Chapter One 1.0 Introduction To The Training Establishment

Industrial Training Report
Techmast Automation (Pvt.) Ltd | 2011
Chapter One
1.0
Introduction to the Training Establishment

Techmast Automation (Pvt.) Ltd is a one of the leading automation company
which provides automation products, consults and provides automation solutions in

the industrial automation field in Sri Lanka.
1.1
Company Profile
Techmast Automation (Pvt.) Ltd was incorporated in 2002, as a specialist in
automated Bulk Material Handling Systems in Sri Lanka. But the bulk handling
process was not suitable as a company because bulk handling is used by larger
manufacturing companies. So the applications of bulk handling are rare in Sri Lanka.
So they switched to an automation company.
Beginning of 2004, Techmast Automation entered the automation components
market with the introduction of AiRTAC Pneumatic Equipment to local industry.
Launching of AiRTAC was a great success, as the product was well accepted by
many, including most of the leading manufacturing companies in the country. The
tremendous response received from hundreds of satisfied AiRTAC customers, so they
added more new products.
The next aim of the company was to introduce other automation products such
as Programmable Logic Controllers (PLC), Variable Speed Drives (VSD), Industrial
Sensors, Human Machine Interfaces (HMI), Pneumatic Equipment, Temperature &
Humidity Controllers, Control Switchgear, Industrial Metal Detectors & Industrial
Weighing Electronics etc. So they carefully chosen brands of this devices and
establish a full range of automation products.
After that they build a technical group that can assist in a case of automation
problem and consult automation problems. Now they have an entire project office
with talented engineers and technicians to design and built new machines. Several
tasks carried out by the project office are shown below.
Mechanical And Manufacturing Engineering
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Design, Fabrication, Installation & Commissioning of custom-built automated
machines.
Design, Installation & Commissioning of PLC/HMI systems, VSDs, Soft-
Starters, MCCs.
Computer Aided Designs and Proto-Typing Services.
System Integration & Engineering Consultation Services.
Retrofitting of PLCs, HMIs, and other types of Industrial Controls &
Instrumentation.
Pneumatic Conveying Systems for Plastics, Chemicals & Food Materials.
Gravimetric & Volumetric Feeding Systems for free flowing bulk materials.
Automatic Weighing and Batching Systems.
Centralized Conveying Systems (custom designed) for plastic moulding &
extrusion plants.
Centralized Dust Collector Systems.
Metal Detection & Separation Systems for Plastics, Chemicals, Food
Materials.
1.2
Vision of the company

Our vision at Techmast Automation (Pvt.) Ltd is to be the best industrial
automation solution provider in Sri Lanka, in the eyes of, our clients and our people.
1.3
Mission of the company

As professionals in Industrial Automation business, we are committed to
provide, innovative automation technologies, superior quality products and associated

services, to the total satisfaction of our clients at the first time and every time.
1.4
Organization Structure
Page 2
Techmast Automation (Pvt.) Ltd basically consists with three different

sections. Sales section maintains the selling of all the kind of automation products and
they maintain the store too. Project office is consulting and provides new solutions or
machine designs. Accounting section balance all the incomes and outgoings of both
sales section and project office.
Figure 1.1: Organization Structure
Chapter Two
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Technical Details
2.0
In this chapter Im going to consider about the technical details about the
automation products such as how they work and what are the specifications of them
we should know before working with them. Also Im going include some details
about the manufacturing processes I saw and studied in my training period and
discuss about how the machineries and other automation techniques involve in that
manufacturing process.
PNEUMATIC SYSTEMS
2.1
Pneumatic systems are widely used in industrial automation world, because it

is a cheap way to transmit power and also easily controllable. So before consider
about the pneumatic systems we should know what is the theory behind pneumatic.
2.1.1
What Is Pneumatic
Pneumatics is a branch of technology, which deals with the study and application of
use of pressurized gas to effect mechanical motion. Its like hydraulic. We use
pressurized gas instead of pressurized liquid. Actually we transmit the power by using
compressed air and we directed them to the actuators which are giving us the
meaningful mechanical works by tubes. Its just like we use electrical current to
actuators such as motors by using electrical wires. So the combination of all
pneumatic actuators and tube system is known as pneumatic systems.
Pneumatic systems are widely used because of its advantages. The main
advantage is the centrally located and electrically powered compressor that powers
cylinders and other pneumatic devices through solenoid valves is often able to provide
motive power in a cheaper, safer, more flexible, and more reliable way than a large
number of electric motors and actuators.
Also pressurized air transmits power quickly. So they are well suited to work
with processing units such as PLC and sensors which can work quickly. This is a good
quality that automation field needs.
Except that pneumatic system have following advantages too.
Simplicity of Design And Control
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Machines are easily designed using standard cylinders & other components.
Machines operate by simple ON - OFF type control.
Reliability
Pneumatic systems tend to have long operating lives and require very little
maintenance. Also gas is compressible. So the equipment is less likely to be
damaged by shock. The gas in pneumatics absorbs excessive force, whereas
the fluid of hydraulics directly transfers force.

Storage
Compressed gas can be stored, allowing the use of machines when electrical
power is lost.
Safety
Very low chance of fire (compared to hydraulic oil).
Machines can be designed to be overload safe.

Pneumatic systems contain different kind of pneumatic
2.1.2
Classification of Pneumatic devices
These devices use for different purposes. So we can classify these pneumatic
items by the purpose. It helps to identify the function of each device or equipment.
They are shown below.
Compressing Unit
This unit is the unit that pressurized the gas and stores the power inside the gas
by compressing gas. But the Techmast Automation (Pvt.) Ltd doesnt import
the compressing unit. So we are not dealing with that unit in this report.
Service unit
This unit maintains and controls the quality of the gas we used inside the
system by cleaning and lubricating the gas.

