SIX WEEKS INDUSTRIAL TRAINING

IN
AUTOMATION
In partial fulfillment for the award of the degree
Of
BACHELOR OF TECHNOLOGY
IN
ELECTRICAL ENGINEERING

Submitted By:-
NAVJEET SINGH
16105002
 COMPANY PROFILE

This report is on 6 weeks industrial training at wonder system (INDIA) Ltd. Automation
is most reputed training provider in automation products in industrial automation
industry. Involvement of modern technology in the process of industrial development
and automation is becoming more and more permanent. The Indian market is fast
growing up with new production technologies. This also helps us to upgrade the skills
of industrial work through short term specialized courses based on the Plc’s
(programmable logic controller) & AC &DC DRIVES, HMI &SCADA in the hi-tech area of
industry. This also provides diagnostics and development curriculum and also
introduced for manufactured

Situated in Mohali industrial area, company has one of the largest facilities in:

• In house fabrication using C.N.C and bendingmachines

• 7 tank metal treatment process

• Fully automatic powder coating plant

• In house software development of PLC, SCADA, HMI, A.C DRIVES, D.C DRIVES.

• Fully equipment’s customer training center as well as on-site training facility

 TRAINING OFFERED IN

• PLC: - GE FANUC, DELTA, UNITRONICS, ABB, SCHNEIDER, ALLEN BRADLEY, SIEMENS,

KINCO, L & T, CO-TRUST.

• A.C DRIVE: - PARKER, CROMPTON GREAVES, GEFRAN, SIEMENS, POWERTRAN,

POWERFLAX4, FUJI ELECTRIC, ALLEN BRADLEY, ABB, DELTA.

• D.C DRIVES :-PARKER , ABB ,GEFRAN, ANALOG SINGLE PHASE ,THREE PHASE

• H.M.I:- DELTA, SCHNEIDER, KINCO, PARKER.

OBJECTIVE

• To train new generation of skilled work force for service, maintenance commission
and programming, operation new range of machine, equipment being introduced by
industrial use, high technology operation andcontrol.

• To upgrade the skill existing industrial workers through short term specialized
course in the newly emerging high tech area of industry

• To provide diagnostic and development curriculum design and high live dialectic
support for training system as well as industrial consultancy facilities
INTRODUCTION

OF

AUTOMATION
Automation
Automation is the use of machines, control systems and information technologies to
optimize productivity in the production of goods and delivery of services. The main
incentive for applying automation is to increase productivity, and quality beyond that
possible with current human labor levels so as to realize economies of scale, and
realize predictable quality levels.

In the scope of industrialization, automation is a step beyond mechanization. The

mechanization provides human operators with machinery to assist them with the
muscular requirements of work. Automation greatly decreases the need for human
sensory and mental requirements while increasing load capacity, speed, and
repeatability.

Automation plays an increasingly important role in the world economy and in daily
experience. Automation has been achieved by various means including mechanical,
hydraulic, pneumatic, computers, electrical, and electronic usually in combination.

Applications
• Automated mining
• Automated highway systems
• Home automation
• Automated waste management
• Industrial automation
• Agriculture
• Transport applications
 • Traffic lights & road lights

Advantages
• Increased productivity.
• Improved quality.
• Improved robustness (consistency), of processes orproduct.
• Reduced direct human labor costs andexpenses.
• Reduce Waste.
• Reduce Production Cost.
• Less troubleshooting time.

Disadvantages

The main disadvantages of automation are:

• Causing unemployment and poverty by replacing human labor.
• High initial cost.
• Unpredictable/excessive development costs.
• Problem of Developing Countries.

Automation tools:-
• ANN - Artificial neural network
• PLC- Programmable Logic Controller
• MMI- Man Machine Interface
• HMI-Human Machine Interface
• AC & DC Motors
• AC & DC Drives
• SCADA- Supervisory Control And Data Acquisition
• DCS - Distributed Control System
• PAC - Programmable automation controller
Introduction to PLC
A Programmable Logic Controller (PLC) is a device that is capable of being
programmed to perform control functions. The first PLC was introduced in the late
1960s to replace relay logic controls in the automotive industry. Compared to relay logic
controls, the PLC's advantages include easy programming and installation, high control
speed, hardware and software security, network compatibility, troubleshooting and
testing convenience, and high reliability. PLCs are currently used widely in industrial and
commercial environments.

