SUMMER internship REPORT

MARUTI, GURGAON (MAY-JULY 2012)

(PLC Based Simulated Automated Weld Gun Robot Prototype)

Amity School of Engineering & Technology

Amity University Haryana
2010-2014

Submitted TO: Submitted By:

Dr. Shiv Sharma VIVEK REKHAN
BTM/10/089
B.TECH (MAE) B-2
 DECLARATION
I hereby declare that the project work entitled ―PLC based automated weld robot
prototype” is an authentic record of my own work carried out at Caparo Maruti Limited as
requirements of two months Industrial Training for the award of the degree of B.Tech. at
University Institute of Engineering & Technology, Panjab University, Chandigarh under the
guidance of Mr. SHEKAR VERMA and Dr. Arvind Kumar Rajput from May to July
2013.

_______________
VIVEK REKHAN
( BTM10/089)

Certified that the above statement made by the student is correct to the best of our knowledge
and belief.

Mr SHEKHAR VERMA

(Manager, Weld Maintenance)

 ACKNOWLEDGEMENT

Industrial training is an indispensable part of our engineering curriculum. It provides the

students an opportunity to gain experience on the practical applications of their knowledge.
My training at Caparo Maruti Ltd, Gurgaon has been very fruitful. I am sure that the hands
of experience I am gaining here will go a long way towards making me a competent engineer.

I would like to convey my sincere gratitude to Mr. Shekhar Verma, Mr. Jaipal Mann and
Mr. Prabhat Thakur who entrusted me with the responsible project work and provided me
with timely and proper guidance whenever required. This enabled me to gain experience in
not only the technical and practical aspects of industry but also in human relations, teamwork
and also provided great insights into the actual working of an industry. Without his efforts
this training would not have been as great a learning experience as it is being.

I take this opportunity to thank my training incharge Mr. Shekhar Verma for their constant
advice.

I would also like to thank my head of department, Dr. Arvind Kumar Rajput for giving me
the opportunity to undergo the industrial training and also Mr. Sumit Budhiraja for his
continuous guidance and advice throughout the project period

I hereby also declare that the contents in this report are true to the best of my knowledge.

VIVEK REKHAN
 TABLE OF CONTENTS

S.NO. TOPIC PAGE NO.

1. ABOUT CAPARO
1.1 Introduction.
1.2 Company profile
1.3 Manufacturing Plant
1.4 Customer profile
1.5 List of manufactured parts
2. PRESS SHOP
2.1 Operations in press shop
2.2 Introduction
2.3 Process Chart
2.4 Specifications
3. WELD SHOP
3.1 Operations in weld shop
3.2 Resistance welding
3.2.1 Nugget test
3.2.2 Spot welding
3.2.3 Projection welding
3.2.4 Stud welding
3.2.5 Multispot welding
3.3 Gun welding (IT Gun)
3.4 MIG welding
3.5 Specifications
4. AUTOMATED WELDING GUNS: PLC BASED AUTOBOTS

4.1 Introduction to Automation and PLC

4.2 Control system
4.3 Introduction to PLC
4.4 Advantages of PLC
4.5 Architecture of PLC
4.5.1 Hardware
4.5.2 Software and Ladder logic
 TABLE OF CONTENTS

S.NO. TOPIC PAGE NO.

5. BASIC INSTRUMENTATION
5.1 Transducers
5.2 Temperature measuring devices
5.3 Sensors
5.3.1 Types of sensors
5.3.2 Inductive proximity sensors

6. ROBOTIC LINE (THE AUTOBOTS)

6.1 Types of robots
6.2 Fanucc robot
6.2.1 Architecture
6.2.3 Programming
6.2.3 Hardware connections and Components

7. PROJECT WORK (SIMULATED PROTOTYPE)

7.1 Introduction
7.2 OPERATION
7.3 How this simulation is similar to the actual robot?
7.4 Solenoid valve
1. ABOUT COPARO
1.1.INTRODUCTION

Caparo maruti limited is a joint venture of Maruti Udyog Limited. Caparo group belongs to
Lord Swraj Paul. It is a U.K based company. It has 19 plants all over India, amongst them 3
are the joint ventures with Maruti Udyog Limited.

Caparo maruti is a medium scale industry. It consists of 600/day employees in Gurgaon

plant. It makes 58 sub components out of which 20 are made only at press shop and
remaining by the help of welding process.

There are 2 shops in this plant-

a. PRESS SHOP- 120/Day Employers

b. WELD SHOP-400/Day Employers

In press shop there are 4 mechanical presses (800T, 400T, 400T, 400T) and one hydraulic
press(100T).

The processes involved in this shop are:

a. Drawing
b. Trimming
c. Piercing
d. Side bending

In weld shop there are 4 welding processes involved:

a. Spot welding (using IT Gun &PSW Machine)

b. Projection welding (M-6 Nut welding)
c. Stud welding.
d. MIG welding.

Recently added are the new robotic lines for weld process. The line consists of two types of
robots:

1. Fanuc robot
2. Motoman robot

Both function for the welding processes only with slight construction differences. They
consist of gun attached to the tips and have 6 degrees of rotation.
 1.2.COMPANY PROFILE

Caparo India, the Indian business arm of Caparo Group, began its operations in 1994, as a
joint venture with India‘s largest car manufacturer— Maruti Udyog. Today, through its two
strategic business entities, Caparo Engineering India Pvt. Ltd. and Caparo Maruti Ltd, the
group offers end-to-end solutions in designing, developing and manufacturing automotive
system, assemblies, advanced composites, modules and components to Indian Automotive
OEMs and Engineering Industry.

Caparo India leverages its exhaustive capabilities in metal Stamping, Fastening, Tubing,
Forging and Aluminium Foundry businesses, coupled with its state-of-the-art Tool Room and
R&D Centre, to service top-notch clients such as GM, Ford, Maruti, Honda, Tata Motors and
JCB. The company‘s ability to offer complete lifecycle solutions backed by a global support
system, technological superiority and customer orientation, make it a force to reckon with in
its areas of expertise. ―Caparo India currently employs 5000 direct and indirect employees
across 25 world-class functional and upcoming facilities.

PEOPLE AT CAPARO MARUTI

RAJESH PRASAD

CEO - CAPARO India

BISWAJIT GOSH

CHIEF OF METAL SYSTEMS (NORTH INDIA)

 DEVELOPMENTS
1968 December 31 Natural gas tubes starts making spiral weld tubes at Huntington with first
year sales 14000$.

1968 November 16: Tredegar spiral weld mill opened by Late Prime Minister of India, Mrs.
Indra Ghandi.

1980 December 31: Acquire control of public Quoted company LK Industrial Investments –
Become Caparo Industries.

1984 December 31: Acquire Wrexham Wire which is now Caparo Wire.

1991 December 31: 2002 Summary: Caparo Engineering India Pvt. Lmt. Pithampur, new
pressing plant commences production.

2004 December 31: Caparo Maruti ,India- Halol and bawal Plants established.

2005 December 31: India:- Caparo Fasteners Constructing new plant in Chopanki (RN).
Caparo Engineering Expansion in Pithampur (NP) and new plant in Greater Noida (UP).

2006 February 01: Creation of vehicle products Division.

2006 November 03: Duke of York Launches Caparo‘s 120 acre site in Chennai, India.

2007 January 18: Caparo Engineering India Pvt. Ltd. Acquire the sheet metal business of
IAL.

2008 July 11: Caparo T1 Smashes track record at Dubai Autodrome.

CENTERS
 1.3.MANUFACTURING PLANTS
Caparo India's stamping operations are currently based out of 11 plants with 3 new plants
under construction. Most of these facilities have been set up close to the site of major
OEMs - a critical strategic ad Caparo India's facility in Greater Noida, primarily services
Honda Siel while the Pithampur plant is dedicated largely to Eicher Motors and Force
Man. Halol has been set up mainly for General Motors and the Gurgaon and Bawal
facilities service Maruti. The plants in Pune and Jamshedpur were acquired in January
2007 and are critical to developing business with Tata Motors.