Controlling units or valves
These valves control the direction of the gas flow and the flow rate in order to
give meaningful work output from the system.

Pneumatic actuators
These are the devices which converted the power of the pressurized gas in to
the motion. Pneumatic cylinders are examples for pneumatic actuators

Connecting Items
In order to work above units they must be connected. That is done with
pneumatic tubes.
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Figure 2.1: Basic Classification of a Pneumatic System

2.1.3
FRL Units
Figure 2.2: Figure of FRL unit
We use atmospheric air as the working gas of pneumatic systems. So that air
should be cleaned. If not due to dust particles the pneumatic actuators such as
cylinders can be damage. Also the gas is pressurized and so there can be water inside
the tubes and actuators due to high pressure. This can make the system inconvenience.
So to avoid these problems we use FRL units which contain
Filter unit
This unit filters away the water vapor which is generated due to high pressure.
This separation is obtained by the special plastic profile inside filter unit. That
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profile allows air to rotate and the water vapor is separated due to centrifugal
force and drained away as water.
It also has a very sensitive filter. So it doesnt allow dust particles to penetrate
in to the pneumatic system.
Figure 2.3: Figure of filter and the special shaped element of the filter
Regulator unit
For proper functioning the pressure inside the pneumatic system should be
maintain in a range. Because low pressure will not able to operate the system
while high pressure damage the pneumatic actuators. Normally pneumatic
systems works pressure range of 0.15 to 0.8 MPa range. We use regulator units
to obtain relevant pressure out of the compressor unit. There is a spring inside
the regulator unit. We can adjust the compression of the spring manually. The
pressure of the fluid flowing through the regulator varies according to the
compression force of the spring. So we can adjust the pressure by using
regulator unit. Except that regulator units have feedback unit which is bit
complicated. It helps to control the pressure in a higher input pressure.
Also there are regulator units which have a barometer. So we can see the
output pressure straight away.
Lubricator unit
Pneumatic actuators like cylinders need some lubrication for proper
functioning. So the lubricator unit mixed some lubricator oil to the air flow.
The theory behind mixing is Bernoulli Effect. So the lubricant is sucked by the
low pressure region created by the flowing fluid. There is a little filter to
maintain the size of the lubricant particle too.
By adding lubricants we can increase the durability of the system.
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Figure 2.4: Figure of the inner parts of FRL unit
2.1.4
Flow Controller Units
Flow controller units are the units that are controlled by us to gain a
meaningful work output by the power of pressurized air. Mainly we control the
direction of the flow and the flow rate of the flow.
2.1.4.1
Direction control valves.
Direction control valves can change the direction of the flow. For a example it can
decide whether the flow is going into the pneumatic actuator or going out the actuator.
So if the actuator is a cylinder then it can maintain the direction of the shaft travel.
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This is done by changing the position of a special shaped rode inside the
valve. It is known as the spool. Due to its shape as shown in figure below it can
generate various flow patterns according to the position of the spool inside the valve.
Figure 2.5: Figure of a spool
Figure 2.6: Figure of a the position of

the spool inside valves
We can classify the directional control valves according to the number of ports
available and the number of directions they have.
2/2 way valves

These valves have two ports and two spool positions which means two flow
directions. This is the simplest type of valve. Just like water tap it allows flow
through the valve and stop flow. These two positions can be clearly identified
by the symbol of the valve.
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Figure 2.7: Figure of a 2/2 way valve
Figure 2.8: Figure of symbol

of a 2/2 way valve
3/2 way valves

As the name implies it has three ports and two positions. These pistons can be
used the single acting cylinders that the shaft is moved to the one side by using
air pressure.
Figure 2.9: Figure of a 3/2 way

valve
Figure 2.10: Figure of symbol

of a 3/2 way valve
5/2 way valves

These valves have five ports and two directions. These valves are used with
dual acting cylinders.
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Figure 2.11: Figure of a 5/2

way valve
Figure 2.12: Figure of symbol of a

5/2 way valve
5/3 way valves

These valves have one intermediate position more than 5/2 way valve which
enables three types of stopping in dual acting cylinders. The physical look of
the valve is very much like above shown 5/2 way valve. Lets consider about
the intermediate stages.
1. Closed center type
In intermediate stage both the output port remains close.
2. Exhaust center type
In intermediate stage both the output port remains open so the air stored
inside can escape to the surrounding.
3. Pressure center type
In intermediate stage both the output port remains open to the pressure port
so the system gets stuck where it was.
Above 3 stages are important when consider about the emergency stopped
situation.
When we consider about the designing we should pay our attention about
the flow characteristic of the relevant valve, because it will decide the speed of
the actuators and the power delivered by it. To decide it we should consider
about the flow characteristic of a pneumatic valve
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Figure: 2.13 Flow characteristic of a pneumatic valve

According to the type of the power we used to change direction there exist there types
of valves.
1. Solenoid valves
Use the magnetic power of the electrical coil to move the spool inside.
2. Air valve
Use the air pressure of the electrical coil to move the spool inside. The air line
which does the changing in the positions is known as pilot signals.
3. Mechanical valves.
Use the magnetic power of the electrical coil to move the spool inside.
2.1.4.2
Flow Control Valves
Control valves are normally fitted with actuators and positioners.

