Question 1

(a) Explain how a quick-exhaust valve operates and illustrate your answer with a sample circuit.
[4]

(b) With respect to specification of electrical switches explain what is meant by the number of
throws and the number of poles. Illustrate you answer with drawings of a double-pole
double-throw switch and a two-pole four-throw switch. [4]

(c) What is meant by relay latching? Illustrate your answer by showing a dominant set and reset
circuits. [4]

(d) Describe how three common types of proximity sensor work and illustrate the use of each in
a circuit where they are used to indirectly actuate a light via a relay. Include arc suppression
for each relay coil in your design. [8]

PTO Page 2 of 5
Question 2

(a) With respect to compressor design what is meant by free air delivery (FAD). [2]

(b) An air compressor running at 1000 rpm has a swept volume of 0.6 litre and a FAD of 500
litres/minute. If the compressor delivers air at 7 bar gauge pressure find the following:
(i) Volumetric efficiency. [3]
(ii) Air output per minute at ambient temperature. [3]

(c) What are the criteria by which compressed air quality is classified. [2]

(d) In a packaging operation for biomedical devices a hot-pressing die seals a thermoplastic
material by application of heat and pressure as depicted in Figure 2d. Upon pressing a
pushbutton switch, (S1) a double-acting cylinder advances the heating rail and the
packaging material is heated and compressed under the rail. Piston end-positions are
detected using reed switches B1 and B2. After the required adhesion pressure has been
reached and detected by a pressure switch B3, the heating rail is returned to its start
position. An indicating light is incorporated in the circuit and shows when the die is about
to retract having reached the desired end-location and pressure.
Based on the above you are required to design the hot-pressing station’s control system.
Your design should show the pneumatic the pneumatic circuit schematic and the electric
circuit drawing. A list of all the major components required should be provided.
[10]

Figure 2d

PTO Page 3 of 5
Question 3

(a) Design an electro-hydraulic mechanism suitable for use in an injection moulding machine as
follows: The device uses one hydraulic cylinder (cylinder A) to close the mould and hold it
shut and another cylinder (cylinder B) to move the screw forward in the barrel and inject
plastic into the mould. Mould opening and closing operations are activated manually by
operating electric switches which in turn activate solenoid valves. (SW1 – closes mould,
SW2 – opens mould). Pressure is supplied by a gear pump driven by an electric motor. The
mould may only be closed if the guard-door at the front of the machine has been closed by
the operator and this has been detected by roller-limit switch SW5 before the operator
presses SW1.

An indicator light should indicate when the required clamping pressure and mould closed
positions have been sensed by pressure switch SW4. At this point cylinder B should be
automatically actuated and molten plastic injected into the mould. When SW2 is pressed
both cylinder A and cylinder B should retract fully.

(i) Sketch the mechanical design and show both hydraulic and electrical circuits. [8]
(ii) Indicate what each component in the circuit is and how it performs. [4]

(b) For the hydraulic circuit shown in Figure Q3b below:

(i) Describe what each component is. [3]
(ii) Describe in detail how the circuit operates [3]
(iii) What possible uses a circuit of this type might have. [2]

Figure Q3b
PTO Page 4 of 5
Question 4

(a) Describe, using explanatory schematics where necessary, how accumulators are used to
damp shock and vibration loading due to flow and pressure fluctuations. [10]

(b) For the hydraulic circuit shown in Figure Q4b indicate what each element is and explain
clearly how the entire circuit works. [10]

Figure Q4b

Question 5

(a) Design a simple ladder logic circuit to control three outputs - a light and two solenoids. Each
output is independently controlled by two dedicated switches which must be simultaneously
actuated to activate the output. All three outputs may be cut off by a single non-specific
emergency stop or override. Show the equivalent conventional electric circuit and the PLC
wiring and mnemonic program code. [10]

(b) Design a circuit using two timers to create a programmed pulse train. The output should be
only on for fifteen seconds of every minute. Show the circuit in ladder logic form and
provide also the mnemonic program code. Explain clearly how your circuit functions.
[10]

Page 5 of 5
Question 1

Answer the following using circuit diagrams, schematics and sketches to illustrate where appropriate:

(a) Explain how solenoid valves and relays may be used as memory elements in electro-pneumatic
circuits. [5]

(b) What types of electrical load is arcing associated with and how may it be suppressed in an
electrical circuit? [5]

(c) Explain how valves are depicted in electro-pneumatic circuits and show clearly the numbering
system used in identifying individual ports and contacts. [5]

(d) List the main issues to be considered when installing a compressed air system. [5]

Question 2

(a) Design a dominant-reset electro-pneumatic memory circuit controlling a single-solenoid 5/2

way valve. Activating the circuit causes a double-acting cylinder to extend and remain in that
position until the reset switch is pressed. Show both pneumatic and electrical circuits, which can
be used to control this operation. [8]

(b) Revise the circuit such that it becomes a dominant-set memory circuit controlling two 5/2 way
single solenoid valves controlling two double acting cylinders. The speed of forward and return
motion of both pistons should be adjustable. Use only one relay. [12]

Page 2 of 5
Question 3

Design an electro-pneumatic circuit with the following specifications to automatically control a

punching machine.
This machine uses a pneumatic cylinder to raise and lower the tool head.
As the work-piece may be fed into the punch in a number of orientations three non-contact
sensors are used to automatically detect the work-piece’s presence and orientation.
Two of these sensors are capacitive proximity switches and the third is an optical sensor.
The punching operation is only triggered, causing the piston to extend, if either one of the
capacitive sensors and the optical sensor simultaneously detect the workpiece. Any other
configuration of sensor inputs does not activate the punching operation.

The control system returns the cylinder to its retracted position when the following two conditions are
simultaneously met: (i) the piston has extended to its end position and made contact with a roller limit
switch, (ii) cylinder supply pressure has reached a required level as detected by a pneumatic-electric
converter or pressure sensor.

The circuit should incorporate a 5/2 way double solenoid valve and a double acting cylinder.
Each of the four sensors should individually actuate relays whose contacts control the output or
power side of the electrical circuit.
Clearly label each component in your circuit. [20]

Question 4

(a) Design a hydraulic circuit to supply oil to a pressure-fed bearing. Clearly label each component
in your circuit drawings. Briefly describe how the circuit functions. [6]

(b) Modify your design in part (a) and redraw to include an accumulator such that emergency
operation of the bearing is possible in the event of loss of power to the pump electrical motor.
[6]

(c) Design a simple electro-hydraulic clamping device with the following specification suitable for
clamping an injection mould shut.
The device uses only one hydraulic cylinder.
Clamp opening and closing operations are activated by operating electric switches which in turn
activate solenoid valves.
Pressure is supplied by a gear pump driven by an electric motor.

Show both hydraulic and electrical circuits, indicating what each component is and how it
performs. [8]

Page 3 of 5
Question 5

(a) Draw a ladder diagram for a latching circuit where an output latches itself on and write the
equivalent mnemonic code program. [3]

(b) Identify the ladder circuit, mnemonic code and structured text PLC programs shown below, (i),
(ii) and (iii), and describe their function. [5]

(c) Revise all three programs shown below, (i), (ii) and (iii) so that an additional input X2 may also
activate the circuit. [6]

(d) Modify all three programs shown below, (i), (ii) and (iii), so that X1 and an additional input X2
are required to operate simultaneously in order to activate the circuits. [6]

(i)

(ii)

Page 4 of 5
(iii)
PROGRAM_CYCLIC question5 
  VAR 
    Flasher_1 :TON;     //TON number 1 
    Flasher_2 :TON;     //TON number 2 
    Start : BOOL;      //Start flag 
  END_VAR 
 
  INPUT_VAR 
    X1 AT %A1.1 : BOOL;    //X1 input at address A1.1 
  END_INPUT_VAR 
 
  OUTPUT_VAR 
    LED_out AT %Q1.1 : BOOL;  //LED output at address Q1.1 
  END_OUTPUT_VAR 
 
  Start = X1; 
 
  Flasher_1 (IN := Start , PT := T#2s ); 
 
  IF (Flasher_1.Q = TRUE) THEN 
    LED_out = TRUE; 
  END_IF 
 
  Flasher_2 (IN := Flasher_1.Q , PT := T#2s); 
 
