INDUSTRIAL TRAINING REPORT

PLC AND CNC SYSTEMS IN INDUSTRIAL MACHINE TOOLS

Submitted in partial fulfillment of the Requirements for the award of

Degree of Bachelor of Technology in Elec ronic! an" Co##$nica ion Engineering

Name: BODDA DURGA TE A Roll No: !""!"#"$!

SUBMITTED TO%

Department of Electronics and Communication Engineering S%hool of En&ineerin& and Te%hnolo&'( Sharda Uni)ersit' Greater Noida( U*+*,-"!#". /-"!-,-"!#0

DECLARATION
1 hereb' de%lare that the 1ndustrial Trainin& Report entitled 2+34 and 4N4 s'stems in industrial ma%hine tools2 is an authenti% re%ord of m' own wor5 as requirements of ., 6ee5s 1ndustrial Trainin& durin& the period from !7,".,-"!# to -8,"8,-"!# for the award of de&ree of B*Te%h* /Ele%troni%s and 4ommuni%ation En&ineerin&0( S%hool of En&ineerin& and Te%hnolo&'( Sharda Uni)ersit'( Greater Noida( under the &uidan%e of 9*Ar)ind 5umar*

&Signa $re of ! $"en ' Bo""a D$rga Te(a )**)*+*,) Da e%

4ertified that the abo)e statement made b' the student is %orre%t to the best of our 5nowled&e and belief*

Signa $re! E-a#ine" .y% !* -* #*

Hea" of De/ar #en &Signa $re an" Seal'

AC0NO1LEDGEMENT
The su%%ess and final out%ome of this pro:e%t required a lot of &uidan%e and assistan%e from man' people and 1 am e;tremel' fortunate to ha)e &ot this all alon& the %ompletion of m' pro:e%t wor5* 6hate)er 1 ha)e done is onl' due to su%h &uidan%e and assistan%e and 1 would not for&et to than5 them* 1 respe%t and than5( for &i)in& me an opportunit' to do the pro:e%t wor5 in B*<*E*3 and pro)idin& me all support and &uidan%e whi%h made me %omplete the pro:e%t on time* 1 am e;tremel' &rateful to him for pro)idin& su%h a ni%e support and &uidan%e* 1 owe m' profound &ratitude to our pro:e%t &uide 9*Ar)ind 9umar(Senior ele%troni%s mana&er of B*<*E*3( who too5 5een interest on our pro:e%t wor5 and &uided us all alon&( till the %ompletion of our pro:e%t wor5 b' pro)idin& all the ne%essar' information for de)elopin& a &ood s'stem* 1 am than5ful to and fortunate enou&h to &et %onstant en%oura&ement( support and &uidan%e from all Tea%hin& staffs of Department of Ele%troni%s and %ommuni%ations whi%h helped me in su%%essfull' %ompletin& m' pro:e%t wor5* Also( 1 would li5e to e;tend our sin%ere re&ards to all the non,tea%hin& staff of department of Ele%troni%s and %ommuni%ations for their timel' support*

BHARAT HEA2Y ELECTRICALS LIMITED 3O2ER2IE1

B<E3 is the lar&est en&ineerin& and manufa%turin& enterprise in 1ndia in the ener&' related=infrastru%ture se%tor toda'* B<E3 %aters to %ore se%tors of the 1ndian e%onom' wise( power &eneration and transmission( industr'( transportation( tele%ommuni%ation( renewable ener&'( defense et%* The wide networ5 of B<E3>s !7 manufa%turin& di)isions( four power se%tor re&ional %enters( o)er !?" pro:e%t sites( $ ser)i%e %enters and !$ re&ional offi%es( enables the %ompan' to promptl' ser)e its %ustomers and pro)ide them with suitable produ%ts( s'stems and ser)i%es,effi%ientl' and at %ompetiti)e pri%es* B<E3 has alread' attained 1SO @""" %ertifi%ation qualit' mana&ement( and 1SO !7""! %ertifi%ation and en)ironment mana&ement*

Po4er Genera ion

+ower &eneration se%tor %omprises thermal( &as( h'dro and nu%lear power plant business* As of #!*# -""!( B<E3,supplied sets a%%ount for nearl' .7( 8##A6 or .?B of the total installed %apa%it' of @@(!7. A6 in the %ountr'( as a&ainst nil till !@.@ to 8"* B<E3 has pro)en 5e' %apabilities for e;e%utin& power pro:e%ts from %on%ept to %ommissionin&* 1t possesses the te%hnolo&' and %apabilit' to produ%e thermal sets with super %riti%al parameters up to !"""A6 unit ratin& and &as turbine,&enerators sets of up to -7" A6 unit ratin&* 4o,&eneration and %ombined,%'%le plant ha)e been introdu%ed to a%hie)e hi&her plant effi%ien%ies* to ma5e effi%ien%ies use of the hi&h,ash %ontent %oal a)ailable in 1ndia( B<E3 supplies %ir%ulatin& fluidiCed bed %ombustion boilers to both thermal and %ombined D%'%le power plant The %ompan' manufa%tures -#? A6 nu%lear turbineD&enerator sets and has %ommen%ed produ%tion of ?""A6 nu%lear turbine &enerator sets* 4ustom,made h'dro sets of Eran%is( pelt on and 9aplan t'pes for different head, dis%har&e %ombinations are also en&ineered and manufa%tured b' B<E3*

1n all( orders for more than 8"" utilit' sets of thermal( h'dro( &as and nu%lear has been pla%ed on the %ompan' as on date* The power plant equipment manufa%tured b' B<E3 is based on %ontemporar' te%hnolo&' %omparable to the best in world( and is also internationall' %ompetiti)e* The %ompan' has pro)en e;pertise plant performan%e impro)ement throu&h reno)ation( moderniCation and upratin& of )ariet' power plant equipment( besides a spe%ialiCed 5now,how of residual life assessment( health dia&nosti%s and life e;tin%tion of plants*