( Gurgaon plant)

Quick Facts

Operational Since – Feb 1996

Total Area - 12,100 sq. m
Built up Area -5,600 sq. m
Capacity - 2.4 mn line strokes p.a.
Investment - INR 100 Cr.
Manpower Employed -330 employees

Plant Highlights

1. Fully automatic press line consisting one press of 800T, three presses of 400T each,
one press of 100T.
2. Bed size of all presses is 2.5 *1.8 mtrs.
3. Product manufactured are Dash panels , Floor panels , Quarter inner, Hood inner,
front member and Door inner.

Facilities

1. Automotive press shop.

2. Die spotting press.
3. Cars weld shop. (Manual and Automated)
4. Quality lab.
 COPARO MARUTI LAYOUT

CREATED IN AUTOCAD
1.4.CUSTOMER PROFILE
 1.5.LIST OF PRODUCTS MANUFACTURED AT CAPARO
MARUTI

S.No. Model Part No. of Stage Stage Stage Stage

Stages 1st 2nd 3rd 4th
(tonne) (tonne) (tonne) (tonne)

1 Alto Quarter inner 4 800 400 400 400

lower RH/LH

2 Alto Panel Dash 4 800 400 400 400

3 Alto Rear wheel 4 800 400 400 400

housing
4 Wagon Hinge pillar 3 800 400 400 400
R
5 Wagon Panel Dash 4 800 400 400 400
R
6 Zen Panel Dash 4 800 400 400 400
Estilo
7 Zen Hinge pillar 3 800 400 400 400
Estilo

8 Omni FFR-LH 4 800 400 400 400

9 Omni FFR-RH 4 800 400 400 400

10 Versa Panel Dash 4 800 400 400 400

11 Versa R.W.HSG 4 800 400 400 400

12 RITZ Panel Dash 4 800 400 400 400

13 Swift Panel Dash 4 800 400 400 400

14 Swift Tunnel 4 800 400 400 400

ALTO

1.PANEL DASH

2.Quarter inner lower LH 3. Quarter inner lower RH

WAGON R

1.PANEL DASH

2.HINGE PILLAR
VERSA

1.PANEL DASH

2. REAR WHEEL HOUSING

ZEN

1.PANEL DASH

2. HINGE PILLAR
SWIFT

1.PANEL DASH 2. TUNNEL

RITZ

PANEL DASH
 2.PRESS SHOP
Press is a machine which undergoes various processes by applying tonnage on the raw
material.

There are various types of presses-

1. hydraulic presses
2. mechanical presses
3. pneumatic presses

In CML there are 4 mechanical presses (800T, 400T, 400T, 400T) and 1 hydraulic press.

The raw material used in press shop is cold rolled forged steel sheet (because CRS has
high tensile strength, elongation is good) as per requirement.

The companies which supply raw material are TATA, ESSAR, and POSCO STEELS.

2.1. OPERATIONS PERFORMED IN PRESS SHOP

The following operations which are held in the press shop are-
1. Blanking – It is the process in which the punch removes a portion of material from a
stock which is a strip of sheet metal of the necessary thickness and width. The removed
portion is called a blank.

2. Drawing – It is the process of making cups, shells, and similar articles from metal
blanks.

3. Trimming - It is the process of removing extra material.

4. Piercing- The process of making holes in sheet.

5. Reforming and piercing- It is the process of providing holes, punches to the part.

6. Side bending- It is a operation of deforming of a flat sheet around a straight axis where
the neutral plane ( plane with no stresses) lies.
2.2. INTRODUCTION OF PRESS

FIG.13

FIG. 14
 FIG. 15

HYDRAULIC PRESS

FIG. 16

Using robotic arm pick-up operation is carried out in which pneumatic force is used.
 2.3PROCESS CHART

PRESS PROCESS FLOW

BENDING &
DRAWING RESTRIKING TRIMMING
PIERCING TO CUSTOMER
OPERATION OPERATION OPERATION
OPERATION

FILTER 1 FILTER2

Wrinkle Flange Gap

Prevention Detection

IMPROVED QUALITY PRODUCT TO CUSTOMER

FIG.17

Specifications

Area 1648 m2
Number of presses 4
Press capacity 800T -1 press
400T – 3 presses
Manpower 32/shift
Operational shift 3
2 types of lines tandem lines
Transverse lines

800 T press - motor of 96 kW

3.3- 3.2 bar atm. Pressure with die
2.8 bar atm. Pressure without die

400T press- motor of 64 kw

2.8 bar with die
2.5 bar without die
Hydraulic clutch is used
Components of dies-

1. Upper die
2. Lower die
3. Blank holder

SPECIFICATIONS OF DIES

Number of dies – 114 dies

Weight of die - 20 ton
Die raw material F/C 25
Cushion pressure -0.9-1.2kg/cm2
 3.WELD SHOP

It is a fabrication technique and is used to join the metals by heating and then pressing
together.

Welding is the process of joining metals

FILLER MATERIAL

MELTING JOINING
HEAT
OF METAL OF METAL

1. CURRENT
2 GAS NO FILLER MATERIAL
3 CHEMICAL
REACTION

FIG . 1

3.1 Welding is of various types:-

1. Resistance welding
a. Spot welding (CAPARO)
b. Seam welding

2. Electric arc welding (CAPARO)

3. Gas welding

In Caparo Maruti Limited (CML) there are different types of welding techniques used for
processing of sub assemblies of the automobiles like-

1. Spot welding
2. Projection welding
3. Stud welding
4. MIG (metal inert gas welding) welding
FIG. 2

3.2. RESISTANCE WELDING

It is the process of joining metal pieces together by raising the temperature of the pieces
to fusion point and applying a mechanical pressure to join them. In this, the pieces to be
joined are held together and a strong electric current of high amperage and low voltage is
passed through them. This current comes across a certain resistance in passing from one
piece to other and it is this resistance offered to the flow of current which results in
raising the temperature of the two pieces to fusion or melting point at their junction. The
mechanical pressure applied at this moment completes the weld.

FIG. 3

Resistance welding process depends upon correct application and proper control of
the following factors:-
1. Welding current – Enough current is needed to bring the metal to its plastic state for
welding.

2. Welding pressure- In this welding mechanical pressure is required to be applied at

two stages- first to hold the metal pieces tightly between the electrodes, while the
current flows through them, and secondly when the metal has been heated to its
plastic state, to forge or squeeze the metal pieces together to form the weld. The
former is known as WELD PRESSURE and the latter FORGE PRESSURE

3. Heat is directly proportional to the square of current and time.

H=I2 R T.

H = Heat
I = Current in amperes,
R = Resistance of the work in 0hms,
T = Time the current flow in cycles
(50 CYCLES IN ONE SECOND)

4. Time of application- It can also be described as cycle time and is the sum total of the
following time periods-

a. Weld time – It is the time period during which the current flows through the
metal pieces to raise their temperature.

b. Squeeze time or forging time- It is the time period during which the forge
pressure is applied to the metal pieces to squeeze them together to form the
weld.

c. Hold time- It is the time period during which the metal pieces are held
together under forge pressure for a short while to enable the weld to solidify. It
can therefore, be called cooling time also.

d. Off-time- After cooling of weld the electrode pressure is released and the
metal pieces removed for the next operation cycle. The time period between
this release of electrodes and the start of next welding cycle is called off-time.

