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STUD WELDING
It is one kind of resistance welding process. An electric arc is produced between stud and flat surface of the workpiece. The arc...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/stud-welding-working-advantages-and-applications/" aria-label="View Post: Stud Welding | Working , Advantages and Applications">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Stud Welding | Working , Advantages and Applications","url":"\/\/www.gunkrazy.com\/stud-welding-working-advantages-and-applications\/","articleBody":"Stud Welding | Working , Advantages and Applications\r\nSTUD WELDING\r\nIt is one kind of resistance welding process. An electric arc is produced between stud and flat surface of the workpiece. The arc melts the end of the stud and the pressure is applied on the stud to fix it on the work metal surface.\r\n\r\nstud welding Diagram\r\n\r\nA special welding gun is used for stud welding which consists of spring, solenoid, trigger, timer etc. The stud is placed in the welding gun. The front end of the gun is held against the work surface. When the trigger of the gun is pressed, welding current flows between end of the stud and work surface. An arc is produced between the gap of the stud and work. It melts the end of the stud. A molten pool is formed on the work surface. Now, the melted end of the stud is pressed on the molten pool of work and it gets welded to the work. The front end of the stud has a flux coated conical surface. The flux protects the welding from atmospheric effects. The ferrule is used to guide and locate the stud to the proper position. The process is automatic and it is used for welding metal studs on bodies without drilling and tapping. The time required for welding is approximately one second. This process is used in mass production.\r\nAdvantages of Stud Welding :\r\n1. The welded joint is stronger than the parent material or the stud.\r\n2. Deep weld penetration is possible.\r\n3. High speed welding of studs on thin steel sheets is possible.\r\n4. It limits down time.\r\n5. It cuts labour and material cost.\r\n6.It is user friendly and easy to operate.\r\n7.Machine is equipped with effective safety operations for user.\r\n8.It allows fast attachment.\r\n9.Sound welds are readily made with good process design and control.\r\n10. Practically, no edge preparation is necessary.\r\n11. The process is suitable for both indoor and outdoor works.\r\n12. It has very low distortion by extremely short welding time.\r\n13. Welds produced are sound, uniform, ductile, corrosion resistant and they have good impact value.\r\n14. The process involves less maintenance cost.\r\n15. Skill of the operator does not influence the quality of spot welds obtained by this process.\r\n16. The process is normally free from smoke and spatter.\r\n17. There are no holes. Hence, there is no leaking or weakening of the sheet.\r\nApplications of Stud Welding :\r\n1. Stud welding is used in fixing fluid, air lines, wiring looms, machine guards. handles, insulation and fireproofing materials.\r\n2. Stud welding is used for applications where access cannot be made to the reverse side of an assembly such as mounting circuit boards, rails, instruments, earth points and many different components.\r\n3. In the automotive industry, the process is used to assemble heat shields, power steering and dashboard components, instrument panels, insulation, exhaust systems, lighting systems, brake lines, trim and electrical wire routing.\r\n4. In the farm equipment industry, it is used to assemble fenders, brackets, cabs, spreaders, shrouding, thresher teeth, wiring and hose management parts. It is also used in lawn and garden equipment such as tractors, mowers and seeders.\r\n5. In the construction equipment industry, it is used to make cover plates, non-skid devices and wiring and hose management parts.\r\n6. In the commercial appliance industry, it is used in commercial dishwashers, bottle washers, cooking equipment and griddle plate assemblies.\r\n7. Furniture manufacturers use it for metal household and office furniture, lawn furniture, shelving and racks.