Po4er Tran!#i!!ion an" Di! ri.$ ion

B<E3 offers wide,ran&e in produ%ts and s'stems for TFD appli%ations* +rodu%ts manufa%tured in%lude: +ower transformers( instruments transforms series and shunt rea%tors( %apa%itor blan5s( )a%uum and SE. %ir%uit brea5ers( &as,insulted swit%h &ear and insulators* A stron& en&ineerin& base enables the %ompan' to underta5e turn 5e' deli)er' of ele%tri% substations up to 7""9G le)el( series %ompensation s'stems /for in%reasin& power transfer %apabilit' of transmission of and impro)in& s'stem and )olta&e re&ulation0( shunt %ompensation s'stems /power fa%tor and )olta&e impro)ement0 and <GB4 s'stems /for e%onomi% transfer of bul5 power0* B<E3 indi&enousl' de)eloped the state,of,the,art %ontrol shunt rea%tor /for rea%ti)e power mana&ement on lon& transmission lines0( +resentl' a 7""9G EA4TS /fle;ible a% transmission s'stem0 pro:e%t is under e;e%ution* 1ndustries

B<E3 is a ma:or %ontributor of equipment and s'stems to industries: %ement( su&ar( fertiliCer( refineries( petro%hemi%als( paper( oil and &as( metallur&i%al pro%ess industries* The ran&e of s'stem and equipment supplied in%ludes: %apti)e power plants(

%o,&eneration plants( DG power plants( industrial steam turbines( industrial boilers and au;iliaries( waste heat re%o)er' boilers( &as turbines( heat e;%han&ers and pressure )essels %entrifu&al %ompressors( ele%tri%al ma%hines( pumps( )al)es( seam less steel tubes( ele%trostati% pre%ipitators fabri% filters( rea%tors( fluidiCed bed %ombustion boilers( %hemi%al re%o)er' boilers and pro%ess %ontrols* The %ompan' is a ma:or produ%er of lar&e siCe th'ristor de)i%es* 1t also supplies di&ital distributed %ontrol s'stems for pro%ess industries and %ontrol and instrumentation s'stems for power plant and industrial appli%ations* The %ompan' has %ommen%ed manufa%ture lar&e desalination plants to help au&ment the suppl' of drin5in& water to people*

Tran!/or a ion
B<E3 is in)ol)ed in the de)elopment desi&n( en&ineerin&( mar5etin&( produ%tion( installation( and maintenan%e and after,sales ser)i%e of rollin& sto%5 and tra%tion propulsion s'stems* 1n the area of rollin& sto%5( B<E3 manufa%tures ele%tri% lo%omoti)e up to ?"""<+( diesel,ele%tri% lo%omoti)es from #?"<+ to #!"" <+( both for main line and shuntin& dut' appli%ations* B<E3 is also produ%in& rollin& sto%5 for spe%ial appli%ations li5e o)erhead equipment %ars( spe%ial well wa&ons( rail,%um,road )ehi%le et%* Besides tra%tion propulsion s'stems for in,house use( B<E3 manufa%tures tra%tion propulsion s'stems for other sto%5 produ%ers of ele%tri% lo%omoti)es( diesel Dele%tri% lo%omoti)es( ele%tri%al multiples and metro parts* The ele%tri% and diesel tra%tion equipment on 1ndian railwa's is lar&el' powered b' ele%tri%al propulsion s'stems produ%ed b' B<E3*

Teleco##$nica ion!
B<E3 also %aters to tele%ommuni%ation se%tor b' wa' of small( medium and lar&e swit%hin& s'stems*

Rene4a.le Energy
Te%hnolo&ies that %an be offered b' B<E3 for e;ploitin& non,%on)entional and renewable sour%e of ener&' in%lude: wind ele%tri%al &enerator( solar photo )oltai% s'stems( solar heatin& s'stems( solar lanterns and batter', powered road )ehi%les* The %ompan' has ta5en up RFD efforts for de)elopment of multi,:un%tion amorphous sili%on solar %ells and fuel based s'stems*

Technology U/gra"a ion an" R 5 D

To remain %ompetiti)e and meet %ustomerHs e;pe%tations( B<E3 la's &reat emphasis on %ontinuous up &radation of produ%ts and related te%hnolo&ies( and de)elopment of new produ%ts* The %ompan' has up &raded its produ%ts to %ontemporar' le)els throu&h %ontinuous in,house efforts as well a%quisition of new te%hnolo&ies from leadin& en&ineerin& or&aniCations of the world* The %orporate resear%h and de)elopment di)ision at <'derabad( spread o)er a !7",a%re %omple;( leads B<E3Hs resear%h efforts in a number of areas of importan%e B<E3Hs produ%t ran&e* Resear%h and produ%t de)elopment at ea%h to the manufa%turin& di)isions pla' a %ontemporar' role* B<E3 has introdu%ed in the re%ent past( se)eral state,of,the,art produ%ts de)eloped in,house: oil=&as burners( %ir%ulatin& fluidiCed bed %ombustion boilers( hi&h effi%ien%' pelts h'dro turbine( petroleum depot automation s'stems( #.96 &as insulated substations( et%* The %ompan' has also transferred a few te%hnolo&ies de)eloped in,house to other 1ndian %ompanies for %ommer%ialiCation* Some of the on,&oin& de)elopment and demonstration pro:e%ts in%lude: smart )al)e blowin& s'stem for %leanin& boiler soot deposits( and mi%ro %ontroller based &o)ernor for diesel D ele%tri% lo%omoti)es* The %ompan' is also en&a&ed in futuristi% areas( su%h as appli%ation of super %ondu%tin& materials in power &eneration and industr'( and fuel %ells for distributed( en)ironment,friendl' power &eneration*

Ta.le of con en !
!* +ro&rammable lo&i% %ontrollers /+340 i* ii* iii* i)* )* i* ii* iii* i)* )* #* +34 histor' 3adder lo&i% and arra's +34 pro&rammin& +34 operation 4ase stud' 1ntrodu%tion Elements of 4N4 ma%hine tool Output elements 4onfi&uration of a 4N4 s'stem Elements of 4N4 ma%hine tool

-* 4N4 s'stems

Tools and te%hnolo&' used i* ii* 3adder lo&i% +ro%ess of Retrofittin&

7* Snapshots ?* 4on%lusion and future s%ope .* Referen%es

Li! of fig$re!
!* A Simple Rela' 3a'outs and S%hemati%s -* A Simple Rela' 4ontroller #* A +34 1llustrated with Rela's 7* A Seal in 4ir%uit ?* A Simple 3adder 3o&i% Dia&ram .* An E;ample of a Anemoni% and Equi)alent 3adder 3o&i% 8* An E;ample of a Sequential Eun%tion 4hart $* An E;ample of Stru%tured Tree +ro&ram @* The Separation of 4ontroller and +ro%ess !"* The S%an 4'%le of a +34