4. Contact area of electrodes- The weld size depends on the contact area of the face of
the electrodes. It can be varied by selecting suitable set of electrodes to provide the
desired area of contact at their tips.
C
U
R
R U O
E W D H F
S P
N E N O F
Q L L
T S
U D S D
E L
L
E O
O
Z P
P
E E
TIME E

FIG.4 WELD TIME CONTROL FOR SPOT WELDING

3.2.1.NUGGET TEST (RELATION BETWEEN CURRENT AND PRESSURE) -

No Nugget
Splash
Large
Pressure Nugget Dia B - will have
(Strength) Good Weld
Good Weld Less Spatters
Small Optimum Nugget Dia
Explosion

Current
A:High Current and High Pressure -SPLASH
B:Medium current and medium Pressure - GOOD WELD
C: Small Current and High Pressure-NO WELD
NO NUGGET
3.2.2. RESISTANCE SPOT WELDING

The principle of spot welding- in which a transformer core is having primary and secondary
winding. One end of the secondary winding is connected to the upper electrode carried in the
movable copper or bronze arm A and the other end to the lower electrode mounted on the
fixed arm B. In operation the metal sheets S1 and S2 are held and pressed between the
electrodes and a strong current at low voltage is switched on. Due to the resistance offered by
the sheet metal to the flow of this current the temperature at the contact surfaces rises to
fusion point and the weld is completed under the contact pressure of the electrodes.

WELD SPOTS

CHIESEL
NUGGET DIA

NUGGET CHECKING METHOD

IF METAL SOUND ----- OK

UTM
SPOT SHOULD NOT FAIL

TENSILE STRENGTH CHECKING METHOD

FIG.6 SPOT CHECKING METHOD

SPOT WELDING ELECTRODES &ELECTRODE HOLDER

The electrode holders should possess the following characteristics-

1. They should be good conductors of electricity.
2. They should be good conductors of heat.
3. They should possess high mechanical strength and hardness.

Most of these holders are water cooled and so are the electrode tips which are made
hollow for this purpose.
3.2.3. RESISTANCE PROJECTION WELDING
This process is similar to spot welding but differs from the latter in that the spots at which the
welding takes place are previously located by providing projections at the desired locations
on the surface of one of the work pieces. Thus the surfaces of the work pieces are in contact
with each other only at the projections. As the current is switched on the projections are
melted and the work piece pressed together to complete the weld, by pressing the upper
electrodes downwards

NG OK
UPPER ELECTRODE

PIN

SPRING
LOWER ELECTRODE
PIN

NUGGET

FIG 7. PROJECTION NUT WELDING

3.2.4. STUD WELDING

It is an arc welding process adopted specifically for welding of studs to structures and other
surfaces for fastening other components to them .it is done with the help of a specially
designed gun called stud welding gun. As soon as the gun trigger is pressed the current is
switched on and a solenoid inside pulls the stud away from work piece by a predetermined
distance. This creates an arc between the stud and the work and the stud end and base metal
melts. It has a controller, 3 phase transformer, and automatic trigger.
DRAWBACK-

If get unbalanced very difficult to balance.

LIFT PLUNGE
STUD

BASE METAL LIFTED CONDITION

EXCITATION
LIFTING OF COIL
ACTION PLUNGE
WELDING
PULSE POINT
PILOT ARC
VOLTAGE PILOT ARC
WELDING
CURRENT

MELT CONDITION

HEATING
TEMPERATURE

FIG 8. STUD WELDING (FLASH WELDING)

3.2.5. MULTI SPOT WELDING (MSW) -

It is similar to spot welding but as the name suggests it is used for doing multiple spots at the
same time. There are number of cylinders having magnetic slips in them which creates
magnetic field.
 FIG. 10

3.3 GUN WELDING

The specific use of this method is in welding of irregular surfaces, such as fabrication of
automobile bodies. The electrodes are actuated either hydraulically or pneumatically. The
equipment consists of a transformer, flexible leads connecting the transformer to the
welding gun, the welding gun unit comprises of two electrodes and a trigger switch.

IT GUN (inbuilt transformer gun)

There are 4 cables in this gun-

1. Power cable (red)

2. Air cable (green)
3. Water cooling cables (black)
 FIG.12

The water is coming from cooling towers with a flow rate of 6 to 8 liters/ minute. The force
produced by trigger is 200kg.

The major components of gun are-

1. firing card
2. control card
3. trigger switch
4. transformer
5. thyristor
6. primary and secondary windings
7. electrode
8. arms
 DISADVANTAGES:

1. Gun weight is very heavy.

2. Carbon deposition is there which creates insulation. It is removed by filing and
cooling.
3. Machine breakdown due to movable arms.
4. Production is slow.
5. Requirement is of 27 deg Celsius is there but the temperature is 45 deg Celsius
in the plant.

3.4. METAL INERT GAS WELDING (MIG)

MIG stands for metal inert gas welding. It involves welding of metals using consumable
metal electrode in an inert gas atmosphere. The arc is struck between the electrodes and
the work piece. The electrode is in the form of continuous wire which is fed into the arc,
by an adjustable speed electric motor, at the same speed at which it is melted and
deposited in the weld. The electrode holder also incorporates passage for supply of inert
gas for shielding the electrode, molten weld metal, arc from atmospheric contamination.
Usually D.C. with reverse polarity is used in MIG welding. Use of this enables a deeper
penetration.

3(a). CO2 MIG WELDING

In this process the electrode used is either flux cored or magnetized flux coated. Co2 is
used as a shielding gas. In either case the filler wire or electrode is fed the arc in the same
way as in MIG welding.
In Caparo Maruti Limited (CML) there are different types of welding techniques used for
processing of sub assemblies of the automobiles like-

1. Spot welding
2. Projection welding
3. Stud welding
4. MIG (metal inert gas welding) welding

WELDING SHOP SPECIFICATIONS-

Area 1728 m2
Welding jigs 83 no.
Number of Guns 125
Manpower 150/shift
Operation shift 2
 4.AUTOMATED WELDING GUNS: PLC BASED AUTOBOTS

4.1.INTRODUCTION TO PLC AND AUTOMATION

What is industrial automation?

Automation or industrial automation is the use of control systems such as PLC, SCADA,
HMI, etc. to control industrial machinery and processes, replacing human operators.
Automation greatly reduces the need for human sensory and mental requirements.
Programmable logic controllers (PLCs), are frequently used to synchronize the flow of inputs
from (physical) sensors and events with the flow of outputs to actuators and events. This
leads to precisely controlled actions that permit a tight control of almost any industrial
process.
Human-machine interface (HMI) or computer human interface (CHI), formerly known as
man-machine interfaces, are usually employed to communicate with PLCs and other
computers, such as entering and monitoring temperatures or pressures from further automated
control or emergency response.

Current emphasis in automation:

Currently, for manufacturing companies, the purpose of automation has shifted from
increasing productivity and reducing costs, to broader issues, such as increasing quality and
flexibility in the manufacturing process.
Moreover, the initial costs of automation were high and often could not be recovered by the
time entirely new manufacturing processes replaced the old.

Automation is now often applied primarily to increase quality in the manufacturing process,
where automation can increase quality substantially. Another major shift in automation is the
increased emphasis on the flexibility and convertibility in the manufacturing process.
Manufacturers are increasingly demanding the ability to easily switch from manufacturing
Product A to manufacturing Product B without having to completely rebuild the production
lines.
Some of the most important advantages of Automation:
1. Optimum contribution of energy and raw material.
2. Optimum co-ordination and co-operation between mechanical and electronic counter
Performance of a task.
3. Performance of a task with the application of least physical efforts.

Need for automation:

1. Higher productivity.
2. Shorter process change time.
3. Accuracy of control.
4. Greater reliability and equipment life.
5. To add flexibility to process.

4.2.CONTROL SYSTEM

A control system is a device or set of devices to manage, command, direct or regulate the
behavior of other devices or systems.

Requirements of a control system:

1. Adaptability and flexibility.

2. Universal application.
3. Defined response time.
4. Extensive diagnostic features.
5. Expandability.

Types of control system:

Basically there are two types of control system.