  IF (Flasher_2.Q = TRUE) THEN 
    LED_out = FALSE; 
  END_IF 
   
  Start = FALSE; 
END_PROGRAM 

Page 5 of 5
Question 1

(a) Describe the principle non-contact sensors used in conventional electro-pneumatic circuit
design and explain how they function, using symbols, schematics and sketches where
necessary. [4]

(b) Describe clearly how compressed air is classified. [4]

(c) Explain the importance of removing atmospheric moisture from compressed air and indicate
how the following systems achieve this: aftercooling; refrigeration drying; adsorption
drying. [4]

(d) Explain how a quick-exhaust valve operates, when it is used and illustrate your answer with
a sample circuit. [4]

(e) What is meant by “latching” with respect to control circuit design? Illustrate your answer by
showing electrical and PLC ladder logic circuits for dominant set and rest. [4]

Question 2

In a semi-manual unloading system, packages can arrive to a central distribution area on any one of
four input conveyors.
If product is detected on any one of the input conveyors by any of the four capacitive proximity
switches positioned above them, an indicator light is activated to alert the operator.
An unloading or output section of conveyor may be aligned with one of these individual input
conveyors at a time to access the product.
In order to achieve this, the operator actuates the relevant switch to align the unloading section of
the conveyor with the input section.
The operating panel thus has four indicator lights and four electrical switches, one for each position.

The switching section actuator uses two double-acting cylinders in series, one twice the length of
the other, to effect conveyor selection. The speed at which both pistons extend and retract must be
controllable. The switching section should remain in the last selected position until a new track is
selected.

Design an electro-pneumatic system, showing both pneumatic and electrical circuits, which can be
used to control this handling system. The system should incorporate the detection sensors and relays
as well as the circuit controlling the two positioning cylinders. [20]

P.T.O. Page 2 of 4
Question 3

Design an electro-pneumatic circuit to control a double-acting cylinder via a 5/2 way single-
solenoid valve. The on switch is of detent type and when actuated, the piston will repeatedly extend
and retract until the switch is released. The length of forward stroke and the speed of forward and
return motion should be adjustable via roller-limit switches and flow control valves respectively.

(a) Show pneumatic and electrical circuits for indirect control of the system described above,
i.e. each switch in the circuit indirectly controls the output components via a dedicated
relay. [15]

(c) Redesign your circuit incorporating non-contact sensing for piston position detection using
three-wire capacitive sensors.             [5]
 

Question 4

(a) Design a simple electro-hydraulic press circuit. The design should use a hydraulic cylinder
which is activated by operating a manually controlled valve. It must be possible to stop the
piston at any point of travel in either extension or retraction. Pressure is supplied by a gear
pump driven by an electric motor. Show the hydraulic circuit schematic. Indicate what each
component in the circuit is and how it performs. [8]

(b) Modify your electro-hydraulic press schematic to incorporate an accumulator in the circuit
so that the piston retracts fully and immediately in the event of loss of electrical power.
What are the benefits associated with this enhancement and how does the design function in
the event of gear pump failure? [4]

(c) Draw a schematic showing how a closed loop hydraulic circuit is laid out. The circuit should
comprise of a pump and motor capable of bidirectional rotation. The circuit should capture
and replace leakage oil. [8]

P.T.O. Page 3 of 4
Question 5

(a) What are marker relays or ghost contacts? Demonstrate how they are used in PLC control
circuits. [2]

(b) Show how NAND, NOR and Exclusive-OR gates are represented in ladder logic. [4]

(c) Draw a simple ladder logic circuit to control three outputs, a motor and two solenoids. Each
output is controlled by two switches that must be simultaneously activated for there to be a
response. All three outputs may be cut off by an emergency stop or override. [4]

(d) A PLC is used to reject incompletely packed components as they are transported on a
conveyor under a capacitive sensor. Well packed components pass underneath the sensor
and are not detected. Protruding components activate the sensor as they pass underneath it.
When a badly packed component is detected a pneumatic cylinder is activated which pushes
the component off the conveyor and into a reject box. All rejected components are to be
counted and the current reject count is to be displayed on an external display unit.

