An Industrial Training Report

On
INDUSTRIAL AUTOMATION SYSTEM
at

Mentor- Mr. Brij Kishore Jaimni

Duration- 4 weeks (June 21th 2017 to July 20st 2017)
Submitted By- Deepak Kumar Sharma
Branch- Electronics (Hons.)
Semester- 4th
Roll No.- ZH-165/15

Zakir Husain Delhi College (University of Delhi)

Jawaharlal Nehru Marg, New Delhi, Delhi 110002
 ACKNOWLEDGEMENT

Apart from my efforts, the success of my project depends largely on the

encouragement and guidelines of many others. I take this opportunity to express
my gratitude to the people who have been instrumental in the successful
completion of this project.

I am highly indebted to Moser Baer India ltd, Greater Noida for providing me with
an excellent and friendly environment to work. Their guidance and constant
supervision played a key factor in completion of this project.

First and foremost, I would like to express my special gratitude and thanks to
Mr. Brij Kishore Jaimni for giving me such attention and time. My sincere
regards goes to Mr. Sanjay Gupta(Senior Vice President) and
Mr. Kamal Chandra for their guidance throughout my entire training. Their
willingness to motivate me contributed tremendously to my project and inspired
me greatly to understand the working in the Jewel Box section.

Finally, Id like convey my sincere thanks to my family and friends for their
understanding and constant support.
 DECLARATION

Moser Baer India ltd. is the second largest manufacturer of optical storage media
in the world. It is the OEM supplier to the biggest brands in the markets like Sony,
Imation, TDK etc. The mission statement of MBI reads as follows
EXCELLENCE BEYOND TODAY, TOUCHING TOMMORROW. Moser
Baer nurtures a vision to rewrite the future.
This report aims at learning about the mechanical, electronic and automation
applied manufacturing in the Jewel Box Plant (Moser Baer) under our guidance.
This is to certify that DEEPAK KUMAR SHARMA(ZH-165/15) of 2rd year of
Zakir Husain Delhi College (University of Delhi)has successfully completed the
project on the topic Industrial Automation System, at Moser Baer India ltd.,
Greater Noida under the supervision of Mr. Brij Kishore Jaimni (Deputy
Manager).

(Mr. Brij Kishore Jaimni) (Mr. J.S Dhaka)

Deputy Manager Head (J.B Section)
 CANDIDATES DECLARATION

I, hereby declare that the work which is being presented in this Industrial Training
Report submitted, as a part of curriculum is an authentic record of my original
work carried out under the guidance of Mr. B.K. Jaimni, Assistant Manager, JB
Plant.
I am highly obliged to Moser Baer,Greater Noida.

Date: ______ Deepak Kumar Sharma

Place: ______

This is to certify that the above statement made by the candidate is correct to the
best of my knowledge.
 Summary

A programmable logic controller (PLC) or programmable controller is an

industrial digital computer which has been ruggedized and adapted for the control
of manufacturing processes, such as assembly lines, or robotic devices, or any
activity that requires high reliability control and ease of programming and process
fault diagnosis.

They were first developed in the automobile industry to provide flexible,

ruggedized and easily programmable controllers to replace hard-wired relays and
timers. Since then they have been widely adopted as high-reliability automation
controllers suitable for harsh environments. A PLC is an example of a "hard" real-
time system since output results must be produced in response to input conditions
within a limited time, otherwise unintended operation will result.

The project is on the study of various Type of Sensors & Basic PLC and machines
using this PLC.
 Index

1. Acknowledgement
2. Declaration
3. Candidates Declaration
4. Summary
5. About Moser Baer
6. The Manufacturing Process
7. Jewel Box Plant
8. Process Flow Diagram of Cake Box
9. Injection Moulding Machine
10.Various components in IMM
11.Junction Box
12.ASRS(Automatic Storage and Retrieval System)
13.PLC (Programmable Logic Controllers)
14.Sensors
15.Other Component Studied
16.Conclusion
 ABOUT MOSERBAER

Moser Baer India Limited

headquartered in New
Delhi, is a leading global
tech-manufacturing
company. Established in
1983, the company is one
of the world's largest
manufacturers of Optical
Storage media like CDs
and DVDs.
Every 5th disc
manufactured globally
belongs to Moser Baer and
it is the lowest cost optical media manufacturer in the world. The company is also
the first to market next-generation of storage formats like Blu-Ray discs and HD-
DVD in India.
Over the years the company has entered into exciting areas of solid-state media
with the launch of pen drives and flash memory cards, content replication, home
entertainment and is a market leader in the high growth photovoltaic space. It is the
only company worldwide to receive the prestigious 5-star rating from TV
Rheinland for 3 years in a row maintaining highest standards of quality in
manufacturing PV modules.
The company has a presence in over 100 countries, serviced through 15 marketing
offices and representatives in India, US, Europe, Japan, Russia, Ukraine, Egypt,
Argentina, Chile, Malaysia and has strong tie-ups with many global technology
players in the optical media storage business. In the PV space, the company has a
presence in the entire value chain with products being sold to more than 82
countries. Its products are manufactured at its three state-of-the-art manufacturing
facilities located in the suburbs of New Delhi employing over 8,000 employees.
Through its wholly owned subsidiaries, the company manufactures photovoltaic
cells and modules using crystalline silicon and thin film technologies. Being one of
the most credible brands focused on hi-tech manufacturing and R & D activities, it
continues to unfold the next generation innovative technologies that will catapult
India into a respectable manufacturing hub

