Description: A sheet metal rolling mill will be designed and prototyped. The controls for the system will be designed and built and tested on the prototype.


Name(s): Bell

Title: Trip Press Control

Description: The controls for a trip press will be designed, built and programmed.


Name(s): Briceno

Title: Control System Replacement

Description: An existing machine is controlled with an Allen Bradley PLC. The current controls will be replaced with GE controls. The project will involve clarifying the process logic, define fault conditions, develop wiring diagrams, programming the PLC, and interfacing to an HMI.


Name(s): Fountain and Tornga

Title: Exhaust Gas Analyzer

Description: An existing system for exhaust gas analysis will be recommissioned and integrated with a computer for data collection.


Name(s): Fox, Hoogewind and Howard

Title: Retrofit of a Hydraulically Actuated Robot

Description: The robot, currently known as ‘Sparky 3000’ will be re-engineered to increase robustness and usability. This will include redesign of the hydraulics, sensors and main controller.


Name(s): Hammill

Title: PLC Based Training and Testing Unit

Description: The project involves the design, construction and testing of a PLC based unit with a variety of inputs and outputs, including pneumatic valves. The unit will be used for training and for verifying end-of-line test equipment.


Name(s): Hesselsweet and Knapp

Title: Intrumentation and Monitoring of Transfer Dies Using an HMI

Description: A set of four transfer dies are mounted in a single press. A number of proximity detectors will be used to detect parts and die position to control the cycle. An HMI will be developed to allow an operator to monitor and control the process.


Name(s): Hough and Montigny

Title: Animatronics

Description: Controls for an existing animatronic mechanism will be designed and implemented. The function of the mechanism is not yet determined.

Deliverable(s): A working device and a web based report.

Name(s): Pastoor and Reimink

Title: A Household Mechanism for Metering

Description: A patent application will be developed, along with a mechanism to prove the utility of the patent. The mechanism will be a consumer item capable of metering common household consumables.

Deliverable(s): A complete patent application and a working mechanism.

Name(s): Przekadzinski, Slotman and Zurschmeide

Title: Motion Control Demonstration System

Description: A mobile system will be designed and build for demonstrating motion control and construction techniques for automated systems. This will include a three axis motion control system and a variety of actuators and sensors.


Name(s): Sponsler and VanLente

Title: Remote Throttle Control for an Dynomometer

Description: A remote system for controlling a throttle on an internal combustion engine will be designed and built to allow remote commands to be issued manually, or by the dynomometer controller.


Name(s): Stevens

Title: Leaf Spring Test Machine

Description: A control system will be designed and built for a multi station leaf spring tester. The unit will cycle each spring up to 1 million cycles, or until it fails.


Name(s): Twa

Title: Shift Mechanism Test Apparatus

Description: A PLC based system will be designed and built to move an automtive gear shifting mechanism through standard motion patterns.

Deliverable(s): A working machine and a report.

Name(s): Woldhuis

Title: Pull Tester Software Redesign

Description: Reprogram a pull tester?????


13.3 Available Equipment

• The following are cards for the Allen Bradley PLC racks

1 1747-L30A A SLC500

3 1747-L40A B SLC500

1771 External Power Supply

1 1771-AA 4 Slot I/O Chasis

6 1771-A2B 8 Slot I/O Chassis

8 1771-IB (12-24V) DC Input Module

4 1771-IBD (10-30V)DC Input Module

1771-IBN (10-30V)DC High True Input Module

2 1771-IFE Analog Input Module (12 bit)

1 1771-IG TTL Input Module (+5V)

2 1771-IJC Encoder/Counter Module 5V I/O

1 1771-IKC Encoder/Counter Module 12-24V I/O

1 1771-IT (12-24V) Fast Response DC Input Module

8 1771-IV (12-24V)DC Driver Logic Input Module

1 1771-IXE Thermocouple/millivolt input module

1771-KA2 Communication Adapter Module

1771-KA3 DH+ PLC-2 Interface

1771-KF Data Highway/RS-232C Interface Module

3 1771-M1 Stepper Motor Controller Module

1771-OA (120V)AC Output Module Series B

15 1771-OB (12-24V) DC Output module: Series B

1771-OBD (10-60V)DC Output Module

1771-OBN (10-30V)DC High True Output Module

1 1771-OFC Analog Output (12 bit) Series B

1771-OFE1 Analog Output Module (12 bit voltage)

2 1771-OFE2B Analog Output Module

2 1771-OGC TTL Output Module (+5V)

2 1771-OGD TTL Output Module

3 1771-OJ Pulse Output Expander Module

2 1771-OW Selectable Contact Output Module

34 1771-WA Small Screw Terminal

1 1771-WD Medium Screw Terminal

22 1771-WH Large Screw Terminal

1784-KTK1 Peer Communication Link Interface Module

1784-KTP Processor Communication Interface

1785-KA Communication Adapter Module

1 1785-L11B/C PLC5/11 processor

4 1785-L11B/E PLC5/11 processor ver. E01

4 1785-LTB PLC5/15 processor ver. B

13.4 Laboratory Experiment Guidelines

General Objective of Laboratories:

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. Prelabs are essential, and must be done before every lab session when required.

2. Prelabs require that some assumptions be made.

3. The lab period should be used for debugging prelab work.

4. Labs are to be handed in before leaving.

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,

PLC Project sheet: identifies the project, packet contents and contact person.

Project Notes:

System Description: a succinct paragraph stating how the system will behave

I/O Notes: description of all inputs and outputs.

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.

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.

Input/Output Card: Detailed plan for attaching the inputs and outputs to the PLC.

Program Listing: A list of ladder logic to implement the system.


• general rules for using the design sheets are,

omit unused design sheets

if a small change is made, modify the design sheets

if a large change is made, leave the original and append updated pages.

do design work in pen. Errors can be crossed out with a single diagonal line


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