CHAPTER 1

INTRODUCTION Formatted: Centered

1.1 INTRODUCTION TO AUTOMATION [1]

Automation deals with manufacturing part of industry. This is derived from Greek words Auto(self)
+Matos(moving). Automation in industry means systematic economic activity (may be manufacture
/service/trade). It means “moving by itself”.

DEFINITION- Industrial automation is a set of technologies that result in operation of industrial

machines and system without significant human intervention and achieves performances. Manual
operations can be performed.

1.2 ROLE OF AUTOMATION IN INDUSTRY-

Industry performs operation on raw/unfurnished materials and manufactures a product. For this it uses
energy, manpower, infrastructure, and processes it and forms a product. Or it uses unfinished product
which can be manufactured from any other industry and processes it to form a product.

FACTORS AFFECTING COST/UNIT IN AUTOMATION INDUSTRY:-

1) MATERIAL- Raw material cost can be reduced as automated machine if wisely programmed
then the amount of scrap will be reduced with number of reduced defected items.
2) ENERGY- Automated machines are programmed to work with optimal energy and thereby the
energy costs reduces.
3) MANPOWER- If manpower required is less or is reduced so it will be it’s costs.
4) INFRASTRUCTURE- As the number of units produced by the infrastructure in the lifetime is
increased, its costs reduces. This leads to decrease in total infrastructure cost per unit.

PRODUCTION VOLUME DEPENDS ON:-

1) PRODUCTION TIME- Reduces on using automation which increases the production value
2) MATERIAL HANDLING TIME- Reduces as large machines are operating automatically.
3) IDLE TIME- Automated machines are highly co-ordinated which reduces the idle time.
4) QUALITY ASSURANCE TIME- Quality factor increases in a given time because of time
reduction by automation.

Production volume is increases in a given time because of time reduction of automation. Process is
enhanced and controlling is improved by sophisticated controls in automation so the overall profit
increases.
EFFECT ON THE PRICE -Price of the product is dependent on demand and quality. As quality is
improved it can be sold at relatively higher price and demand will be same.

INDUSTRIAL AUTOMATON PYRAMID-

LEVEL 0 - SENSORS/ACTUATORS

LEVEL 1 – AUTOMATIC CONTROL

LEVEL 2 - SUPERVISORY CONTROL

LEVEL 3 - PRODUCTION CONTROL

LEVEL 4 – ENTERPRISE

FIG-1.1 BASIC ELEMENTS OF AUTOMATION.

Desired behavior pattern is achieved using control. Output compared with desired value using
Error signal generated is fed to controlled through logical output. Plant is the needed physical
variable which is obtained by actuator.

Automation control is of three types ;-

● Continuous variable control- which controls analog variables like temperature.

● Closed loop control- holds the set point, rejects the disturbance and is tunable.

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 ● Sequence/Discrete event control- controls valued processes like sensors, pressure switch. PLC are
used here , no tuning is needed. Timing control/sequencing is present.

ADVANTAGES OF AUTOMATION:- [1]

● Lower operating costs

Robots can perform the work of three to five people, depending on the task. In addition to savings on
the cost of labor, energy savings can also be significant due to lower heating requirements in
automated operations. Robots streamline processes and increase part accuracy, which means minimal
material waste for your operation.

● Improved worker safety

Automated cells remove workers from dangerous tasks. Your employees will thank you for
safeguarding them against the hazards of a factory environment.

● Reduced factory lead times

Automation can keep your process in-house, improve process control and significantly reduce lead
times compared to outsourcing or going overseas.

● Faster ROI
Automation solutions are based on your unique needs and goals and pay for themselves quickly due
to lower operating costs, reduced lead times, increased output and more.

● Ability to be more competitive

Automated cells allow you to decrease cycle times and cost-per-piece while improving quality. This
allows you to better compete on a global scale. Additionally, the flexibility of robots enables you to
retool a cell to exceed the capabilities of your competition.

● Increased production output

A robot has the ability to work at a constant speed, unattended, 24/7. That means you’ve got the
potential to produce more. New products can be more quickly introduced into the production process
and new product programming can be done offline with no disruption to existing processes.

● Consistent and improved part production and quality

Automated cells typically perform the manufacturing process with less variability than human
workers. This results in greater control and consistency of product quality.

● Smaller environmental footprint

By streamlining equipment and processes, reducing scrap and using less space, automation uses less
energy. Reducing your environmental footprint can save real money.
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 ● Better planning
Consistent production by robots allows a shop to reliably predict timing and costs. That predictability
permits a tighter margin on most any project.