1. Open loop control system.
2. Closed loop control system.

Open loop control system: In case of open loop, output is depending only on the applied
input, there is no feedback. Suppose you want to control the speed of the motor by using open
loop control system then you have to vary the input till the desired speed is reached. In case
of open loop, continuous monitoring of output is necessary. Open loop systems are less
expensive but accuracy is not so good. That is why closed loop control system is always
preferred over open loop control system.

Closed loop control system: A block diagram of a simple closed loop system is shown below.
Let us assume that the output variable to be controlled is non-electrical in nature and control
action is through electrical means. The input is reference which is corresponding to the
output. The input is compared with the output with the help of a comparator. The output is a
non-electrical quantity and is converted into an electrical form by a transducer connected in
the feedback loop. In case the input and output differ, there is a resultant error signal. The
error signal is then amplified and then fed to an actuator, which produces power to drive the
controlled circuitry of the plant (or the process to be controlled).

The corrective action goes on till the output is at the same level as the input, which
corresponds to the desired output. At this stage, there is no error signal and hence there is no
input to the actuator and the control action stops.

1. INTRODUCTION TO PLC

What is a PLC?

A Programmable Logic Controller, PLC, or Programmable Controller is a digital computer

used for automation of industrial processes, such as control of machinery on factory assembly
lines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-
backed or non-volatile memory.
A dedicated PLC is a microprocessor controlled computer that is designed specifically to
perform real-time industrial machine control. There are 3 general sections to all PLC‘s,
INPUT, CONTROLLER, and OUTPUT.

INPUT - The input section consists of integrated inputs, or extension inputs that machine
input devices will be wired to, like limit switches, or transistor sensors. When the input
voltage reaches its specified level the input becomes active. Once active, the input can be
read by controller.

CONTROLLER - The controller is the main unit. Several CPU modules are available
depending on the demands of your application.
OUTPUTS - The third section is the outputs. Based on the condition of the inputs, the
controller will judge which outputs should turn on, to activate machine devices like lights,
buzzers, relays, solenoids, or motors.
The 3 sections are controlled by custom sequencing software called ladder programming,
which takes the place of hardwired circuits. The relationship between inputs and outputs is
controlled by the logic in your ladder program. Because hard-wired circuits are now replaced
by software logic, machine modifications and improvements, are much easier to complete.

SECTIONS OF PLC

1. Rack/Rail
2. Power supply unit
3. Processor nit
4. I/O unit

Features:

The main difference is that the PLCs are armored for severe condition (dust, moisture, heat,
cold , etc) and have the faacility for extensive input/output arrangements. These connect the
PLC to sensors and actuators. PLCs read limit switches, analog process variables (duch as
temperature and pressure), and the positions of complex positioning systems. On the actuator
side, PLcs operate electric motors, pneumatic or hydraulic cylinders, magnetic relays or
solenoids, or analog outputs.
PLCs were invented as replacements for automated systems that would use hundreds or
thousands of relays, cam timers, and drum sequencers. Often, a single PLC can be
programmed to replace thousands of relays.

Even through the electro-mechanical relays (control, pneumatic, etc) have served well for
many generations, often under adverse condition, the ever increasing sophistication and
complexity of modern processing equipment require faster acting. More reliable control
functions that electroechanical relay or timing devices cannot offer.
Relay have to be hardwired to perform a specefic function, and when the specefic
requirements change, the relay wiring has to be changed or modified.
The requireent of highle specialized, high speed manufacturing process created a demand for
smaller, faster acting, more reliable, low power consuming, expaqndable, eliminating much
of the hard wire control devices called PLC‘s.
PLC‘s are designed to be operated by plant engineer and maintenance personel with limited
knowledge of computers. PLC is programmed in LADDER LOGIC (A high level, real world,
graphics language that is easily understood by engineers).
4.4ADVANTAGES OF PLC:

1. Simple wiring
2. Flexibility in programming and reprogramming in the Plant.
3. Low space
4. Wider functions like high speed counters, etc.
5. Faster Scan Time.
6. Simpler installation.
7. Modular installation.
8. Value for money.
9. Minimum maintenance.
10. Ability to communicate with HMI/MMI.
11. Programmable troubleshooting aids which reduce downtime.

4.5.ARCHITECTURE OF PLC

Types of PLC:-
(a) Base PLC
(b) Modular PLC

(a) A base or unitary PLC has a power supply, a CPU and a limited number of inputs
and outputs (20i/p – 12 o/p, 32 I/O). it is sometimes called ―shoebox type‖ and is
mainly used for the control of a small system.

(b) A modular PLC is one that can be constructed using separate modules of power
supply, CPU, inputs, outputs, timers, counters, expansion modules, etc.
PLC OPERATION

A PLC works by continually scanning a program. We can think of this scan cycle as
consisting of 3 important steps.

CHECK INPUT STATUS

EXECUTE PROGRAM

UPDATE OUTPUT STATUS

STEP 1: Check input status- first the PLC takes a look at each input to determine if it is on
or off. In other words, is the sensor connected to the first input on? How about the second
input? The third… it records this data into its memory to be used during the next step.

STEP 2: Execute program- next the PLC executes your program one instruction at a time.
Maybe your program said that if the first input was on then it should turn on the first output.
Since it already knows which inputs are on/off from the previous step it will be able to decide
whether the first output should be turned on based on the first input. It will store the
execution results for later use during next step.

STEP 3: Update Output status- Finally the PLC updates the status of the outputs. It updates
the outputs based on which inputs were on during the first step and the results of executing
your program during step 2. Based on the eg. in step 2 it would now turn on the first output
because the first input was on and your program said to turn on te first output when this
condition is true.

After the third step the PLC goes back to step 1 and repeats the steps continuously. One scan
time is defined as the time it takes to execute the 3 steps listed above.
Numbering system:

The PLC uses several numbering systems besides the Base 10 decimal system. An
understanding of these other systems is crucial to successful programming.

1. BINARY
2. HEXADECIMAL
3. OCTAL
4. BINARY CODE

Numeric data in PLC

Most PLC applications will require the handling of data, whether manipulating counter and
timer values, reading data from Special Function Module and processing then information, or
high-level mathematical computations. It is critical that the programmer understand how the
PLC ‗sees‘ and handles the different types of data that can be encountered.

1. INTEGER HANDLING.
a. 16 bit
b. 32 bit
2. DECIMAL HANDING
a. Scientific notation
b. Floating point
Binary logic is used in wiring the PLC ladder circuit as will be explained.

4.5.1.HARDWARE CONNECTION AND COMPONENTS:

The SC09 cable is used to connect the PLC to a personal computer for program development.
The circular 8 pin port on the PLC CPU module uses the RS422 standard of communication.
Most personal computers only have a RS-232 communication port. For this reason, the SC09
cable has a conversion circuit built into the connector housing.
The cable includes hardware that converts from RS422 to RS232.
 A. Main Units

The main unit contains the CPU that provides the processing power that reads the
inputs, solves the logic, and writes to the outputs. The main unit contains:

1) An integrated power supply that provides power to the CPU, inputs, and a limited
number of connected expansion or special function blocks
2) Integrated inputs. These can be either AC or DC, depending on the model selected.
The largest FX3U main unit has 64 inputs.
3) Integrated outputs. These can be relays, transistors or triacs. The largest FX3U unit
has 64 outputs. In the FX1S and FX1N the ratio of inputs to outputs is 3 / 2 or 4 / 3. In
the FX2N and FX3U line the ratio is 1 / 1.
4) Programming port. This port uses RS-422 as its communication protocol. The PLC
can be programmed through this port, or an HMI (Human-Machine Interface) can be
connected as well.
5) Accessory connection ports. These can be used to connect memory module or an
option board to the main unit.