A Programmable Logic Controller, PLC is an electronic device used for Automation of

industrial processes, such as control of machinery on factory assembly lines. A
programmable controller is a digitally operating electronic apparatus which uses a
programmable memory for the internal storage of instructions for implementing
specific functions, such as logic, sequencing, timing, counting and arithmetic, to control
various machines or processes through digital or analog input/output devices.
Unlike general purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and
resistance to vibrations andimpacts.

Programs to control machine operation are typically stored in battery-backed or non

volatile memory. A PLC is an example of a real time system since output results are
produced in response to input conditions within a bounded time, otherwise unintended
operation results.

History of PLC
In 1968 GM Hydra-Matic (the automatic transmission division of General Motors)
issued a request for proposals for an electronic replacement for hard-wired relay
systems.

The winning proposal came from Bedford Associates of Bedford, Massachusetts. The
first PLC, designated the 084 because it was Bedford Associates' eighty-fourth project.
Dick Morley is considered to be the "father" of the PLC. The computer is connected to
the PLC through Ethernet, RS-232, RS-485 or RS-422 cabling.
Architecture of PLC

Architecture of a PLC

Internal Architecture
The basic internal architecture of a PLC. It consists of a central processing unit (CPU)
containing the system microprocessor, memory, and input/output circuitry. The CPU controls
and processes all the operations within the PLC. It is supplied with a clock that has a frequency
of typically between 1 and 8 MHz. This frequency determines the operating speed of the PLC
and provides the timing and synchronization for all elements in the system. The information
within the PLC is carried by means of digital signals. The internal paths along which digital
signals flow are called buses. In the physical sense, a bus is just a number of conductors along
which electrical signals can flow. It might be tracks on a printed circuit board or wires in a
ribbon cable. The CPU uses the data bus for sending data between the constituent elements,
the address bus to send the addresses of locations for accessing stored data, and the control
bus for signals relating to internal control actions. The system bus is used for communications
between the input/output ports and the input/output unit.

The CPU
The internal structure of the CPU depends on the microprocessor concerned. In general,
CPUs have the following:
•An arithmetic and logic unit (ALU) that is responsible for data manipulation and carrying out
arithmetic operations of addition and subtraction and logic operations of AND, OR, NOT, and
EXCLUSIVE-OR.
•Memory, termed registers, located within the microprocessor and used to store information
involved in program execution.
• A control unit that is used to control the timing of operations.

The Buses
The buses are the paths used for communication within the PLC. The information is transmitted
in binary form, that is, as a group of bits, with a bit being a binary digit of 1 or 0, indicating on/off
states. The term word is used for the group of bits constituting some information. Thus an 8-bit
word might be the binary number 00100110. Each of the bits is communicated simultaneously
along its own parallel wire. The system has four buses:
•The data bus carries the data used in the processing done by the CPU. A microprocessor
termed as being 8-bit has an internal data bus that can handle 8-bit numbers. It can thus
perform operations between 8-bit numbers and deliver results as 8-bit values.
•The address bus is used to carry the addresses of memory locations. So that each word can
be located in memory, every memory location is given a unique address. Just like houses in a
town are each given a distinct address so that they can be located, so each word location is
given an address so that data stored at a particular location can be accessed by the CPU, either
to read data located there or put, that is, write, data there. It is the address bus that carries the
information indicating which address is to be accessed.
If the address bus consists of eight lines, the number of 8-bit words, and hence number of
distinct addresses, is 28 ¼256. With 16 address lines, 65,536 addressesare possible.
•The control bus carries the signals used by the CPU for control, such as to inform memory
devices whether they are to receive data from an input or output data and to carry timing signals
used to synchronize actions.
•The system bus is used for communications between the input/output ports and the
input/output unit.

