R2019 : MESBL601 : Measurement and Automation

Sr. No Title of Experiments

A Metrology
Experiment no 1:
1
Use of linear and angular measuring instruments
Experiment no 2:
2
To measure screw thread elements and different geometries by using optical profile projector
Experiment no 3:
3
Measurement of gear tooth thickness using gear tooth Venire Caliper.

B MMC
Experiment no 4:
4
Study of generalized measurement system and its components.
Experiment no 5:
5
Calibration of Pressure gauge using dead weight pressure gauge tester.
Experiment no 6:
6
Identification of a given Sensor.

C AUTOMATION
Experiment no 7:
7
Design of Electro_Pneumatic (EP) Circuit
Experiment no 8:
8
Design of Electro_Pneumatic (EP) Circuit (Fluid_Simulation)
Experiment no 9:
9
Design PLC (Programmable Logical Controller) for a given Circuit.

D Exam

1 MU Exam_Practical and Orals

Lab Incharge: B. S. Chavan

 Experiment
No. 01

TITLE: Application of basic linear and angular measuring instruments.

PRIOR CONCEPT:
1. Principles of linear and angular measurement
2. Basic units of measurement

LEARNING OUTCOMES:
1. Select appropriate instrument for measuring the dimensions of
given specimens.
2. Measure length, width, thickness, diameters, angles, gaps and pitch of
the screw.

APPARATUS:

1. Instruments for use:

Surface
plate v-
block
spirit
level
bevel
protractor
feeler gauge
screw pitch
gauge Vernier
caliper
Micrometer- External and Internal
2. At least 2-3 specimen with different geometries.
BRIEF THEORY:
1. Surface Plate: Surface plates are mostly rectangular having 4:3 length to width ratio.
These plates are rigid in design & generally ribbed at the bottom to carry heavy load
without deflection. The top surface of the plate is scraped to true flatness.
For big surface plates, four leveling screws are provided for adjusting their top
surface truly horizontal. The standard available sizes of the plates vary from 100 x 100
mm to 2000 x 1000 mm in about 13 ranges. The four edges of the plates are finished,
straight & are square to each other. According to IS-2285-1963, the CI surface plates are
classified into two grades as GRADE – I & GRADE – II.
Surface plate is used to provide datum or a reference surface for measurement in
workshop & laboratories. It is also used to check flatness of any surface.

2. Angle plate: The two working surfaces of the angle plate are truly perpendicular to
each other & these surfaces are scraped. Generally, no sharp edges are allowed in the
plate. They are used along with surface plate in workshop & laboratories for
measurement. Angle plates are manufactured from cast iron and cast steel. The angle
plates are available in two grades depending upon the accuracy (IS – 2554 – 1963).
Grade – I: either grinding or hand scraping operation finishes all exterior &
interior faces and edges.
Grade – II: planning or milling operations finishes all exterior faces.
3. V-block: V-block is a supporting device for cylindrical work-pieces for marking
center accurately and for checking out of roundness. The angle of ‘V’ in ‘V-block’ is 90
degree. All the working surfaces of the V-block are polished. Clamps are also provided
for holding round bars. According to IS-2949-1964, V-blocks are available in two grades,
Grade A & Grade B. While using V-block, it is essential that the cylindrical work piece
should rest firmly on the slides of the vee & not on the edges of the vee.

4. Spirit level: Spirit level consists of a sealed glass tube mounted on a base. The inside
surface of the tube is ground to a convex barrel shape having large radius. A scale is
engraved on the glass at the top of the tube. The tube is nearly filled with Ether or
Alcohol except a small air or vapor bubble. The bubble always tries to remain at the
highest point of the tube. If the base is placed on horizontal surface, then the bubble rests
at the center of the scale. If the spirit level is tilted through small angle, the bubble moves
& tries to remain at the highest point of the tube. They are used for leveling of machines,
for measuring small angle or inclination and for checking straightness & flatness of
surface.