Current scenario
Moser Baer Q1 loss widens to Rs 92 Cr as per the losses for quarter ended june 30,
2011 was 88 crore .over the last one year raw material costs particularly , silver,
plastic, polycarbonate as also fuel has increased . In the quarter review, the net
sale, on a standalone basis, grew about 17 % year- on year to Rs 523 crore. As
per the company overview, company has seen price increase of 15-20 per cent in
june and another 5-7 per cent in july. During the year 2012 the company applied
for corporate debt restructuring (CDR) to restructure its existing debt obligations.
The final letter of approval (LOA) was received in 2012 from the corporate debt
restructuring empowered group (CDREG) to re structure existing obligations,
including interest, additional funding and other terms. The subsidiary of the
company Moser Baer Solar Limited (MBSL) and its subsidiary Moser Baer
Photovoltaic limited (MBPV) were also referred for debt restructuring. In the field
of Energy Efficiency Business Moser Baer has begun to focus on the LED space.
As per the Display search report, globally total average Led penetration in lighting
stood at 1.4% in 2010 and is expected to reach close to 17% by year 2015..
 HISTORY
Moser Baer India was founded in New Delhi in 1983 as a Time Recorder unit in
technical collaboration with Maruzen Corporation, Japan and Moser Baer
Sumiswald, Switzerland.
In 1988, it moved into the data storage industry by commencing manufacturing of
5.25-inch Floppy Diskettes. By 1993, it started manufacturing 3.5-inch Micro
Floppy Diskettes (MFD).
In 1999, it set up a 150-million unit capacity plant to manufacture Recordable
Compact Disks (CD-Rs) and Recordable Digital Versatile Disks (DVD-Rs). The
strategy for the optical media project was identical to what had successfully been
implemented in the diskette business - creating a facility that matched global
standards in terms of size, technology, quality, product flexibility and process
integration.
The company is today the only large Indian manufacturer of magnetic and optical
media data storage products, exporting approximately 85 percent of its production.
In 2006, the company expanded into the Photovoltaic cells and Home
entertainment industries.
In 2010,Moser Baer was among the few players to achieve world's highest single
junction Thin Film module efficiency of 7.3% through its proprietary process,
increasing the module wattage from 340 watt/panel to 400 watt/panel, Moser Baer
launches micro SD Cards and content loaded drives, launch of e-commerce
website offering Moser Baer products, joins hands with leading entertainment
players to form an Anti-Piracy Coalition
MoserBaer in 2011 Commenced production of YUKITA brand junction boxes in
partnership with Yukita Electro for solar PV modules at its Plant in Greater Noida,
sets up a PV reliability laboratory to study quality and reliability aspects of
Crystalline Silicon and Thin Film PV modules, emerges as the first Indian Solar
PV company to achieve installation of 100 MW under its own brand,
commissioning of Moser Baer India's first 5MW Thin Film solar farm in Tamil
Nadu, awarded a grant by MNER towards development of innovative CIGS solar
cell technology, launches 'world's slimmest' USB flash Drive, Moser Baer
Technologies and Universal Display Corporation announced technology and
licensing agreement for energy efficient white OLED lighting, Moser Baer signs a
MoU with C-MET Pune for R&D on "Hybrid Solar Cells based on Organic
Polymers and Inorganic Nano particles.
GLOBAL QUALITY
Enablers
-time process controls: Online management of out-of-control limit
conditions
for tighter process windows

Certifications

Six Sigma & Lean Transformation

a Company-wide Six Sigma initiative

Quality & Manufacturing excellence awards from

In-house R&D lab

ptical media
 THE MANUFACTURING PROCESSES

MATERIAL FEEDING

1. PP (Polypropylene)
Polypropylene, also known as polypropylene, is a thermoplastic polymer used in a wide
variety of applications including packaging and labelling, textiles, stationery, plastic parts
and reusable containers.
Density: 946.00 kg/m