\r\n8. Assemblers of fabricated metal products use arc stud welding in barbecue equipment, enclosures, plumbing apparatus, insulation enclosures, heating, ventilation and air-conditioning units, and water storage systems.","headline":"Stud Welding | Working , Advantages and Applications","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-10","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/stud-welding-Diagram-300x156.jpg","height":156,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/percussion-welding-advantages-and-disadvantages/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/percussion-welding-300x167.jpg')"></div><span class="sr-only">link to Percussion Welding | Advantages and Disadvantages</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/percussion-welding-advantages-and-disadvantages/">Percussion Welding | Advantages and Disadvantages</a></p></header><div class="excerpt"><p>Percussion Welding | Advantages and Disadvantages
It is one type of resistance butt-welding process. The parts to be welded are clamped in copper jaws of the welding machine in which one clamp is...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/percussion-welding-advantages-and-disadvantages/" aria-label="View Post: Percussion Welding | Advantages and Disadvantages">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Percussion Welding | Advantages and Disadvantages","url":"\/\/www.gunkrazy.com\/percussion-welding-advantages-and-disadvantages\/","articleBody":"Percussion Welding | Advantages and Disadvantages\r\nIt is one type of resistance butt-welding process. The parts to be welded are clamped in copper jaws of the welding machine in which one clamp is fixed and other one is movable. The movable clamp is backed up against the pressure from a heavy spring. The jaws act as\r\nelectrodes. Heavy electric current is connected to the workpieces. Now, the movable clamp is released rapidly and it moves forward at high velocity. When the two parts are approximately 1.6 mm apart, a sudden discharge of electrical energy is released thereby causing an intense arc between two surfaces. The arc is extinguished by the percussion blow of the two parts coming together with sufficient force to complete in 0.1 second. No upset or flash occurs at the weld. This method is primarily employed to join dissimilar metals. This method is limited to small areas of about 150 to 300 mm2.\r\n\r\nWelding energy, E = 1\/2 CV2\r\n\r\nwhere\r\nE = energy in watt-seconds (Joules)\r\nC = capacitance in farads\r\nV = voltage.\r\n\r\npercussion welding\r\n\r\nAmount of energy required to make joint depends on the following factors.\r\n(i) Cross-sectional area of joint\r\n(ii) Properties of work metal or metals\r\n(iii) Depth to which metal is melted on workpieces.\r\n\r\nAdvantages of Percussion Welding:\r\n\r\n1. The time cycle involved is very short.\r\n2. Shortness of arc limits melting and heating.\r\n3. Heat-treated and cold worked materials can be welded without annealing.\r\n4. No filler metal is required.\r\n5. No cast structure is produced at interface.\r\n6.Charging rate is low and controlled.\r\n7. It can tolerate some contamination on faying surface.\r\n8. Welding of dissimilar metal and copper to steel is possible.\r\n9. These welders have a long wear life for welding jaws due to very short relatively low current welding pulse.\r\n10. Welding of metals with high melting point such as tungsten, molybdenum etc. are possible by this method.\r\n\r\nLimitations of Percussion Welding:\r\n\r\n1. The welding process is limited to butt joints.\r\n2.Total area is limited.\r\n3. Similar metals can usually be joined more economically by other processes.\r\n4.The process is usually confined for joining of dissimilar metals not normally considered weldable.\r\n5. Welding is typically dirtier and less smooth than resistance welding.\r\n6. With nib start precussive arc welding, a starting nib must be cut onto workpieces.\r\n7. The workpieces must be free of oil or dirt.","headline":"Percussion Welding | Advantages and Disadvantages","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-10","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/percussion-welding-300x167.jpg","height":167,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/upset-butt-welding-diagram-advantages-and-application/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/upbutt-welding-300x261.jpg')"></div><span class="sr-only">link to Upset Butt Welding | Diagram , advantages and application</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/upset-butt-welding-diagram-advantages-and-application/">Upset Butt Welding | Diagram , advantages and application</a></p></header><div class="excerpt"><p>Upset Butt Welding | Diagram , advantages and Application
