HANPLAST

DIRE DAWA UNIVERSITY
DIRE DAWA INSTITUTE OF TECHNOLOGY
SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING
Focus Area: Industrial control Engineering
HOSTING COMPANY: HAN*PLAST MANUFACTURING PLC
NAME OF INTERNS ID. NO.
1 BEMNET ASRES R/5009/09

2 BRUKTAWIT G/MESKEL R/1333/09
3 ERMIAS DEMEKE R/1195/09
4 FUAD MURAD R/1776/09
5 MINALE GASHAW R/1780/09
MENTER: Mr. HAMZA A.
JULY 2021
DIREDAWA ETHIOPIA
DDIT AUGEUST 2021
DECLARATION
We want to assured that this report belongs to us. We have done a project during the internship
program and is included as part of this report. We were fully engaged to write this report.
Except we have taken from reference materials all the descriptions, recommendations are our
own. Finally, we are intended to tell you this document is a good indicator of how much effort
we made to go steps forward in the practical world by integrating it with the theoretical
knowledge.
NAME OF MENTER SIGNATURE DATE
Mr. HAMZA A. __________ __________
NAME OF INTERNS SIGNATURE DATE
1 BEMNET ASRES __________ __________
2 BRUKTAWIT G/MESKEL __________ __________
3 ERMIAS DEMEKE __________ __________
4 FUAD MURAD __________ __________
5 MINALE GASHAW __________ __________
INTERNSHIP REPORT ON HAN*PLAST I

DDIT AUGEUST 2021
ACKNOWLEDGEMENT
Before all, our thank goes to almighty God for his support and protection of us throughout our
life. We thank Han*plast manufacturing plc for accepting us as interns. We also thank our
mentor Mr. Hamza A. For helping us to bring this report and project in organized manner. And
we also thank the engineers of the company along with all the electricians for their support to
develop theoretical knowledge to practical skill. We wish express our profound thanks to all
those who helped us in well done the internship. Last, but not least, we would like to thank our
family, for their, encouragement, patience and support throughout our internship time in every
part of our problems.
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Executive Summary
In this report, we gave some emphasis about what the HAN*plast is, when the company started the
production and where was it. In HAN*plast there are seven working sections namely: spinning section,
waving section, laminating section, printing section, cutting section, converting section and pressing
section. In this factory we have stayed for two months and during this period we have stayed for about
three weeks in each area. Basically all the electrical systems are almost the same but there are
machineries difference.
The overall internship activities, the knowledge we have gained, the problem we have identified and
the project that we designed to minimize the problem is explained. And also different electrical devices,
machines along with their uses and their control mechanism are briefly discussed throughout this report.
As we are assigned to this share company named HAN*plast according to Dire Dawa Institution of
technology university’s curriculums, starting from June 15 to August 15 /2021, over two month, we
have tried to apply our classroom study to the actual world and we have adapted a lot on social
interaction with all co-workers of the company. We also participated in maintenance of different
machines with in the company. Beside to this, we gave some recommendations to the company.
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List of Table
Table 1. Chemicals and their supplier........................................................................................ 3

Table 2. Materials consumption per year .................................................................................. 3
Table 3. Machines ...................................................................................................................... 3
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List of Figure
Figure 1. HAN*PLAST factory bird eye view .......................................................................... 1
Figure 2. Organizational structure ............................................................................................. 5
Figure 3. Overall process of company ....................................................................................... 7
Figure 4.Type of products .......................................................................................................... 8
Figure 5. DOSITEX machine .................................................................................................. 11
Figure 6. TIRATEX machine .................................................................................................. 12
Figure 7. FILATEX machine ................................................................................................... 12
Figure 8. ADVANTEX machine ............................................................................................. 13
Figure 9. ECOTEX machine .................................................................................................... 14
Figure 10. SERVOTEX machine ............................................................................................. 15
Figure 11. CUTTEX machine .................................................................................................. 15
Figure 12. SLITTEX machine ................................................................................................. 16
Figure 13. CONVERTEX machine ......................................................................................... 16
Figure 14. PRESSTEX machine .............................................................................................. 17
Figure 15. Block diagram of plc .............................................................................................. 18
Figure 16. PLC process ............................................................................................................ 18
Figure 17. Induction motor ..................................................................................................... 20
Figure 18. Limit Switch ........................................................................................................... 23
Figure 19. Photoelectric sensor ................................................................................................ 24
Figure 20. Load cell tension sensor ........................................................................................ 24
Figure 21. Proximity sensor .................................................................................................... 25
Figure 22. Print mark sensor .................................................................................................... 25
Figure 23. Pneumatic actuator ................................................................................................. 26
Figure 24. Block diagram ....................................................................................................... 37
Figure 25. Resistor ................................................................................................................... 38
Figure 26. Transistor ................................................................................................................ 39
Figure 27. Buzzer ..................................................................................................................... 39
Figure 28. Motor drive ............................................................................................................ 40
Figure 29. DC motor ................................................................................................................ 40
Figure 30. Oscillator ................................................................................................................ 41
Figure 31. LCD display........................................................................................................... 42
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Figure 32. Ultrasonic sensor working principle .................................................................... 43

Figure 33. Ultrasonic sensor .................................................................................................... 44
Figure 34. Potentiometer ......................................................................................................... 45
Figure 35. Pin configuration ................................................................................................... 46
Figure 36. Microcontroller (PIC16F877A) .............................................................................. 48
Figure 37 Overall circuit connection ....................................................................................... 49
Figure 38. Flowchart ............................................................................................................... 50
Figure 39. Result one .............................................................................................................. 53
Figure 40. Result two ............................................................................................................... 54
Figure 41. Result three ............................................................................................................. 54
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Table of Contents
ACKNOWLEDGEMENT .........................................................................................................ii
Executive Summary ................................................................................................................. iii
List of Table .............................................................................................................................. iv
List of Figure.............................................................................................................................. v
List of Acronyms ....................................................................................................................... x
PART ONE ................................................................................................................................ 1
CHAPTER 0NE ......................................................................................................................... 1
1 BACKGROUND OF HAN*PLAST MANUFACTURING PLC .......................................... 1
1.1 INTRODUCTION ............................................................................................................ 1
1.2 Vision , Mission and Objective of the company .............................................................. 2
1.2.1 Vision......................................................................................................................... 2
1.2.2 Mission of the company ............................................................................................ 2
1.2.3 Objective of the company .......................................................................................... 2
1.3 Social services given to the employee.............................................................................. 2
1.4 Raw materials, Accessory suppliers, Machines and power consumption ........................ 3
1.4.1 Raw materials ............................................................................................................ 3
1.4.2 Accessories and their Suppliers ................................................................................. 3
1.4.3 Power and Raw material consumption ...................................................................... 3
1.4.4 Machines .................................................................................................................... 3
1.5 Products and customers .................................................................................................... 4
1.5.1 The customers of the company .................................................................................. 4
1.6 Environmental policy ....................................................................................................... 4
1.7 Overall organizational structure of the company ............................................................. 5
1.7.1 Task of each section .................................................................................................. 6
1.8 Key Stake Holders of the Company ................................................................................. 7
1.9 Production process of HAN*PLAST manufacturing plc ................................................. 7
1.9.1 production process ..................................................................................................... 7
1.9.2 Production capacity ................................................................................................... 8
CHAPTER TWO ....................................................................................................................... 9
2. Overall Internship Experience ............................................................................................... 9
2.1 Objectives of Internship ................................................................................................... 9
2.1.1 General objective ....................................................................................................... 9
2.1.2 Specific Objective...................................................................................................... 9
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2.2 How we did get the company ......................................................................................... 10

2.3 Work section .................................................................................................................. 10
2.3.1 Overall system components and operation .............................................................. 10
2.4 Controlling unit .............................................................................................................. 17
2.4.1 Programming Logic Controller (PLC) .................................................................... 17
2.5 AC Motors ...................................................................................................................... 19
2.5.1 Motor starting methods in HAN*plast .................................................................... 20
2.6 Sensor and actuator ........................................................................................................ 22
2.6.1 Sensor ...................................................................................................................... 22
2.6.2 Actuator ................................................................................................................... 26
2.7 Major duties of the intern ............................................................................................... 27
2.8 Challenges faced and measures ...................................................................................... 27
2.8.1 Challenges ............................................................................................................... 27
2.8.2 The Measures Taken to Solve the Challenges ......................................................... 28
CHAPTER THREE ................................................................................................................. 29
3. Benefits Gained from the Internship .................................................................................... 29
3.1 Theoretical knowledge and practical skills .................................................................... 29
3.2 Team playing skills ........................................................................................................ 30
3.3 Interpersonal Skills ......................................................................................................... 30
3.4 Leadership Skills ............................................................................................................ 31
PART TWO ............................................................................................................................. 33
CHAPTER FOUR .................................................................................................................... 33
4 Automation of unwinder roll in cutting section .................................................................... 33
4.1 Abstract .......................................................................................................................... 33
4.2 Introduction .................................................................................................................... 34
4.3 Problem identification .................................................................................................... 34
4.4 Problem statement .......................................................................................................... 35
4.5 Objective of the project .................................................................................................. 35
4.5.1 General objective of the project............................................................................... 35
4.5.2 Specific objective .................................................................................................... 35
4.5.3 Significance of the project ....................................................................................... 35
4.5.4 Scope of the project ................................................................................................. 35
4.6 LITRATURE REVIEW ................................................................................................. 36
4.7 Methodology .................................................................................................................. 37
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4.7.1 Block diagram.......................................................................................................... 37

4.7.2 Component description ............................................................................................ 37
4.7.3 Software design and development of the system..................................................... 49
4.7.4 Flow chart ................................................................................................................ 50
4.7.5 Working principle and procedure ............................................................................ 51
4.7.6 Design and calculation of ultrasonic sensor ............................................................ 51
4.8 Simulation and Result .................................................................................................... 53
4.9 Conclusion...................................................................................................................... 55
4.10 Recommendation .......................................................................................................... 55
4.11 Contribution ................................................................................................................. 55
CHAPTER FIVE ..................................................................................................................... 56
5 Conclusion and Recommendation ........................................................................................ 56
5.1 Conclusion...................................................................................................................... 56
5.2 Recommendation ............................................................................................................ 57
5.2.1 Recommendation for HAN*PAST company .......................................................... 57
5.2.2 Recommendation for the School ............................................................................. 57
5.2.3 Recommendation for the Industry Linkage ............................................................. 58
Reference ................................................................................................................................. 59
Appendix .................................................................................................................................. 60
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List of Acronyms
HDPP High density polyethylene