● Reduce need for outsourcing

Automated cells have large amounts of potential capacity concentrated in one compact system. This
allows shops to produce parts in-house that have previously been outsourced.

● Optimal utilization of floor space

Robots are designed on compact bases to fit in confined spaces. In addition to being mounted on the
floor, robots can be mounted on walls, ceilings, rail tracks and shelves. They can perform tasks in
confined spaces, saving you valuable floor space.

● Easy integration
Productivity will work with you to provide a complete system – hardware, software and controls
included. Your cell will be proven out at Productivity and shipped production-ready – allowing you to
start making parts as soon as it’s installed in your shop.

● Maximize labor
Over the next three decades, statistics show that more than 76 million baby boomers will retire and
only 46 million new workers will be available to replace them. During this time, your demand for
labor will continue, making automation a real and viable solution.

Increase productivity and efficiency

● 24/7 production, JIT manufacturing-friendly
● More uptime with historic efficiency figures above 90 percent
● Secondary operations capability — gauging, washing, deburring, etc.
● Real-time factory communications with automated cell and machines
● Quick changeover for multiple parts, tooling and programs
● Flexible multi-operations capability — Op 10, Op 20, etc.

Increase system versatility

● System flexibility, easily retooled and repositioned for new production programs
● Robots are flexible and can easily be redeployed in new applications
● Robots have the ability to easily switch between a wide range of products without having to
completely rebuild production lines
● Quick changeover with auto grippers and vision allows for different part sizes and shapes to be part
of the same run
● Mixed-flow production approach allows for flexibility in adjusting to demand fluctuations

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● Robots are able to instantaneously “learn” new processes
● Reduced changeover time

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 CHAPTER 2
PROGRAMMABLE LOGIC CIRCUIT

PLC stands for “Programmable Logic Controller”. A

PLC is a computer specially designed to operate
reliably under harsh industrial environments – such as
extreme temperatures, wet, dry, and/or dusty
conditions. It is used

FIG 2.1- Programmable logic controller.

to automate industrial processes such as a manufacturing plant’s assembly line, processing plant, or a
waste water treatment plant. [6]

PLCs share many features of the personal computer you have at home. They both have a power supply, a
CPU (Central Processing Unit), inputs and outputs (I/O), memory, and operating software (although it’s a
different operating software). The biggest differences are that a PLC can perform discrete and continuous
functions which a PC can’t do, and a PLC is much better suited to rough industrial environments. A PLC
can be thought of as a ‘ruggedized’ digital computer which manages the electromechanical processes of
an industrial environment.

PLCs plays a crucial role in the field of automation, using forming part of a larger SCADA system. A
PLC can be programmed according to the operational requirement of the process. In the manufacturing
industry, there will be a need for reprogramming due to the change in the nature of production. To
overcome this difficulty, PLC basedcontrol systems were introduced. We’ll first discuss PLC basics
before looking at various applications of PLCs

PLC Basics [6]

PLCs were invented by Dick Morley in 1964. Since then PLC has revolutionized the industrial and
manufacturing sectors. There is a wide range of PLC functions like timing, counting, calculating,
comparing and processing of various analog signals.

The main advantage of PLC over a “hard-wired” control system is that one can go back and change a
PLC after you’ve programmed it, at little cost. In a hard-wired control system, you’re essentially having
to rip out wires and start from scratch (which is more expensive and takes longer). Let’s look at an
example to better understand this advantage.
Imagine you have a light connected to a switch. In general, the light operates under two conditions – ON
and OFF. Now you are given a task that when you turn ON the switch, the light should glow only after 30
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seconds. With this hard-wired setup – we’re stuck. The only way to achieve this is to completely rewire
the circuit to add a timing relay.

FIG 2.2-Light switch

This is where a PLC comes into the picture, which doesn’t require any additional wiring and hardware to
make sure a change. Rather it requires a simply change in code, programming the PLC to only turn on the
light 30 seconds after the switch is turned ON. So, by using a PLC, it is easy to incorporate multiple
inputs and outputs. This is just a simple example – a PLC has the ability to control much larger and more
complex processes. A PLC can be customized depending on the application and needs of the user.

FIG2.3-Light switch with plc.

A PLC Scan Process includes the following steps ;

● The operating system starts cycling and monitoring of time.

● The CPU starts reading the data from the input module and checks the status of all the inputs.
● The CPU starts executing the user or application program written in relay-ladder logic or any
other PLC-programming language.
● Next, the CPU performs all the internal diagnosis and communication tasks.