CHAPTERS INTRODUCTION TO PLC

4ontrol en&ineerin& has e)ol)ed o)er time* 1n the past humans were the main method for %ontrollin& a s'stem* Aore re%entl' ele%tri%it' has been used for %ontrol and earl' ele%tri%al %ontrol was based on rela's* These rela's allow power to be swit%hed on and off without a me%hani%al swit%h* 1t is %ommon to use rela's to ma5e simple lo&i%al %ontrol de%isions* The de)elopment of low %ost %omputer has brou&ht the most re%ent re)olution( the +ro&rammable 3o&i% 4ontroller /+340* The ad)ent of the +34 be&an in the !@8"s( and has be%ome the most %ommon %hoi%e for manufa%turin& %ontrols* +34s ha)e been &ainin& popularit' on the fa%tor' floor and will probabl' remain predominant for some time to %ome* Aost of this is be%ause of the ad)anta&es the' offer* !* Reliable %omponents ma5e these li5el' to operate for 'ears before failure* -* Ele;ible and %an be re,applied to %ontrol other s'stems qui%5l' and easil' #* 4omputational abilities allow more sophisti%ated %ontrol* 7* Troubleshootin& aids ma5e pro&rammin& easier and redu%e downtime* ?* Reliable %omponents ma5e these li5el' to operate for 'ears before failure*

)6) LADDER LOGIC

3adder lo&i% is the main pro&rammin& method used for +34s* As mentioned before( ladder lo&i% has been de)eloped to mimi% rela' lo&i%* The de%ision to use the rela' lo&i% dia&rams was a strate&i% one* B' sele%tin& ladder lo&i% as the main pro&rammin& method( the amount of retrainin& needed for en&ineers and tradespeople was &reatl' redu%ed* Aodern %ontrol s'stems still in%lude rela's( but these are rarel' used for lo&i%* A rela' is a simple de)i%e that uses a ma&neti% field to %ontrol a swit%h( as pi%tured in Ei&ure-*!* 6hen a )olta&e is applied to the input %oil( the resultin& %urrent %reates a

ma&neti% field* The ma&neti% field pulls a metal swit%h /or reed0 towards it and the %onta%ts tou%h(%losin& the swit%h* The %onta%t that %loses when the %oil is ener&iCed is %alled normall' open* The normall' %losed %onta%ts tou%h when the input %oil is not ener&iCed* Rela's are normall' drawn in s%hemati% form usin& a %ir%le to represent the input %oil* The output %onta%ts are shown with two parallel lines* Normall' open %onta%ts are shown as two lines( and will be open /non,%ondu%tin&0 when the input is not ener&iCed* Normall' %losed %onta%ts are shown with two lines with a dia&onal line throu&h them* 6hen the input %oil is not ener&iCed the normall' %losed %onta%ts will be %losed /%ondu%tin&0*

1nput %oil

or
Normall' %losed Normall' opened

or

Figure 1*Simple Relay Layouts and Schematics

Rela's are used to let one power sour%e %lose a swit%h for another /often hi&h %ur, rent0 power sour%e( while 5eepin& them isolated* An e;ample of a rela' in a simple %ontrol appli%ation is shown in Ei&ure -* 1n this s'stem the first rela' on the left is used as normall' %losed( and will allow %urrent to flow until a )olta&e is applied to the input A* The se%ond rela' is normall' open and will not allow %urrent to flow until a )olta&e is applied to the input B* 1f %urrent is flowin& throu&h the first two rela's then %urrent will flow throu&h the %oil in the third rela'( and %lose the swit%h for output 4* This %ir%uit would normall' be drawn in the ladder lo&i% form* This %an be read lo&i%all' as 4 will be on if A is off and B is on*

!!?) a% wall plu&

1nput A Normall' %losed

1nput B Normall' opened

1nput 4 Normall' open

3adder lo&i%

Figure 2 A simple relay controller

The e;ample in Ei&ure - does not show the entire %ontrol s'stem( but onl' the lo&i%* 6hen we %onsider a +34 there are inputs( outputs( and the lo&i%* Ei&ure # shows a more %omplete representation of the +34* <ere there are two inputs from push buttons* 6e %an ima&ine the inputs as a%ti)atin& -7G D4 rela' %oils in the +34* This in turn dri)es an output rela' that swit%hes !!?G A4( that will turn on a li&ht* Note( in a%tual +34s inputs are ne)er rela's( but outputs are often rela's* The ladder lo&i% in the +34 is a%tuall' a %omputer pro&ram that the user %an enter and %han&e* Noti%e that both of the input push buttons are normall' open( but the ladder lo&i% inside the +34 has one normall' open %onta%t( and one normall' %losed %onta%t* Do not thin5 that the ladder lo&i% in the +34 needs to mat%h the inputs or outputs* Aan' be&inners will &et %au&ht tr'in& to ma5e the ladder lo&i% mat%h the input t'pes*

+ush buttons

+ower suppl' I-7) %om

inputs

3adder lo&i%

outputs

!!?) a% power neutral

li&ht

Figure 3 A PLC illustrated with relays

Aan' rela's also ha)e multiple outputs /throws0 and this allows an output rela' to also be an input simultaneousl'* The %ir%uit shown in Ei&ure 7 is an e;ample of this( it is %alled a seal in %ir%uit* 1n this %ir%uit the %urrent %an flow throu&h either bran%h of the %ir%uit( throu&h the %onta%ts labelled A or B* The input B will onl' be on when the output B is on* 1f B is off( and A is ener&iCed( then B will turn on* 1f B turns on then the input B will turn on( and 5eep output B on e)en if input A &oes off* After B is turned on the output B will not turn off*

Note when A is pushed the output B will turn on and the input B alsoturn on and 5eep B on permanentl' until the power is remo)ed

The line on the ri&ht is bein& left off intentionall' and it is implied in these dia&rams