PP Polypropylene
PPE Personal protective equipment
AC Alternate current
LCD Liquid crystal display
RAM Random access memory
ROM Read only memory
PLC Programmable logic control
LED Light emitting diode
M Meter
Caco3 Calcium carbonate
ISO International Organization for Standardization
HR Human resource
DOL Direct on line
NC Normally close
NO Normally open
VCC Voltage common control
TTL Time to live
DC Direct current
HZ Hertz
Cm Centimeter
mA Mili ampere
GND Ground
TRIG Trigger
USART Universal synchronous asynchronous receiver transmitter
PWM Pulse width modulation
SPI Serial peripheral interface
TX Transmitter
RX Receiver
OSC Oscillator
VREF Voltage reference
MCLR Master clear
V voltage
Us Micro second
IC Integrated circuit
EEPROM electrically erasable programmable read-only memory
NPN Negative, positive, negative
GPIO General purpose input output
QFN Quad Flat No-lead
TQFP thin quad flat pack
POT-HG Potentiometer
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PART ONE
CHAPTER 0NE
1 BACKGROUND OF HAN*PLAST MANUFACTURING PLC
1.1INTRODUCTION
Han* plast manufacturing company was established in 2011E.C with capital of 60,000,000. It
is located in DIRE DAWA city administration near ETHIO-DJIBOUTY DIRE DAWA train
station, 520km from Addis Ababa and it is planted by the money obtained from shares of five
individuals. Han*plast manufacturing company is the latest and the second in factories in
Ethiopia with Nano technology.
The company had 44 machines with 700KW total power consumed. Since that period the
company have been worked with the current number of machines. It found in DIRE DAWA
industrial park which covers the total land area of 10 000 000 square meters and of which
4000000 square meters is covered by buildings. The main objective of the enterprise was to
help the peoples around the company and others by creating job opportunities. It was
producing different kinds of woven sacks fabric for local customers. The company hold 340
employee in three working shifts.
Figure 1. HAN*PLAST factory bird eye view
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1.2 Vision , Mission and Objective of the company

1.2.1 Vision
 To be leader in Ethiopia in exporting woven sack
 Making products environmentally sustainable
 Satisfy the need of customers in quality and quantity
 To become the Leading Industrial group in the region
1.2.2 Mission of the company

 To produce 100% HDPE/PP woven sack products
 To satisfy customer need
 To expand the market share and branches
 To maximize the profit and give benefits to all stake holders
 To play vital role in developing countries economy
1.2.3 Objective of the company

 Delivering high quality cement bag from ploy-propylene with affordable price to our
customers
 To sell produces in local market and abroad
 Economic uses of resource
 Promoting the product in a fair and ethical way
 Implementing competitive, productive, well-organized strategies
 Insuring strong, healthy, and transparent way of marketing
1.3 Social services given to the employee
Social services given to the employee in the Han*plast manufacturing company are:-
 Providing pure water
 Providing transportation
 Providing shower and bathroom
 Providing tea and coffee to the workers
 Providing first aid treatment in case of accident
 Consultancy services
 Helping out the employee with money which are in severe condition

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1.4 Raw materials, Accessory suppliers, Machines and power consumption
1.4.1 Raw materials
In Han*plast manufacturing Company the major raw material is polypropylene, poly-ethylene

and the company produce 100% polypropylene(pp) products. According to some oral
information tell us the supplier of the main raw material (polypropylene) is comes from Saudi-
Arabia
1.4.2 Accessories and their Suppliers
Accessories are materials which are used in the company in addition to raw materials to
perform a complete work. Such materials are dye staff chemicals, greases, oil and spare parts
chemicals suppliers
oil Local suppliers
Polyethylene & poly-propylene Saudi-Arabia
Caco3 Saudi-Arabia
Printing dyes Saudi-Arabia
Table 1. Chemicals and their supplier
1.4.3 Power and Raw material consumption
The company’s annual raw materials and power consumption is shown in the following table
s.no Materials Consumed amount per year
1 Polypropylene pellets 14,8500 ton

2 Electric power 21 million KWH
3 Oil 2 million liters
4 Water 40,000mtr cube
Table 2. Materials consumption per year
1.4.4 Machines
There are a number of machines in the factory which has different purposes and it shown in
the table below

Type TIRATEX DOSITEX FILATEX ADVANTEX ECOTEX CUTTEX SLITTEX SERVOTEX CONVERTEX
Number 1 2 1 35 1 1 1 1 1
. Table 3. Machines

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1.5 Products and customers
Among the company’s product the major one is printed woven sacks used for different
cement packaging.
1.5.1 The customers of the company

This company dispatches all its product exclusively for local retailers. Its main customers
are:-
 Ture cement factory

 Mugger cement factory
 Capital cement factory
 Ethio cement
 East cement factory
 New wave cement factory
 Enchain cement factory
 National cement factory
 Dangote cement factory
 Faun hung cement factory
1.6 Environmental policy

Han*plast manufacturing company, while conducting its business activity, is equally
concerned on environmental protection during manufacturing and other operations, which may
have impact on the environment. The company is committed to minimize its impact on
environment through prevention of pollution by applying the implementation of cleaner
production techniques and effective and efficient use of natural resources.
More over the company is committed to comply with environmental related applicable
national, legal and other requirements to which the company subscribes.
To this end, the company implements, maintains and continually improves its environmental
management system that conforms to ISO/4001:2004.The Company will play a leading role to
continually improve its environmental performance by improving all stake holders.

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1.7 Overall organizational structure of the company
Board of directors
General Manager
Executive Secretary
Plant Manager
Production & technique department Finance department HR &ADMIN
HR Security
Shift loom Junior Senior
Shift
department Officer
ECOTEX Accountant Accountant
department
HR Cleaning
Shift Shift
CONVERTEX SERVOTEX Cost Assistant
department department Accountant budget
accountant
Driver
Shift Shift bailing

TIRATEX department
department
Maintenance Quality
department control
department
Figure 2. Organizational structure

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In the company there are different sections that are involved in different jobs. But they work
through interaction
1.7.1 Task of each section
1. Board of directors:- hire the General manager , provide the overall direction and
strategy of the business, establish a policy based governance system. They reports to
the shareholders.
2. General manager:- Creating business plans, overseeing day-to-day activities,
supervising head of departments, directing organizational strategy, control and lead all
over the company, apply yearly plan and occupational program, check if the plan is
applied or not and follow up all over working process of the company.
3. Executive secretory:- provide data and report to the general manager as well as hold
appointments.
4. Plant manager:- prepare reports for the general manager and board. Work as a general
manager in his/her absence.
5. Production and technique department:- this department hold and control different
departments which involves in the production of the bag
6. Finance department:- Follow up and realize financial planning, perform budget
preparation, indicate the direction of financial sources of the company, and controls the
collected finance. This department include different accountant which have their own
role in the department.
7. Human Resource (HR &Admin):- this section is primary governed by the rule and
regulation that was formed in the co-ordination of both workers and the administration.
It also holds the structure hierarchy of the occupation of the type of employee, so when
there is a gap formed it announces a vacancy based on the job criteria that already exist.
Also gives some training assignment for the employers.
8. Maintenance Section -This section stands for the maintenance of electrical and
mechanical parts of the company. For example; controlling the power supply and
maintaining an electrical and mechanical system which is mostly on the machine in
order to minimize maintenance cost.

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9. Quality control department - This section is mostly determined how much the raw
materials and the product at each steps are qualified and checked whether the incoming
goods are the same as the standard or not.
1.8 Key Stake Holders of the Company
Any person or entity interested in a particular business is called a stakeholder. They are affected
by the business activity, and they may be part of the core decision-making team. Internal and
external stakeholders may have different interests and priorities, possibly leading to conflicts
of interest. Internal stakeholders are owners, managers, and workers. HAN*PLAST
manufacturing plc is share between 5 individuals person with different role.
1.9 Production process of HAN*PLAST manufacturing plc
1.9.1 production process
Raw
material
Extrusio
n
spining
weaving
lamination
printing
cutting &
Slitting
CONVERTING
PRESSING
Figure 3. Overall process of company

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Raw material:- the raw materials poly-propylene, polyethylene, calcium carbonate and
dying component are mixed in to stacker.
Extrusion:- the process of delivering the mixture in to melting area using the extruder motor
Spinning:- this process is making a tape from the solid that was melted process in order to
prepare for weaving.
Weaving:- is process of interlacing yarns in order to make sack from the tape that was
delivered from spinning section
Lamination:- the process of coating the woven fabric within a plastic materials in order to
prevent moisture.
Printing:- is a process for mass reproducing text and images using a master form or
template. Depending on the need of the customer.
Cutting and slitting:- is the of process cutting and slitting to prepare the fabric to final
product by making cover and valve patch that are inputs for converting process
Converting:- is the process of finalising the fabric in to a needed woven cement bag through
different process.
Pressing:- is the process of pressing the woven cement bag for bailing and packing
1.9.2 Production capacity
Currently HAN*PLAST manufacturing process is capable of producing:-
 201600 woven cement bags per day

 73584000 woven cement bags per year
Figure 4.Type of products

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CHAPTER TWO
2. Overall Internship Experience
2.1 Objectives of Internship
2.1.1 General objective

The objective of an internship is to expose us to a particular job and a profession or industry.
We might have an idea about what a job is like, but we won’t know until we actually perform
it. Internship helps us to understand if work is what we thought what it was, if we have the
training and skills to do it and if it is something we like. It helps us to facilitate reflection on
experiences obtained in the internship and to enhance understanding of academic materials by
application in the internship setting.
2.1.2 Specific Objective

Some of the specific objective of internship includes:
 To provide us the opportunity to test our interest in a particular career before permanent
commitments are made
 To develop skills and techniques directly applicable to our careers.
 To provide us the opportunity to develop attitudes conducive to effective interpersonal
relationships
 To provide us with an in-depth knowledge of the formal functional activities of a
participating organization
 To gain confidence and know - how for future employment
 To apply our classroom knowledge into practice
 To receive an introduction to an organization within production industry and to gain a
better understanding of its design and structure.
 To provide intensive field experience allowing for hands-on computer work.
 To apply what was learned during coursework (theory, skill development,
professionalism) to the working world.
 To find future employees
 To allow the organization to benefit from a trainee who has gained knowledge about
the latest technologies available and to benefit from the trainee’s objective viewpoint.