Pneumatically-actuated globe valves and Diaphragm Valves are widely used
for control purposes in many industries, although quarter-turn types such as
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(modified) ball, gate and butterfly valves are also used. Some times in the
automation application we control the flow speed by using flow control valve
in order to make the timing correct.
Figure: 2.15 Symbol of flow control

valve
Figure : 2.14 Flow control valve
2.1.5
Pneumatic Actuators
A pneumatic actuator converts energy (typically in the form of compressed

air) into motion. The motion can be rotary or linear, depending on the type of
actuator. Some types of pneumatic actuators include. These are the main
devices we are getting output from the pneumatic systems. Basically they are
the cylinders.
Two types of pneumatic cylinders are used.
Single acting cylinders

Single acting cylinders operate to one side by using air pressure. It comes back
by a force generated by a spring. Not suitable for heavy purposes.
Double acting cylinders

Use air pressure to obtain the motion to both sides so suitable for heavy
purposes.
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Figure: 2.16 Pneumatic cylinders

There are so many applications of the pneumatic cylinders. So there available
various kind of cylinder types such as compact cylinders, mini cylinders, multi
mounting cylinders, twin rod cylinders, slide table cylinders twist clamp
cylinders and etc.
2.1.6
Connecting Items
To complete the pneumatic system we have to connect all the actuators

controllers and other units. This is done by using special tubes and fittings.
These items should have enough strength to withstand the pressure. The tubes
use there is made with polyurethane which has that ability.
Figure: 2.18 One touch fittings

Figure: 2.17 Polyurethane tubes
Except that there are various kind of fittings are available such as manifolds.
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2.1.7
Application of Pneumatic Systems
In my training period I found a fully pneumatic nail hammer machine in the DI

lather industry. We had to study its pneumatic background for repairing purposes.
Figure: 2.19 The nail hammer machine

It was a brilliant design. It had used just simple direction controller valves to have
repeated motion of the hummer which is a double acting pneumatic cylinder and
the flow control valves are used to gain the timing. Nail feeding is automatically
done with an air flow. The pneumatic circuit I obtained and the diagram they
supply is given in Appendix A.
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2.2
SENSORS
Sensors are the devices which are able to identify or sense a physical properties
and they are able to give an output according to change of that property. They are
also known as detectors. There are numbers of sensors which are able to measure
various physical properties such as temperature, light intensity, weight, matter,
metals, pressure variations and moisture. Those are some of physical properties
that can detect by a sensor. Except that, there numbers of physical properties. Also
the scientists are searching for new ones. Because introducing a new sensor means
introducing a new machine or improve existing one in that particular field. Due to
the accuracy and speed of these new sensors are widely used in industrial
automation fields, medicine and robotics. In this part we consider about some
sensors types I found in my industrial training period.
2.2.1
Photo Sensors
These devices have photodiode or phototransistors which varies electrical

properties according to light intensity as receivers. It also creates some kind of
electromagnetic wave such as infrared by using a transmitter. They identify the
objects by the effects such as diffusion and reflection happens to the generated
electromagnetic wave. By different combination of this transmitter and
receiver it can identify various kinds of objects.
Diffusion type photo sensors.
This has transmitter and receiver together so that it is capable of
detecting the reflection on the object. It can be used to identify the
distance to some extend because the intensity of the reflected ray is
weakening according to the distance.
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Figure 2.20: Diffusion type photo sensor
Reflective type photo sensors

This has transmitter and receiver together and a mirror is used to
reflect. If an object gone through it cuts the beam and it can identify it.
Figure 2.21: Reflective type photo sensor
Thru beam type photo sensors.

This has transmitter and receiver separately so if any object gone
through it can identify. This have a very long working range up to 20m.
So this can be used for security purposes.
Figure 2.22: Thru beam type photo sensor

When we consider about the designing done with this kind of photo
sensors we have to consider about following facts. Because the machines
use in industrial automation field should be reliable and should be
accurate.
Sensing distance
Emitting light
kind of objects going to detect
color of the object
Operating voltage
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Operating temperature
Vibration resistance
Photo sensors are widely used in dipping machines in glove

manufacturing and packaging machines. There are so many variations are
available such as different types of shapes like u shape photo sensors for
different kind of applications.
When the diameter of a photo sensor (barrel type) decreases we
consider the sensitivity of the sensor increases. But normally photo sensors
have higher diameters. So for more sensitive cases, there exists another type of
optical sensors such as fiber optic sensors.
2.2.2
Fiber Optic Sensors

The basic theory behind the fiber optic sensors is very much same as
the photo sensors. But the fiber optic technology is used in these sensors. Main
difference is that they have fiber optic probe with amplifier unit which
increase the sensitive of the sensor.
There numbers of fiber optic sensors which have different kinds of
probe such as Antibleeding fiber optic, high quality fiber optic, plastic fiber
optic, glass fiber optic, silica fiber optic according to different applications.
There are variations in sensing distances according to the fiber optic used.
Fibers have many uses in remote sensing. Depending on the
application, fiber may be used because of its small size, or the fact that no
electrical power is needed at the remote location, or because many sensors can
be multiplexed along the length of a fiber by using different wavelengths of
light for each sensor, or by sensing the time delay as light passes along the
fiber through each sensor. Also the amplifying unit provides different types of
functions which enable us to use the sensor more accurately.
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Figure: 2.23 Figure of application of a fiber optic sensor
2.2.3
Proximity Sensors
Proximity sensors are widely use in industrial automation field. They are used to
identify a presence of matter because of their durability due to lack of mechanical
contacts. For example if we want to identify some product going on conveyor belt we
use proximity sensors.
There are two well known proximity sensors are used in automation field. I
described them below.
Capacitive Proximity sensors

These sensors are mainly use to identify nonmetallic objects. The principle is
the capacitance variation with the distance. When the object comes near, the
capacitance of the sensor increases.
Figure 2.24: Capacitive Proximity sensor