B. Inputs

Input devices are the interface between PLC and machine. The base unit of an FX PLC has a
number of integrated inputs available. If more are needed, input extension blocks and units
are available to be connected.
There are 2 different input types:

1. DC Inputs
Fast response
90% of new designs use this type of input
mostly 24VDC, but FX1N has 12VDC option
sink or source logic

2. AC Inputs
Slow response
Easy to interface AC devices
All AC inputs are 120VAC
 Integrated Inputs

SINK or SOURCE logic refers to the voltage level that will cause the input to become
active.

SINK logic: the input becomes active when connected to GROUND. The S/S pin is tied to
+24V.

Use SINK for NPN SENSORS

SOURCE logic: the input becomes active when connected to +24VDC

The S/S pin is tied to GROUND

Use SOURCE for PNP SENSORS

 C. Outputs

The output device allows the PLC to control a machine. Integrated outputs are available on
the base unit. If more outputs are required, extension blocks and units can extend the number
of I/O.

Integrated outputs
There are 3 different output types:
• Relay Outputs
• Triac Outputs
• Transistor Outputs

1. Relay outputs

Relays are dry contacts, so whatever you input on the common is switched out when the
output is activated. This is the most common type of output module used. Loads up to 2
Amps, 100VAC~240VAC or 30VDCcan be switched, with a maximum of 8 Amps per
Common. Most base units and extension modules have 4 outputs per common.

2. Triac outputs

Triacs are solid state AC switches. When the output is active the module connects the load to
the AC source. Load switching is up to 0.3Amps, up 240 VAC per point, with a max of 0.8
Amps per Common. Each base unit or extension module has up to 4 outputs per common.

3. Transistor outputs

Fast response is the main characteristic. Transistors are solid state DC switches. When the
output is active, the module connects the load to the DC source. Load switching is up to
0.5Amps per point, up to 0.8 Amps per Common. Voltage that can be switched is 5VDC- 30
VDC. 4 points per common is typical.

D. OTHER COMPONENTS (system devices):

M – Auxiliary Relays

M relays are internal bit devices. They are internal bits that can be used for any function
needed. When an M device coil is energized, the corresponding M device contact becomes
active.
In GX-Developer, it is possible to configure M bits to be battery-backed. This means the bits
will maintain their current state (Off or On) in the event of power loss.
There is a group of M devices that have dedicated functions. They are M8000 ~ M8511. The
meanings are described in tables in chapter 36 of the FX3U Programming Manual.

S – State Relays

S relays are internal bit devices. They are used in STL programming to indicate which step,
or section of ladder logic code, is active. If STL programming is not used, these bits can be
utilized in the same manner as M bits.
In GX-Developer, it is possible to configure M bits to be battery-backed. This means the bits
will maintain their current state (Off or On) in the event of power loss.
If STL programming is utilized in conjunction with the IST instruction (Initial State) causes
certain state relays to have special operations. 2 examples are: S0 is the manual operation
return state and S2 is the automatic operation return state.
One last use of state relays is as a fault annunciator. Through programming techniques
described in chapter 4.4 of the FX3U Programming Manual, S900 ~ S999 can be used as user
defined fault indicators.

T – Timers

T devices are timer devices by default timers are either 100msec time increments, 10msec
time increments, or 1msec time increments depending on the timer address. Most timers,
depending on their address, are non-retentive, meaning they do not hold their current value if
the input conditions stop conducting. In the FX2N, FX, FX2NC, timers with
addresses T246 and above are retentive. This means the timer hold its value until it is reset.
Retentive timers have a time base of either 100msec or 1msec, depending on the address.
When a timer reaches the associated preset value the T device coil is energized, the
corresponding T device contact becomes active also. All timers are 16 bit, meaning the
maximum preset is +32767. Valid presets are K values and D data registers. For a 100msec
timer the maximum time is 3276.7 seconds.
In GX-Developer, it is possible to assign a range of timers to be batterybacked. This means
the timers will hold their accumulated value in the event of a power loss – provided the logic
that drives the rung is batterybacked as well. Otherwise the timer will be reset.

C – Counters

C devices are counter devices. The standard is all counters are retentive, holding their current
count until reset. In GX-Developer you can assign counters to be battery-backed. When a
counter reaches the associated preset value, the C device coil is energized, the corresponding
C device contacts become active also. Counters can be 16 or 32 bit, meaning the
maximum count range is –32768 to +32767 (16 bit) or -2,147,483,648 to 2,147,483,647 (32
bit). Negative presets are not very useful, as will be explained in more detail in Lesson 12.
Valid presets are K values and D data registers.
There are 3 types of counters: 16 bit up counters, 32 bit up/down counters, and 32 bit high-
speed counters. Within the high-speed counter category there are 1 phase, 2 phase, and A/B
phase counters. Counters will be covered in more detail in the chapter on Timers and
Counters.

D – Data Registers
D devices are data registers. Data registers can be used for any purpose. All data registers are
16 bit, meaning the limits of numeric data is from - 32768 to 32767. In ladder you can
perform 32 bit operations, in that case 2 consecutive D registers are used together and the
maximum numeric value can be 2,147,483,647 to -2,147,483,648.
In GX-Developer, it is possible to configure D devices to be batterybacked. This means the
bits will maintain their current value in the event of power loss. It is possible to retain data in
all registers by turning on special relay M8033.
File registers are data registers that are stored with the program, rather than with the PLC.
They are declared in the Parameters section in groups of 500

Timers

Types-
• 100ms (.1 second)
• 10ms (.01 second)
• 1ms (.001 second)

Communication Modules and Option Boards

Many times, more is required of a PLC system than monitoring inputs and controlling output
devices. Data may need to be passed to another PLC or even a PC. A programmer may need
to access the program to monitor an error or make program changes, but the front port is
occupied by an HMI. The FX family has several modules that can be added to add
communications ability and solve problems like those stated above. Sometimes the solution
requires the implementation of a network to get the required connectivity. The modules used
for this will be discussed in the next section. In this section modules used to simply augment
the communications ability of the PLC will be discussed.
The FX3U family of PLCs supports the addition of 2 serial ports via the option boards and
left side bus ADP modules. If using a BD board, only one ADP module can be used. When
not using the BD board, two ADP modules can be connected.

RS-232 Communication Interface Module(s)

There are three modules that can be used to add an RS-232 port to the FX3U PLC, the
FX3U-232ADP, the FX2N-232IF and the FX3U-232-BD. For the FX1S, FX1N, FX2N, and
FX2NC, the FX2NC-232ADP will work. The FX*N-CNV-BD is required for PLCs other
than the FX2NC.

RS-232 Option Board – FX3U-232-BD

This board connects to a special port that is located on the left side of the PLC. This method
saves the special function module space that would be occupied by the FX2N-232IF, or
the adapter space used by the FX3U-232ADP. Like the 232ADP, this board requires special
programming to configure the port. If using an open protocol, the RS
instruction is required to transmit and receive data. The BD board can be used for dedicated
communications protocols, requiring only the setup of the D8120 register.

RS-422 Option Board – FX3U-422-BD

The HMI lines carried by Mitsubishi commonly connect to the FX3U PLC through its
programming port. If the programmer needs to interface with the PLC program without
disconnecting the HMI, this board is the simplest method to accomplish this
goal. The part is plug-and-play, and adds a second programming port to the PLC. Note that
an HMI will interface with the PLC through this port as well. Some setup of the
D8120 register may be required.
This port cable is used in the project followed.

4.5.2.PROGRAMMING SOFTWARE and LADDER LOGIC :

Programming Software

There are 2 software packages that can be useful in the programming and troubleshooting of
all Mitsubishi PLCs. These packages are GX-Developer and GX-Simulator. Some users may
be familiar with some of the previous software packages, including MEDOC (DOS
application), FX-WIN, and GPP-Win (previous version of GX-Developer). This class will
deal with the latest version of GX-Developer.