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 To allow us to assume responsibilities of a non-Intern staff member and be able to

function with a minimum of supervision.
 To help us to make better career choices in the future.
 To allow us to prepare for our future non-Internship job by seeking potential places
of employment, practicing resume and cover letter preparation, gaining references,
and interviewing if applicable.
2.2 How we did get the company
As the HAN*plast manufacturing plc company is recent all the machineries and controlling
method are latest more advanced even there is a machinery which is used Nano technology.
All Controlling mechanisms are automated it can be controlled within a few officer or operator.
Most of the machines are controlled with plc. We were so surprised to see such modern
controlling mechanism. We have seen motors and there controlling mechanism that we didn’t seen
before.
2.3 Work section
In the company there are seven main section. These are:
 spinning section
 weaving section
 Laminating section
 printing section
 converting section
 cutting section
 pressing section
2.3.1 Overall system components and operation
Spinning section: Spinning is a part of textile manufacturing process where polymers such
as polypropylene (HDPE/PP) converted into tape. In Han*plast manufacturing company melt
spinning is used to produce the tape. In this section there three machineries these are:-
 DOSITEX
 TIRATEX

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 FILATEX
DOSITEX:- It is a machine that is used to suck and provide for melting the raw materials to
produce the tape. This DOSITEX has different stacker that can hold different raw materials.
Each stacker hold different type of component i.e poly-propylene, calcium carbonate, colour
and other additives
Figure 5. DOSITEX machine

TIRATEX:- is a tape extrusion and -stretching line for production of polyolefin tapes made of
PP. The machine is designed for high output and best product quality such as LS tapes (Light
and Strong) at high production rates and maximum energy efficiency. Modular design and
several optional extras allow for an optimized execution, depending on process- and product
requirements.
This TIRATEX have different section the extrusion, dye, water bath, blading, oven and
annealing process
Extruder:- this section drives the raw materials to the dye using large motor
Dye:- this section have heaters which is used for melting the raw material which was driven by
the extruder
Water bath:- this used to change the melted raw material in to solid fabric
Blading:- this section slit the solid fabric in to tape. The blading has 220 blades
Oven:- the oven is used for stretching the tape

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Annealing:- this used to strength the tape that was stretched by the oven this process has 3 parts
the oil heater, normal and cold section.
Figure 6. TIRATEX machine
FILATEX:- The FILATEX winder is used for the cylindrical cross winding of polyolefin
tapes on cylindrical tubes. The winding principle is based on stepped precision winding. This
FILATEX has 200 tape winder and it has a maximum speed 530 meter per minute.
Figure 7. FILATEX machine

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Weaving section:- Weaving is the process of formation of fabrics by interlacing of warp and
weft yarns to produce fabric on any type.
This section has a machine called ADVANTEX. And the process is as follow below
Handle
Guide hole
Comb
Guide roller
Scorcher
Compensator
Eye late
Weft insert
Weaving
Roller (to convert tubular form to flat form)
Take-up roller
The ADVANTEX circular loom family covers a range of tubular fabric with widths from 30
cm to 225 cm double lay flat for a wide range of applications. All ADVANTEX circular looms
are built using the latest technology and offer maximum output at low operation cost.
Figure 8. ADVANTEX machine

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Laminating section:- The process of manufacturing PP woven sacks involves mixing raw
materials starting with PP pellets and other additives, extruding the materials into a yarn PP
resin is heated with feeler of caco3 and pigment, melted and extruded as a flat film. It is then
slit into tape yarn by the slitting unit and stretched and annealed.
Next, a take-up winder winds the heat oriented tape yarn onto a bobbin. The raw material (pp
& filler) in the granules form is fed to a raffia tape manufacturing plant to obtain the raffia
tapes of PP. The raw material mix is prepared in a tray adjacent to the feed hopper. The prepared
mix is sucked into the hopper by vacuum. The raw material mix is fetched to the extruder of
the plant; where the same is melt by applying controlled external heat on the barrel. The molten
mass is forced out through the die head into a cooling tank, in the form of sheet/film. The
cooled or solidified sheet/film is passed through the knives to obtain raffia tapes of higher
denier. The ECOTEX extrusion coating/laminating line offers superior coating/laminating and
efficient operation at high speed.
Figure 9. ECOTEX machine

Printing section:- Colour printing woven sacks printing ink selection; uses special plastic
ink, strong adhesion on the woven sacks, not easy to fall off. In Han*plast manufacturing
there is two side printing and one side printing is available which is done by SERVOTEX
printing machine
The SERVOTEX is specially designed to print PP fabric, circular woven or flat, coated or
uncoated. In one single process step 4 or 6 colours on both sides can be applied. Advanced

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features such as fully automatic unwinding and winding ensure highest possible efficiency at
a minimum amount of waste. Proven European workmanship allows for high production
speed at maximum reliability. Camera system for print register monitoring on front and back
side of the fabric
Figure 10. SERVOTEX machine

Cutting section:- The fabric slitting machine CUTTEX is designed to produce and rewind
two layers of flat fabric cut out of tubular cloth. Edge-cutting and sealing is done by two high
performance ultrasonic cutting units. The machine is available in two sizes: CUTTEX 750
and 1300. CUTTEX PLUS is a dual-purpose machine for ultrasonic edge cutting of tubular
fabric and roll slitting of coated woven fabric and allows for maximum versatility in the
production of sacks
Figure 11. CUTTEX machine

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The fabric slitting machine SLITTEX 750 is designed to produce strips of coated PP woven
fabric, wound on rolls for use on CONVERTEX machines for top/bottom patches and valves
Figure 12. SLITTEX machine

Converting section:- Is the finishing section in Han*plast manufacturing which is done by
CONVERTEX machine. The CONVERTEX SLC conversion line produces up to 140 AD
block bottom valve sacks per minute, using a highly advanced adhesive-free production
process. This CONVERTEX machine use a Nano technology that is NANOTEX perforator
In this section there are 6 main parts this are
 Unwinder
 Nano technology (perforator)
 Lift up
 Opening section
 Closing section
 Delivery
Figure 13. CONVERTEX machine

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Pressing section:- The hydraulic baling press PRESSTEX compact is especially designed for
the baling of PP bags or raffia bags. It is of very rigid design, suitable for baling stacks with a
very large number of bags. The stacks can be loaded directly onto pallets. A loading ramp is
also provided, to allow the use of pallet lifting carts.
Figure 14. PRESSTEX machine
2.4 Controlling unit
2.4.1 Programming Logic Controller (PLC)

PLC is a digital computer used for the automation of various electro-mechanical processes in
industries such as control of machinery on factory assembly lines. It also is a special form of
microprocessor-based controller that uses programmable memory to store instructions and to
implement functions such as logic, sequencing, timing, counting, and arithmetic in order to
control machines and processes. Input devices (that is, sensors such as switches) and output
devices (motors, valves, etc.) in the system being controlled are connected to the PLC. The
operator then enters a sequence of instructions, a program, into the memory of the PLC. The
controller then monitors the inputs and outputs according to this program and carries out the
control rules for which it has been programmed.
The PLC system has the following main parts or units.

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1. The power supply: - it provides the constant voltage level required by the PLC. As the main
supply is AC, the rectifier converts the AC into DC typically 24V. Generally the power supply
unit: Is typically non-redundant. Hence a failure of the power supply can cause the control
system to fail.
Figure 15. Block diagram of plc
2. Processor or central processing unit (CPU): -is the brain of the PLC. It consists of
microprocessor, memory chip and other integrated circuits to control logic, monitoring and
communication. PLC is a dedicated controller i.e. it will only process one program over and
over again. One cycle through the program is called a scan time and involves reading the inputs
from the other modules, executing the logic based on these inputs and then updated the output
accordingly. The scan time happens very quickly (in range of 1/100th of the second).
Figure 16. PLC process

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3. Memory: The memory stores data and program that the CPU needs to perform various
functions. The program memory receives and holds program instruction. Data memory is used
to temporarily hold data generated from processor or acquired through I/O devices. There are
two memory elements in a PLC system:
 Read-Only-Memory (ROM) gives permanent storage for the operating system and
fixed data used by the CPU.
 Random-Access Memory (RAM) is used for the user’s program. This is where
information is stored on the status of input and output devices and the values of timers
and counters and other internal devices. 
2.5 AC Motors
An AC motor is an electric motor driven by an alternating current (AC). There are two main
types of AC motors, depending on the type of rotor used. The first type is the induction motor
or asynchronous motor; this type relies on a small difference in speed between the rotating
magnetic field and the rotor to induce rotor current. The second type is the synchronous motor
which can rotate exactly at the supply frequency.
Induction motor
It is an AC motor that converts electrical energy in to mechanical energy in which alternating
current from a power source is fed through a primary winding and induces a current in a
secondary winding, with the parts arranged so that the resulting magnetic field causes a
movable rotor to rotate with respect to a fixed stator.
In HAN*plast manufacturing plc, there are many induction motors which are used to move
from one process to the other process. These motors are ranged from smaller motors, like screw
and rotary, having a power rating up to 0.7KW and line voltage of 220-400V to larger motors
, like fan motor and mill motor, with a power rating up to and line voltage of 6000V.