Design the PLC electrical schematic showing the input and output connections to the PLC
for the reject system described above. Show the ladder logic circuit and associated
mnemonic logic instructions that control the reject system and describe clearly how your
design works. [10]

Page 4 of 4
Question 1

(a) Explain how a quick-exhaust valve operates and illustrate your answer with a sample circuit.
[4]

(b) With respect to specification of electrical switches explain what is meant by the number of
throws and the number of poles. Illustrate your answer with drawings of a double pole
double throw switch and a two pole four throw switch. [4]

(c) What is meant by relay latching? Illustrate your answer by showing dominant set and reset
circuits. [4]

(d) Describe how three common types of proximity sensor work and illustrate the use of each in
a circuit where they are used to indirectly actuate a light via a relay. Include arc suppression
for each relay coil in your design. [8]

P.T.O. Page 2 of 6
Question 2

(a) With respect to compressor design what is meant by FAD or free air delivery. [2]

(b) An air compressor running at 1000 rpm has a swept volume of 0.6 litre and a FAD of 500
litres/minute. If the compressor delivers air at 7 bar gauge pressure find the following:
(i) Volumetric efficiency. [3]
(ii) Air output per minute at ambient temperature. [3]

(c) What are the criteria by which compressed air quality is classified? [2]

(d) In a packaging operation for biomedical devices a hot-pressing die seals a thermoplastic
material by application of heat and pressure as depicted in Figure 2d. Upon pressing
pushbutton switch, (S1) a double-acting cylinder advances the heating rail and the
packaging material is heated and compressed under the rail. Piston end-positions are
detected using reed switches B1 and B2. After the required adhesion pressure has been
reached and detected by pressure switch B3, the heating rail is returned to its start position.
An indicating light is incorporated in the circuit and shows when the die is about to retract
having reached the desired end-location and pressure. Based on the above you are required
to design the hot-pressing station’s control system. Your design should show the pneumatic
circuit schematic and the electric circuit drawing. A list of the major components required
should be provided. [10]

Figure 2d

P.T.O. Page 3 of 6
Question 3

(a) Design an electro-hydraulic clamping mechanism suitable for use in an injection moulding
machine. The device uses one hydraulic cylinder (cylinder A) to close the mould and
another cylinder (cylinder B) to move the screw forward in the barrel and inject plastic into
the mould. Clamp opening and closing operations are activated manually by operating
electric switches which in turn activate solenoid valves. (SW1 – closes mould, SW2 – opens
mould). Pressure is supplied by a gear pump driven by an electric motor. The mould may
only be closed if the guard-door at the front of the machine has been closed by the operator
and this has been detected by roller-limit switch SW5 before the operator presses SW1.

An indicator light should indicate when the required clamping pressure and mould closed
positions have been sensed by pressure switch SW4. At this point cylinder B should be
automatically actuated and molten plastic injected into the mould. When SW2 is pressed
both cylinder A and cylinder B should retract fully.

(i) Sketch the mechanical design and show both hydraulic and electrical circuits. [8]
(ii) Indicate what each component in the circuit is and how it performs. [4]

(b) For the hydraulic circuit shown in Figure 3b below:

(i) Describe what each component is. [3]
(ii) Describe in detail how the circuit operates [3]
(iii) Describe the possible uses a circuit of this type might have. [2]

Figure 3b

P.T.O. Page 4 of 6
Question 4

(a) Describe, using explanatory schematics where necessary, how accumulators are used to
damp shock and vibration loading due to flow and pressure fluctuations. [10]

(b) For the hydraulic circuit shown in Figure 4b indicate what each element is and explain
clearly how the circuit works. [10]

Figure 4b

P.T.O. Page 5 of 6
Question 5

(a) Draw a ladder diagram for a latch circuit and write its equivalent ladder code program.
Explain clearly how it operates. [4]

(b) Draw a delay-on timer circuit and write its equivalent ladder code program. Draw the
circuit’s timing diagram and explain clearly how the circuit operates. [8]

(c) Identify the circuits shown below and clearly describe how they work. [8]

Figure 5c1

Figure 5c2

Figure 5c3

Page 6 of 6