Most of the moving machine parts are metallic. So these types of
sensors are widely used to manage the motion of the machine. Before apply
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these sensors to a machine we should know what are the limits relevant to
following factors.
Sensing distance
Operating voltage
Temperature range
Hysteresis
Inductive Proximity sensors
This sensor generates a magnetic field. It consists of an oscillator which
generates the magnetic field. This field is coming out from the sensor surface.
The intensity of the magnetic field increases due to metal. That absorbs some
part of energy from the oscillator. So the amplitude of the oscillator decreases.
That decrease is proportional to the distance between the sensors surface. That
is how the Inductive Proximity sensors work.
Figure: 2.25 Figure of application of a fiber optic sensor

Important facts that we should consider about the sensor before using it is shown
below.
2.2.4
Sensing distance
Operating voltage
Temperature range
Response time
Ultrasonic Sensors
These sensors also work as photo sensors. The main difference is they use
ultrasonic wave. These sensors are introduced in recently.
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Figure 2.26: Ultrasonic sensor

Important facts that we should consider about the sensor before using it is shown
below.
2.2.5
Maximum sensing distance(900mm)

Beam Angle(8)
Operating voltage
Ripple
Temperature range
Thermocouples
Thermocouples are well known as temperature sensors.
Figure 2.27: Thermocouples
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2.2.5.1
The working principle of Thermocouples
Thermocouples are made with two different conductors. When the two ends of
the conductors are in different current an electrical voltage is generated. This voltage
value varies with the temperature difference between two ends. So if we know the
temperature of one end we can identify the temperature of the other end. By
calibrating particular thermocouple we can use it as a thermal sensor.
There are special controlling units which have calibrated to the relevant type
of thermocouples so that they can indicate the current temperature value. Also there
we can set a value so a relay switch or a contactor can be used to control the
temperature below some value. We have worked with them in the project of heat print
machine in my training period.
To keep one end in a known temperature (usually cold end) an artificially cold
junction is made by using a thermally sensitive device such as a thermistor or diode to
measure the temperature of the input connections at the instrument. There are
different combinations of conductors used so that numbers of type such as k type, E
type, J type and etc. among these k type is widely use in industry.
Figure: 2.28 Figure of temperature control unit.

Some important specifications we should consider before using thermocouple is
shown below.
Type of conductors use.
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Calibration type
Whether the type is K, J, T etc
Temperature range.
K type has range of 0 to +1100C
Limit of error
K type +or-2%
Application of the thermocouples
Temperature measurement for kilns

Gas turbine exhaust
Diesel engines
Industrial processes such as automated machines with heaters.
2.2.6
Encoders
Encoders are used to identify the location of a moving part of a machine or moving
objects. For a example dipping machine use encoders to identify the amount of the
immersed part of the machine. Also servomotors use encoders to get a feedback of
how much rotation have done.
There are two types of encoders available. They are
Rotary encoders
A rotary encoder, also called a shaft encoder, is an electro-mechanical
device that converts the angular position or motion of a shaft or axle to an
analog or digital code. The output of incremental encoders provides
information about the motion of the shaft which is typically further processed
elsewhere into information such as speed, distance, RPM and position. The
output of absolute encoders indicates the current position of the shaft, making
them angle transducers.
In my training period I have use a rotary encoder with the PLC unit to
measure the angle of rotation of a stepper motor. There are several types of
rotary encoders are available. Some encoders only can measure the angle and
some can measure both the angle and the direction too.
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Working principle of the rotary encoder is simple. When the encorder

rotates it generate pulses by two optical sensors (other types of sensors also
use) due to a rotating plate that has two marks of sensing point. These two
pulse modules have two different phases. So bu considering the phases we can
get the angle well as the direction.
Figure: 2.29 Figure of Two square waves in quadrature (clockwise

rotation).
Rotary encoders are used in many applications that require precise
shaft unlimited rotation including industrial controls, robotics, special purpose
photographic lenses, and rotating radar platforms.
Linear encoders
A linear encoder is a sensor, transducer or readhead paired with a scale
that encodes position. The sensor reads the scale in order to convert the
encoded position into an analog or digital signal, which can then be decoded
into position by a digital readout (DRO) or motion controller Linear encoder
technologies include optical, magnetic, inductive, capacitive and eddy current.
Optical technologies include shadow.
In my training process I found a packaging machine that contains a
linear encoder. In this case a resistance of a coil is used. There is an arm which
comes down and seals the package. The position was taken by that encoder.
When the arm comes down, the resistance of the coil changes due to changing
of the effective length of the coil. Then it was converted to the voltage signal
by a circuit and used.
Linear encoders are used in metrology instruments, motion systems
and high precision machining tools ranging from digital calipers and
coordinate measuring machines to stages, CNC Mills, manufacturing gantry
tables and semiconductor steppers.
2.2.7
Touch Panels
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Touch panels are kind of sensors. They are used give the users input to the system.
Normally the touch panels should be programed before use them so the user can go
through the instructions to input his ideas. This was done by the software which is
given by the manufacture.
Also we should allow touch panels to input data by keeping PLC program ready to
accept it. That means the program should have a variable or a previously define values
which are stored in the unit so that the user can chose them.
Figure:2.30 Touch panels
2.3
Controller Units
There are several types of controlling units are available in automation field
such as timers, contactors and relay switches. These units have the ability to control
the system according to a signal of a sensor or signal of the operator.
But above mentioned controller units are not widely used in complex
machineries. Because the technology have developed to a certain standard that all
these processes can be achieved by using one unit such as programmable logic
controllers or by using microcontrollers. But these devices are expensive. So the
controller units like relay switches are using in the automation field too.
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2.3. 1
Relay switches and Contactors
A relay is an electrically operated switch. Many relays use an electromagnet to

operate a switching mechanism mechanically, but other operating principles are also
used. Relays are used where it is necessary to control a circuit by a low-power signal
(with complete electrical isolation between control and controlled circuits), or where
several circuits must be controlled by one signal. The first relays were used in long
distance telegraph circuits, repeating the signal coming in from one circuit and retransmitting it to another. Relays were used extensively in telephone exchanges and
early computers to perform logical operations.
Relay switches are available as shown in the figure below. It must contact to
the circuit by using a base. The connection details of the pins are indicated on the
relay switch.
Figure:2.31 Figure of relay switch