Upset Butt Welding
For making upset welding, edges of the workpiece should be cleaned perfectly and flatten. The parts to be welded are...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/upset-butt-welding-diagram-advantages-and-application/" aria-label="View Post: Upset Butt Welding | Diagram , advantages and application">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Upset Butt Welding | Diagram , advantages and application","url":"\/\/www.gunkrazy.com\/upset-butt-welding-diagram-advantages-and-application\/","articleBody":"Upset Butt Welding | Diagram , advantages and Application\r\nUpset Butt Welding\r\nFor making upset welding, edges of the workpiece should be cleaned perfectly and flatten. The parts to be welded are clamped in copper jaws as shown in Figure . The jaws act as electrodes. Both work pieces edges are prepared and butted together. There may be some gap between parts but it should be such that no arcing takes place. Then the jaws are brought together in a solid contact when the current flows through the point of contact of jaws to form a locality of high electric resistance. At this point, the applied pressure upsets or forges the parts together.\r\n\r\nupset butt welding\r\n\r\nUpset welding (UW)\/resistance butt welding is a welding technique that produces coalescence simultaneously over the entire area of abutting surfaces or progressively along a joint, by the heat obtained from resistance to electric current through the area where those surfaces are in contact. Pressure is applied before heating is started and is maintained throughout the heating period. The equipment used for upset welding is very similar to that used for flash welding. It can be used only if the parts to be welded are equal in cross-sectional area. The abutting surfaces must be very carefully prepared to provide for proper heating. The difference from flash welding is that the parts are clamped in the welding machine and force is applied bringing them tightly together. High-amperage current is then passed through the joint, which heats the abutting surfaces. When they have been heated to a suitable forging temperature an upsetting force is applied and the current is stopped. The high temperature of the work at the abutting surfaces plus the high pressure causes coalescence to take place. After cooling, the force is released and the weld is completed.\r\n\r\nAdvantages of Upset Butt Welding :\r\n1. Upset butt-welding is more suitable for welding many alloys which are difficult to weld using fusion welding. The metal retains base metal characteristics because the base metal does not melt during welding.\r\n3. The welded joint is stronger because the hot working structure is maintained.\r\n4. The introduction of composite materials and inclusion of secondary materials on the base metal are almost minimal.\r\n5. Upset welding is mainly adapted to fabricate very large structures compared to conventional resistance welding.\r\n\r\nApplications of Upset butt Welding :\r\n\r\n1. This process is mainly used for welding nonferrous materials of smaller cross section such as bars, rods, wires, tubes etc.\r\n2. Upset welding is used to make closure of capsules, small vessels and containers,\r\n3, It is applied in welding steel-rails.","headline":"Upset Butt Welding | Diagram , advantages and application","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-10","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/upbutt-welding-300x261.jpg","height":261,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/resistance-welding-advantages-disadvantages-and-application/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/Resistance-Spot-Welding-300x200.jpg')"></div><span class="sr-only">link to Resistance Welding | Advantages , Disadvantages and Application</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/resistance-welding-advantages-disadvantages-and-application/">Resistance Welding | Advantages , Disadvantages and Application</a></p></header><div class="excerpt"><p>Advantages, Limitations and Applications of Resistance Welding
Features of Resistance Welding
(i) No flux such as solder is necessary. So, welded parts can be easily recycled.