Figure 4 A seal-in circuit

)6+ PROGRAMMING
The first +34s were pro&rammed with a te%hnique that was based on rela' lo&i% wirin& s%hemati%s* This eliminated the need to tea%h the ele%tri%ians( te%hni%ians and en&i, neers how to pro&ram a %omputer , but( this method has stu%5 and it is the most %ommon te%hnique for pro&rammin& +34s toda'* An e;ample of ladder lo&i% %an be seen in Ei&ure ?* To interpret this dia&ram ima&ine that the power is on the )erti%al line on the left hand side( we %all this the hot rail* On the ri&ht hand side is the neutral rail* 1n the fi&ure there are two run&s( and on ea%h run& there are %ombinations of inputs /two )erti%al lines0 and outputs /%ir%les0* 1f the inputs are opened or %losed in the ri&ht %ombination the power %an flow from the hot rail( throu&h the inputs( to power the outputs( and finall' to the neutral rail* An input %an %ome from a sensor( swit%h( or an' other t'pe of sensor* An output will be some de)i%e outside the +34 that is swit%hed on or off( su%h as li&hts or motors* 1n the top run& the %onta%ts are normall' open and normall' %losed* 6hi%h means if input A is on and input B is off( then power will flow throu&h the output and a%ti)ate it* An' other %om, The first +34s were pro&rammed with a te%hnique that was based on rela' lo&i% wirin& s%hemati%s* This eliminated the need to tea%h the ele%tri%ians( te%hni%ians and en&i, neers how to pro&ram a %omputer , but( this method has stu%5 and it is the most %ommon te%hnique for pro&rammin& +34s toda'* An e;ample of ladder lo&i% %an be seen in Ei&ure ?* To interpret this dia&ram ima&ine that the power is on the )erti%al line on the left hand <ot A B Neutral

<

NOTE : +ower needs to flow throu&h some %ombination of the inputs /A(B4(D(E(E(G(<0 to turn on inputs /J(K0

Figure

A simple ladder logic

The se%ond run& of Ei&ure ? is more %omple;( there are a%tuall' multiple %ombi, nations of inputs that will result in the output K turnin& on* On the left most part of the run&( power %ould flow throu&h the top if 4 is off and D is on* +ower %ould also /and simultaneousl'0 flow throu&h the bottom if both E and E are true* This would &et power half wa' a%ross the run&( and then if G or < is true the power will be deli)ered to output K* 1n later %hapters we will e;amine how to interpret and %onstru%t these dia&rams* There are other methods for pro&rammin& +34s* One of the earliest te%hniques in)ol)ed mnemoni% instru%tions* These instru%tions %an be deri)ed dire%tl' from the lad, der lo&i% dia&rams and entered into the +34 throu&h a simple pro&rammin& terminal* An e;ample of mnemoni%s is shown in Ei&ure .* 1n this e;ample the instru%tions are read one line at a time from top to bottom* The first line """"" has the instru%tion 3DN /input load and not0 for input """"!* This will e;amine the input to the +34 and if it is off it will remember a ! /or true0( if it is on it will remember a " /or false0* The ne;t line uses an 3D /input load0 statement to loo5 at the input* 1f the input is off it remembers a "( if the input is on it remembers a ! /note: this is the re)erse of the 3D0* The AND statement re%alls the last two numbers remembered and if both are true the result is a !( otherwise the result is a "* This result now repla%es the two numbers that were re%alled( and there is onl' one number remembered* The pro%ess is repeated for lines """"# and """"7( but when these are done there are now three numbers remembered* The oldest number is from the AND( the newer numbers are from the two 3D instru%tions* The AND in line """"? %ombines the results from the last 3D instru%tions and now there are two numbers remembered* The OR instru%tion ta5es the two numbers now remainin& and if either one is a ! the result is a !( otherwise the result is a "* This result repla%es the two numbers( and there is now a sin&le number there* The last instru%tion is the ST /store output0 that will loo5 at the last )alue stored and if it is !( the output will be turned on( if it is " the output will be turned off*

""""" """"! """"""""# """"7 """"? """". """"8 """"$

3DN 3D AND 3D 3D AND OR ST END

""""! """"-

""""# """"7

""!"8

""""!

""""-

""!"8

""""#

""""7

end

Figure !" An eample o# mnemonic program

The ladder lo&i% pro&ram in Ei&ure .( is equi)alent to the mnemoni% pro&ram* E)en if 'ou ha)e pro&rammed a +34 with ladder lo&i%( it will be %on)erted to mnemoni% form before bein& used b' the +34* 1n the past mnemoni% pro&rammin& was the most %ommon( but now it is un%ommon for users to e)en see mnemoni% pro&rams* Sequential Eun%tion 4harts /SE4s0 ha)e been de)eloped to a%%ommodate the pro, &rammin& of more ad)an%ed s'stems* These are similar to flow%harts( but mu%h more powerful* The e;ample seen in Ei&ure 8 is doin& two different thin&s* To read the %hart( start at the top where is sa's start* Below this there is the double horiContal line that sa's follow both paths* As a result the +34 will start to follow the bran%h on the left and ri&ht hand sides separatel' and simultaneousl'* On the left there are two fun%tions the first one is the power up fun%tion* This fun%tion will run until it de%ides it is done( and the power down fun%tion will %ome after* On the ri&ht hand side is the flash fun%tion( this will run until it is done* These fun%tions loo5 une;plained( but ea%h fun%tion( su%h as power up will be a small ladder lo&i% pro&ram* This method is mu%h different from flow%harts be%ause it does not ha)e to follow a sin&le path throu&h the flow%hart*
Start

+ower up E;e%ution follows multiple +ower down

flash

end #igure $"se%uential #unction chart

Stru%tured Te;t pro&rammin& has been de)eloped as a more modern pro&rammin& lan&ua&e* 1t is quite similar to lan&ua&es su%h as BAS14* A simple e;ample is shown in Ei&ure $* This e;ample uses a +34 memor' lo%ation N8:"* This memor' lo%ation is for an inte&er( as will be e;plained later in the boo5* The first line of the pro&ram sets the )alue to "* The ne;t line be&ins a loop( and will be where the loop returns to* The ne;t line re%alls the )alue in lo%ation N8:"( adds ! to it and returns it to the same lo%ation* The ne;t line %he%5s to see if the loop should quit* 1f N8:" is &reater than or equal to !"( then the loop will quit( otherwise the %omputer will &o ba%5 up to the RE+EAT statement %ontinue from there* Ea%h time the pro&ram &oes throu&h this loop N8:" will in%rease b' ! until the )alue rea%hes !"* N8:" :L "M RE+EAT N8:" :L N8:" I !M UNT13 N8:" NL !" ENDORE+EATM An e;ample of stru%tured pro&ram

)67 PLC connec ion!