2. HIPS (High Impact Polystyrene)

Pure polystyrene is brittle, but hard enough that a fairly high-performance product can be
made by giving it some of the properties of a stretchier material, such as polybutadiene
rubber. If polybutadiene is added during polymerization it can become chemically bonded to
the polystyrene, resulting in high-impact polystyrene or HIPS, often called "high-impact
plastic".
Commercial name: Bextrene.
Common applications: toys and product casings. HIPS is injection moulded here in
Moserbaer for production.
Autoclaving polystyrene can compress and harden the material.
3. GPPS (General Purpose Polystyrene)
CHARACTERISTICS
o Very high molecular weight
o High heat grade
o Good Clarity and Mechanical Strength
o High Melt Strength
APPLICATIONS
Extruded embossed sheets, OPS (oriented polystyrene sheets)
Food and medical applications like disposable pipette, tablet packaging bottles, ampoule
trays, caps & closures.

These materials are stored in various silos, structures for storing bulk materials and then
distributed to the respective injection moulding machines (IMMs) in required quantity.

4. PC (Poly Carbonate)

Polycarbonates used in engineering are strong, tough materials, and some

grades are optically transparent.

They are easily worked, molded, and thermoformed.

Polycarbonate is also known by a variety of trademarked names, including

Lexan, Makrolon and Hammerglass.

Application at Moser Baer : manufacturing Compact Disks.

 THE JEWEL BOX PLANT
At Moser Baer, the cases in which CDs are packed are called jewel boxes. These
boxes are made from the polymers mentioned in the earlier section. Moser Baer
CD-Rs are available in:

-Pack Slim Jewel Case Boxes
-Pack Cake Boxes
-Pack Cake Boxes
-Pack Cake Boxes
-Pack Tin Cans

Fig.- Jewel box Plant Layout

 PROCESS FLOW DIAGRAM
(CAKE BOX)

Polypropylene fine pieces Suck in mixer using vaccum

Mixture is melt and injection Mix with other materials in

moulding is done appropriate proportions.

Melt applied on mould Delay for cooling and setting

Force is released Delay for cooling and setting

Cake box holded through vaccum Robotic arm take the cake box
using vaccum through handshaking

Cake box is put on conveyer belt and collected in jumbo bags.

INJECTION MOULDING MACHINE (IMM)

In Moser Baer, the Jewel box plant is the site for the manufacturing the jewel
boxes, cake boxes and the pend drive cases. Injection Moulding machines,
designed in Japan are used in this plant.
The machines are designed by JSW Japan Steel Works

INJECTION MOULDING

Injection moulding is a manufacturing process for producing parts by injecting

material into a mould. Injection moulding can be performed with a host of
materials, including metals, glasses, elastomers, confections, and most commonly
thermoplastic and thermosetting polymers. Material for the part is fed into a heated
barrel, mixed, and forced into a mould cavity where it cools and hardens to the
configuration of the cavity.

PROCESS INVOLVED DURING INJECTION MOULDING

ing utilizes a ram or screw-type plunger to force molten plastic
material into a mould cavity; this solidifies into a shape that has conformed to the
contour of the mould.

mould which shapes the polymer into the desired shape. Moulds are generally
made from tool steels, but stainless steels and aluminium moulds are suitable for
certain applications. Aluminium moulds typically are ill-suited for high volume
production or parts with narrow dimensional tolerances, as they have inferior
mechanical properties and are more prone to wear, damage; but are cost-effective
in low-volume applications as mould fabrication costs and time are considerably
reduced.

rward through a check valve and collects at the front of the

screw into a volume known as a shot.

through a hopper into a heated barrel with a reciprocating screw. The screw
delivers the raw material forward, mixes and homogenizes the thermal and viscous
distributions of the polymer, and reduces the required
heating time by mechanically shearing the material and adding a significant
amount of frictional heating to the polymer.

for shrinkage, and provide a cushion (approximately 10% of the total shot volume,
which remains in the barrel and prevents the screw from bottoming out) to transfer
pressure from the screw to the mould cavity. When enough material has gathered,
the material is forced at high pressure and velocity into the part forming cavity.
Often injection times are well under 1 second.
packing pressure is applied,
which completes mould filling and compensates for thermal shrinkage, which is
quite high for thermoplastics relative to many other materials. The packing
pressure is applied until the gate (cavity entrance) solidifies. Due to its small size,
the gate is normally the first place to solidify through its entire thickness. Once the
gate solidifies, no more material can enter the cavity; accordingly, the screw
reciprocates and acquires material for the next cycle while the material within the
mould cools so that it can be ejected and be dimensionally stable. This cooling
duration is dramatically reduced by the use of cooling lines circulating water or oil
from a thermolator.
o Once the required temperature has been achieved, the mould opens and an array
of pins, sleeves, strippers are driven forward to demould the article. Then, mould
closes and the process is repeated.
Technical details of 890H model being used in JB during training
VARIOUS COMPONENTS IN MOULDING MACHINE
Every Injection Molding Machine (IMM) consists of 3 and 2 parts for slim case and regular case
resp.:
- Lid
- Bottom
- Assembler

