1. What is purpose of FMS trainer?

The YalongYL-335A is a FMS (Flexible Manufacturing System) is to give insight of the

automatic production trainer liner for installation, materials feed, processing, assembly,
transmission and distribution where each unit adopts pneumatic drive, frequency converter drive
and stepper motor position control technology.

2. Explain the systems involved in Yalong 335-A Automatic production line trainer ?

SUPPLY UNIT

The supply unit is to supply materials for other units in the system for the mechanical arm to
catch and transfer to the other units.The task is to supply the workpiece (small white cylinders)
thus there are two optical sensors that are sensing the workpieces in the workpiece box and
magnetic switches attached on the cylinders. The optical sensors see the workpiece and
resultantly the cylinders push or retract. The proximity sensor used in FMS is more specifically
called optical proximity switch as it works using reflected light. It works as follows :

PROCESSING UNIT

The purpose of this unit is to catch the work piece transferred from the supply unit, punch it
and return it for the mechanical arm to transfer to the further units.

ASSEMBLY UNIT

The assembly unit will assemble the cylinder and caps with the help of a pneumatic finger.

DISTRIBUTION UNIT

The distribution unit is the final unit in YL-335A trainer and its purpose is to distribute the
work piece into different slots depending upon the color.
3. Briefly Explain the difference between stepper and servo motor

Servos and Steppers are the names of two different device types used to control motors. From a
distance, both device types can appear similar, as they both allow a user to control speed,
position, and torque.

Steppers are an Open Loop system, meaning that they simply move incremental pulses. When
trying to accelerate too quickly, or if exceeding the torque, there is a chance at missing steps,
which could result in incorrect positions. Without an encoder in the stepper system, there is
no way to know and correct for the off position

Servos are closed-loop systems, meaning they use an encoder, or resolver, to provide feedback
of the actual position vs the commanded position, the servo then adjusts the current to control
the motor position

4. Explain the difference between Inductive and Capacitive proximite sensors?

Inductive sensors use currents induced by magnetic fields to detect nearby metal objects. The
inductive sensor uses a coil (an inductor) to generate a high frequency magnetic field as shown
in Figure 1 below. If there is a metal object near the changing magnetic field, current will flow in
the object
(An inductor, also called a coil, choke , or reactor, is a passive two-terminal electrical component
that stores energy in a magnetic field when electric current flows through it. An inductor
typically consists of an insulated wire wound into a coil around a core).
This resulting current flow sets up a new magnetic field that opposes the original magnetic field.
The net effect is that it changes the inductance of the coil in the inductive sensor.
By measuring the inductance the senor can determine when a metal have been brought nearby.

5.What is the function of cylindrical throttle valves in FMS ?

To keep the cylinder stable and reliable, the cylinder throttle valves are installed. The cylinder
throttle valves are for cylinder speed regulation.

6.Brifly explain working of Photoelectric sensor/optical sensor ?

A photoelectric sensor emits a light beam (visible or infrared) from its light-emitting element. A
reflective-type photoelectric sensor is used to detect the light beam reflected from the target
Both the light emitting and light receiving elements are contained in a single housing. The sensor
receives the light reflected from the target.
7. What Is The Function Of Pnuematic Actuation Valve In FMS ?

Pneumatic actuation refers to a valve being tripped through the use of compressed air (gas). At a
particular point in an industrial or manufacturing process, compressed air is released, causing a
valve to open or close.

8. Write brief notes on types of Manufacturing system?

REPETITITIVE MANUFACTURING SYSTEM

1. Production volume is stable and predictable

2. Lead Time is short (Time between commencement and end of a process)

Examples Electronic goods, Automobiles, Durable customer goods, like washing machines,
Refrigerator, etc

DISCRETE MANUFACTURING

Production of distinct items e.g. Automobiles, furniture, smart phones which are easily
identifiable and differ greatly from process manufacturing

PROCESS MANUFACTURING SYSTEM (BATCH & CONTINUOS)

1. Involves intermediate steps e.g. curing, baking, preparation

2. Require Processing

BATCH PRODUCTION

Batch Processing is a non-continuous process where each new batch is undertaken only when
work on all items of a batch is complete

Co Products/Bi products can be generated

Example Pharmaceutical, Foods, Inks, Paints, glues, oil or chemical

Co-Product: Sealable end item that results from a process

By-Product: Material or value produced as a residue of process

CONTINUOS MANUFACTURING

1. Production runs typically continue for an extended duration

2. Equipment is dedicated to one product or production line e.g. Petroleum products ,Water
purification

Note: Both batch and continuous processing methods require extensive record keeping

JOB SHOP

Job shop is a small company or business that makes specific products for one customer at a time.
Manufacturing unit that specializes in small quantity e.g. paint shop, machine tool shop, gear
manufacturing etc.