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 ● According to the program results, it writes the data into the output module so that all outputs are
updated.
● This process continues as long as the PLC is in run mode.

The working of a PLC can be easily understood as a cyclic scanning method known as scan cycle.

Input

FIG 2.4-Scan cycle

Physical Structure of PLC

The structure of a PLC is almost similar to a computer’s architecture.

FIG 2.5-PLC Block Diagram

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Programmable Logic Controllers continuously monitors the input values from various input sensing
devices (e.g. accelerometer, weight scale, hardwired signals, etc.) and produces corresponding output
depending on the nature of production and industry.

Types of PLCs [2]

The two main types of PLC are fixed / compact PLC and modular PLC.

Compact PLC
Within a single case, there would be many modules. It has a fixed number of I/O modules and external
I/O cards. So, it does not have the capability to expand the modules. Every input and output would be
decided by the manufacturer.

Modular PLC

FIG2.6-A Modular Type PLC

PLC are divided into three types based on output namely Relay output, Transistor output, and Tri Output
PLC. The relay output type is best suited for both AC and DC output devices. Transistor output type PLC
uses switching operationsand used inside microprocessors.

According to the physical size, a PLC is divided into Mini, Micro and Nano PLC.

PLC Applications
PLCs have a variety of applications and uses, including:

1. Process Automation Plants (e.g. mining, oil &gas)

2. Glass Industry
3. Paper Industry

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 4. Cement Manufacturing
5. In boilers – Thermal Power Plants

PLC Programming
When using a PLC, it’s important to design and implement concepts depending on your particular use
case. To do this we first need to know more about the specifics of PLC programming. A PLC program
consists of a set of instructions either in textual or graphical form, which represents the logic that governs
the process the PLC is controlling. There are two main classifications of PLC programming languages,
which is further divided into many sub-classified types.

1. Textual Language
● Instruction list
● Structured text
2. Graphical Form
● Ladder Diagrams (LD) (i.e. Ladder Logic)
● Function Block Diagram (FBD)
● Sequential Function Chart (SFC)
PLC Architecture:

The full form of PLC is programmable logic controllers. PLCs are mostly used to operate and control
automated systems in the industries. Being one of the latest and easiest type of control system,they are
now substituting hard wired logic relays on a great scale.

FIG 2.7- PLC ARCHITECTURE

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A simple PLC system contains the following segments:

● Input/ Output Section: Devices such as sensors, switches and many other sources falls into input
section/module. Connector rails connect the input from the i/p sources to the PLC. The functioning of
the output section/module (can be motor, solenoid, lamp or a heater) is controlled by fluctuating the
signal from the input source.
● CPU (Central Processing Unit): It is known as the brain of the PLC. CPU is basically a
microprocessor which can be hexagonal or octal. CPU is responsible for all the processes associated to
input signal so as to control the output signals as required.
● Programming Device: The program or the logic is written on the programming device. Examples of
such devices are handhelds, laptops, computers.
● Power Supply: PLC generally requires a power supply of around 24 V, used to provide power to
input and output devices.
● Memory: The memory has 2 parts- One is data memory and other is the program memory. The
program or the control logic is kept in the program memory. The CPU takes the instructions from the
program memory. The input and output signals and the timer and counter signals are stored in the
input and output external image memory respectively.

PROGRAMMING IN PLC: [6]

The basic working of the PLC depends on the control logic or the method used. Flowcharts/Ladder logic/
statement logic or mnemonics are used to do programming. Using all these together, let’s see how we can
actually compose a program in PLC.

The symbolic demonstration of the instructions is called a Flowchart. Flowchart is the most basic and
simplest type of control logic which comprises of only logic choices. Various symbols are as given
below:-

FIG 2.8- BLOCKS FOR FLOWCHART IN PLC PROGRAMMING

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Boolean algebra commonly comprises of logic operations such as AND, OR, NOT, NAND and NOR.
Some symbols are:
+ OR operator
. AND operator
! NOT operator

Ladder Logic Program: The most significant fragment of PLC programming is Ladder Logic. Before
talking about ladder logic programming, let’s talk about some symbols and terms:
Rung: One step in the ladder is called a rung. In other words, the basic statement is called a Rung.
Y- Normal Output signals, M – Motor symbol, T – Timer, C – Counter

SYMBOLS FOR LADDER LOGIC:

Simple Logic Functions using Ladder Logic:

2.1 LADDER PROGRAMMING [4]

Ladder logic is a programming language that creates and represents a program through ladder diagrams
that are based on circuit diagrams. It is mainly used in developing programs or software for
programmable logic controllers (PLCs), which are used in industrial applications.