5. Bevel Protractor: It is a simplest instrument for measuring the angle between two
faces of a component. It consists of a base plate attached to a main body and an
adjustable blade which is attached to a circular plate containing vernier scale.
The adjustable blade is capable of sliding freely along the groove provided on it and can
be clamped at any convenient length.
The adjustable blade along with the circular plate containing the vernier can rotate freely
about the center of the main scale engraved on the body of the instrument and can be
locked in any position with the help of a clamping knob. The adjustable blade along with
the circular plate containing the vernier can rotate freely about the center of the main
scale engraved on the body of the instrument and can be locked in any position with the
help of a clamping knob.
6. Straight Edge: Straight edge is rectangular or ‘I’ shaped in section with beveled edge.
Steel straight edges are available up to 2 meter length & CI straight edges are available
up to 3 meter length & are widely used for testing machine tool slide ways. It is used in
conjunction with surface plate & spirit level for measurement of straightness and flatness
of parts. For checking the straightness of the part, the straight edge is placed along the
full length of the surface against the bright light. The absence of the light between
straight & surface indicates the straightness of the element. Similarly the flatness of the
surface can be tested by placing the straight edge in different directions at different places
on the surface. By using Prussian blue & straight edge, the irregularities on the surface
can also be found out. According to IS-2220-1962, straight edges are provided into two
grades.
Grade A – for inspection purpose
Grade B – for workshop purpose
Stepwise procedure:
1. Put the straight edge on surface under test
2. Observe the gap between the straight edge and surface under test
3. If there is no gap, the surface is straight.
7. Feeler Gauge: Feeler gauge is a narrow strip of steel sheet made up of required
thickness. The complete set consists of number of gauging blades of different thickness.
Its working is based on the sense of feel & hence it is called as feeler gauge. If necessary,
two blades can be joined together to check dimensions. They are available from 0.03 to 1
mm size. Each blade is permanently marked with the nominal thickness & grade. It is
used to measure the gap between two parallel flat faces, to measure clearance between
piston & cylinder, spark plug gap and setting tappet clearance.
Stepwise procedure:
1. Take the job to measure the gap
2. By trial & error method insert the leaf of feeler gauge in the gap.
The leaf of feeler gauge that matches exactly with the gap is the gap distance. The
dimension is written on each leaf of feeler gauge.
8. Screw pitch gauge: In this gauge, one edge of the blade is notched to various pitches
& contours of specific threads. The blades are stamped with the pitch size. These gauges
are available for metric, British and American form of threads. By matching these gauges
with the job to be measured, the pitch of the job can be found easily.
Stepwise procedure:
1. Take the threaded job to measure the pitch.
2. By trial and error method match the leaf of pitch screw gauge with the threads.
3. The leaf that exactly matches with the thread form gives the pitch of the thread,
which is engraved on the leaf of the gauge.

9. Radius gauge: Radius gauge is used for determining radius of a fillet. Radius gauge
consist of set of blades on each of which the corresponding radius is marked. By placing
the correct gauge & by observing the light source with eyes the correct radius can be
checked.
Stepwise procedure:
1. Take the job to measure the radius.
2. By trial and error method match one of the leaves of the radius gauge with the
job radius.
3. The leaf that matches exactly with the radius of the job gives the radius of the
job that is engraved on the leaf of the gauge.
10. VERNIER CALIPER

11. VERNIER MICROMETER

PROCEDURE:
1. Study the construction, working and applications of the above mentioned
measuring instruments and the accessories provided with the instruments.
2. Note the span, range and least count of the measuring instruments.
3. Select the appropriate measuring instrument for measurement of the different
geometrical dimensions of the given specimen.

OBSERVATIONS AND CALCULATIONS:

SN Name of the Instrument Range Least count

1 Vernier caliper
2 Vernier micrometer external
3 Vernier Caliper Internal
4 Bevel Protractor
5 Filler gauge
6 Thread pitch gauge
7 Spirit level
 EXPERIMENT NO. 02
TITLE: - To measure screw thread elements and different geometries by using optical
profile projector.