Servo Motors
AC operated
Used for Mould Open/Close
Used for Ejection of work piece
Have encoders attached for positioning
Two of them are coupled with ball screw. While rotating A.C.W, left servo acts like master
motor and on rotating in C.W direction, right servo acts as master motor.
Encoders
Incremental type.
Put on servo motor for accurate positioning, not with induction motors where winding cause
rotation
 PID Controller
Control loop feedback mechanism
(controller)
Calculates an error value as difference
between desired setpoint and measured
process variable.
Attempts to minimise the error over time
by adjusting control variable.

Tie Bar
4 tie bars each in Injection and Moulding units are present.
Increases chassis rigidity.
Provides platform for movement of the movable platen for moulding purpose.

Ball Screw
They are rotary to linear movement with very little friction.
Have nut that rides on a screw spindle
Within nut are tracks that let a set of balls engage the screw spindle.
CARDS
1- RCU: Rapid Controller Unit(01&02) controls ejector return interlock, ejector advance interlock,
mould open interlock, mold close interlock, spear output signal safety guard close, mold open end,
mould clamping completion etc.

2- KBU: Keyboard Unit controls air core pull, air blow, unscrew motor circuit, mold open, screw
rotation, ejector rotract etc.

3- TCU: Temperature Controller Unit controls phase heater current, HV heater, hopper threat and
different heaters etc.

4- SSR : Solis State Relay (01,02,03&04) H3-1 heater, LNH heater ,injector unit retract, injector
unit advance etc.

5- SDIO : Secure Digital Input Output (01,02&03) grease level low, parts dropping conformation,
valve gate open, air core, oil cooler etc.

PLC used in the J.B plant

1- A1SHCPU Mitsubishi
2- Simantec S7-300 Siemens

Software Malsec for Mitsubishi

 Junction Box
The PV junction box has a simple, but important role: housing all the electric bits
on a solar panel and protecting them from the environment. Wires connect to
diodes inside, providing an easy way to link panels together.

Moser Baer starts Indias first domestic production of YUKITA Brand junction
boxes in partnership with Yukita Electric for solar PV modules at its Greater
Noida plant.

AP Model - MBPV CAAP

(a) (b)
Fig:-Junction box(a)outer view (b)internal view
Blocking Diodes
Blocking diodes can prevent night time battery discharging and
also prevent modules from loss of array output and damage by reverse current
flow. Moser Baer PV modules do not contain blocking diodes when shipped from
the factory however most battery charge regulators do have this feature.

By Pass Diodes
In systems with modules in series strings, high reverse current
can flow through cells that are shaded partially or when part of a module is
shaded and rest is exposed to the sun. These currents can cause affected cells to
heat up (hot spot phenomenon) and even damage the module.To protect
modules from high reverse currents bypass diodes are provided in the junction

The junction box has a breather port and the breather port must not be exposed to
direct rain/water. Hence the Junction box should be mounted on the higher side of
box (factory fitted). Diode rating -12A,200V
MODULE SPECIFICATIONS
 AS/RS
Godrej Consoveyo Logistics Automation
Ltd. (GCLA) (formerly Godrej Efacec
Automation and Robotics Ltd.) is pioneer
and leader in offering automated
warehousing solutions

Moser Baer (I) Ltd., Indias biggest

company in manufacturing of CD/DVD/
Optical Media was searching ways to
improve WIP (Work in progress) storage
at their Greater Noida Plant. With major
expansion in production present
warehouse was unable to support the
operations and supply chain was forced to
store WIP in shipping container at high
cost & low rotation of inventory.

In feasibility studies AS/RS was compared

with other storage & handling solutions on
a). Storage density b). Operating cost c).
Space & cost for constructing the planned
capacity etc. Godrej Efacec emerged the
preferred supplier for implementing
AS/RS.

System Features
Handling Unit : Euro Pallets
Storage Capacity (Pallets) : 14880 Pallets Achieved Benefits
Height : 21 Meters Operational cost savings
Width : 38 Meter High density double-deep
Length : 100 Meter storage
Handling Rate : 38 Pallets / Hour Increased efficiency
No. of Aisles : 5 High throughput & uptime
No. of Curving Cranes : 2
 PLC
(PROGMMABLE LOGIC CONTROLLER)
INTRODUCTION
Most recently electricity has been used for control and early electrical
control were based on relays. These relay allow power to be switched on and
off without a mechanical switch. It is common to use relays to make simple
logical control decisions. The development of low cost computer has
brought the most recent revolution, the programmable logic controller
(PLC).
Industry has begun to recognize the need for quality improvement and
increase in productivity in the sixties and seventies. To increase the
production we install number of sensors on the machine to detect belt
misalignment, so that, it can be repaired before you put out bad product, and
before it can fail-it shut down the machine to repair it.