The computer is connected to the PLC through USB, Ethernet, RS-232, RS-485, or RS-422 cabling.
Under the IEC 61131-3 standard, PLCs can be programmed using standards-
based programming languages. The most commonly used programming language is Ladder diagram (LD)
also known as Ladder logic.

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Ladder diagrams are specialized schematics commonly used to document industrial control logic systems.
They are called “ladder” diagrams because they resemble a ladder, with two vertical rails (supply power)
and as many “rungs” (horizontal lines) as there are control circuits to represent.

ladder logic is the only one directly modeled after electromechanical relay systems.

It uses long rungs laid out between two vertical bars representing system power. Along the rungs are
contacts and coils, modeled after the contacts and coils found on mechanical relays. The contact act as
inputs and often represent switches or push-buttons; the coils behave as outputs such as a light or a
motor. Outputs don't have to be physical, though, and can represent a single bit in the PLC's memory.
This bit can then be used later on in the code as another input. Contacts are placed in series to represent
AND logic and in parallel when using OR logic. As with real relays, there are normally open contacts
and normally closed contacts.

Below is the Ladder logic programs to implement various logic gates, along with program description and
run time tests.

1) AND GATE

FIG-2.9-AND GATE LADDER LOGIC

2) OR GATE

FIG-2.10 OR GATE LADDER LOGIC

3)NOT GATE

FIG-2.11- NOT GATE LADDER LOGIC

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 4)EX-OR

FIG2.12- EX-OR LADDER LOGIC

5)EX-NOR

FIG2.13 EX-NOR LADDER LOGIC

TRUTH TABLE :

FIG 2.14 TRUTH TABLE OF ALL LOGIC GATES

LADDER PROGRAMMING LOGIC

Understanding the basic concepts of ladder logics and applying it to create different projects with the help
of the software GX Works 3

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Ladder logic for two-simultaneous working RED light.

FIG 2.15(a)- LADDER LOGIC OF RED LIGHT

FIG 2.15(b) LADDER LOGIC OF RED LIGHT CONTINUED

In the above example timer logic is used to turn the lights on (output) and after some delay it switches off
automatically due to feedback input. In total there are 6 lights and 6 timers each with different time delay.

PROGRAMME LOGIC FOR A/D CONVERTER

FIG 2.16 -LADDER LOGIC FOR A/D CONVERTE

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In the above example the basic MOV instruction block is used along with 4 registers to save the digital
value- D0,D4,D8,D10. INT and EXPONENTIAL blocks are also used.

The SM400 block is used to provide continuous power supply to the converter. The analog value is varied
physically on the kit and for that particular value corresponding digital value is observed on the display.

PROGRAMME LOGIC FOR D/A CONVERTER

FIG- 2.17 LADDER LOGIC FOR D/A CONVERTER

This is very much similar to the A/D converter but here RST and OUT blocks are also used and output is
noted like the previous converter

2.2 SINKING AND SOURCING [1]

When choosing the type of input or output module for your PLC system, it is very important to have a
solid understanding of sinking and sourcing concepts. Use of these terms occurs frequently in
discussion of input or output circuits. It is the goal of this post to make these concepts easy to understand,
so you can make the right choice the first time when selecting the type of I/O points for your application.
This post provides short definitions, followed by general example circuits.

sinking and sourcing terminology applies only to DC input and output circuits. Input and output points
that are sinking or sourcing can conduct current in one direction only. This means it is possible to connect
the external supply and field device to the I/O point, with current trying to flow in the wrong direction,
and the circuit will not operate. However, the supply and field device can be connected every time based
on an understanding of sourcing and sinking.

The figure below depicts a sinking input. To properly connect the external supply, it must be connected so
the input provides a path to supply common (-). So, start at the PLC input terminal, follow through
the input sensing circuit, exit at the common terminal, and connect the supply (-) to the common terminal.
By adding the switch between the supply (+) and the input, the circuit is completed. Current flows in
the direction of the arrow when the switch is closed.

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 FIG 2.18 SOURCING AND SINKING

By applying the circuit principles to the four possible combinations of input/output sinking/sourcing
types, there are four circuits, as shown above. The common terminal is the terminal that serves as
the common return path for all I/O points in the bank.

FIG 2.19- TYPES OF INPUT AND OUTPUT

Sink/source I/O circuits combine sinking and sourcing capabilities. This means that the I/O circuitry in
the PLC will allow current to flow in either direction, as shown below. The common terminal connects to
one polarity, and the I/O point connects to the other polarity (through the field device). This provides
flexibility in making connections to your field power supply.