9. What is the linear movement range in SIS ?

9mm

10. What is the Rotary to linear ratio in SIS ?

360° to 1 mm

11. What is the Material of Rotary potentiometer ?

Conductive plastic

12. State the frequency and voltage ranges of the panel meter?

0 to ±10 V in 0.1 V steps 0 to 500 Hz

13. Which type of strain gauge and what is its nominal resistance in SIS ?

Wire type ( 120 Ω)

14. For Differential Amplifier what is k1 Range: k2 Gain ?

k1 Range: × 1; ×10; ×100

k2 Gain: 0.1 to 100

15. Describe the available power supplies in SIS?

Power Supply Ref1 : 0 to 5 V variable

Ref2: ±5 V variable
16. Label the layout of the linear assembly shown below?
17. Label the layout of the linear assembly shown below?

18. Explain what do you mean by a Stain gauge?

Strain gauges are devices designed and constructed so that their resistance changes when they are
strained: that is their physical dimensions increase or decrease

19. What happens when the 4 strain gauges are mounted and deflected while carrying out
the strain gauge experiment in SIS?

Two strain gauges mount on each side of the beam, such that when the beam deflects to
the left, two of the gauges are in tension (increase in their resistance) and the other two in
compression (decrease in their resistance). Deflecting the beam to the right reverses this effect.

20. How are output voltages and resistances related in a Strain gauge potential divider?

The output is governed by the ratio of the strain gauge resistance, Rsg, to the total resistance,

Rsg +R.
21. When can set zero control be used in the strain gauge potential divider experiment?

Initially Ref1 is used to make the indicated meter value as small as possible (less than 5 V ).After
this ‘set zero’ control is used to zero the reading

22. What is the objective of the strain gauge half bridge ?

The object of this experiment was to determine the performance of the half-bridge and compare
it with the results of the potential divider and quarter-bridge

23. What is Sensitivity? Rank the Strain gauges in the order of their Sensitivity?

Full bridge > Half bridge > Quarter bridge

The sensitivity can be found using the slope of the Voltage-displacement graph.

The Sensitivity of Full bridge is approximately 4 times the sensitivity of quarter bridge.

24. In case of potential divider , what would be the effect of reversing the polarity of supply
?

The measured value which was in the range of 0 to 5V and centered around 2.5 V will now be in
the range of 0 to -5V and centered around -2.5 V

25. What would be the effect of reducing the voltage supplied to the potential divider
circuit?

This would reduce the variation in the output voltage for a given range of displacements, leading
to proportional reduction in sensitivity.

26. What are the main parameters, which affect the quality of the measurement system in
the strain gauge experiment?

a. Type of Strain gauge (Material & Gauge factor)

b. Power supply voltage

c. Position of Strain Gauges on the beam.

27. Describe how can this experiment be modified (circuits & procedures) to be able to
measure temperature using bridge techniques ?

The strain gauge in the quarter bridge could be replaced by either a thermistor or a platinum
resistance thermometer (or similar) and the value of fixed resistors chosen to match. Changes in
temperature will unbalance the bridge circuit and so produce a variable output, which can be
calibrated for temperature

28. What is the objective of the capacitor experiment in SIS ?

The object of this experiment is to investigate the use of a variable area capacitor to measure
linear displacement.

29. How can capacitance be equated with displacement in SIS ?

The capacitance varies in direct proportion to the area. By changing the area in direct proportion
with displacement allows measurements of capacitance to be equated with displacement

30. Why capacitance is usually measured in micro, pico farads ?

Because of the magnitude of eo capacitance is, under all but exceptional circumstances, very
small, capacitance is usually measured in microFarads (mF) or picoFarads (pF).

31.What is chosen to be the variable quantity in SIS capacitance experiment ?

In the variable capacitor used in the SIS the parameter chosen to be variable is the area of
overlap of the plates. The relationship between the area of overlap and the capacitance is: C ∝ A
32. How can variable dielectric capacitor be used as a liquid level sensor ? Explain

The 2 plates , flat and parallel or concentric cylinders, are positioned such that when the level
changes the liquid replaces air as the dielectric and so the capacitance changes. The output can
be calibrated to give a direct reading of level.