6hen a pro%ess is %ontrolled b' a +34 it uses inputs from sensors to ma5e de%i, sions and update outputs to dri)e a%tuators( as shown in Ei&ure @* The pro%ess is a real pro%ess that will %han&e o)er time* A%tuators will dri)e the s'stem to new states /or modes of operation0* This means that the %ontroller is limited b' the sensors a)ailable( if an input is not a)ailable( the %ontroller will ha)e no wa' to dete%t a %ondition*

pro%ess Eeedba%5 from sensors=swit%hes pl%

4onne%tions to a%tuators

#igure &"'he separation o# control and process

The %ontrol loop is a %ontinuous %'%le of the +34 readin& inputs( sol)in& the lad, der lo&i%( and then %han&in& the outputs* 3i5e an' %omputer this does not happen instantl'* Ei&ure !" shows the basi% operation %'%le of a +34* 6hen power is turned on initiall' the +34 does a qui%5 sanit' %he%5 to ensure that the hardware is wor5in& prop, erl'* 1f there is a problem the +34 will halt and indi%ate there is an error* Eor e;ample( if the +34 ba%5up batter' is low and power was lost( the memor' will be %orrupt and this will result in a fault* 1f the +34 passes the sanit' %he%5 it will then s%an /read0 all the inputs* After the inputs )alues are stored in memor' the ladder lo&i% will be s%anned /sol)ed0 usin& the stored )alues , not the %urrent )alues* This is done to pre)ent lo&i% problems when inputs %han&e durin& the ladder lo&i% s%an* 6hen the ladder lo&i% s%an is %omplete the outputs will be s%anned /the output )alues will be %han&ed0* After this the s'stem &oes ba%5 to do a sanit' %he%5( and the loop %ontinues indefinitel'* Unli5e normal %omputers( the entire pro&ram will be run e)er' s%an* T'pi%al times for ea%h of the sta&es is in the order of millise%onds*

Figure 1( "'he scan cycle o# plc

)68 LADDER LOGIC INPUTS

+34 inputs are easil' represented in ladder lo&i%* 1n the below Ei&ure there are three t'pes of inputs shown* The first two are normall' open and normall' %losed inputs( dis%ussed pre)iousl'* The 11T /1mmediate 1npuT0 fun%tion allows inputs to be read after the input s%an( while the ladder lo&i% is bein& s%anned* This allows ladder lo&i% to e;amine input )alues more often than on%e e)er' %'%le*

Ladder Logic )nputs

La""er Logic O$ /$ !
1n ladder lo&i% there are multiple t'pes of outputs( but these are not %onsistentl' a)ailable on all +34s* Some of the outputs will be e;ternall' %onne%ted to de)i%es

outside the +34( but it is also possible to use internal memor' lo%ations in the +34* Three t'pes of outputs are shown in below Ei&ure* The first is a normal output( when ener&iCed the output will turn on( and ener&iCe an output* The %ir%le with a dia&onal line throu&h is a normall' on output* 6hen ener&iCed the output will turn off* This t'pe of output is not a)ailable on all +34 t'pes* 6hen initiall' ener&iCed the OSR /One Shot Rela'0 instru%tion will turn on for one s%an( but then be off for all s%ans after( until it is turned off* The 3 /lat%h0 and U /unlat%h0 instru%tions %an be used to lo%5 outputs on* 6hen an 3 output is ener&iCed the output will turn on indefinitel'( e)en when the output %oil is de ener&iCed* The output %an onl' be turned off usin& a output* The last instru%tion is the 1OT /1mmediate Output0 that will allow outputs to be updated without ha)in& to wait for the ladder lo&i% s%an to be %ompleted*

Ladder logic outputs

)69 CASE STUDY%

Swit%h ! li&ht Swit%h -

li&ht

swit%h ! swit%h - swit%h # +roblem: Tr' to de)elop a rela' based %ontroller that will allow three swit%hes in a room to %ontrol a sin&le li&ht* Solution: There are two possible approa%hes to this problem* The first assumes that an' one of the swit%hes on will turn on the li&ht( but all three swit%hes must be off for the li&ht to be off*

Swit%h #

The se%ond solution assumes that ea%h swit%h %an turn the li&ht on or off( re&ardless of the states of the other swit%hes* This method is more %omple; and in)ol)es thin5in& throu&h all of the possible %ombinations of swit%h positions* Kou mi&ht re%o&niCe this problem as an e;%lusi)e or problem* swit%h ! swit%h - swit%h # swit%h ! swit%h - swit%h # swit%h ! swit%h - swit%h # li&ht

Note: 1t is important to &et a %lear understandin& of how the %ontrols are e;pe%ted to wor5* 1n this e;ample two radi%all' different solutions were obtained based upon a simple differen%e in the operation*

2. CNC Sy! e#! :6) In ro"$c ion

The 4N4 is a %omputer based ele%troni% equipment that re%ei)es %ommands in di&ital form from perforated tape or other t'pes of input( as well as positional information of %ertain elements of the ma%hine* The 4N4 interprets %ertain of these di&ital data as requirements for new positions of the ma%hine elements and &i)es appropriate %ommands of dire%tion and )elo%it'* The 4N4 also interprets %ertain other additional data as %ommand of )elo%it'( of dis%rete fun%tions( of a%tions et%*

Numeri%al %ontrol /N40 is a method emplo'ed for %ontrollin& the motions of a ma%hine tool slide and its au;iliar' fun%tions with an input in the form of numeri%al data* A %omputer numeri%al %ontrol /4N40 is a mi%ropro%essor based s'stem to store and pro%ess the data for the %ontrol of slide motions and au;iliar' fun%tions of the ma%hine tools* The 4N4 s'stem is the heart and brain of a 4N4 ma%hine whi%h enable the operation of the )arious ma%hine members su%h as a slides( spindles( et%* as per the sequen%e pro&rammed into it( dependin& on the ma%hinin& operations*