Figure:2.32 Figure of contactor
A type of relay that can handle the high power required to directly control an
electric motor or other loads is called a contactor. Normally these are the switches
mostly used in the automation field. For example the heat print machine which is
one of a recent project of Techmast Automation (Pvt.) Ltd used contactors to control
the heat of the heaters used. Thermocouple which combined with the calibrated
control unit gives the input signal to the contactor.
2.3. 1
Timers
Some relays are constructed with a kind of "shock absorber" mechanism attached
to the armature which prevents immediate, full motion when the coil is either
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energized or de-energized. This addition gives the relay the property of time-delay
actuation. Time-delay relays can be constructed to delay armature motion on coil
energization, de-energization, or both.
Time-delay relay contacts must be specified not only as either normally-open
or normally-closed, but whether the delay operates in the direction of closing or in the
direction of opening
Figure 2.33: Figure of industrial automation time delay relay switches
2.3. 2
Application of Relay switches and Timers
In the industrial automation field there exist so many machines working only with this
kind of simple controlling units. I found an old creation of Techmast Automation
which fully worked with relays and timers. The purpose of the machine is to count
gloves. So they have used true beam type sensors. The sensor is counting not only the
gloves but also it counts the fingers because the sensor is too fast. So they had to
delay the system for little while.
The right handed and left handed gloves separately fell through two buckets
automatically by another machine.
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Figure:2.34 Glove counting machine

To overcome the difficulty they have used an arrangement which is attached to the
Appendix B
2.3. 3
Programmable Logic Controllers
A programmable logic controller (PLC) or programmable controller is a digital

computer used for automation of electromechanical processes, such as control of
machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are
used in many industries and machines. 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-up or non-volatile
memory. A PLC is an example of a hard real time system since output results must be
produced in response to input conditions within a bounded time, otherwise unintended
operation will result.
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Figure: 2.35 Figure of PLC unit
As shown in the figure the PLC unit has input ports output ports and a
processing unit. So it is a microprocessor-based electronic device. Which have inbuilt
Logic controls, Timers, Counters, Analogue signals, closed loop control, arithmetic
function and Etc. These units are arrange in a way like in the below figure so that it
can control the machine easily.
Figure : 2.36 Compact PLC

We have to program the PLC before we used. To do so we used XCPPro
ladder programing software. There we give instruction by ladder diagrams. Then the
software generates a code according to our instruction and we can store this
instruction inside the PLC unit by connecting it to the computer. Then the PLC itself
can handle the system according to our program.
In industrial automation field the large machines or production lines such as
glove manufacturing process, or shoe manufacturing process they have to work all the
machineries work at once in order to improve the efficiency. In this case all the PLC
units can be networked. It is a very useful quality of PLC units.
In our training period I had a chance to program a PLC unit and check it. The
concept and the ladder program of it are attached to the Appendix C.
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2.4
Motors
Motors are very widely used in almost all the fields of the world. Because of this
there are so many different types of motors are available. But when we consider about
the automation field the motors should be accurate and should be easy to control with
the control units such as PLC. If the motors are not that much accurate then we should
use some feedback mechanism to control it within the manageable range. Geared
motors, servo mechanism, variable speed drivers and stepper motors are some
commonly used motors and mechanism to gain accurate output.
2.4.1
Servo Mechanism
A servomechanism, sometimes shortened to servo, is an automatic device that uses

error-sensing negative feedback to correct the performance of a mechanism.
A common type of servo provides position control. Servos are commonly
electrical or partially electronic in nature, using an electric motor as the primary
means of creating mechanical force. Other types of servos use hydraulics, pneumatics,
or magnetic principles. Servos operate on the principle of negative feedback, where
the control input is compared to the actual position of the mechanical system as
measured by some sort of transducer at the output. Any difference between the actual
and wanted values (an "error signal") is amplified (and converted) and used to drive
the system in the direction necessary to reduce or eliminate the error. This procedure
is one widely used application of control theory.
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Figure: 2.37 Figure of servo motor
2.4.2
Geared Motors
Gears motors are such type of motors which have a large reduction
system. The gearbox is pertained into the motor. This type of integral
arrangement is done in order to increase the mechanical rotational speed of the
motor. But simultaneously, this arrangement reduces the output speed.
The important feature of a Gear Motor is that the driven shaft and the
driving shaft may be coupled directly in it. In order to reduce the speed of such
motors, some other devices like pulley, belts, chains etc. are required. The
separate use of speed reducers has been prohibited for the purpose of reducing
the speed of a Gear motor. The term Gear motor is used to describe such a
motor which has an integrated gearbox (gear reduction unit) within the motor.
The benefit of the integrated gearbox is to enhance the mechanical rotational
energy of the motor. The other important thing is that this integrated system
also reduces the output speed of the motor.
The most prominent advantage which comes from the gears of the
Gear motor is that the direct coupling is possible for driving shaft to the driven
shaft. Another advantage of the Motor gear is that it omits the requirement of
coupling the motor to a distinct outer speed reducer. Therefore, these Motor
gears are useful in hot melt glue pump, conveyor drives, labellings box case
electors etc.
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Figure: 2.38 Figure of servo motor
2.4.3
Variable Speed Drivers