Programmable Logic Controller (PLC) is a ruggedized special purpose

computer that reads a bunch of input signals; a run control logic, and then
writes output signals. These PLCs are basically smart relay boxes sensors
and switches go in on one side, and solenoids, bell, lights, motors-whatever
we need to turn on or off-comes out on the other side. PLCs are easy to
install, apart from this advantage this system require software and cables.
 WORKING

PLC are just the brains behind many machines, it controls the machine
according to the execution of the program, which was programmed by the
programmer in the PLC. PLC is similar to relay system but there are some
problems in the relays, one of the major problems is that-as we know relays
are the electromagnetic switch it does not able to work in high efficiency
(e.g. in turning switch on and off fastly) relay become hot and will damage.
To solve this problem engineers introduce PLC system that work on the
program, which is stored in the micro controller in the PLC by the
programmer. It senses the input from sensor which are installed on the
machine everywhere and according to the input it gives the output to the
machine. Therefore, PLC acts as a simple computer- waiting for inputs and
sending out outputs. Programming a PLC is relatively simple-today there are
many PLC programming software, which are icon driver means that we have
to drag and drop graphical pictures of the switch and sensors on the PLC
only. There is a software loaded in PLC which converts the graphical
pictures into its own logic.
 PROGRAMMING A PLC

PLC controller can be reprogrammed through a computer (usual way), but also
through manual programmers (consoles). This practically means that each PLC
controller can programmed through a computer if you have the software needed for
programming.

Today's transmission computers are ideal for reprogramming a PLC controller in

factory itself. This is of great importance to industry. Once the system is corrected,
it is also important to read the right program into a PLC again. It is also good to
check from time to time whether program in a PLC has not changed. This helps to
avoid hazardous situations in factory rooms. Correctly documented ladder diagram
allows any technician to understand thoroughly how system functions.

PLC CONTROLLER INPUTS

Intelligence of an automated system depends largely on the ability of a PLC

controller to read signals from different types of sensors and input devices. Keys,
keyboards and by functional switches are a basis for man versus machine
relationship. On the other hand, in order to detect a working piece, view a
mechanism in motion, check pressure or fluid level you need specific automatic
devices such as proximity sensors, marginal switches, photoelectric sensors, level
sensors, etc. Thus, input signals can be logical (on/off) or analogue. Smaller PLC
controllers usually have only digital input lines while larger also accept analogue
inputs through special units attached to PLC controller. Intelligent devices such as
robots, video systems, etc. often are capable of sending signals to PLC controller
input modules (robot, for instance, can send a signal to PLC controller input as
information when it has finished moving an object from one place to the other.)

PLC CONTROLLER OUTPUTS

Automated system is incomplete if it is not connected with some output devices.

Some of the most frequently used devices are motors, solenoids, relays, indicators,
sound signalization and similar. By starting a motor, or a relay, PLC can manage or
control a simple system such as system for sorting products all the way up to
complex systems such as service system for positioning head of CNC machine.
Digital output signal works as a switch; it connects and disconnects line. Analogue
output is used to generate the analogue signal (ex. motor whose speed is controlled
by a voltage that corresponds to a desired speed).
 OUTPUT ADJUSTMENT INTERFACE

Output interface is similar to input interface. CPU brings a signal to LED diode
and turns it on. Light incites a photo transistor which begins to conduct electricity,
and thus the voltage between collector and emitter falls to 0.7V , and a device
attached to this output sees this as a logic zero. Inversely it means that a signal at
the output exists and is interpreted as logic one. Photo transistor is not directly
connected to a PLC controller output. Between photo transistor and an output
usually there is a relay or a stronger transistor capable of interrupting stronger
signals.
EXTENSION LINES

Every PLC controller has a limited number of input/output lines. If needed, this
number can be increased through certain additional modules by system extension
through extension lines. Each module can contain extension both of input and
output lines. Also, extension modules can have inputs and outputs of a different
nature from those on the PLC controller (ex. in case relay outputs are on a
controller, transistor outputs can be on an extension module).

TYPES OF PLC PROGRAMMING

~ FBD (Functional Block Diagram)

~ LAD (Ladder Logic Diagram)
~ STL (Statement List)
In the plant we use ladder structure or logic for programming the PLC while the
PLC
used OMRON with 10 I/O ports.