The main ad)anta&e of a 4N4 s'stem lies in the fa%t that the s5ills of the operator hitherto required in the operation of a %on)entional ma%hine is remo)ed and the part produ%tion is made automati%*

The 4N4 s'stems are %onstru%ted with an N4 unit inte&rated with a pro&rammable lo&i% %ontroller /+340 and sometimes with an additional e;ternal +34 /non,inte&rated0* The N4 %ontrols the spindle mo)ement and the speeds and feeds in ma%hinin&* 1t %al%ulates the tra)ersin& paths of the a;es as defined b' the inputs* The +34 %ontrols the peripheral a%tuatin& elements of the ma%hine su%h as solenoids( rela' %oils( et%* 6or5in& to&ether( the N4 and +34 enable the ma%hine tool to operate automati%all'*

Ele#en ! of a CNC Machine Tool

1n a 4N4 ma%hine tool there are three ma:or &roups of elements 4ontrol and ele%troni%s Ele%tri% dri)es /ele%trome%hani%al dri)es0 Ae%hani%al elements /table( Slide( tool holder( et%*0

1n addition( there %an be h'drauli% and pneumati% s'stems( whi%h are inte&rated with the 4N4 ma%hine tool*

The primar' fun%tion of the dri)e is to %ause motion of the %ontrolled ma%hine tool member /spindle( slide( et%*0 to %onform as %losel' as possible to the motion %ommands issued b' the 4N4 s'stem*

1n order to maintain a %onstant material remo)al rate( the spindle and the tool mo)ements ha)e to be %oordinated su%h that the spindle has a %onstant power and the slide has a %onstant torque*

In/$ Ele#en !
So#e of he co##only e#/loye" in/$ ele#en ! are /$!h;.$ on< foo !4i ch< /ro-i#i y !4i ch< floa !4i ch< relay con ac < /ho o ran!i! or !4i ch< !elec or !4i ch< /re!!$re !4i ch< li#i !4i ch an" flo4 !4i ch6

O$ /$ Ele#en !
O$ /$ Ele#en ! ha are co##only $!e" are% 1ndi%atin& 3amps D4 %ontrol rela's /ele%troma&neti%0 +ower %ontra%tors D4 and A4 solenoids Ele%troma&neti% %lut%h and bra5e Solid state rela' A %ontrol rela' /4R0 is an ele%troma&neti% de)i%e e;%ited throu&h an a% or d% ele%tri% %oil* The d% rela's are used as interfa%e between the 4N4,+34 and the a% or d% power swit%hin& de)i%es* 4ontra%tors /40 are also ele%troma&neti% de)i%es whi%h are e;%ited with a% )olta&es /!!" G or --" G used for ON=OEE fun%tions of indu%tion motors( indu%tion %oils( dri)e power %ir%uits( et%* +ower %ontra%tors are desi&ned to swit%h %urrents up to se)eral hundreds of amperes at 77" G a% three,phase*

O=erloa" &OL' Relay!

Bi,metalli% thermal o)erload rela's are )er' %ommonl' used as o)erload prote%tion de)i%es for )arious a% motors su%h as h'drauli% pump motor( %oolant pump motor( lubri%ation motor( blower indu%tion motor( or an' other power a% %ir%uit* The o)erload /O30 rela'( when %onne%ted in series with the power %ir%uit( will open out when the %urrent in%reases be'ond a preset )alue*

Minia $re Circ$i Brea>er &MCB'

An A4B is a prote%ti)e de)i%e( whi%h will pro)ide both o)erload and short %ir%uit prote%tion when %onne%ted in a %ir%uit* <en%e an A4B will repla%e a fuse and a bi, metalli% o)erload rela'* 6hen an A4B trips( it has to be reset manuall'* 4ompa%t A4Bs with au;iliar' trip %onta%t are used in the ele%tri%al %ontrol panel for 4N4 ma%hines*

Config$ra ion of a CNC Sy! e#

A s%hemati% dia&ram of the wor5in& prin%iple of an N4 a;is of a 4N4 Aa%hine and the interfa%e of a 4N4 %ontrol* A 4N4 s'stem basi%all' %onsists of the followin&: 4entral pro%essin& unit /4+U0 Ser)o,%ontrol unit Operator %ontrol panel Aa%hine %ontrol panel Other peripheral de)i%es +ro&rammable lo&i% %ontroller

Cen ral Proce!!ing Uni &CPU' The 4+U is the heart and brain of a 4N4 s'stem* 1t a%%epts the information stored in the memor' as part pro&ram* This data is de%oded and transformed into spe%ifi% position %ontrol and )elo%it' %ontrol si&nals* 1t also o)ersees the mo)ement of the %ontrol a;is or

spindle and whene)er this does not mat%h with the pro&rammed )alues( a %orre%ti)e a%tion is ta5en*

S/ee" Con rol Uni This unit a%ts in unison with the 4+U for the mo)ement of the ma%hine a;es* The 4+U sends the %ontrol si&nals &enerated for the mo)ement of the a;is to the ser)o,%ontrol unit and the ser)o,%ontrol unit %on)erts these si&nals into a suitable di&ital or analo& si&nal to be fed to a ser)o,dri)er for ma%hine tool a;is mo)ement* This also %he%5s whether ma%hine tool a;is mo)ement is at the same speed as dire%ted b' the 4+U* Ser=o Con rol Uni The de%oded position and )elo%it' %ontrol si&nals( &enerated b' the 4+U for the a;is mo)ement forms the input to the ser)o,%ontrol unit* This unit in turn &enerates suitable si&nals as %ommand )alues* The %ommand )alues are %on)erted b' the ser)o,dri)e unit whi%h are interfa%ed with the a;es and the spindle motors* The ser)o,%ontrol unit re%ei)es the position feedba%5 si&nals for the a%tual mo)ement of the ma%hine tool a;es from the feedba%5 de)i%es /li5e linear s%ales( rotar' en%oders( resol)ers( et%*0* The )elo%it' feedba%5 are &enerall' obtained throu&h ta%ho &enerators* The feedba%5 si&nals are passed on to the 4+U for further pro%essin&* Thus( the ser)o, %ontrol unit performs the data %ommuni%ation between the ma%hine tool and the 4+U* The amount of mo)ement and the rate of mo)ement are %ontrolled b' the 4N4 s'stem*