A variable-frequency drive (VFD) is a system for controlling the
rotational speed of an alternating current (AC) electric motor by controlling

the frequency of the electrical power supplied to the motor. A variable
frequency drive is a specific type of adjustable speed drive. Variable frequency
drives are also known as adjustable frequency drives (AFD), variable-speed
drives (VSD), AC drives or inverter drives. Since the voltage is varied along
with frequency, these are sometimes also called VVVF (variable voltage
variable frequency) drives.
Variable-frequency drives are widely used in ventilation systems for
large buildings; variable-frequency motors on fans save energy by allowing
the volume of air moved to match the system demand. They are also used on
pumps, elevators, conveyors and machine tool drives.
2.4.4
Stepper Motors
This is very widely using motor type because of the accuracy. This
motor rotates one step for one pulse it gains. So by controlling the pulse
number they can rotate in very sharp angles such as 1.80. This can be couple
with an encoder to get feedback and use as servo mechanism.
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Figure : 2.39 Stepper motor

2.4.4.1 The Working Principle of Stepper Motors
This consists of different separated coils. The motions of steps are gain by giving
voltages to different coil in a special order. The figure bellow shows how the steps
come.
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Figure : 2.40 The Working Principle of Stepper Motors
The voltages to the coils are given by a special driver call stepper driver. Some time
we use different circuits to achieve these orders. By changing the order we can gain
different steps out from the same motor.
2.4.4.2 The Combination of PLC and Stepper Motors in Automation
We are allowed to work with a stepper motor with a drive in our training
period. There are various kinds of stepper drivers are available. A driver can rotate a
stepper motor in both directions with variable speed as set before. So we have to tell
the stepper driver that.
Which direction should it rotate
When should it rotate
How many revolutions should it rotate?

So we have to give the driver these details. By sending pulses we can rotate
the stepper motor. So by sending the pulses using transistor output PLC unit
we can rotate the motor. By controlling the amount of pulses by the program
we can achieve accurate angle of rotation.
Also the drivers got another ports ready. If we give that port a positive voltage
then it rotates clockwise and negative voltage then it rotates antilock wise or
wise versa. So we can achieve the direction.
Also there is an enable port in the driver. It should be positive voltage to drive
the motor.
So by giving three inputs to the driver the PLC unit can easily manage the
motion of the stepper motor.
Stepper motor drivers should powered externally to run the motor and it can
rotate the motor in various angles for a step input by changing the way of
giving current to different windings of the motor
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Figure : 2.41 The Combination of PLC and Stepper

2.5
The Heat Printing Machine

Heat printing machine is a new innovation. It was designed for a Pakistan gloves
manufacturing company. The purpose of building this machine was to print a label on
the glove. To do so they used heat press stickers.
Figure: 2.42 The Heat Printing Machine
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There are two production lines, which are worked by two chains are shown the
figure. Inputs of the machine are gloves and stickers. Then we can get able printed
gloves as output. Gloves are loaded and unloaded by a worker. When the worker
wears the glove to the machine, it automatically detects the glove. Then it places a
sticker on the glove and prints it by pressing it at the temperature around 180 . Then
the same worker can remove the glove from the machine.
Mechanical structure of the machine is build with box bars, chains, gear
wheels and etc. to provide better, quick and reliable motion. All the parts are
well design to bear the stress and pressure developed by the motion, such as
heaters. Also used heat resistive materials such as Teflon to necessary places.
All the moments of the machine is done with the pneumatic actuators.
To govern the moments, a PLC unit was used.
Several sensors are used to help with the governing process of the PLC unit.
Diffusion type sensor
To detect the glove
Magnetic read switches
Use in the pneumatic system to identify the positions of each and every
cylinders. So the PLC can help to simulate the movements by
controlling direction controlling values.
K type thermocouple is used to control and observe the heat of the
heaters.
The process of controlling heat of heaters is done by several
controlling units which work independent from PLC unit.
2.5.1 Flow of the machine

In order to gain the maximum output and maintain the safety, the machine flow is
controlled. That was achieved by the PLC program. The general idea about the
process is figured below.
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Figure: 2.43 Flow of the heat print machine
1. There is a stop button which enables to stop the machine at the any moment of
the process. Then it should be reset by reset button before start the process
again.
2. There is an emergency button which helps to stop the machine during the
process.
3. Waiting times shown in above figure allows the worker to remove and wear
gloves to the machine, and keep the pressing times can also change the
pressing times.
4. There are controlling units to control the heat at heaters.
2.6
Extrusion Process
We had several chances to visit industry during our training. One of important
manufacturing process we studied is the extrusion process. Lets see what
extrusion means.
Extrusion is a process used to create objects of a fixed cross-sectional
profile. A material is pushed or drawn through a die of the desired crosssection. The two main advantages of this process over other manufacturing
processes are its ability to create very complex cross-sections and work
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materials that are brittle, because the material only encounters compressive
and shear stresses. It also forms finished parts with an excellent surface finish.
2.6.1
Aluminum Extrusion
We have seen so many aluminum partitioning and works. They use
different kind of aluminum profiles to do so. These aluminum profiles are