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Figure 17. Induction motor
2.5.1 Motor starting methods in HAN*plast

Different starting methods are employed for starting induction motors because Induction Motor
draws more starting current during starting. To prevent damage to the windings due to the high
starting current flow, we employ different types of starters. The starting methods of the motors
in HAN*plast are DOL (Direct Online), star delta, forward reverse
Common components for most of the starting methods are listed and explained below:
i. Circuit barker – is an automatic operated electrical switch designed to protect an

electric circuit from damage caused by excess current from an over load or short
circuit. Its basic function is to interrupt current flow after a fault is detected.
ii. Push button – is a switching mechanism that completes an electric circuit when we
press on it. When it’s on, a small metal spring inside makes contact with two wires,
allowing electricity to flow. When it’s off, the spring retracts, contact is interrupted
and current won’t flow. The body of the switch is made of non-conducting plastic.
In DOL and star delta starting mechanism we use two push buttons, one with
normally open contact and the other with normally closed contact, but in forward
reverse starting mechanism we use two start NO push buttons and one NC stop push
button to control the motor.
iii. Over Load Relay (Overload protection) – is used to prevent burnout and to ensure
maximum operating life for an electric motor. Under any condition of overload, a
motor draws excessive current that causes overheating. Overload relays are

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employed on a motor control to limit the amount of current drawn. The overload
relay does not provide short circuit protection. This is the function of over current
protective equipment like fuses and circuit breakers, generally located in the
disconnecting switch enclosure. Overload relays are renewable and can withstand
repeated trip and reset cycles without need of replacement. Overload relays cannot,
however, take the place of over current protection equipment. Overload relays can
be classified
a. Thermal Relay - As the name implies, thermal overload relays rely on the rising
temperatures caused by the overload current to trip the overload mechanism.
b. Magnetic Relay - Magnetic overload relays react only to current excesses and are not
affected by temperature.
c. Electronic Relay - Electronic or solid-state overload relays provide the combination of high-
speed trip, adjustability, and ease of installation. They can be ideal in many precise
applications.
I. Direct on line starter
The simplest form of motor starter for the induction motor is the direct on line starter. It consists
of a Circuit Breaker, Contactor and an overload relay for protection. The contactors are
electromagnetic type which can be opened by the thermal overload relay under fault conditions.
Typically, the contactor will be controlled by separate start and stop buttons, and an auxiliary
contact on the contactor is used, across the start button, as a hold in contact. I.e. the contactor
is electrically latched closed while the motor is operating.
II. Star- delta starter

This is another motor starting method that is used in HAN*plast. It is a type of reduced voltage
starter. This starting method is used for reducing the starting current of the motor without using
any external device or apparatus. It reduces the inrush current by a factor 3 compared to DOL
starter. The starter can be used with all squirrel cage induction motors that are delta-connected
for normal operations. It consists of contactor, overload relay, timer, circuit breaker, and push
buttons (start and stop).

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III. Forward reverse starter

It is used to run the motor in both sides forward and reverse. The forward reverse motor control
is used in a system where forward and backward or upward and downward movement in the
operation is needed. It is simply obtained by interchanging any two of its three terminals. In
the control circuit both the forward and reverse contactors interlocked in a way that only one
contactor should be in closed condition whiles the other is in open condition.
Materials used in the construction of forward reverse control circuit are
 Circuit barker
 Over load relay
 Contactors
 Push buttons
2.6 Sensor and actuator
In this factory we have seen different type of sensor and actuators that enable the machines do their
work properly and efficiently.
2.6.1 Sensor
A sensor is a device that measures physical input from its environment and converts it into
data that can be interpreted by either a human or a machine. Most sensors are electronic (the
data is converted into electronic data), but some are more simple, such as a glass thermometer,
which presents visual data. People use sensors to measure temperature, gauge distance, detect
smoke, and regulate pressure and a myriad of other uses. There are two types of electronic
sensors: analogue and digital.
Sensors that we saw in the factory are as follow:-
 Limit sensor (switch)
 Position sensor
 Diameter sensor
 Counter sensor
 Load cell sensor
 Edge adjustable sensor
 Print mark sensor

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Limit switch:- A limit switch is a mechanical device that requires the physical contact of an
object with the switch’s actuator to make the contact change state (open/closed).As the object
or target contacts the operator of the switch, it eventually moves the actuator to the “limit”
where the contacts change state. In a Normally Closed (NC) circuit, this mechanical action
opens the electrical contacts and in a Normally Open (NO) circuit, it closes them. The
contacts then start or stop the flow of current in the electrical circuit.
Figure 18. Limit Switch
Position sensor:- As their name implies, position sensors provide position feedback. They
are able to perform precise motion control, encoding and counting functions by determining
the presence or absence of a target or by detecting its motion, speed, direction or distance.
Position sensors detect a target object, a person, a substance or the disturbance of a magnetic
or an electrical field and convert that physical parameter to an electrical output to indicate the
target's position. There are different types of sensors which are used for positioning the main
that we saw in our host company is photoelectric sensor. A device that detects a change in
light intensity. Typically, this means either non-detection or detection of the sensor’s emitted
light source. The type of light and method by which the target is detected varies depending on
the sensor.
Photoelectric sensors are made up of a light source (LED), a receiver (phototransistor), a
signal converter, and an amplifier. The phototransistor analyses incoming light, verifies that it
is from the LED, and appropriately triggers an output..

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Figure 19. Photoelectric sensor
Load cell sensor:-works by converting mechanical force into digital values that the user can
read and record. The inner working of a load cell differs based on the load cell that you choose.
There are hydraulic load cells, pneumatic load cells, and strain gauge load cells. Strain gauge
load sensors are the most commonly used among the three. Strain gauge load cells contain
strain gauges within them that send up voltage irregularities when under load. The degree of
voltage change is covered to digital reading as weight. Load cell sensor is defined as a
transducer that converts an input mechanical load, weight, tension, compression or pressure.
Figure 20. Load cell tension sensor
Counter sensor:- A Counter is a device that counts the number of objects or the number of
operations. It is called a Counter because it counts the number of ON/OFF signals input from
an input device, such as a switch or sensor.

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Figure 21. Proximity sensor
A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact. A proximity sensor often emits an electromagnetic field or a beam
of electromagnetic radiation (infrared, for instance), and looks for changes in the field or
return signal. The object being sensed is often referred to as the proximity sensor's target.
Different proximity sensor targets demand different sensors.
Print mark sensor:- These sensors have been specially designed to recognize print marks.
They have a very small spot, and use a white light LED with long service life. Only one sensor
is required for the recognition of all colour combinations, as well as the difference in brightness
between printed markings and the background.
Applications
 Differentiation of up to 100 grey scales

 Print mark recognition
 Detection of prints, stamps and labels of all kinds
 High-speed print mark recognition
 Recognition of smallest stamps by a very small spot
Figure 22. Print mark sensor

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2.6.2 Actuator
An actuator is a device that uses a form of power to convert a control signal into mechanical
motion. From electric door locks in automobiles, to ailerons on aircraft, actuators are all around
us. Industrial plants use actuators to operate valves, dampers, fluid couplings, and other devices
used in industrial process control. The industrial actuator can use air, hydraulic fluid, or
electricity for motive power. These are referred to as pneumatic, electro-hydraulic, or electric
actuators.
Actuator that we saw in the factory is Pneumatic Actuators
Pneumatic actuators are devices that convert the energy of compressed air or gas into a
mechanical motion that regulates one or more final control elements. They are used as a form
of automation control to reduce mandatory human interaction with a system’s internal
mechanisms, which is particularly beneficial for automatic modulation and emergency
shutdowns. The motion of a pneumatic actuator may be linear or rotary depending on the
device’s design. Prototypical actuators use an external compressive force, such as compressed
air or gas, to move a piston along the inside of a hollow cylinder and build pressure. This
generates a linear force relative to the piston’s pressure differential multiplied by its surface
area, which is used to move a load along a straight line. So-called linear pressure actuators have
been in service for decades but enhancements in diaphragm design and sealing capabilities
have vastly improved the technology’s efficiency and scope of functionality.
Industrial pneumatic systems typically utilize pressures of 80 – 100 pounds-per-square-inch

(psi). Actuators are subsequently used for the movement of comparatively small to large loads
such as the manipulation of dampers, inlet vanes, louvers, valves, turbine governors, fluid
drives, and other final control elements.
Figure 23. Pneumatic actuator

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2.7 Major duties of the intern
Internship provides the opportunities to build a relationship with the company, network with
other people in the field and gain valuable first-hand experience. It gives us the knowledge
and experience we need to be confident in our career activities. We understand that our duties
include the following tasks.
 Obey the rules of the company
 Work the given tasks in the company with the guidance of the company
supervisor and Assisting company operators
 Write and submit reports on each area
 To be Committed to work
 To be reliable and punctual
 Making problem solving project
2.8 Challenges faced and measures
2.8.1 Challenges
During our stay in national cement we faced many challenges that make our time a little bit
difficult over there. Those challenges are listed below:
 Lack of personal protective equipment
 as we are not familiar with the staff members, they don’t tell us anything unless they
are asked
 some of the technicians are not well skilled, so when we had questions they either
confuse us or they don’t answer at all even though they are willing to tell us how the
machine works and the internal electrical component
 since the machineries had high sound, it makes difficult to hear some of the
explanations from our supervisors
 some of the working sections have high smell because of chemicals
 we were unable to get the manual for some machineries
 Since we were theoretical student, it was difficult for us to know even some of the
electrical instruments
 Some of operators are foreign and do not speak English well we had much difficulties
in communication with them

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2.8.2 The Measures Taken to Solve the Challenges
For each of the above challenges here are the lists of measures that we take:
 As the company makes wearing PPE mandatory and they do not provide, we bought safety
shoes, earphone, face mask by our own
 In order to overcome the communication problem, we started taking part in their
conversation and we started asking questions in site about each and every electrical related
components and processes
 For questions that are not well explained by electricians, we start searching for details in
the internet
 For the explanations that we missed due to the sound problem, we start asking them again
in the office
 By taking the necessary precautions like by shielding our face and by wearing eye glass we
try to learn in the dusty environment
 We searched on the internet to get the manuals for some machineries
 For the electrical components that we don’t have exposure in the past, we ask the
electricians what it is and how it woks

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CHAPTER THREE
3. Benefits Gained from the Internship

The internship time was the most challenging time. We examine ourselves how much we
understand from the lecture classes and how the theories and formulas that we took in our
previous courses align with the practical world. It is obvious that along with the theoretical
part, experience is very important in real world. Being familiar with the work flow is a key to
understand ones role properly and be able to make competent decisions. For something that
takes inputs there is something in return (output), a benefit. In our internship too, there were
some benefits gained accordingly.
3.1 Theoretical knowledge and practical skills

When we first started in the company everything was new for us. It was really fascinating and
inspiring to see and experience the lessons we have been learning for the past three and half
years. As it’s commonly practiced, most of the courses we took in class dealt with the
theoretical side of it. The theoretical concepts that we developed in the class helped us during
our internship time.
We spent most of our time with HAN*plast manufacturing plc electricians to develop our
practical skills, theoretical skills, to understand working procedures, to learn how to use
materials properly and identifying the right material for the right purpose.
This internship program provided us with the opportunity to expand our horizon, broadening
our intellectual knowledge and gives us a chance to improve our theoretical and practical
knowledge from this grateful experience. Generally, we gained the following essential things.
 Creative and logical approach to solve problems.
 Clearly understand different electronic devices working principle and interconnection.
 We understand the control and power distribution system in the industry
 Able to give maintenance for some electrical device which are used in industrial
application.
 Able to apply our basic electrical knowledge to the solution of more advanced electrical
engineering problems.
 Effective assessment and management of risk, resource and time.