33.What is the objective of the Reed switch Experiment ?

The objective is that how, and where, a reed switch is positioned within a system to measure
proximity OR The object of this experiment is to investigate the operation of a reed switch in
sensing the proximity of a magnet

34. Explain the operation of Reed Switch ?

The operation of the reed switch is based upon the principle of magnetic induction. When a
magnet,whether permanent or electromagnetic, is in close proximity to a soft iron material the
soft iron magnetises. The polarity will be such the soft iron always attracts the magnet –
dissimilar poles attract – but only for as long as the magnet is present. This is shown graphically
in Figure below

35. What is the material used in Reed Switch and what is the reason ?

In the reed switch the contact material is selected because it has the properties of being a good
conductor, flexible and ferromagnetic. The material used in the SIS reed switch is rhodium
36. List down applications of Reed switch ?

Security doors/windows opening r closing

Push buttons with magnet/reed switch built-in

Switching in dangerous situations such as where flammable materials are present and there is
risk of fire--non spark

37. What other magnetic sensors may be used to replace reed switch for measuring
proximity?

Hall effect device, Search Coil, Inductance probe

38. What is the objective of the opto reflector experiment?

Understand how an optical reflective sensor positions within a system to measure proximity

39. What can be the possible source of error in opto reflector experiment?

Effect of external light on the conduction of the phototransistor

40. What advantages are there in using an opto reflective sensor for proximity
measurement compared with a reed switch ?

In addition to allowing on/off proximity measurement,the opto-reflector also has a measure of

position contained within the signal.Also the distance between the sensor and body can be made
greater.

41. Briefly explain the construction of optical Tachogenerator ?

The Optical Tachogenerator included in the SIS Hardware Module comprises an LED and
phototransistor mounted either side of a perforated disc.The perforations comprise a series of
slots in the disc,arranged to provide a four-bit Gray scale, but only the Least Significant Bit
(LSB) in this experiment is used.

42. What is the objective of the optical tachogenerator experiment ?

The object of this experiment is to investigate the use of an optical tachogenerator, using an
optotransmissive technique, for the measurement of rotational speed.

43. What is dead zone in case of optical tachogenerator experiment ?

The range of supply voltages for which the speed is zero of the motor is termed as dead zone of
the motor.
44. If the slots in the disc were shortened in the optical tachogenerator experiment what
effect would this have on the results?

The optical measurement system using LED/phototransistors is based on frequency only, not the
timing of events. As long as light reaches the transistor it will respond to it by changing its
conduction state and this would be registered as a measure of speed.

45. Can the SIS optical tachogenerator be used to determine the direction of rotation?

No, the transition from slot to solid and then solid to slot would occur whichever way round the
disc was rotating. Therefore, direction cannot be measured with this system

46. While studying about the motor characteristics during the optical tachogenerater
experiment you found a frequency of 148 Hz .Show how you will convert this into rev/min

Speed in rev/min is given by

So 148 x 60 = 8880

8880/8 = 1110 rev/min

47. Describe an alternative optical technique that could be used for measuring speed of
rotation.

The Alternative optical method is reflective rather than transmissive. In this technique a
photodetector, a phototransistor or similar, is positioned to sense the light emitted by a source
being returned from a rotating body. The light is made to be pulse to some suitable target
attached to a rotating body

48. Explain Pulse width modulation and explain two main components that define its
behavior ?

A PWM signal consists of two main components that define its behavior: a duty cycle and a
frequency. The duty cycle describes the amount of time the signal is in a high (on) state as a
percentage of the total time of it takes to complete one cycle. The frequency determines how
fast the PWM completes a cycle (i.e. 1000 Hz would be 1000 cycles per second), and therefore
how fast it switches between high and low states. By cycling a digital signal off and on at a fast
enough rate, and with a certain duty cycle, the output will appear to behave like a constant
voltage analog signal when providing power to devices. Pulse width modulation (PWM),
or pulse-duration modulation (PDM), is a method of reducing the average power delivered by
an electrical signal, by effectively chopping it up into discrete parts.
49. Explain about void loop () and void setup() in Arduino programming.Write a sample
code for onboard LED blinking.

Setup : It is called only when the Arduino is powered on or reset. It is used to initialize
variables and pin modes

loop : The loop functions runs continuously till the device is powered off. The main logic
of the code goes here.