GX-DEVELOPER – This is Windows based software (95, 98, NT, 2000, XP). It can be used
to program all PLC lines, including FX-series, Q-series, A-series and the Motion A-series
PLCs. This software, which replaces the previous Windows package, GPP-WIN, has a large
number of troubleshooting and diagnostic 34 features, as well as the ability to easily
communicate over networks. It also has import capabilities to bring in programs written in
older software packages.

GX-DEVELOPER-FX – This is Windows based software (95, 98, NT, 2000, XP), is based
on the GX-Developer software package. This software has all the features of GX-Developer,
but only supports the entire FX Series and its functionality. This package is offered at a
discounted price versus the entire GXDeveloper package, making it a cost saving option for
anyone who does not need to program the rack-based PLC controllers.
GX-SIMULATOR – This Windows based software isn‘t used to program PLCs, but to assist
in program troubleshooting. This software will actually act as a PLC, allowing a GX-
Developer program to be tested, without having to download to an actual PLC system. This
software is not included with GX-Developer, it must be purchased separately. It must be
loaded on the same computer that GX Developer is installed on.
Using GX-Simulator in troubleshooting allows the programmer to debug roughly 90% of the
problems in a program before hardware is ever connected. It has the ability to simulate
discrete and analog I/O, serial and network communications, and special function modules.
You can build timing charts and simulate inputs such as a run signal based on the run output
turning on automatically. You can step the processor through the system step by step, partial
execution, or skip.

The FX Line of PLCs

Each of the PLCs in this family have certain characteristics in common:

1) An integrated power supply. Most of the PLCs in this line have a built in
Power supply that requires 100-240 VAC power. Several of the PLCs have a DC power
version available as well.

2) Integrated I/O. The main unit has a varying number of inputs and outputs, dependent on
the model chosen. The inputs are typically DC, although certain models have AC inputs as
well. All models have relay and transistor output versions (except the FX0S), and several
offer trial outputs.

3) Common Instructions. Although the higher-end PLCs have more instructions, all PLCs at
least support a common instruction set of 20 basic and 35 applied instructions.
4) Built-in special functions. All FX PLCs have a built-in high speed counter (or several high
speed counters) and a pulse train output.

The FX Series Legacy

The F Series of PLCs was originally introduced in 1981 with the F PLC. The F was then
improved and revised several times, resulting in the F1, F1J and F2 models. After the F2
came the FX Series PLCs. Some of these models were the FX, FX0, FX1, FX2, FX0S,
FX0N, and FX2C, as well as the current offerings FX1S, FX1N, FX2N, FX2NC, and FX3U.

Sales of the Mitsubishi F Series PLCs have exceeded 6 million units worldwide!
LADDER LOGIC:

Symbols:

NORMALLY OPEN CONTACT: This symbol conducts when the associated device is
energized. In instruction mode, the mnemonic is LD, which stands for LOAD. This symbol
occupies 1 step of program space.

NORMALLY CLOSED CONTACT: This symbol conducts when the associated device is
de-energized. In instruction mode the mnemonic is LDI, for LOAD INVERSE. This symbol
occupies 1 step of program space.

COIL CONTROL: This symbol always appears just before the right vertical ladder rail. It
becomes energized when the logic before it conducts. When energized, the output with the
same address becomes active. In instruction mode the mnemonic is OUT, for OUTPUT
ACTIVATE. This symbol occupies 1 step of program space, unless being used for a timer or
counter instruction, when it can occupy up to 5 steps.

-------(Y000)-------
BRACKET CONTROL: This symbol usually appears just before the right vertical ladder
rail when used for bit control. This symbol is typically used for word device commands;
however there are a few bit instructions that use the brackets as well. It becomes energized
when the logic before it conducts. This symbol occupies multiple steps of program space
depending on the command used.

-------{END}-------
INVERT: This symbol inverts the state of all logic before it. If the logic is true (positive) at
the point of the invert, the output of the invert is false (negative). If the logic is false, the
invert output is true.
It is important that the above concepts are clear before moving on. The symbols are used to
indicate the device in its non-actuated state. When it‘s stated that a device is conducting, that
means electricity is allowed to flow through. For example, a light switch is usually in the off
position (non-actuated), no current is flowing (the switch is open) until someone turns it on
(actuates it and energizes it). At this point, electricity starts to flow (the switch is conducting)
and the lights turn on. A light switch is a normally open contact. The normally closed contact
is the opposite in every respect. Current flows until the switch is actuated. A common
example of this is an E-stop. It allows current to flow until an operator hits the switch in an
emergency. The switch is actuated and the current flow stops.

10.2 Ladder Basics

The alignment of contacts and coils determine how a rung of ladder logic is
processed. If two or more devices are positioned in series (one after another), they are
operated as an AND instruction. In order for power to flow through the rung, all the
conditions must be made true.

If the devices are in parallel, they are operated as an OR condition. OR conditions provide
multiple paths for the power to flow.

To write a program for a PLC, it is necessary to be familiar with the devices that are used in
the instructions.
A common question when discussing system devices is the number of each that is available
to use. This varies depending on the CPU. Make sure to check the user‘s manual for the
model of CPU under question.

Manual for the appropriate model of PLC.

Part Number Series Of PLC Covered

JY992D48301 FX, FX0, FX0S, FX0N, FX2C
JY992D88101 FX1S, FX1N, FX2N, FX2NC
JY997D16601 FX3U
Basic Program Instructions

This category refers to the 4 basic bit devices (X, Y, M, and S), the timer device, the counter
device, and operation that pertain to these devices. This includes SET, RESET, and the
PULSE functions. These instructions will make up about 80 ~ 90 percent of a program.

Step Ladder Instructions

Step ladder instructions are used in Step Ladder Programming (STL). This programming is
similar to SFC programming in that it implements a flow chart, but the flow chart is implied,
and the code is actually created in ladder logic. When programming in ladder logic, the STL
contact is a common instruction used to check if a state is active. S relays are used to indicate
states. STL Programming is not typically covered in this class. However, and excellent
explanation and examples can be found in Chapter 34.2 of the FX3U Programming Manual.
 5.BASIC INSTRUMENTATION

5.1
TRANSDUCERS:

The input quantity for most instrumentation systems is a ‗non-electrical quantity‘. In order to
use electrical methods and techniques for measurement, manipulation or control, the non-
electrical quantity is generally converted into an electrical form by a device called a
‗transducer‘. We can define a transducer as a device which, when actuated transforms energy
from one form to another.
The broad definition of a transducer includes, for example, devices, which convert
mechanical force into an electrical signal. These devices form a very large and important
group of transducers commonly used in industrial instrumentation area. These transducers
provide an output signal when sensing an input; a photoconductor converts light intensity into
electrical energy, a thermocouple converts heat energy into electrical voltage and so on.

Transducers are classified as:

1. Analog and Digital transducers
2. Primary and Secondary transducers
3. Active and Passive transducers
4. Transducers and Inverse transducers
5. On the basis of conduction principal used
i. Resistive type
ii. Capacitive type
iii. Inductive type

1. Analog transducers are that whose output is analog in nature (continuous function
of time) for example LVDT, thermocouple, potentiometer, thermometer, etc

Digital transducers are that whose output is digital in nature for example Photo
electric sensors, encoder, etc.

2. Let us consider the case of pressure measurement by using LVDT and bourdon tube.
There are two stages of transduction, firstly the pressure is converted into a
displacement by bourdon tube then the displacement is converted into analogous by
LVDT, the bourdon tube is called a primary transducer while the LVDT is called a
secondary transducer.

3. Active transducers are those which do not requires any external power source for
converting the input quantity into electrical one (voltage, current and frequency). For
example thermocouple, piezo-electric crystal, etc.

Passive transducers are those which require external power source for the
conversion process to take place eg. LVDT, potentiometer, thermometer, etc.