Memory
To operate the PLC system there is a need for it to access the data to be processed and
instructions, that is, the program, which informs it how the data is to be processed. Both are
stored in the PLC memory for access during processing. There are several memory elements in
a PLC system:
•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.
•Random-access memory (RAM) is used for data. 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. The data RAM is sometimes referred to as a data table or register table. Part of this
memory, that is, a block of addresses, will be set aside for input and output addresses and the
states of those inputs and outputs. Part will be set aside for preset data and part for storing
counter values, timer values, and the like.
•Possibly, as a bolt-on extra module, erasable and programmable read-only-memory (EPROM) is
used to store programspermanently.
Input/Output Unit
The input/output unit provides the interface between the system and the outside world, allowing
for connections to be made through input/output channels to input devices such as sensors
and output devices such as motors and solenoids. It is also through the input/output unit that
programs are entered from a program panel. Every input/output point has a unique address that
can be used by the CPU. It is like a row of houses along a road; number 10 might be the “house”
used for an input from a particular sensor, whereas number 45 might be the “house” used for
the output to a particular motor.

The input/output channels provide isolation and signal conditioning functions so that sensors
and actuators can often be directly connected to them without the need for other circuitry.

Electrical isolation from the external world is usually by means of optoisolators (the term
optocoupler is also often used). Figure 1.8 shows the principle of an optoisolator. When a digital
pulse passes through the light-emitting diode, a pulse of infrared radiation is produced. This
pulse is detected by the phototransistor and gives rise to a voltage in that circuit. The gap
between the light-emitting diode and the phototransistor gives electrical isolation, but the
arrangement still allows for a digital pulse in one circuit to give rise to a digital pulse in another
circuit.

The digital signal that is generally compatible with the microprocessor in the PLC is 5 V DC.
However, signal conditioning in the input channel, with isolation, enables a wide range of input
signals to be supplied to it (see Chapter 3 for more details). A range of inputs might be available
with a larger PLC, such as 5 V, 24 V, 110 V, and 240 V digital/discrete, that is, on/off, signals
(Figure 1.9). A small PLC is likely to have just one form of input, such as 24 V.
The output from the input/output unit will be digital with a level of 5 V. However, after signal
conditioning with relays, transistors, or triacs, the output from the output channel might be a 24
V, 100 mA switching signal; a DC voltage of 110 V, 1 A; or perhaps 240 V, 1 A AC or 240 V, 2 A
AC, from a triac output channel (Figure 1.10). With a small PLC, all the outputs might be of one
type, such as 240 V, 1 A AC. With modular PLCs, however, a range of outputs can be
accommodated by selection of the modules to be used.

Outputs are specified as being of relay type, transistor type, or triac type (see Chapter 3 for
more details):
•With the relay type, the signal from the PLC output is used to operate a relay and is able to
switch currents of the order of a few amperes in an external circuit. The relay not only allows
small currents to switch much larger currents but also isolates the PLC from the external circuit.
Relays are, however, relatively slow to operate. Relay outputs are suitable for AC and DC
switching. They can withstand high surge currents and voltage transients.
•The transistor type of output uses a transistor to switch current through the external circuit.
This gives a considerably faster switching action. It is, however, strictly for DC switching and is
destroyed by overcurrent and high reverse voltage. For protection, either a fuse or built-in
electronic protection is used. Optoisolators are used to provide isolation.
•Triac outputs, with optoisolators for isolation, can be used to control external loads that are
connected to the AC power supply. It is strictly for AC operation and is very easily destroyed by
overcurrent. Fuses are virtually always included to protect such outputs.

Advantages
• Easily understood programming language.
• Rugged and designed to withstand vibrations, temperature, humidity, and noise.
• Interfacing for inputs and outputs already inside the controller.
• Speed of operation.
• Security.
 • No. of contacts can beattached
• Flexibility.
• Easily operated.
• Pilot running.
• Reliability.
• Documentation.

Disadvantage
• Because it is a new technology, so that should require training.
• Some applications that perform a single function, is not efficient in the use of
PLC.
• Limited usage environments, high temperatures and harsh vibrations can
disrupt electronic equipment on the PLC.
• Fail-Safe operations.
• PLC is not considered necessary when applied to industrial systems that do
not need to change the wiring.

Logic gate
A logic gate is an idealized or physical device implementing a Boolean function, that is,
it performs a logical operation on one or more logical inputs, and produces a single
logical output. There are three basic types of logic gates:

• NOT gate

• AND gate

• OR gate
There are four universal logic gates:-

• NAND gate

• NOR gate
 • EX-OR gate

• EX-NOR gate

Relay
A relay is an electrically operated switch. Many relays use an electromagnet to operate
a switching mechanism mechanically. Relays are used where it is necessary to control a
circuit by a low-power signal (with complete electrical isolation between control and
controlled circuits), or where several circuits must be controlled by one signal.

Relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled circuits), or where several
circuits must be controlled by one signal. The first relays were used in long distance
telegraph circuits, repeating the signal coming in from one circuit and re-transmitting it
to another. Relays were used extensively in telephone exchanges and early computers
to perform logical operations.

Applications
• Electromagnetic relays are employed for the protection of various ac and dc
equipments.
• The over/under current and voltage protection of various ac and dc equipments.
• For differential protection.
• Used as auxiliary relays in the contact systems of protective relay schemes.
Advantages
• Decreased electrical noise when switching.
• Totally silent operation.
• Much less sensitive to storage and operating environment factors such as
mechanical shock, vibration, humidity, and external magneticfields.
• Relays can switch AC and DC, transistors can only switch DC.
• Relays can switch higher voltages than standardtransistors.
• Relays are often a better choice for switching large currents (> 5A).
• Relays can switch many contacts at once.
• Electromagnetic relays have fast operation and fast reset.
• They have the properties such as simple, robust, compact and most reliable.

Disadvantages
• Relays cannot switch rapidly (except reed relays), transistors can switch many
times per second.
• Relays use more power due to the current flowing through their coil.
• Relays require more current than many ICs can provide, so a low power transistor
may be needed to switch the current for the relay's coil.
• Requires periodic maintenance and testing unlike staticrelays.
• Relay operation can be affected due to ageing of the components and dust,
pollution resulting in spurious trips.

Contactor
A contactor is an electrically controlled switch used for switching a power circuit,
similar to a relay except with higher current ratings. A contactor is controlled by a circuit
which has a much lower power level than the switched circuit.

Contactors come in many forms with varying capacities and features. A contactor has
three components. The contacts are the current carrying part of the contactor. This
includes power contacts, auxiliary contacts, and contact springs. The electromagnet (or
"coil") provides the driving force to close the contacts. The enclosure is a frame housing
the contact and the electromagnet.

Contactors range from those having a breaking current of several amperes to

thousands of amperes and 24 V DC to many kilovolts. The physical size of contactors
ranges from a device small enough to pick up with one hand, to large devices
approximately a meter (yard) on aside.

Advantages
• In can operate high rating circuits.

• It is used in power circuits & control circuits.

• It can operate on AC & DC power supply.

• It works in single phase and three phase power supply.

Disadvantages
• It produces more noise at the time of switching.

Difference between Contactor and Relay

• Contactor is also more expensive and requires higher load than relay.
• Relay has limited current rating; contactors are available in higher current range.
• Relays are available in very small size but contactor has some limitations that it
is very difficult to get contactors in very low ratings.
• Maintenance of contactor will be difficult compare to relay in polluted
environment.
• A relay is cheaper than a contactor. A contactor is used for a higher load.
• Relays are usually used for circuitry control, where as contactors are used for
motor control.
Power supply
A power supply is a device that supplies electric power to an electrical load. This 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.
Every power supply must obtain the energy it supplies to its load, as well as any energy
it consumes while performing that task, from an energy source. Depending on its design,
a power supply may obtain energyfrom:
• Electrical energy transmission systems. Common examples of this include
power supplies that convert AC line voltage to DC voltage.
• Energy storage devices such as batteries and fuelcells.
• Electromechanical systems such as generators andalternators.
• Solar power.

Switched-mode power supply

A switched-mode power supply (SMPS) is an electronic power supply that incorporates

a switching regulator to convert electrical power efficiently. An SMPS transfers power
from a source, like main power, to a load while converting voltage and current
characteristics. The pass transistor of a switching-mode supply continually switches
between low-dissipation, full-on and full-off states, and spends very little time in the high
dissipation transitions, which minimizes wasted energy. This higher power conversion
efficiency is an important advantage of a switched-mode power supply. Switched-mode
power supplies may also be substantially smaller and lighter than a linear supply due to
the smaller transformer size andweight.

Switches
The simplest example of sensor outputs is switches and relays. A simple example is
shown in

Figure 1.1 An Example of Switched Sensors

In the figure a NO contact switch is connected to input 01. A sensor with a relay output
is also shown. The sensor must be powered separately; therefore the V+ and V-
terminals are connected to the power supply. The output of the sensor will become
active when a phenomenon has been
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