Common terminals and how to use them

In order for a PLC I/O circuit to operate, current must enter at one terminal and exit at another. This
means at least two terminals are associated with every I/O point. In the figure below, the input or output
terminal is the main path for the current. One additional terminal must provide the return path to the

17
power supply. Together, the main path and the return path create a loop, or a complete circuit for current
to flow.

If there was unlimited space and budget for I/O terminals, then every I/O point could have two dedicated
terminals. However, providing this level of flexibility is not practical or even necessary for
most applications. So, most input or output points on PLCs are in groups that share the return path (called
commons). The figure at the right shows a group (or bank) of four input points that share common return
path. In this way, the four inputs require only five terminals.

INTEGRATED MODULAR CONTROLLER [2]

The IQ-R series CPU offers dramatic improvements in performance, setting new benchmark standards for
processing speed. This not only enables users to realize enhanced system designs, but also provides the
basis for significant reduction in hardware costs. At the same time, the IQ-R series offers reductions in
development cost, maintenance cost and risk of system failure, while providing an innovative upgrade
path that will enable users to take advantage of ongoing developments through software upgrades rather
than hardware upgrades.

BENEFITS-

With a scan time of 0.14 ms, the ability to process up to 419 instructions per millisecond, and a LD
instruction speed of 0.98 ns, the IQ-R series sets new benchmark performance standards, helping to
deliver increased productivity.

The IQ-R series offers a synchronized PLC and network scan to avoid data transfer delays and improve
manufacturing quality. In addition to that all output modules are synchronized for much more precise
control, removing the need for position detect sensors and reducing total system costs.

Important manufacturing information like programs can be stored in the IQ-R built-in database preventing
the whole automation system to stop when for example the network fails and communication to a PC
database server stops. IQ-R can also backup/restore all parameters/data of the whole PLC system
including CC-Link IE Field network devices.

For example, users can define errors and events to be automatically stored to SD card through the in-built
SD card slot. In the case of an error or certain event the PLC can store all relevant process information,
the error & event log including operation history to an SD card. This data can then easily be analyzed and
help to reduce downtime and maintenance effort.

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A feature of the IQ-R series is the ability to plug a hardware security key into the CPU, without which the
CPU module will not run. The data held in this key is encrypted, and cannot be copied by outsiders.
Further, authorized device IP addresses can be set up, and access denied to unauthorized devices,
reducing the risk of hacking or altering of the PLC program by unauthorized personnel. All this is on top
of a user authentication function.

FEATURES OF IQR

● High performance CPU

● Scalable platform

● Synchronized control

● Secure data storage

● Reduced maintenance effort

● Seamless connectivity via SLMP communication

● Efficient engineering – GX Works3

● System security

● MELSEC System Q compatibility

2.3 GOT (GRAPHIC OPERATIONAL TERMINAL) [5]

The GOT provides new art of design and development to the world. A huge range of lineup meets the
requirements of fabrication locations. The GOT advanced functionality, plays a role as a smooth
entrance to different industrial automation devices, with incrementing productivity and effectiveness .
GOT stands for "Graphic Operation Terminal".
Switches, lamps and numeric displays had been conventionally attached to a process panel as hardware.
By using the display design software, hardware can be formed, and shown and functioned on the
monitorscreen of the GOT, the touch-panel HMI.

FIG 2.20- GOT HMI

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ADVANTAGES OF GOT

● REDUCING THE SIZE OF OPERATIONAL PANEL:As switches and lamps are

formed by software, the no. of constituents attached to the operation panel in the form of
hardware can be condensed and the size of the panel can be reduced.

● CUTTING COSTS FOR WIRING: The screen design can replace the wiring used between
different components, eradicating the requirement of wiring, which needs a huge total of time and
cost.

● STANDARDIZING OPERATIONAL PANEL: Although the required specifications

varies, we just need to adjust the settings using software. Hence, operation panels can be
standardized.

● ADDING EXTRA VALUE AS AN HMI:The GOT can simply display graphics, text, and
alarms in accumulation to switches and lamps. Hence, the added value of your whole equipment
can be improvised.

FIG2.21 ADVANTAGES OF GOT

VARIOUS OBJECTS IN GOT SCREEN: [5]

A GOT screen comprises of positioned frame figures, known as objects. Few examples of such objects
are switch figures, lamp figures and numeric displays. On the basis of the device of the PLC CPU,
operations will be allocated to positioned objects to turn on the GOT functions.