PRIOR CONCEPT: -
1. Screw thread terminology
2. Use of micrometer.

NEW CONCEPT:
Optical Profile projector: It is the instrument used to measure geometrical parameters of
gear / screw threads & compare the profile with the standard templates by projecting the
image of the object on a screen.

APPARATUS:
The experiment requires following equipments:
1. Optical profile projector
2. Screw thread component

LEARNING OUTCOMES:
1. Explain construction and working of profile projector for linear and angular
measurement.
2. Apply the knowledge of profile projector to measure the different
parameters of threads and other geometries.
 DIAGRAM:

PROCEDURE:
Brief theory:
An optical profile projector consist of:
□ A projector having a light source, a condenser or collimating lens.
□ Work holding table.
□ Projection system having mirrors & lenses.
□ Screen on which image of the work piece is to be projected.
□ Measuring devices.
The light source is the tungsten lamp, filament lamp or high pressure mercury lamp. A
strong beam of light consisting of concentrated bundle of parallel rays is produced by
optical means. The image of the object may be produced on vertical or horizontal screen.
Surface illumination produces a reflected image of the object on the screen.
The object to be tested is placed on the work table. The light beam after passing the
object to be projected passes in to the projection system comprising lenses & mirrors.
The lenses are used to obtain the desired magnification, normally 10x, 20x, 50x, 100x
magnification is done.

Screens usually made of acrylic plane glass are used for measurement. The work table is
provided with the means for measurement like micrometer. Angles can be measured by
rotating the screen. The screen is divided in to 360 degrees with 90 degrees cross
markings. Various charts can fixed on the screen by using four clamps.
 Stepwise Procedure: -
1. Switch on the optical profile projector.
2. Place the clean work piece on the glass of the table.
3. Focus it properly by moving the focusing wheel & moving the work table to
obtain correct magnified image of the object.
4. Horizontal X axis measurement can be taken by right hand side micrometer
& the vertical measurement can be taken from front side micrometer.
5. To measure pitch take the distance between two similar points on adjacent fl
ank or crest to crest or root to root on adjacent threads, parallel to the axis of the
screw thread.
6. Adopt the similar procedure for the measurement of the depth of the screw.
7. For measurement of thread angle match the reference line between flanks &
note down the angle.
8. Image of the component can be compared with master templet or chart.

OBSERVATIONS:
Ref. Point Ref. Point Difference
Dimension to be measured
Reading 1 Reading 2 (Measured Value)
1. Pitch
2. Minor Diameter
3. Major Diameter
4. Flank Angle

RESULTS:
1. Pitch of the given component is .
2. Minor diameter of the given component is .
3. Major diameter of the given component is .
4. Flank angle of the given component is .

CONCLUSION:
 EXPERIMENT NO. 03
TITLE: -
Measurement of gear tooth thickness using gear tooth Venire Caliper
PRIOR CONCEPT: -
1. Knowledge of gear terminology
APPARATUS:
Gear tooth venire caliper.

LEARNING OUTCOME:
1. Measure the gear tooth thickness using Gear tooth vernier caliper.