The software used for programming is ZENTool support software.

a).Power supply is 12-24 V DC

. b).Inputs: 6 Io-I5
c).Outputs: 4 Qo-Q5
Digital logic functions
We can construct simply logic functions for our hypothetical lamp circuit, using
multiple contacts, and document these circuits quite easily and understandably with
additional rungs to our original "ladder." If we use standard binary notation for the
status of the switches and lamp (0 for unactuated or de-energized; 1 for actuated or
energized), a truth table can be made to show how the logic works:

Now, the lamp will come on if either contact A or contact B is actuated, because
all it takes for the lamp to be energized is to have at least one path for current from
wire L1 to wire 1. What we have is a simple OR logic function, implemented with
nothing more than contacts and a lamp.
We can mimic the AND logic function by wiring the two contacts in series instead
of parallel:
Now, the lamp energizes only if contact A and contact B are simultaneously
actuated. A path exists for current from wire L1 to the lamp (wire 2) if and only if
both switch contacts are closed.
The logical inversion, or NOT, function can be performed on a contact input
simply by using a normally-closed contact instead of a normally-open contact:

Now, the lamp energizes if the contact is not actuated, and de-energizes when the
contact is actuated.
If we take our OR function and invert each "input" through the use of normally-
closed contacts, we will end up with a NAND function. In a special branch of
mathematics known as Boolean algebra, this effect of gate function identity
changing with the inversion of input signals is described by DeMorgan's Theorem,
a subject to be explored in more detail in a later chapter.
The lamp will be energized if either contact is unactuated. It will go out only if
both contacts are actuated simultaneously.
Likewise, if we take our AND function and invert each "input" through the use of
normally-closed contacts, we will end up with a NOR function:

A pattern quickly reveals itself when ladder circuits are compared with their logic
gate counterparts:

Parallel contacts are equivalent to an OR gate.

Series contacts are equivalent to an AND gate.
Normally-closed contacts are equivalent to a NOT gate (inverter).

We can build combinational logic functions by grouping contacts in series-parallel

arrangements, as well. In the following example, we have an Exclusive-OR
function built from a combination of AND, OR, and inverter (NOT) gates:
The top rung (NC contact A in series with NO contact B) is the equivalent of the
top NOT/AND gate combination. The bottom rung (NO contact A in series with
NC contact B) is the equivalent of the bottom NOT/AND gate combination. The
parallel connection between the two rungs at wire number 2 forms the equivalent
of the OR gate, in allowing either rung 1 or rung 2 to energize the lamp.
To make the Exclusive-OR function, we had to use two contacts per input: one for
direct input and the other for "inverted" input. The two "A" contacts are physically
actuated by the same mechanism, as are the two "B" contacts. The common
association between contacts is denoted by the label of the contact. There is no
limit to how many contacts per switch can be represented in a ladder diagram, as
each new contact on any switch or relay (either normally-open or normally-closed)
used in the diagram is simply marked with the same label.
Sometimes, multiple contacts on a single switch (or relay) are designated by a
compound labels, such as "A-1" and "A-2" instead of two "A" labels. This may be
especially useful if you want to specifically designate which set of contacts on each
switch or relay is being used for which part of a circuit. For simplicity's sake, I'll
refrain from such elaborate labeling in this lesson. If you see a common label for
multiple contacts, you know those contacts are all actuated by the same
mechanism.
If we wish to invert the output of any switch-generated logic function, we must use
a relay with a normally-closed contact. For instance, if we want to energize a load
based on the inverse, or NOT, of a normally-open contact, we could do this:

We will call the relay, "control relay 1," or CR1. When the coil of CR1 (symbolized
with the pair of parentheses on the first rung) is energized, the contact on the
second rung opens, thus de-energizing the lamp. From switch A to the coil of CR1,
the logic function is no inverted. The normally-closed contact actuated by relay
coil CR1 provides a logical inverter function to drive the lamp opposite that of the
switch's actuation status.
Applying this inversion strategy to one of our inverted-input functions created
earlier, such as the OR-to-NAND, we can invert the output with a relay to create a
no inverted function:
From the switches to the coil of CR1, the logical function is that of a NAND gate.
CR1's normally-closed contact provides one final inversion to turn the NAND
function into an AND function.

REVIEW:
Parallel contacts are logically equivalent to an OR gate.
Series contacts are logically equivalent to an AND gate.
Normally closed (N.C.) contacts are logically equivalent to a NOT gate.
A relay must be used to invert the output of a logic gate function, while
simple normally-closed switch contacts are sufficient to represent inverted
gate inputs.
PROGRAMMING EXAMPLES

1. Water Plant

Schematic layout of water plant

I0 is pressed, pump is ON
 I1 pressed, pump off, heating
starts

After 5 sec, heating stop, outlet

valve open
2. WAP to toggle a bulb continuously:

As there is a timer to attached to the first rung it asks for the time you want to
make the bulb to go on and timer T1 for the time you want to make the bulb go off
3.WAP to manage traffic light:

Here the timers are set for different values which are specified for displaying the
different lights,here are red,yellow and green as in standard traffic lights.
4.WAP for a counter to count till a preset and then reset the counter using
timer:

Here the counter is activated as the input is given and RCo stores the updated value
of counter. After the timer To, counter is reset.
2.9 BASIC ADVANTAGES AND DISADVANTAGES OF PLC

Advantages:

Plcs bring all functions of the machine speeds, swatches, sensors, temperature,
and position Alarms, safety into one central processing computer.