(ii) Easy operation...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/resistance-welding-advantages-disadvantages-and-application/" aria-label="View Post: Resistance Welding | Advantages , Disadvantages and Application">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Resistance Welding | Advantages , Disadvantages and Application","url":"\/\/www.gunkrazy.com\/resistance-welding-advantages-disadvantages-and-application\/","articleBody":"Advantages, Limitations and Applications of Resistance Welding\r\nFeatures of Resistance Welding\r\n(i) No flux such as solder is necessary. So, welded parts can be easily recycled.\r\n(ii) Easy operation as only pressing buttons facilitates process automation and it does not require trained skills unlike arc welding and gas welding.\r\n(iii) As this welding is performed efficiently in a short period of time, it is suited high-volume production of low-cost products.\r\n(iv) Since welding is done in short time duration, it gives less heat-affected area on workpieces by resulting a beautiful appearance with less indentation.\r\n(v) Electric facility is required in some cases due to use of large current. Optimum welding parameters must be figured out before actual welding since those parameters depend on material and thickness of parts to be welded. Welding condition setting must be prepared.\r\n\r\nRead More :\u00a0Principle of resistance welding | LearnMech\r\n\r\napplication of resistance spot welding\r\nAdvantages Of Resistance Welding :\r\n1. Less skill is required to operate the resistance welding machine.\r\n2.This type of welding is well suited for mass production as it gives a high production rate.\r\n3.There is no need of using consumables such as brazing materials, solder or welding rods in this process except for the electrical power and a relatively smaller electrode wear.\r\n4.Heating the workpiece is confined to a very small part which results less distortion.\r\n5. It is possible to weld dissimilar metals as well as metal plates of different thickness.\r\n6. It has a short process time.\r\n7. It offers more safety to operator because of low voltage.\r\n8. It produces clean and environmentally friendly weld.\r\n9. A reliable electro-mechanical joint is formed.\r\n10. The heat is localized, action is rapid and no filler metal is required.\r\n11. The operation can be easily mechanized and automated due to the need of less skill.\r\n12. Both reliability and reproducibility can be obtained with high degree.\r\n13. The welding process is more economical.\r\nLimitations of resistance Welding :\u00a0\r\n1. The resistance welding machine is highly complex with various elements such as a heavy transformer, electrodes and heavy conductors for carrying the high currents, electrode force applying mechanism such as a pneumatic cylinder and its supply, heavy machine structure to support the large forces and an expensive timing arrangement.\r\n2. Certain resistance welding processes are limited only to lap joints.\r\n3. Spot welds have low tensile and fatigue strength.\r\n4. Equipment is not portable as it is heavy.\r\n5. The cost of equipment is high.\r\nApplications Of Resistance Welding :\r\n1. Resistance welding is used in mass production for welding sheet metal, wire and tubes.\r\n2. It is used in welding bars, boxes, cans, rods, pipes and frames metals of medium and high resistance materials such as steel, stainless steel, monei metal and silicon bronze which are easy to weld.\r\n3. It is used in welding aircraft and automobile parts\r\n4. It is used for making cutting tools.\r\n5. It is used for making fuel tanks of cars, tractors etc.\r\n6. It is used for making wire fabrics, grids, grills, mesh weld, containers etc.","headline":"Resistance Welding | Advantages , Disadvantages and Application","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-10","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/Resistance-Spot-Welding-300x200.jpg","height":200,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/principle-of-resistance-welding-learnmech/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/principle-of-resistance-welding-300x208.jpg')"></div><span class="sr-only">link to Principle of resistance welding | LearnMech</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/principle-of-resistance-welding-learnmech/">Principle of resistance welding | LearnMech</a></p></header><div class="excerpt"><p>Principle of resistance welding | LearnMech
FUNDAMENTALS OF RESISTANCE WELDING