BRIEF THEORY:
TERMINOLOGY OF GEAR TOOTH
(i) Pitch circle diameter (PCD): It is the diameter of a circle which by pure
rolling action would produce the same motion on the toothed gear wheel.
It is equal to D = (N X OD)/ (N+2), OD = outside diameter N = number of teeth
(ii) MODULE: It is defined as the length of the pitch circle diameter per truth. Module m=D/N
and is expressed in mm.
(iii) CIRCULAR PITCH (CP): It is the arc distance measured around the pitch circle from the
flank of one truth to a similar flank in the next 1.00th CP==ΠD/N=Πm.
(iv) ADDENDUM: This is the radial distance from the pitch circle to the tip of the truth. It is
equal to one module.
(v)Clearance: This is the radial distance from the tip of a tooth to the bottom of the mating tooth
space when the teeth are symmetrically engaged. Its standard value is 0.157m or 0.25m.
(vi) DEDENDUM: This is the radial distance from the pitch circle to the bottom of tooth space.
Dedendum = Addendum +Clearance = m +0.157m =1 .157m=1.25m (metric gearing system)
ii) TOOTH THICKNESS: This is the arc distance measured along the pitch
from the intercepts with one flank to the intercepts with the other flank of the same tooth.
DIAGRAM:
PROCEDURE:
For finding PCD, module, addendum, dedendum and clearance:
1. First find the blank diameter, OD by a vernier caliper and also count the number of teeth N of
the spur gear.
2. Next calculate pitch circle diameter D= (NxOD)/ (N+2)
3. Find addendum, clearance, pitch, module and dedendum as per the formulae given in the
theory.
4. Find the theoretical value of “w” by formula

5. Find the theoretical value of “d” by formula

6. set the value of “d” in the vertical scale of the gear tooth venire caliper and check the value of
“w” matching with the theoretical value.
7. Find the difference in the value (at least for 5 teeth) and calculate % error.

OBSERVATIONS:
Sr.No. Value of “d” Theoretical Actual value of % error
value of w w
CALCULATIONS:
1. Addendum=

2. Clearance=

3. Pitch=

4. Module=

5. Dedendum=

6. value of d=

7. value of w=

CONCLUSION:
Subject: Measurement and Automation Subject code: MESBL601

Experiment no: 04
TITLE: Study of generalized measurement system and its components.

AIM: To Study the generalized measurement system and its components with at least one practical
example.
LEARNING OUTCOME:
1. Identify various elements in measurement systems/devices and its function.
2. Describe construction and working of given measuring instrument and relate it with
generalized measurement system architecture.

OBJECTIVES: To know the concepts:

1) Measurement
2) Measurand
3) Generalized Measurement System.
4) Standards

APPARATUS : Any measurement system like pressure measurement using Bourdon's pressure
gauge, level measurement, temperature measurement, speed measurement, U - tube manometer,
Rota meter, Speedometer of two wheeler, Pressure switch, Turbine Flow meter, etc.
DIAGRAM:

Fig 1.1 Block diagram of Generalized Measurement System.

 Subject: Measurement and Automation Subject code: MESBL601

Fig. 1.3 Bourdon tube pressure gauge

OBSERVATIONS:
Observe & study the following measuring instrument & write down functional element of them.
Name of the
Measured Data Data Data Data
measuring Data conversion
Quantity sensing transmission magnification presentation
instrument
Bourdon’s tube
pressure gauge

Conclusion:
 There is loss of data due to mechanical engagement between elements
 Material property plays an important role.
 Contact deteriorates life of the components due to impinging of forces on each element.
Subject: Measurement and Automation Subject code: MESBL601

Experiment no: 05
TITLE: Calibration of Pressure gauge using dead weight pressure gauge tester.

AIM: To calibrate the given pressure gauge with dead weight pressure gauge tester.

OBJECTIVES: To know:
1. Pressure
2. Pressure sensors
3. Dead weight e.g. Pressure cooker whistle.
4. Construction and types of Bourdon tube sensors
5. Application of Pressure sensors
6. Calibration of Pressure gauge with dead weight pressure gauge tester.
LEARNING OUTCOMES:
1. Describe the construction and working of the dead weight pressure gauge tester.
2. Identify the errors in the pressure gauge under calibration.
THEORY: 1) Pressure Sensors:
Pressure sensors like Bourdon tube, diaphragms and bellows works on principle of Hooke’s law i.e.
deflection is proportional to pressure applied. Bourdon tube is used for measurement of high
pressure while diaphragm and bellows are use for measurement of low and medium pressure
respectively.