made by the extrusion process.
We had a chance to visit Alumex aluminum extrusion (Pvt.) Ltd and
see the manufacturing process. They started their manufacturing process by
starting with aluminum billet which is imported row cylindrical aluminum.
Then they heated it near 400 0C and cut it. The cutting was done by
automatically with the machine which can calculate the most efficient length
according to the cross section of the profile. Then the aluminum piece is
pushed hard through the die and obtains relevant shape. Then the stretched the
profile to straight product.
Then the profile put in the 400 0C for a long time to make fine
microstructure. Then there is complex process going on to get a better surface
finish including electroplating and other chemical reactions.
The process of powder coating also done in a case of a very better
surface finish needed. In that process the powder like paint and the aluminum
profile is electrically charged in opposite signs so the powder comes and hit all
the parts of the profile making a better finish.
The shapes of the profile directly depend on the precision of the die. So
they pay a great care about it and they maintain the dies after every time it
used.
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Figure: 2.44 Dies used to extrusion process
2.6.2
Plastic extruder
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Figure: 2.45 Plastic Extruder

Plastic backs are manufactured by extruding them. The theory is very simple.
The input of the machine is plastic chips like powder. Then these materials are heated
with colorings to temperature nearly melting point. Then the mixture is extruded in
round shape die and the other side it is rolling to a roller which is controlled by the
servo motor. Before rolling there is a time that the air is blowing through the extruded
plastic which increases the diameter of the extruded plastic tube. By controlling the
speeds of the motor and the blowing speed we can get different kind of thicknesses
for the backs.
2.7
Welding
Since there are so many projects were doing in my training period I was able
to participate to welding processes too. Also the company was building a new
workshop at Kadawatha. The structure is done with the steel H bars and lot of
gas cutting and welding processes were taken place. Here is some details
about that processes.
2.10.1 Arc Welding

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Arc Welding is the welding process, in which heat is generated by an

electric arc struck between an electrode and the work piece.
Electric arc is luminous electrical discharge between two electrodes through ionized
gas.
Any arc welding method is based on an electric circuit consisting of the following
parts:
Power supply (AC or DC);
Welding electrode;
Work piece;
Welding leads (electric cables) connecting the electrode and work

piece to the power supply.
Figure : 2.46 Welding Plant

2.10.2 Gas Cutting
The common methods used in cutting metal are
1. Oxy-gas flame cutting,
2. Air carbon arc cutting
3. Plasma arc cutting.
The method used depends on the type of metal to be cut and the availability of equipment.
The oxy-gas cutting torch has many uses in steel- work. At most naval activities, the
Steelworker finds the cutting torch an excellent tool for cutting ferrous metals. This
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versatile tool is used for operations, such as beveling plate, cutting and beveling pipe,
piercing holes in steel plate, and cutting wire rope.
When using the oxy-gas cutting process, heat a spot on the metal to the kindling or
ignition temperature (between 1400F and 1600F for steels). The term for this oxygas flame is the PREHEATING FLAME. Next, direct a jet of pure oxygen at the
heated metal by pressing a lever on the cutting torch. The oxygen causes a chemical
reaction known as OXIDATION to take place rapidly. When oxidation occurs
rapidly, it is called COMBUSTION or BURNING. When it occurs slowly, it is
known as RUSTING
When using the oxy-gas torch method to cut metal, the oxidation of the metal is
extremely rapid and part of the metal actually burns. The heat, liberated by the
burning of the iron or steel, melts the iron oxide formed by the chemical reaction and
accelerates the preheating of the object you are cutting. The molten material runs off
as slag, exposing more iron or steel to the oxygen jet.
2.10.3 Types of Flames of The Flame Cutter
Carburizing Flame
Oxidizing Flame
Natural Flame
Natural flame has the highest temperature. Therefore it is used for cutting plates.
When the nozzle has the natural flame, sharp corns can be seen at the end of the
nozzle. When cutting from the flame cutter it should never touch the plate. If it
happens, it gives an undesirable noise and may damage the nozzles. When shutting
down the flame the user should first open the oxygen valve more. Then the flame
stops. Then close both valves. When cutting plates, nozzle should be held
perpendicular to the plate.
A special feature of acetylene control valve is, it opens clockwise, opposite direction
to the oxygen valve. The valve is marked in red where oxygen valve is marked in
blue.
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Does not eject as sparks, but rather mixes with the clean melt near the cut.
Figure:2.47 Oxy gas flame cutting torch
Chapter Three
3.0
Management Details
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We have already consider about the background of Techmast Automation (Pvt.) Ltd in
chapter one. In chapter two we studied about their recourses and their product range.
But even though a company has enough employers, enough money and enough
resources that company can be fail due to another important factor. That is how they
are going to manage their resources. So in this chapter I consider about the details
regarding to the management of the company.
3.1
Management Techniques
Before considering about the management technique lets see what management
means is.
Management in all business and organizational activities is the act of getting
people together to accomplish desired goals and objectives using available resources
efficiently and effectively. Techmast Automation (Pvt.) Ltd has so many resources and
they always try to manage them to get maximum output from these available sources.
The available resources in Techmast Automation (Pvt.) Ltd are shown below.
human resources
Techmast Automation (Pvt.) Ltd has got about twenty five permanent
employers.
Financial resources.
Techmast Automation (Pvt.) Ltd has got a strong stock of full range of
automation products.
Technological resources.
Techmast Automation (Pvt.) Ltd got numbers of well-educated and
experienced automation engineers and technical officers with huge
amount of technical details such as catalogs.