In ancient times, metal welding was done in the form of forge welding (metals heated up to melting point are pressed...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/principle-of-resistance-welding-learnmech/" aria-label="View Post: Principle of resistance welding | LearnMech">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Principle of resistance welding | LearnMech","url":"\/\/www.gunkrazy.com\/principle-of-resistance-welding-learnmech\/","articleBody":"Principle of resistance welding | LearnMech\r\nFUNDAMENTALS OF RESISTANCE WELDING\r\nIn ancient times, metal welding was done in the form of forge welding (metals heated up to melting point are pressed together) and brazing (weld using alloy of low melting point). Resistance welding processes are pressure welding processes in which heavy current is passed for short time through the area of interface of metals to be joined with the application of pressure. In other way, it may be defined as \u201cResistance welding is a thermo-electric process in which heat is generated at the interface of the parts to be joined by passing an electrical current through the parts for a precisely controlled time and under a pressure\u201d.\r\n\r\n The various types of resistance welding are as follows:\r\n(a) Spot welding -\r\n(b) Seam welding\r\n(c) Projection welding\r\n(d) Resistance Butt welding\r\n(e) Flash Butt welding .\r\n(f) Percussion welding.\r\n\r\nRead more :\u00a0Types of Resistance Welding | LearnMech\r\nPrinciple of Resistance Welding\r\nThe name \u201cresistance\" welding derives from the fact that the resistance of the workpieces and electrodes are used in combination or contrast to generate the heat at their interface. Heat is generated by the passage of electrical current through a resistance circuit. Heat is generated in localized area which is enough to heat the metal to sufficient temperature so that the parts can be joined with the application of pressure. The force applied before, during and after the current flow forces the heated parts together so that coalescence will occur. Pressure is required throughout the entire welding cycle to assure a continuous electrical circuit through the work. Pressure is applied through electrodes. The pressure is applied by mechanical, hydraulic or pneumatic systems.\r\n\r\nIn resistance welding, the parts to be joined are heated to plastic state by their resistance to the flow of electric current and mechanical pressure is applied to complete the weld. In this process, there are two copper electrodes in a circuit of low resistance as shown in Figure 2.1. When the current is passed through electrodes, the electrical resistance at the metal joints becomes very high. So, the metals are brought to red-hot plastic condition. Now, the mechanical pressure is applied to complete the weld. The heat developed by the current is proportional to the electric resistance of the weld.\r\n\r\n principle of resistance welding\r\n\r\nAC with suitable transformer is used for the power supply. Usually, 4 V to 12 V is used dependent on the composition, area and thickness of the metal to be welded. The power supply ranges from 6 to 18 kw per cm3 area used.\r\n\r\nResistance welding processes differ from other welding processes in the aspect that no fluxes are used and filler metal rarely used. All resistance welding operations are automatic. Therefore, all process variables are preset and maintained constant. Resistance welding equipment utilizes programmers for controlling current, time cycles, pressure and movement. Welding programs for resistance welding can become quite complex. In view of this, quality welds do not depend on welding operator skill but more on the proper set up and adjustment of the equipment and adherence to weld schedules. Three major factors involved in weld quality are as follows:\r\n\r\n \tThe amount of current that passes through the work\r\n \tThe pressure that the electrodes transfer to the work\r\n \tThe time the current flows through the work.\r\n\r\nThe important characteristics of the resistance welding process is the transfer of heat to two parts being welded for obtaining a proper fusion even if the plates are dissimilar from the stand point of material or thickness.\r\n\r\nIf the proper heat balance is existed only, the proper fusion can be obtained by providing an electrode with a smaller contact area at the thinner sheet and a thicker electrode at the thicker sheet together with very high current densities for short times. If two dissimilar metals with different electrical conductivities or thermal conductivities are to be joined,\r\n\r\n1. Large contact area electrode should be used for the one which has higher electrical conductivity, and\r\n2. Small contact area electrode should be used for the one which has higher thermal conductivity.","headline":"Principle of resistance welding | LearnMech","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-10","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/principle-of-resistance-welding-300x208.jpg","height":208,"width":300},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <article class="article-card horizontal "> <a href="//www.gunkrazy.com/programmable-logic-controller-basic-interview-question-answers/" rel="nofollow"><div class="image-container" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2019/04/PLC-SYSTEM.png')"></div><span class="sr-only">link to Programmable logic controller Basic | Interview Question &#038; answers</span></a><div class="copy-container"><header><p><a style="color: #ff392e!important" href="//www.gunkrazy.com/programmable-logic-controller-basic-interview-question-answers/">Programmable logic controller Basic | Interview Question &#038; answers</a></p></header><div class="excerpt"><p>Programmable logic controller Basic | Interview Question &amp; answers
PLC interview , oral , viva examination questions For Mechanical and Electrical Engineering Students .  1.Define a...</p><div class="button-container"><a rel="nofollow" class="button reverse" href="//www.gunkrazy.com/programmable-logic-controller-basic-interview-question-answers/" aria-label="View Post: Programmable logic controller Basic | Interview Question &#038; answers">View Post</a></div></div></div></article> <script type="application/ld+json">{"@context":"http:\/\/schema.org\/","@type":"BlogPosting","name":"Programmable logic controller Basic | Interview Question &#038; answers","url":"\/\/www.gunkrazy.com\/programmable-logic-controller-basic-interview-question-answers\/","articleBody":"Programmable logic controller Basic | Interview Question &amp; answers\r\nPLC interview , oral , viva examination questions For Mechanical and Electrical Engineering Students .\r\n\r\n1.Define a programmable logic controller.\r\n\r\nA Programmable Logic Controller (PLC) is a microprocessor based controller that uses a programmable memory to store instructions and to implement functions such as logic, sequencing, timing, counting and arithmetic in order to control machines and process\r\n\r\n2. What are the main components parts of a PLC?\r\n\r\n1. Central Processing Unit (CPU)\r\n2.The input\/output unit\r\n3.The programming device\r\n4. Memory Unit\r\n\r\nPLC SYSTEM\r\n\r\n3. What is the function of programming device?\r\n\r\nThe programming device is used to enter the required program using ladder logic into the memory of the processor. The sequence of operation and ultimate control of equipment or machinery is specified and determined by ladder programme.\r\n\r\n4. List various types of PLC programming devices.\r\n\r\n1. Use of hand held programmer\r\n2.Terminal with video display unit\r\n3. A personal computer with appropriate software\r\n\r\n5. What is ALU? State is function.\r\n\r\nThe ALU is responsible for data manipulation and performs arithmetic and logical operations such as addition and subtraction. In addition, the ALU contains number of control inputs, which specify the data manipulation function to be performed. ALU is combinational logic circuit, whose output is an instantaneous function of its data and control inputs.\r\n\r\n6. What are counters?\r\n\r\nCounters allow a number of occurrences of input signals to count or record the number of times some event occurs. PLCs include some form of counting element and are set to some preset number value. When this value of input pulse has been received, it will operate its contact, the normally open contacts would be closed and a normally closed contact would be opened.\r\n\r\n7. \u00a0Write down various types of counters.\r\n\r\n1. Down counters\r\n2. Up-counters\r\n\r\n8.\u00a0List down PLC programming methods.\r\n\r\n1. Structured text\r\n2. Ladder diagrams\r\n3. Function block diagram\r\n4. Sequential function charts\r\n5. Instruction list\r\n\r\n9. List down the different types of Timers.\r\n\r\n1. On delay timer\r\n2. Off delay timer\r\n3. Retentive timer\r\n4. Pulse delay timer\r\n\r\n10. What are the types of bus?\r\n\r\n(a) Address bus\r\n(b) Databus\r\n(c) Control bus\r\n\r\n11. What is ladder programming?\r\n\r\nA ladder programming involves each program task being specified as though a Rung of ladder. Thus such a rung could specify that the state of switches A and B, the inputs, be examined and if A and B are both closed then a solenoid, the output is energized.\r\n\r\n12. Write about the relay?\r\n\r\nWith the relay type, the signal from the PLC output is used to operate a relay and so is able to switch currents of the order of a few amperes in an external, circuit. The relay isolates the PLC from the external circuit and can be used for both D.C. and A.C. switching. Relays are, however, relatively slow to operate.\r\n\r\n13. What is continuous updating?