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 FIG-2.22-OPETATION CONTROL PANEL

As from the figures shown below we can clearly see that the switch , lamp and numeric display settings
can be easily accessed or edited very simply. We just have to select our required function and it will pop
it on screen we can drag and adjust those functions in whichever way we want.

SWITCH SETTINGS:

SWITCH: Touch a switch to turn ON/OFF a bit device.

FIG-2.23 SWITCH SETTINGS

LAMP SETTINGS:

LAMP: Turn ON/OFF a lamp by turning ON/OFF a bit device.

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 FIG-2.24- lamp settings

NUMERIC DISPLAY SETTINGS:

NUMERIC DISPLAY: Displays the data present in PLC devices.

FIG-2.25-NUMERIC DISPLAY SETTINGS

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 FIG 2.26-MAIN GOT SCREEN

2.4 SERVO BASICS [3]

Introduction to Servo Systems

Any electro mechanical or hydraulic system that follows speed, position or time in a closed loop is
defined as a servo system. This system can consist of apparatus, feedback sensor & logic. It is generally
electronic but can also be mechanical which can be used to get desired set point.

Example of servosystem:
In case of electric motor with an encoder and a motion controller, it creates a motion profile and
controller takes the position information from the encoder and compares to set point if both the positions
are same then it does nothing and if not it drives the motor until it matches the positions.

A servo system has a heart known as servo controller. It has 2 main tasks to perform :
● track commanded input.
● improve system disturbance rejection
The most powerful method of control is PID control, which stands for proportional integral derivative
control. PID is a combination of 3 control systems: proportional control, integral control & derivative
control

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 FIG 2.27 basic servo system block diagram

A PID control method works on error signal which is the difference between command value and actual
value of an output. This also drives the error to zero. The proportional value can also be thought as gain
value. The integral value integrates over error value over a time period and the derivate value helps to
stabilize a system.

FIG2.28 PID controller block diagram

Servo Motor
Any electrical device which can rotate or push an object with great precision is known as servo motor.

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If rotation is required for an object which is at specific distance or angles then servo motor comes into
play. It is a simple motor which run through servo mechanism. A servo motor can be of two types
depending upon the type of input provided DC servo motor and AC servo motor. With the help of this we
can get high torque in small and light package. There can be numerous application of a servo motor like
planes, helicopters, RC toy car, robotics etc.

FIG 2.29 A basic servo motor structure

FIG 2.30 Difference between ac servo motor & dc servo motor

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Servo mechanism: there are 3 main parts in a mechanism

1. Controlled device
2. Output sensor
3. Feedback system

SERVO ENCODERS:

The first servo motor was developed in sync with their encoders. A servo motor may use a potentiometer
as its position encoder, these are used when budget is very low. This system may face wear & tear and
electrical noise although it is possible to differentiate the position signal.

FIG 2.31 Block diagram of encoder

TYPES OF ENCODERS:

1. Incremental type
2. Rotary type
3. Absolute
4. Linear
5. Magnetic rotary
6. commutation

2.5 SCADA [3]

SCADA is an acronym for supervisory control and data acquisition, a computer system for gathering
and analyzing real time data. SCADA systems are used to monitor and control a plant or equipment in
industries such as telecommunications, water and waste control, energy, oil and gas refining and
transportation.

SCADA WORKING [3]

A SCADA system gathers information, such as where a leak on a pipeline has occurred, transfers the
information back to a central site, alerting the home station that the leak has occurred, carrying out

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necessary analysis and control, such as determining if the leak is critical, and displaying the information
in a logical and organized fashion. SCADA systems can be relatively simple, such as one that monitors
environmental conditions of a small office building, or incredibly complex, such as a system that
monitors all the activity in a nuclear power plant or the activity of a municipal water system. SCADA
systems were first used in the 1960s.

Data Acquisition - Data acquisition is the process of collecting needful data while the process is on. For
example when an automated process is applied to fill buckets with water, fetching and storage of data
related to this process is called data acquisition. Data could be - number of buckets filled, water quantity
used, water quantity left etc.

Types of SCADA
1. 1.D+R+N ( Development +Run + Networking)
2.R+N ( Run +Networking )
3.Factory focus

Features of SCADA
1.Dynamic process Graphic
2.Alarm summary
3.Alarm history
4.Real time trend
5.Historical time trend
6.Security (Application Security)
7.Data base connectivity
8.Device connectivity
9.Scripts
10.Recipe management

Hardware Architecture
One distinguishes the two basic layers in a SCADA system: the "client layer" which caters for the man
machine interaction and the "data server layer" which handles most of the process data control activities.
The data servers communicate with devices in the field through process controllers. Process controllers,
e.g. PLCs, are connected to the dataservers either directly or via networks or fieldbuses that are
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proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profibus). Data servers are connected to each other
and to client stations via an Ethernet LAN. The data servers and client stations are NT platforms but for
many products the client stations may also be W95 machines.