Figure 4.1: Classification of Pressure Sensors

Subject: Measurement and Automation Subject code: MESBL601

Principles in Common Balance/lever and Pascal’s law for differentiating Dead weight/Pressure
plate and weight.
2) Construction of Bourdon tube:
Bourdon tube has elliptical cross section; it is bent into a C shape. At the bottom it is welded to a
socket through which pressure connection is made. The free end is sealed and is know as a tip. As
the fluid under pressure enters a bourdon, the tube unwinds non-linearly. This motion is suitable
guided and amplified to read pressure.

Figure 4.2: Construction & working of Bourdon tube sensor. Figure 4.3: Types of Bourdon tubes
available in four different shapes as Helix, Spiral, and Twisted and C shape.

4) Dead weight pressure gauge tester:

The dead weight tester consists of an arrangement by which a piston may be allowed to float
over a liquid (usually oil) under internal pressure and a force in the opposite direction imposed
on the piston by weights placed as indicated in the figure. The oil pressure is changed by the
pumping piston. The pressure is calculated as the weight placed on the piston divided by the
cross section area of the piston (the piston is to be oriented with its axis vertical). The gage
under test experiences the same pressure by being connected to a side tube communicating with
the oil. A dead weight tester is a precision device and is available from many manufacturers.
Subject: Measurement and Automation Subject code: MESBL601

Figure 4.4: Working Principle of Dead weight pressure gauge tester. Figure 4.5: Dead weight
pressure gauge tester.
PROCEDURE:
1. Keep the apparatus on leveled table. Confirm the leveling by using level bottle.
2. Fill up SAE 40 oil in oil cup. Open the needle valve of the cup side limb & close the
needle valve of pressure gauge side limb.
3. Rotate the handle anticlockwise so that maximum oil comes in the cylinder.
4. Close the needle valve of the cup side limb.
5. Load the initial weight on the plunger (0.5 kg). This weight also acts as a base for the
other weights.
6. Now load with the known weight.
7. Slowly rotate the handle clockwise till the weight gets lifted up by the plunger.
8. At the same instant note down the pressure gauge reading.
9. Repeat the reading by putting more weights till the limb of the pressure gauge.
10. Repeat the procedure for ascending and descending weights on table and corresponding
measurement on Bourdon pressure gauge.
11. Plot the graph of applied weights (X-axis) verses pressure on gauge (Y-axis).
12. After completion of the testing remove all the weights from the plunger.

OBSERVATIONS:

Sr. No. Applied weight (Kg/cm2) Pressure gauge reading (Kg/cm2) % Error

1
2
3
4

CONCLUSION:
Subject: Measurement and Automation Subject code: MESBL601

Experiment no: 6
Title: Identification of a given Sensor.
AIM
To study and identify sensors.
OBJECTIVES
To identify given sensors, its function and principle of operation.
REQUIREMENTS
Different types of proximity sensors contact and non-contact type
THEORY:
PNP - Transistor NPN – Transistor
NO (Normally Open) NC (Normally Closed)
VCC to GND VCC to Output

PNP Transistor:

The transistor in which one n-type material is doped with two p-type materials such type of
transistor is known as PNP transistor. It is a current controlled device. The small amount of base
current controlled both the emitter and collector current. The PNP transistor has two crystal diodes
connected back to back. The left side of the diode in known as the emitter-base diode and the right
side of the diode is known as the collector-base diode.

NPN Transistor:

The transistor in which one p-type material is placed between two n-type materials is known as
NPN transistor. The NPN transistor amplifies the weak signal enter into the base and produces
strong amplify signals at the collector end. In NPN transistor, the direction of movement of an
electron is from the emitter to collector region due to which the current constitutes in the transistor.
Subject: Measurement and Automation Subject code: MESBL601

Such type of transistor is mostly used in the circuit because their majority charge carriers are
electrons which have high mobility as compared to holes.