Clo!e" Loo/ Sy! e#

The %losed loop s'stem is %hara%teriCed b' the presen%e of feedba%5* 1n this s'stem( the 4N4 s'stem sends out %ommands for mo)ement and the result is %ontinuousl' monitored

b' the s'stem throu&h )arious feedba%5 de)i%es* There are &enerall' two t'pes of feedba%5 to a 4N4 s'stem,position feedba%5 and )elo%it' feedba%5*

O/en Loo/ Sy! e#

The open loop s'stem la%5s feedba%5* 1n this s'stem( the 4N4 s'stem sends out si&nals for mo)ement but does not %he%5 whether a%tual mo)ement is ta5in& pla%e or not* Stepper motors are used for a%tual mo)ement and the ele%troni%s of these stepper motors is run on di&ital pulses from the 4N4 s'stem*

O/era or Con rol Panel

The operator %ontrol panel pro)ides the user interfa%e to fa%ilitate a two,wa' %ommuni%ation between the user( 4N4 s'stem and the ma%hine tool* The %onsists of two parts: Gideo displa' unit 9e'board

2i"eo Di!/lay Uni &2DU'

The GDU displa's the status of the )arious parameters of the 4N4 s'stem and the ma%hine tool* 1t displa's all %urrent information su%h as: 4omplete information on the blo%5 %urrentl' bein& e;e%uted a%tual position )alues( set or a%tual differen%e( %urrent feed rate( spindle speed A%tual position )alue( set or a%tual differen%e( %urrent feed rate( spindle speed* A%ti)e G fun%tions( mis%ellaneous fun%tions

Aain pro&ram number( subroutine number Displa' of all entered data( user pro&rams( user data( ma%hine data( et%* Alarm messa&es in plain te;t Soft 5e' desi&nations*

0ey.oar"
A 5e'board is pro)ided for the followin& purposes: Editin& of part pro&rams( tool data( ma%hine parameters* Sele%tion of different pa&es for )iewin&* Sele%tion of operatin& modes( e*&*( manual data input( :o&( et%* Sele%tion of feed rate o)erride and spindle speed o)erride E;e%ution of part pro&rams E;e%ution of other tool fun%tions

Machine Con rol Panel &MCP'

1t is the dire%t interfa%e between the operator and the N4 s'stem( enablin& the operation of the ma%hine throu&h the 4N4 s'stem* Durin& pro&ram e;e%ution( the 4N4 %ontrols the a;is motion( spindle fun%tion or tool fun%tion on a ma%hine tool( dependin& upon the part pro&ram stored in the memor'* +rior to the startin& of the ma%hinin& pro%ess( ma%hine should first be prepared with some spe%ifi% tas5s li5e( Establishin& a %orre%t referen%e point 3oadin& the s'stem memor' with the required part pro&ram 3oadin& and %he%5in& of tool offsets( Cero offsets( et%*

Mo"e! of O/era ion

+reset mode Aanual data input /AD10 mode Automati% mode Referen%e point mode o& mode 1n%remental mode

De!ign of #o"ern CNC M?CS

The desi&n F %onstru%tion of %omputer numeri%all' %ontrolled /4N40 m=%s differs &reatl' from that of %on)entional m=% tools* 1mportant parts and aspe%ts of 4N4 m=%Hs to be %onsidered in their desi&nin& : /a0 A=4 stru%ture /b0 Guide wa's /%0 Eeed dri)es /d0 Spindle F spindle bearin&s /e0 4ontrollers( software F operator interfa%e /f0 Aeasurin& instruments /&0 Gau&in& /h0 Tool monitorin& (a) M/c Structure: The A=% stru%ture is the load %arr'in& F supportin& member of the A=% tool* All the motors( dri)e me%hanism F other fun%tional assemblies of ma%hines tools are

ali&ned to ea%h other F ri&idl' fi;ed to the A=% stru%ture* The A=% stru%ture is sub:e%ted to stati% of d'nami% for%es F it is( therefore( essential that the stru%ture does not deform or )ibrate be'ond the permissible limits under the a%tion of these for%es* (b) Guide ways: Guide wa's are used in A=% tools to: i0 ii0 (c) 4ontrol the dire%tions or lines of a%tion of the %arria&e or the table on whi%h a tool or a wor5 pie%e is held* To absorb all the stati% F d'nami% for%es*

eed Dri!es: On a 4N4 A=% the fun%tion of feed dri)es is to %ause motion of the slides as per the motion %ommands* Sin%e the de&ree of a%%ura%' requirement is hi&h( the feed dri)e should ha)e hi&h effi%ien%' F response* The fed dri)e %onsists of /a0 ser)omotor /b0 Ae%hani%al transmission s'stem*

(d) Spindle / Spindle "earings: Aaterial remo)al usin& sin&le point or multi point wor5 pie%e requires rotational speeds of the order of #",.""" rpm and e)en hi&her* All wor5 or tool %arr'in& spindles rotatin& at these speeds are sub:e%ted torsional and radial defle%tions* The' are also sub:e%ted to thrust for%es dependin& on the nature of the metal %uttin& operation bein& performed* To intorsional strain on the spindles the' are desi&ned to be as stiff as possible with a minimum o)er han&* Also( the final dri)e to the spindle should be lo%ated as near as possible the bearin&s* (e) Gauging: Gau&in& on a A=% tool is basi%all' used for wor5 pie%e inspe%tion( for definin& tool off,sets F for tool brea5in& dete%tion* (f) #ool monitoring systems: A tool monitorin& s'stem monitors the tool wear F tool brea5a&e* (g) Controls$ Software % &ser 'nterface: 4N4 %ontrols are the heart of the 4N4 A=4s* The earl' 4N4 %ontrols were de)eloped for simple appli%ations in turnin&( ma%hinin& %entres F &rindin&* The new &eneration %omputer numeri%al %ontrols allow simulations %ontrol of more a;es( interpolate positions faster( and use more data points for pre%ise %ontrol*