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 To be familiar with the operation principle, control mechanism, and networking system
of programming logic controller (PLC).
 To analysis the starting and speed control mechanism of electric motors.
 We got an experience to read and interpret information and ideas presented in electrical
documentation drawings for different types of electrical machines as all the electrical
maintenance and installation system is based on the electrical documentations designed
by engineers.
 How to solve industrial problem by correlating our theoretical knowledge with the
required instruction manuals and asking professional persons for problems beyond our
skill.
3.2 Team playing skills

We learn a lot how to improve interactions with our team members. When activities are done
in group the acceptability, reasonability and accuracy found to be always better than those done
individually. Therefore we really understand team work is important to strength the effort to
accomplish the task. Ideas that are raised in team work help us to see one thing in different
angles and to be a multi-directional thinker for elaborating our knowledge regarding the given
issue. We understand that for the proper functioning of a team, each member should have:
 Good communication skill
 Fast decision making skill
 Self-confidence
 Respect each other’s
 Listen each other’s
 Treat each other
 Encourage team members to share ideas.
3.3 Interpersonal Skills

Interpersonal skills are the skills that we use every day when we communicate and interact with
each other. We have seen that without effective communication skills, an employee cannot
succeed in the workplace. If communication can fail or if a message can be understood in
different ways, it will be understood in the way which does the most harm. During our
internship time we understood that, people with good interpersonal skills tend to be able to

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work well in a team as they are able to communicate effectively with other colleagues.
Generally we have gained the following interpersonal communication skills at HAN*plast.
 Communication skills: which in turn covers:
 Verbal communication-what we say and how we say it
 Non-verbal communication-what we have communicate without word
 Listening skills-how we interpret both the verbal and non-verbal message sent by others
 Emotional intelligent: being able to understand and manage our own and other’s
emotion
 Conflict resolution and mediation: working with each other’s to resolve interpersonal
conflict and disagreement in a positive way
 Problem solving and decision making: working with others to identify, define and solve
problem, which includes making decisions about the best course of action
 Listening skill
 Forwarding precise messages or instructions
 We do not dictate or criticize a person's work in front of others and understanding about
their needs
 We are interested in the people communicating with us
 We learn from one another interaction by correcting our faults
3.4 Leadership Skills
Leadership, a critical management skill, is the ability to motivate a group of people toward a
common goal. A leader is a person who has strong principles, courage, and dedication to a clear
vision. A person who is in the position leadership seeks optimal solution to problems and
should be smart enough to manage those individual whom he/she is leading and must possess
leadership quality and ability to handle intricate interpersonal relationships effectively within
a company to increase productivity. For effective leadership we understood that personal values
like confidence, effective communication and devotion are very important role. We have learnt
how to satisfy customers and works without any felling which makes them happy and
productive. We also develop the ability how to lead a person who is not willing to take his
responsibility and how to make him a productive worker by giving advice and other
measurements.
During our internship period, we have understood the following leadership techniques:

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 We have seen how each worker is controlled and organized to perform its day to day
activities. Among all other managements we have understood that human resource
management is the most important one.
 We have actually observed the method of controlling; the working time and amount of
work done by each worker so that the work proceeds according to the work plan.
 For effective leadership we understood that personal values like confidence, effective
communication and devotion are very important.
 If there is, conflict between the consultants leader must resolve the conflict in a good
way with his problem solving method or negotiate them.
Finally we identify the following listed items as a key to develop our leadership skill:
 Getting and giving information

 Understanding group needs and characteristics
 Knowing and understanding group resources
 Managing the group

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PART TWO
CHAPTER FOUR
4 Automation of unwinder roll in cutting section
4.1 Abstract
In response to today's highly competitive business environment, companies are forced to

analyse and improve their existing manufacturing system continuously to minimize production
losses, due to production disturbances, that hinder the system efficiency, performance and
reduce profitability. A major problem at one of the production lines of HAN*plast, which is
cutting section, is related to CONVERTEX the finalizing machine for valve patch and cover
patch which intern decreases the production capacity.
The Purposes of this project is to design automatic roll change which increase production rate,
minimize production loss by saving the time loss which is happen during roll change and save
the company from related crises. To implement this project we used proteus software to
simulate it. We use one ultrasonic sensor to measure the fabric meter and send signal to the
microcontroller. We also used two unwinder roll motors in order to change the empty roll to
the full one.

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4.2 Introduction
Today's production systems in HAN*plast manufacturing plc are required to deliver high
efficiency and productivity, since the demand for cement bag has been rising. Productivity
improvement is one of the core strategies towards manufacturing excellence and it also is
necessary to achieve better financial and operational performance. Improvement can be in the
form of correction of ineffective processing, simplifying the process, optimizing the system,
reducing variation, maximizing throughput, reducing cost, improving quality and reducing set
up time.
Increasing productivity can be achieved in so many ways. The first step is all about identifying
pain point of the current workflow. Next we need to analyse the people, technology and process
required for production as well as procedures and resource available across the company.
This project relates to automation of unwinder roll where by the empty roll change to the full
one automatically without stopping the machine which save the loss of time that leads to the
loss of production of bag.
4.3 Problem identification
In HAN*plast we identified some problem which have direct impact on production efficiency.
Some of them are:-
 The unwinder roll in cutting section is adjusted manually and also luck automatic roll
change which cause time loss that means in each minute 140 bags loss
 The dye in spinning section also adjusted manually
 In printing section the printing problems are detected by
 Oversized lamination in the ECOTEX
 Dye is adjusted manually in the TIRATEX
 The wrap is jumped during weave in the ADVANTEX
 The sprinter is adjusted manually for each type of bags
 The ultrasonic cutter in the CUTTEX does not indicate any error happened

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4.4 Problem statement
There is cutting section in HAN*plast manufacturing plc. In this section there are two machines
i.e CUTTEX and SLITTEX. This two machines luck automation in roll change when the roll
become empty it do not indicate as well as do not change the roll automatically to the next roll.
This work is done by a man power which cause in loss of time during the adjustment. The time
which is lost during adjustment will have the direct impact in the production efficiency because
in each minute it manufacture 140 bags. In order to avoid this problem we have designed an
automatic roll indicator and changer system using proteus software, sensors and motors
4.5 Objective of the project
4.5.1 General objective of the project

This project aims to design a program for automation of unwinder roll in cutting section
4.5.2 Specific objective

 Study and analyse the problem in detail
 Perform all the pre design procedures
 To develop a PROTEUS program
 To simulate the design program
4.5.3 Significance of the project
This project has a number of significance. The primary significance of the project is to reduce
the time loss during each roll change, since this process needs more time that leads to stack the
production of 140 bags in each minute.
Another significance is that it reduce man power. That is needed to change roll in each time.
Last but not least this project was also a great educating scenario for us all interns. It was a
great practice in guiding us through all the steps in performing a project.
4.5.4 Scope of the project

This project will focus on the design of automatic roll change and alert which is used to reduce
the time waste during production. By enable us to change the roll while getting empty in to
another full one. This include the design of the system using PROTEUS software.

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4.6 LITRATURE REVIEW
This is not a new idea about automation of unwinder roll in machines. The idea was there in
different machines before we implement here but not in way that we implemented now. But
those idea was helpful for our project.
Project Review on Ultrasonic Distance Measurement. Prakhar Shrivastava, Praveen Kumar,

Ankit Tiwari International Journal of Engineering and Technical Research ISSN: 2321-0869,
Special Issue.[1] “Ultrasonic sensors generate high frequency sound waves and evaluate the
echo which is received back by the sensor.”
Distance Sensing with Ultrasonic Sensor and Arduino. N. Anju Latha1, B. Rama Murthy, K.
Bharat Kumar Department of Instrumentation, Sri Krishnadevaraya University, Anantapur,
A.P., India. [2]“The sensor is perfect for distance measurements between moving or stationary
objects.”
Distance Measurement using Ultrasonic Sensor and Arduino CH. Neeraja Soni1, CH.Sarita,
Shrikant Maheshwari, Basant kumar Sahu, Bhavishya Jain, Garima Shrivastava Student,
Assistant ProfeesorYITM, Rajnandgaon, India. [3] “This distance measurement system can be
widely used as range meters and as proximity detectors in industries”.
Wireless distance measurement system. Affiliated to Maulana Abul Kalam Azad University of
Technology, West Bengal CANAL SOUTH ROAD, BELIAGHATA, and KOLKATA –
700015 MAY, 2018[4] “Distance measurement has important applications in automotive and
industrial applications.”
Modelling and control of a rotating turret winder used in roll-to-roll manufacturing Aravind
Seshadri, Prabhakar R.Pagilla. School of Mechanical & Aerospace Engineering, Oklahoma
State University, Stillwater, OK74078, United States [5]“Winding is a critical operation in sack
manufacturing and affects the overall productivity and quality of the finished products”
PP Woven Bag Production Founded in 1972, Phyllis has been in the machinery business for
over 40 years.” [6]Automatic roll change system with max machine running speed at 80
m/min”