Observation table:

SN Sensor Image Sensor type Function

Inductive sensor Switch ON proximity

1.
switch of Metal objects

Switch ON proximity
Capacitive sensor
2 of both Metal & Non
switch
Metal objects

Switch ON proximity
3 IR sensor switch of any type of
obstacle as objects

Switch ON under
influence of
4 Reed Switch
Magnetism (FMCG
industry, eatables)

Switches ON when
Roller lever actuated externally
5
proximity switch via a roller through a
Lever.

CONCLUSION:
The life of electronic Non_Contact switches (Sensors) is more than the mechanical Contact
type of switches.
Subject: Measurement and Automation Subject code: MESBL601

Experiment no: 7
Title: Design of Electro_Pneumatic (EP) Circuit
AIM
To study control of a cylinder using Electric and Pneumatic Memory Valve (single and Double
solenoid valves resptively) using Latching and Dominant ON/OFF logics.
OBJECTIVES
To select appropriate symbols from the library and logically simulate the given sequence to
ensure no leak current in the circuit. Take a print and use to hard wire the circuit on a trainer.
REQUIREMENTS
Festo’s Simulation FluidSIM, hard wiring, EP components, hoses, compressor and electric
power to execute the designed circuit.

CIRCUIT SOLUTION:
Subject: Measurement and Automation Subject code: MESBL601

Experiment no: 8
Title: Design of Electro_Pneumatic (EP) Circuit
AIM
To study,identify, Select and execute a given EP sequence.

OBJECTIVES
To select appropriate symbols from the library and logically simulate the given sequence to
ensure no leak current in the circuit. Take a print and use to hard wire the circuit on a trainer.

REQUIREMENTS
Festo’s Simulation FluidSIM, hard wiring, EP components, hoses, compressor and electric
power to execute the designed circuit.

CIRCUIT SOLUTION:
a) Process/operation sequences 
Job clamping, operation commence and retract, and finally unclamp the job.
The general sequence is
A+ B+ B- A-
B+ A+ A- B-

i.e. the first cylinder commences the sequence and ends the sequence the other
middle cylinder extends does the operation and retracts.

Again, the selection and combination of DCV results in 4 four different circuit design as given

Seq A-cyl B-cyl

1 DS DS
2 DS SS
3 SS DS
4 SS SS

b) Material handling sequences 

Eject the job piece and retract then the other cylinder pushes the job on the required
position and retracts

The general sequence is

A+ A- B+ B-
B+ B- A+ A-
Subject: Measurement and Automation Subject code: MESBL601

i.e. the first cylinder commences the sequence and retracts before the end of sequence, the other
cylinder then extends does the operation and retracts and end the sequence.

Again, the selection and combination of DCV results in 4 four different circuit design as given

Seq A-cyl B-cyl

1 DS DS
2 DS SS
3 SS DS
4 SS SS

Thus total 8 variety of circuit design is possible due to selection of DCV for every cylinder and
these are generally used design in day to day application.
Subject: Measurement and Automation Subject code: MESBL601

Experiment no: 9
Title: Design PLC (Programmable Logical Controller) for a given Circuit.
AIM
To study,identify, Select and prepare a Allocaztion table to design a PLC Ladder logic.

OBJECTIVES
To select appropriate symbols from the library and logically simulate the given sequence to
ensure no leak current in the circuit. Upload the *.lld file in the PLC controller and commission
the programme to execute the circuit designed and hardwired from the Electro_Pneumatic
circuitry in the previous experiment.

REQUIREMENTS
Festo’s Simulation FluidSIM, Logo Soft Siemens PLC and software in a PC, RS232 cable, EP
components, hoses, compressor and electric power on the EP Trainer to execute the designed
PLC Ladder logics.

CIRCUIT SOLUTION:
Subject: Measurement and Automation Subject code: MESBL601

STEP B AND STEP C:

Subject: Measurement and Automation Subject code: MESBL601

STEP D: PLC LADDER LOGIC :