4. Transducer is a device which converts non-electrical quantity into electrical one, eg.
Thermocouple, LVDT, etc.

Inverse transducer is a device which converts electrical quantity into a non-electrical

one. Eg. Motor, loud speaker, etc.
 5. i. Resistive transducers convert non-electrical into electrical quantity by using
change in resistance for example RTD (resistive temperature detector), thermister, etc.

ii. Inductive transducers convert non-electrical into electrical quantity by using

change in inductance for example LVDT, RVDT, etc.

iii.Capacitive transducer non-electrical quantity into electrical quantity by using

change in capacitance for example variable capacitance pressure gauge, capacitor
microphone, di-electric gauge etc.

5.2 TEMPERATURE MEASURING DEVICE:

1. Thermocouple: its operation is based on the principle that when two wires composed of
dissimilar metals are joined at both ends and one of the ends is heated, there is a
continuous current which flow in the thermocouple circuit.
Emf produced in a thermocouple circuit is given by:

Term in the bracket is the differeence in temperature between the hot thermocouple
junction and the reference junction of the thermocouple.
And a,b = constants.

2. Thermometer RTD (resistive temperature detector): The resistance of a conductor

change when its temp. is changed. This property is utilized for measurement of
temperature. All metal produce a positive change in resistance with temp. with resistance
i.e resistance increases when temp. is increased. The relationship is as follows:

Ro = resistance at temp. T=0

Alpha = constants.

The resistance thermometer uses the change in the electrical resistance of conductor to
determine the temp.
5.3 SENSORS:

These are ―no touch‖ sensors. They operate with no mechanical contact or wear. In the
following application, for example, a sensor is used to determine if cans are in the right
position on a conveyor

5.3.1 Type of sensors:

There are four types of 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 electrstatic field to detect the presence of an 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 specefic color.

Type Object detected Technology

Inductive Metal Electromagnetic Field

Capacitive Any Electrostatic Field
Ultrasonic Any Sound waves
Photoelectric Any Light

Since only inductive type proximity sensors are used at CPAPRO MARUTI LIMITED, only
that type of sensors is going to be discussed further in the report and will be mentioned.

5.3.2. INDUCTIVE PROXIMITY SENSOR:

Theory of operation

In this section, we will look at the inductive proximity sensor, and how they detect the
presence of an object without coming into physical contact with it. Inductive proximity
sensors are available in a variety of sizes and configurations to meet varyiing application.

Electromagnetic coil is used to detect the presence of a conductive metal object. The sensor
will ignore the presence of an object if it is not metal.
ECKO: Inductive proximity sensor are operated using an Eddy Current Killed Oscillator
(ECKO) principle. This type of sensor consists of 4 elements: coil, oscillator, trigger circuit,
and an output. The oscillator is an inductive capacitive tuned circuit that creates a radio
frequency. The electromagnetic field produced by the oscillator is emitted from the coil away
from the face of the sensor. The circuit has just enough feedback from the field to keep the
oscillator going. When a metal target enters the field, eddy currents circulate within the
target. This causes a load on the sensor, decreasing the amplitude of the electromagnetic
field. As the target approaches the sensor, the eddy current increases, increasing the load on
the oscillator and further decreasing the amplitude of the field. The trigger circuit monitors
the oscillators amplitude and at a predetermined level switches the output state of the sensor
from its normal condition (on or off). As the target moves away from the sensor, the
amplitude increases and at a predetermined level changes the state of the output (on or off).

Operating voltages: 24VDC

The output configuration of the sensors are of two types:

1. NPN- it gives a egative output upon state change. The load is connected between the
positive side of the power supply and the output. It switches the load to negative side
of power supply. Also known as current sinking
 2. PNP- it gives a posititve output and is just the opposite of the NPN sensor.

Normally open (NO) or Normally closed (NC) are present based on the condition of the
transistor when a target is absent. For example, if the PNP output is off when the target is
absent then it is a normally open device. If the PNP output is on when the target is absent it is
a normally closed device.

INDUSTRIAL APPLICATION OF SENSORS

 6.ROBOTIC LINE: THE AUTOBOTS

Most recently, new robotic installations have been made at caparo maruti limted to employ
the weld processes. The major advantages of using automated machines are:

1. Greater accuracy.
2. Higher efficiency.
3. Faster production.
4. Less labor requirement.
5. Continual production.

Some of the disadvantages along woth the robots can be summarizes as:

1. Regular maintenance.
2. Difficult to detect faults.
3. Regular checkup for accuracy variations.
4. Cannot be progammed internally. Only availale change is through PLC.

6.1.TYPES OF ROBOTS
There are two different types of robotic line installations:

1. Fanucc
2. Motoman

There are very little differences between the two robot lines. Currently major production is
done on the fanucc robot and the motoman is being programmed for further production.

Fanucc robot
Motoman robotic line

FIG 1

FIG 2
The major difference between the two lines are :

1. While the production parts are manually mounted on the jig by worksman in the
Fanucc robot, the Motoman line on the other hand automatically picks up the
material from the inventory lot and no manual mounting is required.

2. Another major difference is that while prgramming the Fanucc Robot teach pendant,
the cooordinated for the weld point is given and the welding gun moves to the
designated location. On the other hand, in Motoman, the Gun is fixed at one position
while the loaded part is moved in the coordinate axes to make the point of weld reach
the gun tip.

3. The next but smaller difference is in the commands used to write or load the program
for location of coordinated. These commands vary slighly in language though have
the same meaning for doing specefic jobs on routine.

NOTE: Since most or almost all the production is currently done on the fanucc line, this
is going to be discussed further as well as the prototype made as a project is based on
the fanucc line functionality.

6.2.FANUCC MODEL:

6.2.1.Architecture:

This was the first model installed at the Caparo Maruti Plant in the year 2011.The robot has
six degrees of rotation referred as J1,J2,….,J6. These specify the movement of the robot
armature in all posible directions. The axes helps move the arm in horizontal, vertical and
around the horizontal axis at the same time.

The robot arm is connected to the gun. The tips of the gun move towards each other
according to the operaton performed by the soleniod valve. The valve consists of a piston
which moves back and forth depending on the input from the field, thus bringing the tips in
contact.

The loaded part is satbilized on the JIG. A jig is a hard formed caste made to mount the
different parts at the exact location as the requirement of the design and then welded together.
The design of the jig varies as the parts manufactured varies. For each part a special jig is
present and no other part can be made to fit in different jigs.

When the materials are mounted on the jig, proxiity metal detecting sensors confir the
presence of the parts at exact location and send the signal to the PLC. The PLC performs its
logic using the ladder circuit on a given PC and gives the Robot a ―go‖ to perform the weld
process. The PC and the PLC are connected through an RS232 Port available on the PLC
rack using a connector RS422 cable.
JIG

6.2.2. Programming:

The allocation of the coordinates in 3D space is done using FX training manual which
consists of all the commands required by the robot.

A teach pendant is used as an interface between the user and the robot microcontroller. The
teach pendant is just like the keyboard of a normal computer with special commands for the
understanding of the robot. The robots are first moved at a slow speed of about 5% and the
locations are kept on being saved where a weld is required.

It must be kept in mind that the motion of the robot looks for the shortest path between two
weld locations, hence in order that there is no obstruction in between new points are allocated
so that the arm moves along a longer path intetionally. The following is the image of the
teach pendant. At the bottom is the cable connector between the pendant and the PLC.
Apart from teaching the robot to weld, it is also progrsmmed to go for ―TIP DRESSING‖.
This refers to the cleaning of the gun tip after every specified number of weld so as to
maintain the amount of curretn required for further welding and maiintain accuracy.

6.2.4.Hardware Connection and Componenets:

The connections in the Fanucc robotic line is as follows.

1. The jig consists of sensors mounted at various contact points. Once the part is
mounted, the sensors detect its presence and send the signal to the PLC in the PLC
box. The signal is known as to be coing from the field or the inputs to the PLC.