These pro%essors perform multi tas5s run one pro&rammin& F simulatin& a se%ond D whi%h ma;imiCes the A=% use* (() Measuring systems: On all 4N4 A=%( an ele%troni% measurin& s'stem is emplo'ed on ea%h %ontrolled a;is to monitor the mo)ement F to %ompare the position of the slide F the spindle with the desired position* Aeasurin& s'stems are used on 4N4 A=%s for: /i0 Aonitorin& the positionin& of a slide on a slide wa'* /ii0 Orientin& the spindle table F measurin& the speed of the spindle* #urning Centre De!elopments

<istori%all'( the 4N4 te%hnolo&' was applied on turnin& ma%hines with a %on)entional horiContal bed %onfi&uration ha)in& two ser)o a;es D are for the saddle and the other for %ross slide D and with an inde;able tool turret* O)er a period of time the %on%ept of slant bed %onfi&uration was adopted for hi&her ri&idit'( better %hip disposal and eas' a%%ess for loadin& and unloadin& of %omponents to&ether with dis% t'pe turret to a%%ommodate mo)e number of tools*

A"=an age! of CNC Machine!

4N4 ma%hines offer the followin& ad)anta&es in manufa%turin&: <i&her fle;ibilit' 1n%reased produ%ti)it' 4onsistent quantit' Redu%ed s%rap rate Reliable operation Redu%ed non,produ%ti)e time Redu%ed manpower Shorter %'%le time <i&her a%%ura%' Redu%ed lead time ust,in,time / 1T0 manufa%ture Automati% material handlin&

3esser floor spa%e 1n%reased operational safet' Aa%hinin& of ad)an%ed materials Elimination of operator errors Ele;ibilit' in %han&es of %omponent desi&n Redu%ed inspe%tion A%%urate %ostin& and s%hedulin&

Tool! an" Technology U!e" La""er Logic

La""er logic has e)ol)ed into a pro&rammin& lan&ua&e that represents a pro&ram b' a &raphi%al dia&ram based on the %ir%uit dia&rams of rela' lo&i% hardware* 3adder lo&i% is used to de)elop software for pro&rammable lo&i% %ontrollers /+34s0 used in industrial %ontrol appli%ations* The name is based on the obser)ation that pro&rams in this lan&ua&e resemble ladders( with two )erti%al rails and a series of horiContal run&s between them* 3adder lo&i% is widel' used to pro&ram +34s( where sequential %ontrol of a pro%ess or manufa%turin& operation is required* 3adder lo&i% is useful for simple but %riti%al %ontrol s'stems or for rewor5in& old hardwired rela' %ir%uits* As pro&rammable lo&i% %ontrollers be%ame more sophisti%ated it has also been used in )er' %omple; automation s'stems*

Re rofi ing
Re rofi ing refers to the addition of new te%hnolo&' or features to older s'stems*

power plant retrofit( impro)in& power plant effi%ien%' = in%reasin& output = redu%in& emissions home ener&' retrofit( the impro)in& of e;istin& buildin&s with ener&' effi%ien%' equipment seismi% retrofit( the pro%ess of stren&thenin& older buildin&s in order to ma5e them earthqua5e resistant

Sna/!ho !
!* 4N4 s'stem After retrofittin& -* 4N4 s'stem before retrofittin&

#* 4N4 s'stem

7*+34

Concl$!ion
This report has dis%ussed the role that pro&rammable lo&i% %ontrollers ha)e in the effi%ient desi&n and %ontrol of me%hani%al pro%esses* Also dis%ussed about the understandin& 4N4 S'stems and the operation of it* Einall'( the report has dis%ussed rela' lo&i% and the e)olution that ladder lo&i% made from it* !* +ro&rammable 3o&i% <istor': This se%tion dis%ussed the histor' and ad)an%ement of %ontrols te%hnolo&'( with a %omparison of pro&rammable lo&i% %ontrollers and hard,wired rela's -* +34 %omponents: This se%tion defined what pro&rammable lo&i% is and des%ribed all hardware asso%iated with it* #* +34 +ro&rammin&: This se%tion %o)ered )arious te%hnique of +34 pro&rammin&*

@$ $re Sco/e
The +34 offers a %ompromise between ad)an%e %ontrol te%hniques and present da' te%hnolo&'* 1t is e;tremel' diffi%ult to fore%ast the rate and form of pro&ress of +34s( but there is stron& e)iden%e that de)elopment is both rapid and %umulati)e* Thou&h a +34 is not desi&ned to repla%e a %omputer( it is useful and %ost effe%ti)e for medium siCed %ontrol s'stems *6ith the %apabilit' of fun%tionin& as lo%al %ontrollers in distributed %ontrol s'stems* +34s will retain their appli%ation in lar&e pro%ess plants*

A further de)elopment of +34s leads to the de)elopment of pro&rammable fun%tion %ontroller /+E40 is %ompatible to +4s and dire%tl' %ontrols the desired fun%tions*

1n 1ndia e)er' pro%ess industr' is repla%in& rela' %ontrol s'stems b' +34s and will &o for +E4s in near future* 1n the near future e)er' flats and offi%es ma' possess +E4s to %ontrol room temperature( as ele)ator %ontroller( maintain water tan5 le)els( as small telephone e;%han&e et%*

CNC
The ma%hine that we ha)e retrofitted is :ust an e;ample of preliminar' retrofittin& 5eepin& in mind the use and the %osts in%urred* There is a hu&e s%ope for further impro)ements in the ma%hine* These %an be listed as below: A multi station tool turret %an be in%orporated in the e;istin& 4N4 ma%hine* Automati% 4lampin& me%hanism %an be installed /Draw bar Ae%hanism0* Automati% Tool 4han&in& /AT40 de)i%es usin& Roboti% Arm Te%hnolo&'* Automati% +allet 4han&er /A+40 for automati% wor5 pie%e %han&in&* A 4hip 4on)e'or %an be in%orporated for eas' and hassle free disposal of %hips*

Reference!
!* http:==en*wi5ipedia*or&=wi5i=Retrofittin& -* http:==en*wi5ipedia*or&=wi5i=3adderOlo&i% #* http:==web*bhelh'd*%o*in