Example Program

void setup() {

pinMode (LED_BUILTIN, OUTPUT);

void loop() {

digitalWrite(LED_BUILTIN, HIGH);

delay(1000);

digitalWrite(LED_BUILTIN, LOW);

delay(1000);

50. what is a thermistor. briefly explain the difference between NTC and PTC
thermistor.

Thermistor is a thermally sensitive resistor and is generally composed of semi conductor

materials.

Negative temperature coefficient : Resistance decreases with increasing temperature

Positive temperature coefficient : Resistance decreases with increasing temperature

51. Comment on accuracy and response time of thermistors when compared to RTDs
or thermocouples over ambient temperature ranges?

Thermistor has excellent accuracy over ambient temperature ranges when compared to
RTDs or thermocouple

Also response time is generally faster than RTDs

52. Compare RTD and thermocouples in terms of accuracy and stability

RTD is generally more accurate and more stable than thermocouples

53. What is a bimetallic thermometer?

The bimetallic thermometer uses a bimetal, which is composed of two types of metals
with different thermal coefficients of expansion and they are wound into a helical form,
change according to temperature is transmitted to the indicator.

54. What are the temperature ranges for thermocouple and RTD ?

RTD : -182.96 to 630.74 degrees Celsius

Thermocouple: type k: -249.75 to 1373.625 degrees Celsius

Type J: -189.81 to 999 degrees Celsius

54. Label the Arduino and give details of pins ?

The pins on your Arduino are the places where you connect wires to construct a circuit
(probably in conjuction with a breadboard and some wire. The Arduino has several
different kinds of pins, each of which is labeled on the board and used for different
functions.

 GND (3): Short for ‘Ground’. There are several GND pins on the Arduino, any of
which can be used to ground your circuit.
 5V (4) & 3.3V (5): the 5V pin supplies 5 volts of power, and the 3.3V pin supplies
3.3 volts of power. Most of the simple components used with the Arduino run
happily off of 5 or 3.3 volts.
 Analog (6): The area of pins under the ‘Analog In’ label (A0 through A5 on the
UNO) are Analog In pins. These pins can read the signal from an analog sensor
(like a temperature sensor) and convert it into a digital value that we can read.
 Digital (7): Across from the analog pins are the digital pins (0 through 13 on the
UNO). These pins can be used for both digital input (like telling if a button is
pushed) and digital output (like powering an LED).
 PWM (8): You may have noticed the tilde (~) next to some of the digital pins (3,
5, 6, 9, 10, and 11 on the UNO). These pins act as normal digital pins, but can also
be used for something called Pulse-Width Modulation (PWM
 AREF (9): Stands for Analog Reference. Most of the time you can leave this pin
alone. It is sometimes used to set an external reference voltage (between 0 and 5
Volts) as the upper limit for the analog input pins.
Reset Button
the Arduino has a reset button (10). Pushing it will temporarily connect the reset pin to
ground and restart any code that is loaded on the Arduino. This can be very useful if your
code doesn’t repeat, but you want to test it multiple times.

Power LED Indicator

Just beneath and to the right of the word “UNO” on your circuit board, there’s a tiny LED
next to the word ‘ON’ (11). This LED should light up whenever you plug your Arduino
into a power source. If this light doesn’t turn on, there’s a good chance something is
wrong. Time to re-check your circuit!

TX RX LEDs
TX is short for transmit, RX is short for receive. These markings appear quite a bit in
electronics to indicate the pins responsible for serial communication. In our case, there
are two places on the Arduino UNO where TX and RX appear -- once by digital pins 0
and 1, and a second time next to the TX and RX indicator LEDs (12). These LEDs will
give us some nice visual indications whenever our Arduino is receiving or transmitting
data (like when we’re loading a new program onto the board).

Main IC
The black thing with all the metal legs is an IC, or Integrated Circuit (13).

Voltage Regulator
The voltage regulator (14) is not actually something you can (or should) interact with on
the Arduino. But it is potentially useful to know that it is there and what it’s for. The
voltage regulator does exactly what it says -- it controls the amount of voltage that is let
into the Arduino board. Think of it as a kind of gatekeeper; it will turn away an extra
voltage that might harm the circuit. Of course, it has its limits,
NOTE: Do NOT use a power supply greater than 20 Volts as you will overpower
(and thereby destroy) your Arduino. The recommended voltage for most Arduino
models is between 6 and 12 Volts.