2. Push buttons are used to lock the mounted part and actaute the sensors.

Push Button

3. The PLC then prforms the logic which is loaded into it using a GX develepor software
on a PC. The output sent to the field is mainly to give a go ahead to the robot to
perform the weld.

4. The teach pendant used for programming the robot is attached to the PLC box but can
be taken to various locations using 422 cable and can be handled easily. It gets power
from the supply unit in the PLC unit.
 5. Inside the PLC unit is a number of relays that are used as switching devices. It
performs a simple on/off logic to send signals to the PLC. It requires a 24VDC supply

Power supply PLC unit CPU Relay Series

6. The welding process is controlled using a solenoid valve that perfors the action of
piston and provides the current for melting parts during weld process.

7. The robot after performing the weld goes back to its home postion and waits for
further command.

8. The PLC unit consists of a key for opening the main door for working with the PLC
and relay switches.

9. It also consists of an auto/manual key that allows to program and move the robotic
arm manually as well depending on the requirement.
Cable Manual/Auto Locking Teach Proximity
To Robot Switch Panel Pendant Sensor

Robot Controller
 7.PROJECT WORK
(SIMULATION OF FANUCC ROBOT WITH A PROTOTYPE MODEL)

7.1.Introduction:

Coming under the requirement of more skilled labor for the production of weld parts using
the robotic line, it became necessary, as time passed, to impart robotic knowledge to that
section of workers who previously worked in the manual weld gun line.

Together with the help of my mentor Mr. Jaipal Mann and the Weld shop maintenance
Manager Mr. Shekar verma , we came up with the idea of developing a prototype for the
model on a rather small scale to clearly explain the circuitry that governs the Fanucc Robot.

The circuit would thus consist of all the major parts required for the simulation of robot while
explaining clearly how different devices opertate on a timeline basis. It would on the other
and not consist of the actual weld gun as well as armature that moves the gun.

The simulation is again done on the GX Develepor software using the ladder circuit. The only
major part missing from the model is the robotic armature and thus automatically the teach
pendant and the PLC Bob although there would be presents a PLC and relays that make up
the PLC box.

The following devices are used to build up the prototype:

1. MCB for supplying 220 VAC

2. Power supply unit working as a rectifier to give a 24 VDC

3. Input sources:
a. Proximity sensors
b. Push buttons

4. Output devices:
a. LEDs
b. Solenoid valve

5. PLC panel

6. Relay switches

7. Connecting wires

8. Holders for PLC and other devices on the plank

9. A computer device with installed GX develepor software for reading and writing
program from/to the PLC.

10. RS422 connector between laptop and the PLC.

All these have been previously explained before under the system hardware.
 Push button PLC MCB
Power Supply
(Rectifier) Connecting Wires

Solenoid Valve Proximity Sensor LEDs

7.2. OPERATION:

Connections and function:

As metioned before, this is just a simulaition of actual robot for better a understanding and
hence it performs the very same logic. The circuit starts from the MCB which is used for
circuit breaking. It provides a 220VAC. The supply goes to two places, the power supply unit
and the input of the PLC

Rest all devices require a 24VDC and hence comes the requirement of the recifier present in
the power supply unit. It takes in the 220 Ac from MCS and converts it to a 24VDC and
supplies this to the sensors, switches, the solenoid valve, relay switches and also to the PLC .

The function of the relay is also to prevent the 220VAC to go through until and unless
required and hence protect the devices from damage due to excessive voltages.

The programming is first done on the software and then written into the PLC. The following
project is just a simple program to switch the LEDs on and off on will. The ladder circuit of
the program is as follows:
The above run program does the following operation:

1. When the on push button is pushed on the right side hand side, it sends the signal to
the fourth pin of the PLC (hence X004 in the ladder circuit). Since the switch is a
NORMALLY CLOSED one, we chose the X004 to be NC type accordingly. An NC
type switch means it normally passes the signal until it is supplied with power. In that
case it switches to open and cuts the supply.
 Normally closed switch part always touching and completing the circuit

2. The current is then passed to SET the parameter M0. Since the Timer1 is an NC type
used, it passes the signal to start the Timer 0 for a time period of K30. This is
equivalent to 3 seconds.

3. As soon as the timer goes ON, it switches on the Right LED denoted by Y001. Hence
the LED starts and so does the timer.

Left LED (Y002) Right LED(Y001)

4. In the above program only two LED are used and connected. The rest can also be
utilized but for the sake of simplicity, we use only two of them. It requires a 24VDC
for operation coming from the supply unit and is given to both the switches
separately.
 5. The timer counts to 3 seconds before it triggers the paramedter M1 bypassing the T1
NC connection during its rising pulse.

Rising pulse
At the end of 3 seconds

6. The signal is just passed for a fraction of a second to switch on the parameter M1 but
M1 keeps itself ON due to the infinite loop created. The only way to stop the
parameter M1 from getting any signal is when T1 goes from NC to NO in the above
figure which occurs when its timer runs out.

7. In the next instance (i.e after 3 seconds) M1 and NC T1 switched on the left hand side
LED denoted by Y002. This LED again glows for 3 sec following which T1 becomes
NO and cuts the supply.

8. The second part of the circuit is for the SWITCH OFF push button on the left side. As
it is pushed, since it is also an NC, it RESETS the M0 and shuts down the operation
of the circuit

9. Apart from the switch off push button, the circuit also stops performing if each LED
glows 10 times, that is after 60 sec I al. this is done by placing a counter at the end of
the ladder which counts till 10 and then resets M0. Also the count goes to 0 by
resetting itself.

Note: The above project and the program utilizes only the push button for input supply
and the LEDs for output function. Although programs can also be made for using
sensors or the valve depending upon interest.
7.3. How this simulation is similar to the actual robot?

The prototype build thus expplains how the PLc in the Unit gets command to send the output
to the main robot. The programming is done from a computer device and is loaded into the
memory of the PLC

The PLC gets its input from the field. This in real implies the following:

1. The sensors could be touch sensors which detect the presence of mounted material by
getting in contact and thus actuating itself and sending the signal

2. The sensors could be proximity sensors which detect the presence of material in close
vicinity and thus actuating.

3. Or we can manually tell the PLC that the material has been mounted and it‘s a go for
weld by using the push buttons as has been used in the prototype.

After performing the program, the PLC gives output to the Robot to perform the weld. Here
in the prototype, this has been shown with the help of LEDs. In the robot, the signal sent from
the PLC actuated the solenoid valve.

7.4.Solenoid valve:

The solenoid valve is a device that is used to perform the actual weld process. It consists of
the following:

1. Magnetic coil
2. Piston
3. Inlet air pressure gauge
4. Outlet air pressure gauge

When the PLC sends the signal to the valve, its magnets are activated which produce a
magnetic field. This field further induces an electric voltage and this voltage starts the piston
movement. The inlet and outlet gauge provide air pressure alternatively one time thus moving
the piston back and forth. This piston is connected to the two arms of the gun which come in
contact together thus melting the material and welding it.

The required amount of current for heating the material is produced by the induced voltage
due to EMF and thee time required for the tips of gun to be in contact is predetermined by
the time the air pressure moves in and out of the two openings. Thus weld process occurs in
robots. For simplicity, we have only actuated the LEDs. In the robots LEDs perform the
function of visual notification that welding is taking place and nothing else. Those LEDs also
get triggered by output of te PLC.

In the fanucc robot, a number of relays are used as switching devices to control many outputs
of the PLC qas there are as many as tens of input and output through a PLC. Here the
requirement was for just a few of them, and it performs the function of supllying 220VAC
only when required and not otherwise. It passes the signal only when the relay itself gets a
24 VDC through the power supply unit.

A very simple yet instructive program is developed in the above project although comlplex
program is used to run the actual robot.