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4.7 Methodology
4.7.1 Block diagram
LCD
Power display
supply
Buzzer
and led
Oscillator
Micro controller
Motor Dc
drive motor
Potentiometer Ultrasonic
sensor
Motor Dc
drive motor
Figure 24. Block diagram

4.7.2 Component description
Power supply
A power supply is a device that supplies electric power to an electrical load. The term is most
commonly applied to electric power converters that convert one form of electrical energy to
another, though it may also refer to devices that convert another form of energy (mechanical,
chemical, solar) to electrical energy. A regulated power supply is one that controls the output
voltage or current to a specific value; the controlled value is held nearly.
The input to controlling circuit is applied from the regulated power supply. The AC input (i.e.,
220v) from the main supply is step down by the transformer to 5v and fed to rectifier. The
output obtained from the rectifier is DC voltage. So, in order to get a pure DC voltage, the
output voltage from rectifier is feed to a diode filter to remove any AC components even after
rectification. Now this voltage is given to voltage regulator to obtain a pure constant DC
voltage.
Resistor
Resistors are components used to resist the flow of electric current. Many types of resistors are
used having different uses and construction. The most common types have a fixed value of

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resistance so are often called fixed resistors. Resistors are also used to reduce voltages and
currents around a circuit so that ‘active components’, transistors and integrated circuits for
example, that carry out tasks such as producing or amplifying signals within the circuit are
supplied with the correct voltages and currents to work properly. Because resistors are ‘passive
components’ they cannot amplify or increase voltages currents or signals, they can only reduce
them.
Figure 25. Resistor

Transistors
Transistors are a three terminal semiconductor device used to regulate current, or to amplify an
input signal into a greater output signal. Transistors are also used to switch electronic signals.
The circulation of electrical current through all types of transistors is adjusted by electron
addition. This process creates variations in voltage to cause proportionally larger variations in
output current, creating amplification.
Transistors can also work as switches. A tiny electric current flowing through one part of a
transistor can make a much bigger current flow through another part of it. In other words, the
small current switches on the larger one.
The PN2222 is a conjoint NPN bipolar junction transistor which is used for common
persistence less power intensifying or swapping circuits applications. The PN2222 is an NPN
transistor the pin out of emitter and collector will be uncluttered when we attach base pin with
the ground and these pins will be fastened when a signal is delivered on base. Its gain value is
110 to 800; this value governs the intensification capability of the transistor. The maximum
quantity of current that can drift by the collector pin is 800mA; here after we cannot attach
loads which devour more than 800 mA by this transistor.it is used where high current consumer
loads in the circuit, in numerous swapping submissions, to control the speed of different types
of motors, in inversion and rectification circuits.

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Figure 26. Transistor
Buzzer
Buzzer is a kind of voice device that converts audio model into sound signal. It is mainly used
to prompt or alarm. According to different design and application, it can produce music sound,
flute sound, buzzer, alarm sound, electric bell and other different sounds. It is widely used in
household appliance, alarm system, automatic production line, low voltage electrical
equipment, and other products. In home security system the buzzer alarm is included in the
circuit to come on when a wrong pin is inserted, so as to alert against intruders. When a wrong
pin is entered the microcontroller activates the port to which the Buzzer is connected to.
Figure 27. Buzzer
Motor driver
Motor drivers act as an interface between the motors and the control circuits. Motor require
high amount of current whereas the controller circuit works on low current signals. So the
function of motor drivers is to take a low-current control signal and then turn it into a higher-
current signal that can drive a motor.
L6201 is a motor driver that can be interfaced with an Arduino microcontroller or any 3.3v-5v
based microcontroller. This motor driver module can be handle up to 48v and handle a

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maximum of 1 amp of current.(sufficient cooling is required to pull out 2 amp.)This motor

drive is based on the L6201, which is a full bridge drive controller board allowing for
backwards and forwards motion.
Figure 28. Motor drive

DC motor
The direct current motor is a device that used in many industries in order to convert electrical
energy to mechanical energy. DC motor plays a significant role in modern industry. The
purpose of a motor speed controller is to take a signal representing the demand speed, and to
drive a motor at that speed. There are many applications in our life that requires DC motor
speed control. In home appliance, washers, dryers and compressors are good example. Dc
motors have been used in variable speed drivers for a long time.
Basically there are three main objectives
1. To design the hardware of the controller to control DC motor speed.
2. To develop controller using microcontroller as programming.
3. To develop precisely control the DC motor.
Figure 29. DC motor

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Oscillator
Oscillators are used to provide clock to the microcontroller.in a microcontroller or
microprocessor, every instruction is executed in synchronization with clock.it provides timing
for different operations in a microcontroller. A crystal oscillator is an electronic oscillator
circuit that uses mechanical resonance of a vibrating crystal of piezoelectric material to create
an electrical signal with a constant frequency.
This frequency is often used to keep track of time, as in quartz wristwatches, to provide a stable
clock signal for digital integrated circuits, and to stabilize frequencies for radio transmitters
and receivers. The most common type of piezoelectric resonator used is the quartz crystal, so
oscillator circuits incorporating them became known as crystal oscillators.
Figure 30. Oscillator
LCD
LCDs are alphanumeric (or graphic) displays which are frequently used in microcontroller-
based applications. Some LCDs have forty or more-character lengths with the capability to
display several lines, and other can be programmed to display graphic images. Some modules
offer colour displays, while others incorporate backlighting so they can be viewed in dimly lit
conditions. There are basically two types of LCDs as far as the interfacing technique is
concerned: parallel and serial. Parallel LCDs (e.g., the Hitachi HD44780 series) are connected
to the microcontroller circuit such that data is transferred to the LCD using more than one line,
usually four or eight data lines. Serial LCDs are connected to a microcontroller using one data
line only, and data is transferred using the RS232 asynchronous data communications protocol.
Serial LCDs are generally much easier to work with but more costly than parallel ones. In this
activity only parallel LCDs are discussed, as they are used more often in microcontroller-based
projects. The LCD display is a module that contains its own data pins. Accessing these pins

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and connecting to proper connection to the microcontroller will give the correct display.
Always check the datasheet for every LCD display module.
Figure 31. LCD display

Applications of LCD
 The LCDs are commonly used in all the digital wrist watches for displaying time.
 The LCD (liquid crystal display) is used in aircraft cockpit displays.
 It is used for displaying images used in digital cameras.
 It is used in instruments panel where all the lab instruments uses LCD screens for
display.
 It is used as a display screen in calculators.
 The television is main applications of LCD.
 Mostly the computer monitor is made up of LCDs.
 The LCDs are used in mobile screens.
 It is also used in video players.
Ultrasonic sensor
An ultrasonic sensor is an electronic device that measures the distance of a target object by
emitting ultrasonic sound waves, and converts the reflected sound into an electrical signal.
Ultrasonic waves travel faster than the speed of audible sound (i.e. the sound that humans can
hear). Ultrasonic sensors have two main components: the transmitter (which emits the sound
using piezoelectric crystals) and the receiver (which encounters the sound after it has travelled
to and from the target).

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In order to calculate the distance between the sensor and the object, the sensor measures the
time it takes between the emissions of the sound by the transmitter to its contact with the
receiver. The formula for this calculation is D = ½ T x C (where D is the distance, T is the
time, and C is the speed of sound ~ 343 meters/second). For example, if a scientist set up an
ultrasonic sensor aimed at a box and it took 0.025 seconds for the sound to bounce back, the
distance between the ultrasonic sensor and the box would be: D = 0.5 x 0.025 x 343.
Ultrasonic sensors are used primarily as proximity sensors. They can be found in automobile
self-parking technology and anti-collision safety systems. Ultrasonic sensors are also used in
robotic obstacle detection systems, as well as manufacturing technology. In comparison to
infrared (IR) sensors in proximity sensing applications, ultrasonic sensors are not as susceptible
to interference of smoke, gas, and other airborne particles (though the physical components are
still affected by variables such as heat).
Ultrasonic sensors are also used as level sensors to detect, monitor, and regulate liquid levels
in closed containers (such as vats in chemical factories). Most notably, ultrasonic technology
has enabled the medical industry to produce images of internal organs, identify tumours, and
ensure the health of babies in the womb.
How Ultrasonic Sensors Work.
Ultrasonic sensors work by sending out a sound wave at a frequency above the range of
human hearing. The transducer of the sensor acts as a microphone to receive and send
the ultrasonic sound. Our ultrasonic sensors, like many others, use a single transducer to
send a pulse and to receive the echo. The sensor determines the distance to a target by
measuring time lapses between the sending and receiving of the ultrasonic pulse.
Figure 32. Ultrasonic sensor working principle

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Ultrasonic sensor which has a transmitter, receiver. The pin configuration is,
 VCC - +5 V supply
 TRIG – Trigger input of the sensor. Microcontroller applies 10 us trigger pulse to the
HC-SR04 ultrasonic module.
 ECHO–Echo output of the sensor. Microcontroller reads/monitors this pin to detect the
obstacle or to find the distance.
 GND – Ground
Sound is a mechanical wave travelling through the mediums, which may be a solid, or liquid
or gas. Sound waves can travel through the mediums with specific velocity depends on the
medium of propagation. The sound waves which are having high frequency reflect from
boundaries and produce distinctive echo patterns.
Features of an Ultrasonic Sensor
1. Supply voltage: 5V (DC).