1. PLCs are good at turning outputs on or off based on the state of inputs.
(Control)
2. PLCs are good at bringing together and concentrating a lot of data and status
that is uploaded into a computer in a compact form
3. PLCs are more rugged than computers and typically last five, seven, ten
years without needing replacement
4. Cost effective for controlling complex systems.
5. Flexible and can be reapplied to control other systems quickly and easily.
6. Computational abilities allow more sophisticated control.
7. Trouble shooting aids make programming easier and reduce downtime.
8. Unlimited number of inputs and outputs arte available.
9. Small and compact in size and less number of wires are used.

Disadvantages:

1.PLC were designed for Relay logic ladder and had some difficulties with some
smart devices.

2.To maximize PLC performance and flexibility,a number of optical modules must
be added.
ERRORS IN PLC

Plc controller features additional functions that make locating errors easier. Errors
can be divided into two categories according to severity.

Fatal Errors are serving and they prevent PLC controller from operating until
their cause is located and solved.
Non Fatal Errors are those that do not prevent PLC controller from operating.
After detecting one or more non-fatal, program execution will continue.
Nevertheless, it is necessary to correct these errors as soon as possible,

Non-fatal:
When one of theses errors takes place, indicators POWER and RUN will be on,
and the indicator ERR/ALM will blink. Upon locating non-fatal error, manual for
the given PLC controller should be consulted and the flags checked in order to
understand the cause of a problem and correct the error.

Fatal:

When any of these fatal errors takes place, Plc controller stops operating and all
outputs are shut down. Plc controller cannot be put back to work until the
controller is turned of and then turned back on, or until it is switched to program
mode via peripheral device and the fatal error corrected. With these errors,
indicators ERR/ALM are on, while the RUN indicator remains off. It is necessary
to check the error flag in the given PLC in order to locate the cause of the problem
and the correct the error.

User defined error:

There are three instructions for user to define his own errors or messages. FAL
(06) causes non-fatal error; FAL (07) causes fatal error, while MSG (46) sends a
message to program console or to the host computer connected to the PLC
controller.
Failure alarm:

Instruction FAL (06) generates the code of non-fatal error that took place to
provide the information on the possible cause of the problem for the programmer.
Upon execution of the instruction FAL (06) following events take place:

1. Indicator ERR/ALM will blink, while PLC continues to work.

2. Two-digits BCD number of instruction FAL (01 do 99) is written from
SR253000 to SR25307.
3. Same number must not be assigned to both FAL and FALS instruction. to
delete the code of an error ,error should be corrected and FAL 00 instruction
executed.

Severe failure alarm:

Instruction FALS (07) generates the code of fatal error that took place. In this case
the following happens:
1. Program stops and all outputs are shut down.
2. Indicator ERR/ALM is turned on.
3. Two-digit BCD number (01 do 99) of instruction FALS is written from SR
253000 to SR25307.
4. If memory card with RTC is used, part of the memory where the presence of
error is recorded will also contain numbers of FALS instruction and exact time
when error took place.
Numbers of FALS instruction can be assigned to certain states. Same number must
not be assigned to both FAL and FALS instructions. To delete FALS error, PLC
controller must be in PROGRAM mode, cause of error solved and then error code
deleted.

Message:

MSG (46) is used for printing messages on program console display. Message
cannot exceed 16 characters, and it appears when specified condition is fulfilled.
 Sensors
One type of feedback frequently needed by industrial-control systems is the
position of one or more components of the operation being controlled. Sensors are
devices used to provide information on the presence or absence of an object.
Sensors include limit switches, photoelectric, inductive, capacitive, and ultrasonic
sensors. These products
are packaged in various configurations to meet virtually any requirement found in
commercial and industrial applications. Some Industrial sensors used are as
follows:
1. Limit Switches
A typical limit switch consists of a switch body and an operating head. The switch
body includes electrical contacts to energize and deenergize a circuit. The
operating head incorporates some type of lever arm or plunger, referred to as an
actuator.
The standard limit switch is a mechanical device that uses physical contact to
detect the presence of an object (target). When the target comes in contact with the
actuator, the
actuator is rotated from its normal position to the operating position. This
mechanical operation activates contacts within the switch body.
2. BERO Sensors
BERO is the trade name used by Siemens to identify its line of no-touch sensors.
Siemens BERO sensors operate with no mechanical contact or wear. There are four
types of BERO sensors: inductive, capacitive, ultrasonic, and photoelectric.
Inductive proximity sensors use an electromagnetic field to detect the presence of
metal objects.
Capacitive proximity sensors use an electrostatic field to detect the presence of any
object. Ultrasonic proximity sensors use sound waves to detect the presence of
objects. Photoelectric sensors react on changes in the received quantity of light.
Some
Photoelectric sensors can even detect a specific color.
3. Capacitive Proximity Sensors
Capacitive proximity sensors are similar to inductive proximity sensors. The main
difference between the two types is that capacitive proximity sensors produce an
electrostatic field instead of an electromagnetic field. Capacitive proximity
switches will sense metal as well as nonmetallic materials such as paper, glass,
liquids, and cloth.
The sensing surface of a capacitive sensor is formed by two concentrically shaped
metal electrodes of an unwound capacitor. When an object nears the sensing
surface it enters the electrostatic field of the electrodes and changes the capacitance
in an oscillator circuit. As a result, the oscillator begins oscillating. The trigger
circuit reads the oscillators amplitude and when it reaches a specific level the
output state of the sensor changes. As the target moves away from the sensor the
oscillators amplitude decreases, switching the sensor output back to its original
state.
4. Photoelectric Sensors
A photoelectric sensor is another type of position sensing device. Photoelectric
sensors, similar to the ones shown below, use a modulated light beam that is either
broken or reflected by the target.
The control consists of an emitter (light source), a receiver to detect the emitted
light, and associated electronics that evaluate and amplify the detected signal
causing the
photoelectrics output switch to change state. We are all familiar with the simple
application of a photoelectric sensor placed in the entrance of a store to alert the
presence of a customer. This, of course, is only one possible application.
 OTHER COMPONENTS STUDIED
DC power supply (I/P: 230VAC, O/P: 24VDC)
Transformer : Load 8KW
Relays
Contactors
Push Buttons
MCB (2 pole)
PLC (OMRON)

1. POWER SUPPLY

A power supply is an electronic device that supplies electric power to an electrical

load. The primary function of a power supply is to convert one form of electrical
energy to another and, as a result, power supplies are sometimes referred to as
electric power converters. Some power supplies are discrete, stand-alone devices,
whereas others are built into larger devices along with their loads. 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 energy from various types of energy sources,
including electrical energy transmission systems, energy storage devices such as a
batteries and fuel cells,electromechanical systems such as generators and
alternators, solar power converters, or another power supply.

~Control Power Flow Inside IMM

PLC>>Relays>> DRV Board>> IGBTs>> CT>> SCP Board>> Bus Bar>> 3 (u,v,w)

where DRV : Drive Board

IGBT : Insulated Gate Bipolar Transistor
CT : Current Transformer
SCP : Servo Control Process
2. TRANSFORMER

A transformer is an electrical device that transfers energy between two or more

circuits through electromagnetic induction. A varying current in the transformer's
primary winding creates a varying magnetic flux in the core and a varying
magnetic field impinging on the secondary winding. This varying magnetic field at
the secondary induces a varying electromotive force (emf) or voltage in the
secondary winding. Making use of Faraday's Law in conjunction with high
magnetic permeability core properties, transformers can thus be designed to
efficiently change AC voltages from one voltage level to another within power
networks.
Transformers range in size from RF transformers with volume less than 0.1 cc to
units weighing hundreds of tons interconnecting the power grid. A wide range of
transformer designs are used in electronic and electric power applications.
Transformers are essential for the transmission, distribution, and utilization of
electrical energy.

3.

RELAYS

A relay is an electrically operated switch. Many relays use an electromagnet to

mechanically operate a switch, but other operating principles are also used, such
assolid-state relays. 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 as amplifiers:

they repeated the signal coming in from one circuit and re-transmitted it on
another circuit. Relays were used extensively in telephone exchanges and early
computers to perform logical operations.
A 24V DC relay, Cover opened to see the NO & NC contact point clearly
4. CONTACTORS

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. Unlike a circuit breaker,
a contactor is not intended to interrupt a short circuit current. 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 a side. Contactors are used to control electric motors, lighting,
heating, capacitor banks, thermal evaporators, and other electrical loads.
 CONCLUSION

A Programmable Logic Controller (PLC) is a device that was invented to replace

the necessary sequential relay circuits for machine control. A person
knowledgeable in relay logic systems can master the major PLC functions. These
are used extensively in nuclear reactor building and security control system. It is a
reliable compare to other control systems. These may be used to run a robot. By
using the PLC application logic we can control the airlocks logic control panel of
reactor buildings. These PLCs are used in many Real World applications. So
using these PLCS nuclear reactor building doors namely Main Airlock &
Emergency Air Lock .