Software Architecture

The products are multi-tasking and are based upon a real-time database (RTDB) located in one or more
servers. Servers are responsible for data acquisition and handling (e.g. polling controllers, alarm checking,
calculations, logging and archiving) on a set of parameters, typically those they are connected to.
However, it is possible to have dedicated servers for particular tasks, e.g. historian, datalogger, alarm
handler.

2.6 PNEUMATICS [1]

A pneumatic system is a system that uses compressed air to transmit and control energy. Pneumatic
systems are used extensively in various industries. Most pneumatic systems rely on a constant supply of
compressed air to make them work. This is provided by an air compressor. The compressor sucks in air
from the atmosphere and stores it in a high pressure tank called a receiver. This compressed air is then
supplied to the system through a series of pipes and valves.

The word ‘Pneuma’ means air. Pneumatics is all about using compressed air to do the work. Compressed
air is the air from the atmosphere which is reduced in volume by compression thus increasing its pressure.
It is used as a working medium normally at a pressure of 6 kg/sq mm to 8 kg/sq mm. For using pneumatic
systems, maximum force up to 50 KN can be developed. Actuation of the controls can be manual,
pneumatic or electrical actuation. Compressed air is mainly used to do work by acting on a piston or vane.
This energy is used in many areas of the steel industry.

BASIC COMPONENTS OF PNEUMATIC SYSTEM

1. A compressor—compresses air.
2. A reservoir (or receiver)—stores air.
3. One or more valves—control air.
4. A circuit—moves air between the other components.

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 FIG 2.32-MAIN COMPONENTS OF PNEUMATIC SYSTEM

When analyzing or designing a pneumatic circuit, the following four important considerations must be
taken into account

● Safety of operation
● Performance of desired functions
● Efficiency of operation

Application of pneumatic systems

There are several applications for pneumatic systems. Some of them are pneumatic presses, pneumatic
drills, operation of system valves for air, water or chemicals, unloading of hoppers and bins, machine
tools, pneumatic rammers, lifting and moving of objects, spray painting, holding in jigs and fixtures,
holding for brazing or welding, forming operations, riveting, operation of process equipment etc.

2.6 INDUSTRIAL VISIT

INDUSTRIAL VISIT TO LUMAX INDUSTRY (HARYANA)

A full day industrial visit was conducted by Mitsubishi to enhance the knowledge of trainee about the
industrial atmosphere and automation. The place was well equipped with industrial robots where some
needed man power and some were fully automatic. Lumax industry manufacture headlamps, taillamps

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both LED and HALOGEN for 4 wheeler and 2 wheeler. Lumax industry has collaboration with
Mitsubishi electric as they use all Mitsubishi products for their product manufacture. There are all types
of robots installed as described in chapter 1 along with modular PLCs interfaced with the GOT2000 series
for HMI (human machine interaction).

The students were well taught about the assembly lines and how a headlight is produced along with
different kinds of defects one can identify in the product and how a single defect can land the product in
trash.

They have a separate enclosed area for manufacturing LED products and only authorized people are
allowed to enter in the compartment.

There are huge machines installed which contain dyes for the headlights.

There is a separate area for the control panel from where the whole power supply of the industry is
controlled which is also fully automated.

2.7 TIMERS AND COUNTER [4]

TIMERS= PLC timers are instructions that provide the same functions as on-delay and off-delay
mechanical and electronic timing relays. A PLC timer provides a preset delay to the control actions. In
general, there are three types of PLC timer delays, ON-delay timer, OFF-delay timer and
retentive timer on.

COUNTERS = A counter is a PLC instruction that either increment (counts up) or decrements (counts
down) an integer number value when prompted by the transition of a bit from 0 to 1 (“false” to
“true”). Counter instructions come in three basic types: up counters, down counters, and
up/down counters

2.8 INDUSTRIAL ROBOTS [2]

FIG 2.33-WORK HAND ROBOT

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Mitsubishi Electric’s India additional includes safety controllers and enables, the robots to be integrated
into a common safety concept. Different concepts of projects make it possible for anyone to put together
even complex systems quickly and effectively. Also ensures “ More safety”.