2. Supply current: 15mA.
3. Modulation frequency: 40Hz.
4. Output: 0 – 5V (Output high when obstacle detected in range).
5. Beam Angle: Max 15 degrees.
6. Distance: 2 cm – 400 cm.
7. Accuracy: 0.3cm.
8. Communication: Positive TTL pulse.
Figure 33. Ultrasonic sensor

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Potentiometer
A potentiometer is a three-terminal resistor with a sliding or rotating contact that forms an

adjustable voltage divider. If only two terminals are used, one end and the wiper, it acts as
a variable resistor or rheostat.
The measuring instrument called a potentiometer is essentially a voltage divider used for
measuring electric potential (voltage); the component is an implementation of the same
principle, hence its name.
Potentiometers are commonly used to control electrical devices such as volume controls on
audio equipment. Potentiometers operated by a mechanism can be used as position transducers,
for example, in a joystick. Potentiometers are rarely used to directly control significant power
(more than a watt), since the power dissipated in the potentiometer would be comparable to the
power in the controlled load.
Figure 34. Potentiometer
Micro controller (PIC16F877A)
The PIC microcontroller PIC16f877a is one of the most renowned microcontrollers in the
industry. This microcontroller is very convenient to use, the coding or programming of this
controller is also easier. One of the main advantages is that it can be write-erase as many times
as possible because it uses FLASH memory technology. It has a total number of 40 pins and
there are 33 pins for input and output. PIC16F877A is used in many pic microcontroller
projects. PIC16F877A also have much application in digital electronics circuits.
PIC16f877a finds its applications in a huge number of devices. It is used in remote sensors,
security and safety devices, home automation and many industrial instruments.

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An EEPROM is also featured in it which makes it possible to store some of the information
permanently like transmitter codes and receiver frequencies and some other related data. The
cost of this controller is low and its handling is also easy. It is flexible and can be used in areas
where microcontrollers have never been used before as in microprocessor applications and
timer functions etc.
 It has a smaller 35 instructions set.
 It can operate up to 20MHz frequency.
 The operating voltage is between 4.2 volts to 5.5 volts. If you provide it voltage more
than 5.5 volts, it may get damaged permanently.
 It does not have an internal oscillator like other PIC18F46K22, PIC18F4550.
 The maximum current each PORT can sink or source is around 100mA. Therefore, the
current limit for each GPIO pin of PIC16F877A is 10 mili ampere.
 It is available in four IC packaging such as 40-pin PDIP 44-pin PLCC, 44-pin TQFP,
44-pin QFN
Pin configuration and description of PIC16F877A microcontroller
As it has been mentioned before, there are 40 pins of this microcontroller IC. It consists of two
8 bit and one 16 bit timer. Capture and compare modules, serial ports, parallel ports and five
input/output ports are also present in it. This picture shows the pinout diagram of PIC16F877A.
Figure 35. Pin configuration

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PIN 1: MCLR: The first pin is the master clear pin of this IC. It resets the microcontroller and
is active low, meaning that it should constantly be given a voltage of 5V and if 0 V are given
then the controller is reset. Resetting the controller will bring it back to the first line of the
program that has been burned into the IC.
PIN 2: RA0/AN0: PORTA consists of 6 pins, from pin 2 to pin 7, all of these are bidirectional
input/output pins. Pin 2 is the first pin of this port. This pin can also be used as an analogue pin
AN0. It is built in analogue to digital converter.
PIN 3: RA1/AN1: This can be the analogue input 1.
PIN 4: RA2/AN2/Vref- : It can also act as the analogue input2. Or negative analogue reference
voltage can be given to it.
PIN 5: RA3/AN3/Vref+: It can act as the analogue input 3. Or can act as the analogue positive
reference voltage.
PIN 6: RA0/T0CKI: To timer0 this pin can act as the clock input pin, the type of output is
open drain.
PIN 7: RA5/SS/AN4: This can be the analogue input 4. There is synchronous serial port in the
controller also and this pin can be used as the slave select for that port.
PIN 8: RE0/RD/AN5: PORTE starts from pin 8 to pin 10 and this is also a bidirectional input
output port. It can be the analogue input 5 or for parallel slave port it can act as a ‘read control’
pin which will be active low.
PIN 9: RE1/WR/AN6: It can be the analogue input 6. And for the parallel slave port it can act
as the ‘write control’ which will be active low.
PIN 10: RE2/CS/A7: It can be the analogue input 7, or for the parallel slave port it can act as
the ‘control select’ which will also be active low just like read and write control pins.
PIN 11 and 32: VDD: These two pins are the positive supply for the input/output and logic
pins. Both of them should be connected to 5V.
PIN 12 and 31: VSS: These pins are the ground reference for input/output and logic pins. They
should be connected to 0 potential.
PIN 13: OSC1/CLKIN: This is the oscillator input or the external clock input pin.
PIN 14: OSC2/CLKOUT: This is the oscillator output pin. A crystal resonator is connected
between pin 13 and 14 to provide external clock to the microcontroller. ¼ of the frequency of
OSC1 is outputted by OSC2 in case of RC mode. This indicates the instruction cycle rate.

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PIN 15: RC0/T1OCO/T1CKI: PORTC consists of 8 pins. It is also a bidirectional input

output port. Of them, pin 15 is the first. It can be the clock input of timer 1 or the oscillator
output of timer 2.
PIN 16: RC1/T1OSI/CCP2: It can be the oscillator input of timer 1 or the capture 2
input/compare 2 output/ PWM 2 output.
PIN 17: RC2/CCP1: It can be the capture 1 input/ compare 1 output/ PWM 1 output.
PIN 18: RC3/SCK/SCL: It can be the output for SPI or I2C modes and can be the input/output
for synchronous serial clock.
PIN 18: RC3/SCK/SCL: It can be the output for SPI or I2C modes and can be the input/output
for synchronous serial clock.
PIN 24: RC5/SDO: It can be the data out of SPI in the SPI mode.
PIN 25: RC6/TX/CK: It can be the synchronous clock or USART Asynchronous transmit pin.
PIN 26: RC7/RX/DT: It can be the synchronous data pin or the USART receive pin.
PIN 19, 20, 21, 22, 27, 28, 29, and 30: All of these pins belong to PORTD which is again a
bidirectional input and output port. When the microprocessor bus is to be interfaced, it can act
as the parallel slave port
PIN 33-40: PORT B: All these pins belong to PORTB. Out of which RB0 can be used as the
external interrupt pin and RB6 and RB7 can be used as in-circuit debugger pins.
Figure 36. Microcontroller (PIC16F877A)

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4.7.3 Software design and development of the system
The software design is performed using PROTEUS 8 professional software as follows:

1. Open the Proteus 8 professional software.
2. Create a new Project
3. Insert the components below
 MCU(PIC16F877A)
 Resistor
 Crystal
 LM016L (LCD)
 Ultrasonic sensor
 Transistor (PN2222)
 POT-HG(potentiometer)
 Dc motor
 Led yellow
 Buzzer
 L6201(motor drive)
4 connect the above components as follow:
Figure 37 Overall circuit connection

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4.7.4 Flow chart
Figure 38. Flowchart

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4.7.5 Working principle and procedure

 12v and 5v dc power supply from power bank
 The 5v dc Supply is given to Microcontroller, LCD and Buzzer and 12v for motor drive.
 The first roll is on the work
 The ultrasonic sensor receive the input from potentiometer
 Then it changes the input from potentiometer in to the distance
 Then the micro controller compare the given distance within the limit
 If the distance reach the limit the buzzer alarm and automatically the roll changed to
the next
 The LCD display the fabric meter as well as the roll situation
4.7.6 Design and calculation of ultrasonic sensor
1. Send a pulse of at least 10 us through the trigger pin,

2. Set pin B0 as interrupt on rising edge
3. When interrupt occurs, clear timer 1 and start timer1
4. Set pin B0 as interrupt on falling edge
5. When interrupt occurs, read the value of timer1 and in a variable.
6. Multiply the value of timer1 by 0.0034
7. The final result gives your distance in meters. You can now display it
This are the procedures that I followed so I make use of timer 1 which is a 16bit timer, timer1
interrupt and external interrupt. I use timer1 interrupt because I noticed that timer1 overflows
before 23 ms, hence it measures only a fraction of the distance. So using the interrupt, I was
able to know exactly how many times the timer overflows and added it to the timer value. You
will see me do that in the code.
I know you will be wondering where I got the figure 0.0034. Let explain it step by step.
I used 20MHz crystal so I have 20/4 = 5 million instructions per second.
Period = 0.2 us.
So timer increments every 0.2 us

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Time = TIMER1 * 0.2 us.
Distance = velocity*time (speed of sound is 340m/s)
Distance = TIMER1 * 340*0.2*10^-6
Distance = TIMER1*68*10^-6 (but the distance is through and fro. So we divide by 2)
Distance = TIMER1*34*10^-6 (we multiply by 100 to have it in cm)
Distance = TIMER1*0.0034.

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4.8 Simulation and Result
Result one:- roll one is on the work until the distance of the fabric is less than 50 m this roll is
also the LCD display will show the status of the fabric in meter depending on the value given
from ultrasonic sensor
Figure 39. Result one

Result two:- when the distance of the fabric is reach its limit 50m, then the buzzer and the
led will be turn on simultaneously for 5 seconds until the roll become empty. The LCD will
also display “roll 1 empty”.

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Figure 40. Result two

Result three:- the roll is less than the limit that is 50m the roll 1 changed to the roll two as
well as the led and the buzzer will turn off and the LCD display ”roll changed”.
Figure 41. Result three

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4.9 Conclusion
To sum up all and conclude our project, we have earned a lot during our stay in this internship
program at HAN*plast manufacturing plc. And we have worked on this project on a problem
we pointed out in the manufacturing process of the company, particularly on cutting section,
and proposed a new designed system to make better manufacturing process.
We have included all the needed predesign procedures in our paper work, related with all the
study introductory, data collection, analysis, feasibility studies, Design procedures, Simulation
and illustration.
During our project work here, we had gone through all the steps required, and this step was
filled with new challenges and new ideas to beat these challenges. And we have earned great
experience in each and every step we made. Since this project integrates the concepts of
Electrical Engineering disciplines, we have gained a lot in doing it so. Alongside with learning
how to manage and work on a successful deign as an Engineer.
4.10 Recommendation
First and for most we recommend HAN*plast manufacturing plc to make an overall overview
on our designed Project and support our idea so as to solve the mentioned problem in the
particular line.
We also recommend those whom concerns to put further progressive works and studies on
developing this idea furthermore.
4.11 Contribution
As the main work of the electricians in the factory is maintenance, either preventive or
corrective, we participated as much as we can.