\r\n\r\nThis involves the CPU scanning the input channels as they occur in the program instructions. Each input point is examined individually and its effect on the program is determined. Each input is scanned with a 3 ms delay, before the program has the instruction for a logic operation to be executed and an output to occur. This process is called continuous updating.\r\n\r\n14. Write about the mass input\/output copying?\r\n\r\nTo allow a more rapid execution of a program, a specific area of RAM is used as buffer store between the control logic and the input\/output unit. At the start of each program cycle the CPU scans all the inputs and copies their status into the input\/output address in RAM. At the end of each program cycle all the outputs are transferred from RAM to the output channels. The outputs are latched so that they retain their status until the next updating.\r\n\r\n15. Write about timer circuit.\r\n\r\nA timer circuit is specified by stating the interval to be times and the conditions or events that are to start and\/or stop the timer. They are commonly regarded as delays with coils which, when energized, result in the closing or opening of input contacts after some preset time.\r\n\r\n16. What are the inputs of shift register?\r\n\r\nThere are three inputs of shift register. They are,\r\n(a) One to load data into the first element of the register (OUT)\r\n(b) One as the shift command (SFT)\r\n(c) One for resetting (RST)\r\n\r\n17. What is the criteria need for the selection of a PLC?\r\n\r\nThe criteria needed for the selection of a PLC are the following,\r\n(a) Input\/ Output capacity is required\r\n(b) Types of inputs\/outputs are required\r\n(c) Size of memory required\r\n(d) Speed and power is required for the CPU\r\n\r\n18. What are the axes of a pick and place robot?\r\n\r\nThe robot has three axes about which motion can occur.\r\n(a) Rotation in a clockwise or counter clockwise direction of the unit on its base.\r\n(b) Arm extension or contraction and arm up or down\r\n(c) Gripper can open or close.\r\n\r\n19. Define Adaptive control.\r\n\r\nThe control system which can adapt changes and it can change its parameters depending on the situation. It is known as adaptive control system.\r\n\r\n20. State the purpose of Jump controls\r\n\r\nBy causing Jump instruction, the processor scan time is reduced by Jumping over instruction not pertinent to the machine operation. It is achieved by missing intermediate program and can skip instructions when a production fault occurs.\r\n\r\n21 \u00a0How will you process the input and output of PLC?\r\n\r\nFrom the input\/output module, the information about in and out of PLC is obtained. The input module terminals receive signals from wires connected to input sensors and transducers. The output module terminals provide output voltages to energize actuators and indicating device.","headline":"Programmable logic controller Basic | Interview Question &#038; answers","author":{"@type":"Person","name":"Sachin Thorat","url":"\/\/www.gunkrazy.com\/"},"datePublished":"2019-04-10","mainEntityOfPage":"False","dateModified":"February 20, 2020","image":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2019\/04\/PLC-SYSTEM.png","height":184,"width":273},"publisher":{"@context":"http:\/\/schema.org\/","@type":"Organization","name":"Learn Mechanical Engineering","logo":{"@type":"ImageObject","url":"\/\/www.gunkrazy.com\/wp-content\/uploads\/2020\/01\/learn-mech-logo-1-300x300.png","height":600,"width":60}}}</script> <nav class="pagination-wrapper" aria-label="article pagination"> <a class="prev page-numbers" href="?page_num=73">&laquo; PREV</a> <a class="page-numbers" href="?page_num=1"><span class="screen-reader-text">Page </span>1</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=72"><span class="screen-reader-text">Page </span>72</a> <a class="page-numbers" href="?page_num=73"><span class="screen-reader-text">Page </span>73</a> <span aria-current="page" class="page-numbers current"><span class="screen-reader-text">Page </span>74</span> <a class="page-numbers" href="?page_num=75"><span class="screen-reader-text">Page </span>75</a> <a class="page-numbers" href="?page_num=76"><span class="screen-reader-text">Page </span>76</a> <span class="page-numbers dots">&hellip;</span> <a class="page-numbers" href="?page_num=338"><span class="screen-reader-text">Page </span>338</a> <a class="next page-numbers" href="?page_num=75">NEXT &raquo;</a></nav></section></main><aside id="secondary" class="widget-area"><div class="about-wrapper"><h2 class="widget-title" style="background: #d693c6; color: #ff392e">About Us</h2><div class="about-image" style="background-image: url('//www.gunkrazy.com/wp-content/uploads/2020/03/Sachin-Thorat-300x300-min.png')"></div><p class="about-copy">LearnMech.Com is a Mechanical Project-oriented platform run by Sachin Thorat who is a B-Tech Graduate in Mechanical Engineering. 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