The DIN ISO-10218 is a code for safety standard is common to all robots and therefore guarantees safe
operation in all applications . “MELFA SafePlus” the name of safety technology for the F series robot
controllers which includes functions like

● reduced safe speed control,

● safe limited control range and
● safe torque monitoring,

which can be activated via safety inputs. The Logic for each safe I/O can be changed and in

combination with the positioning and monitoring function a safe system can be constructed without

using a Safety PLC. Based on these functions, reduction of safeguarded space is possible which leads
to

a reduction of cost and space while meeting all safety requirements at the same time.

Sensor-controlled robots with image processing Mitsubishi Electric’s industrial robots can be
connected to any object recognition camera system via the Ethernet port or the robot controller’s
RS232 interface. This enables static and moving parts to be detected with the correct positional
information.There is F-Q series – full PLC functionality in the robot As robots are never installed on
a standalone basis, the system must be easy to integrate into its working environment to enable it to

communicate with PLC and motion systems as well as operating panels and other systems. Together
with the modular robot CPU, the Mitsubishi Electric IQ Platform provides the ideal basis for
integrating the full functionality of a PLC into the robot.

High-performance industrial robots also require high-performance software. For this reason, more and
more automation engineers are opting for the versatile and convenient Mitsubishi Electric software.
All tasks, such as the creation of projects, programming and simulation, are implemented intuitively
and mesh perfectly with one another. This results in optimum movement sequences in the shortest
possible installation and commissioning time. Programming Offline and online programming with
simulation is also possible.. The integral USB port enables data to be exchanged conveniently, and
complete controller backups can be uploaded and downloaded through a memory stick.

RV ROBOTS: These are the vertical type robots having 6 axis arms for maximum flexibility and
payloads up to 70kg. RV robots provide the flexibility and performance required for even the most
complex of applications.

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 FIG 2.34 RV ROBOTS

RH ROBOTS: These are the horizontal type robots having 4 axis for high speed material handling. robots
are ready and able to provide the performance and reliability.

FIG 2.35 RH ROBOTS

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 CHAPTER 3
CONCLUSION
The industrial training done in the past few months bought in new set of technologies and expanded
knowledge in the field of industrial automation. The best part was to be able to put known concepts

In real world applications. The students got opportunity to learn new concepts, work on new technology
and equipments and even experienced management and working of factory automation because of
industrial visit to LUMAX at Dharuhera.

Keeping the code quality, trying various approaches to determine the best method to complete project,
With success.

Also during the training they learnt about encryption and controlling of equipment in long distance
through SCADA. Apart from all that the training was very interesting as they got to learn about ladder
programming in plc.

With all the technical training aside, They also learnt about handling projects , punctuality, regularity
,working environment in industry and adaptation of environment friendly technology.

Hence, The Students can say that their goal for industrial training was fulfilled. They acknowledge the
great help of MITSUBISHI ELECTRIC INDIA LTD.

3.1 ADVANTAGES OF TRAINING

● The main objective of training is to get first hand information and practical knowledge of the
industry.
● Student would get familiar with industrial environment so that they can take up future challenges
when they turn up in industry with good confidence
● The student will understand the flow of control and functioning in an industry.
● The training also includes enhancement of students administrative skills, information on the
respective modules. And field trip
● The field trip will provide student to experience workplace environment,

3.2 FUTURE SCOPE

There is a vast pool of opportunity in the field of training taken by me. As Automation and other
processing technology like sensors, driver circuits, SCADA, pneumatics , industrial robots, computerized
numerical controllers are expected to replace almost half the global workplace workforce. Multiple
industries, from manufacturing to banking, are adopting automation to drive productivity, safety,
profitability, and quality. Automation will bolster connectivity and reliability in a hyper-competitive
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ecosystem. As manufacturing becomes more and more about just-in-time production and cost-effective
products, factories are automating more of their processes Industrial automation is the use of various
control devices like PC's/PLC's/DCS, used to have control on various operations of an industry without
significant intervention from humans and to provide automatic control performance.

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 REFERENCES:-
1. WIKIPEDIA-https://en.wikipedia.org/?title=Factory_automation&redirect=no
2. MITSUBISHI WEBSITE- https://www.mitsubishielectric.com/fa/products/hmi/got/index.html
3. ABOUT SCADA-https://www.electrical4u.com
4. LADDER PROGRAMMING-https://www.allaboutcircuits.com/technical-articles/ladder-logic-
programmable-logic-controller/
5. GOT-https://eu3a.mitsubishielectric.com/fa/en/products/hmi/got/
6. PLC-https://unitronicsplc.com/what-is-plc-programmable-logic-controller/

Formatted: Indent: Left: 0", First line: 0"

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