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CHAPTER FIVE
5 Conclusion and Recommendation
5.1 Conclusion
All in one, we think it would be fair to say that the internship program has been an enlightening
experience .We tried to put what we have been learning in the university, which is theoretical
knowledge, into practice and we got insight into practical work. The internship helped us to
gain the exposure to real-world problems and issues that, some of them, perhaps are not found
in textbooks. So we can say it was the time for us to challenge our knowledge. It also helped
us to recognize the environment that we will join after graduation. During our internship period
we have gained practical skills such as:
 Identifying many electrical and control devices that are installed in the automation
system of the factory.
 We had been familiar with different electrical inputs (sensors) to output devices
installed to control the production of the company.
 We have gotten a better skill, experience and personal qualities in the working
environment.
 We find out what it’s like to work in business environment.
 Investigate organization cultures and learns career- related skill.
Generally, the internship helped us to upgrade our theoretical knowledge and improve practical
skills, team playing skills, leader ship skills, interpersonal communication, written and oral
communication skill, and be aware of ethical issues. We perceive this opportunity as big mile
stone in our career development, we will strive to use gained skills and knowledge in the best
possible way, and we will continue to work on our improvement, in order to attain career
objectives.
The internship also helped us to find out what our strengths and weakness are. This helped us
to identify the skills and knowledge that must be improved in the coming time.
At last this internship was a useful experience and has given us new insights and motivation to
continue in the field of electrical engineering.

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5.2 Recommendation
5.2.1 Recommendation for HAN*PAST company

 To work on safe environment, the company should think on providing PPE’s for
intern students
 The work load and the payment of employees are uncompensated and due to
this some of the engineers are leaving the company. So they should improve the
wage for employees
 The company should employ additional electricians as there is work load in

every section
 We would like to address the employees working discipline. Most of the

employees in the company are frustrated due to their wage, so they should do
their job ethically and ask for payment improvement in ethical way
 Supervisors in the company should give enough time for the students. As we see
in the company, everything is done by the endeavour of the student. The human
resource management should think about this so as to decrease the load of the
student.
 The company should considered to open café for the employees because it’s
difficult to find lunch and dinner from the environment and surroundings.
 The company should build a network to identify employees with skill problems
and give them enough training so as to make them well skilled
 The company should prepare additional taxi services to the employees.
 The company should consider to give pocket money to internship student
 The company should give priority to students who attend their internship on the
company
5.2.2 Recommendation for the School
Two or three month are not enough for the students to know the external non-academic world.
If it possible, more time must be given for this internship time from the five year. If it is not

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possible, giving more time for laboratory, workshop and experiment class may improve the
student’s ability to know more knowledge than theoretical studying
5.2.3 Recommendation for the Industry Linkage

If the linkage builds good relationship with the industries and factories in the country, they
may willingly accept more students. This will reduce the tiredness of the student for searching
a factory to spend their internship period. So the industry linkage should strengthen relations
with factories and industries

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Reference
[1] P. Shrivastava, P. Kumar, and A. Tiwari, “Project Review on Ultrasonic
Distance Measurement,” Int. J. Eng. Tech. Res., no. Special Issue, pp.
218–220, 2014.
[2] N. Anju Latha, B. Rama Murthy, and K. B. Kumar, “ISSN: 2454-132X

Impact factor: 4.295 Distance Sensing with Ultrasonic Sensor and
Arduino,” Int. J. Adv. Res. Ideas Innov. Technol., vol. 2, pp. 1–5, 2016.
[3] S. Sunitha, “Distance Measurement using Ultrasonic Sensor and

NodeMCU,” Int. Res. J. Eng. Technol., vol. 4, no. 6, pp. 1794–1797,
2017, [Online]. Available: https://irjet.net/archives/V4/i6/IRJET-
V4I6575.pdf.
[4] R. No, “WIRELESS DISTANCE MEASUREMENT SYSTEM

Registration No :,” 2018.
[5] A. Seshadri and P. R. Pagilla, “Modeling and control of a rotating turret

winder used in roll-to-roll manufacturing,” Control Eng. Pract., vol. 41,
no. June, pp. 164–175, 2015, doi: 10.1016/j.conengprac.2015.04.009.
[6] “Introduction.”
[7] Company document

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Appendix
sbit LCD_RS at RB2_bit;
sbit LCD_EN at RB3_bit;
sbit LCD_D4 at RB4_bit;
sbit LCD_RS_Direction at TRISB2_bit;
sbit LCD_EN_Direction at TRISB3_bit;
sbit LCD_D4_Direction at TRISB4_bit;
sbit TRIG at RC3_bit;
sbit TRIG_Direction at TRISC3_bit;
sbit ECHO at RC2_bit;
sbit ECHO_Direction at TRISC2_bit;
unsigned long int dist=0,limit,cnt;
unsigned char txt[15];
void interrupt() {
if (INTCON.INTF == 1){ // detect rising edge
if (OPTION_REG.INTEDG ==1){
T1CON.TMR1ON = 1; // put on timer1
OPTION_REG.INTEDG = 0; // set interrupt on falling edge
}
else if (OPTION_REG.INTEDG == 0){ // detect falling edge
T1CON.TMR1ON = 0; // put off timer1
dist =((65536*cnt)+(TMR1L | (TMR1H<<8)))*0.0034;
limit =14705.89*0.0034;
//alert = 41177*0.0034;
TMR1L=0; // clear timer1L

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TMR1H=0; // clear timer1H

cnt=0; // clear cnt variable
OPTION_REG.INTEDG = 1; // set interrupt on rising edge
}
INTCON.INTF = 0;
}
else if (PIR1.TMR1IF == 1){ // timer1 overflow
cnt++;
PIR1.TMR1IF =0;
}
}
void main() {
adcon1=7;
OPTION_REG.INTEDG = 1; //INTERRUPT ON RISING EDGE
T1CON = 0x09; // timer control register
INTCON = 0xD0; // interrupt control register
PIE1.TMR1IE=1; // timer1 interrupt enable bit
T1CON.TMR1ON = 0; // timer1 0ff initially
trisb0_bit=1;
trisc=0;
trisa=0;
portc=0;
trisd=0;
porta=0;
portd.f0=0;
lcd_init();
Lcd_Cmd(_Lcd_Clear);
Lcd_Cmd(_Lcd_Cursor_off);
Lcd_out(1,1,"unwinder-roll");
Lcd_out(2,1,"diameter measurm");
delay_ms(1000);

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Lcd_Cmd(_Lcd_Clear);
Lcd_out(1,1,"fabricmtr= ");
do{
Inttostr(dist,txt);
Ltrim(txt);
Lcd_out(1,11,txt);
Lcd_out_cp(" m ");
TRIG=1;
delay_us(10);
TRIG=0;
delay_ms(100);
if(dist<=limit){
portd.f0=~portd.f0;
delay_ms(50);
lcd_cmd(_lcd_clear);
Inttostr(dist,txt);
Ltrim(txt);
Lcd_out(1,12,txt);
Lcd_out_cp(" m ");
TRIG=1;
delay_us(10);
TRIG=0;
Lcd_out(2,1,"roll 1 empty");
delay_ms(5000);
porta.f0=0;
porta.f1=0;
porta.f2=1;
portd.f0=0;
lcd_out(2,1,"roll 2 changed");

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delay_ms(50000);
}
else
{
porta.f0=1;
porta.f2=0;
}
}
while(1);
}

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DIRE DAWA UNIVERSITY

DIRE DAWA INSTITUTE OF TECHNOLOGY

SCHOOL OF ELECTRICAL AND COMPUTER ENGINEERING

Focus Area: Industrial control Engineering

HOSTING COMPANY: HAN*PLAST MANUFACTURING PLC

NAME OF INTERNS ID. NO.

1 BEMNET ASRES R/5009/09

MENTER: Mr. HAMZA A.

NAME OF MENTER SIGNATURE DATE

Mr. HAMZA A. __________ __________

NAME OF INTERNS SIGNATURE DATE

1 BEMNET ASRES __________ __________

2 BRUKTAWIT G/MESKEL __________ __________

3 ERMIAS DEMEKE __________ __________

4 FUAD MURAD __________ __________

5 MINALE GASHAW __________ __________

INTERNSHIP REPORT ON HAN*PLAST I

INTERNSHIP REPORT ON HAN*PLAST II

INTERNSHIP REPORT ON HAN*PLAST III

Table 1. Chemicals and their supplier........................................................................................ 3

INTERNSHIP REPORT ON HAN*PLAST IV

INTERNSHIP REPORT ON HAN*PLAST V

Figure 32. Ultrasonic sensor working principle .................................................................... 43

INTERNSHIP REPORT ON HAN*PLAST VI

INTERNSHIP REPORT ON HAN*PLAST VII

2.2 How we did get the company ......................................................................................... 10

INTERNSHIP REPORT ON HAN*PLAST VIII

4.7.1 Block diagram.......................................................................................................... 37

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HDPP High density polyethylene

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Figure 1. HAN*PLAST factory bird eye view

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1.2 Vision , Mission and Objective of the company

1.2.2 Mission of the company

1.2.3 Objective of the company

1.3 Social services given to the employee

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1.4 Raw materials, Accessory suppliers, Machines and power consumption

1.4.1 Raw materials

In Han*plast manufacturing Company the major raw material is polypropylene, poly-ethylene

1.4.2 Accessories and their Suppliers

1 Polypropylene pellets 14,8500 ton

the table below

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1.5 Products and customers

1.5.1 The customers of the company

 Ture cement factory

1.6 Environmental policy

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1.7 Overall organizational structure of the company

Production & technique department Finance department HR &ADMIN

Shift Shift bailing

Figure 2. Organizational structure

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1.7.1 Task of each section

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1.8 Key Stake Holders of the Company

1.9 Production process of HAN*PLAST manufacturing plc

1.9.1 production process

Figure 3. Overall process of company

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Mr. HAMZA A.

1 BEMNET ASRES

2 BRUKTAWIT G/MESKEL

3 ERMIAS DEMEKE

4 FUAD MURAD

5 MINALE GASHAW