Natural resources.
The company and the workshop are situated in western province and it
can access harbor and other technical valid places quickly. Also it is
close to Katunayaka and Biyagama free trade zones which use
automation widely.
Customer base.
The company has maintained a good and trusted customer base by
providing a standard service to them.
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Automation field is very competitive field. There are numbers of well-known

companies are available in Sri Lanka. So Techmast has to manage above identified
resources well. They used several managing techniques to overcome this.
Management Techniques used by Techmast Automation (Pvt.) Ltd is shown
below.
controlling an organization
The organization must be controlled well to by assigning specific task
to each and every member. So there will not any confusion in the
process and the efficiency will be increased.

leading or directing
The company must be led by someone or a group so that there will be a
person who takes responsibility of the works carried out.

Planning
The company should work to a plane. These plans can be long term or
short. But these plans should be decided well by a group. In the
Techmast they organize meeting and take decisions.

Organizing
After planning the members are organized to execute the plan. This
could be a new project or design or may be new sales promotion plan.

Improve Communication
As I discussed in chapter one Techmast Automation (Pvt.) Ltd is
functioning with three separated departments. They are sales section,
accounting section and project office. So Techmast always try to
improve their communication within these departments.

Use S5 concept
Techmast Automation (Pvt.) Ltd use S5 concept so it makes workers to
work quickly. It also makes very comfortable feeling for both workers
and the customers. So using S5 improves the productivity of the
organization.
By using above management techniques Techmast Automation (Pvt.) Ltd have

manage to give a good service to their customers while competing with other
automation companies. Lets see how these techniques are used in the various sections
of the department.
3.2
Workers Management
Page 45
Techmast Automation (Pvt.) Ltd has different workers which have different abilities.
All these workers should manage to get their maximum out of them. So that is why
the company clearly sectioned and also the workers too. So each worker has his own
responsibility and all together they represent a responsible company.
For an example the company has strong sales section. They went almost all the
places that need automation products and services. They keep in touch with customers
and try to work with them friendly while the project office doing new creations and
consulting customers. Store keeper always watching the stock and provide all the
needs and inform administration about the states of the stock.
Always a good management tries to keep workers happy so that they are working
better for the company. Techmast Automation (Pvt.) Ltd also tries to make workers
happy by giving them so many benefits. They provide a good salary to workers and
also give commissions to them. Give special bonus for special occasions and they are
organizing trips and sport events which enhance the satisfaction of the workers.
But workers management is not only getting maximum output. It has such a legal
background. These rules are useful in case of illegal thing happen to both
administration and the worker. So the company cares these things well.
3.3
Keeping Documents
This is one of the important tasks of any organization. Documents are very important
for any organization. Account section has to keep all the details about the financial
things. Sales section has to keep their documents about the progress of sales and take
decisions regarding to the observations from there details. Project office which is very
relevant to us has to keep all the documents such as drawings, technical details about
the products uses for their machines. So Techmast Automation (Pvt.) Ltd maintains
and keeps their documents separately. But members on the section also can access the
data too. So there is no confusion happen. But the details like newly design machines
or drawings are kept safely.
Project office designs a machine or part according to a procedure. First the
customer should request a quotation by sending details about the requirement. Then
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the engineers visit and study about the problem well and gather information about the
requirement. Then they are providing solution by discussing and make the best
solution they can have. Then they asses the maximum amount of money that the
project will consume and send them the quotation. May be they attach some details
about the design too. If the customer agrees then they started a document according to
the next work order number in their registry and start to draw the drawings.
These drawings are done by using AUTOCAD software or SOLIDWORKS
software. Then they manufacture the machine and sell it under another ID which is
called purchase order number. They keep all the details and drawings safely.
3.4
Financial Management
Financial management is control by the account section of Techmast Automation

(Pvt.) Ltd. This is very important task because it includes all the expenses as well as
all the incomes of the company.
All the details about the purchases done by the customers are recorded in a
special registry under a purchase order number. No matter the purchase was done
through project office or sales section the bills and invoices are sending to account
section. So the all incomes are recorded.
Likewise all the expenses of the company is calculated. All the expenses of the
company should be recorded to the account section of the company with details. Also
the salaries of the workers and other expenses for the functions they organized and the
maintaining cost of the company and its properties are taking into account.
After every month they check the financial states of the company. They also
held meetings and discuss about the situation and take new decisions to improve the
financial states of the company.
3.5
Managing The Stock
The stock should ready to supply any need of the customer in order to keep customer
happy for their service. But the company cant invest huge money to maintain a huge
stock too. Because they can invest this money for some new project like new
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workshop or the can enhance their busyness by investing the money in different case.
So managing the stock is not easy as it seems.
To overcome this they always try to analyze customers needs and maintain
the stock according to their demand. Also the sales section tries to study the new
trends of the automation field and try to update stock. There are numbers of well
experienced workers are working there. So they have good understanding about this
fact too.
A computer based database system is maintained by the company to keep all
the details about the automation products in the stock.
3.6
Managing The Customer Base
The company needs a strong customer base. So to do that the management must
consider about how they are managing the customer base. This is an important factor
that directly effected to the future of the company.
So the company has taken several actions to care about customer base. The
customers are given chance to access the company quickly by providing them a
chance to inform their needs directly to the sales section via internet. They can also
use fax, emails, and telephone lines if they want. The company maintains a delivery
service too. So when the customer inform about his needs he can have them quickly.
Also the workers are well aware about how important the customers are. So
they pay special attention when they dealing with the customers. The prices are listed
in a transparent way that the customers also can accept it.
3.7
Safety Management
A good organization should have a good safety management. Actually this is the
most important part of an organizational management. The employers and the

customers should be safe in the process of the company.
Techmast Automation (Pvt.) Ltd maintains good safety management inside the
workshop area. The existing workshop is not that much of a huge building. But it is
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being kept well according to the 5S concept. So the all dangerous machines and tools
are arranged in a way that harmful effect is minimized. Also the workers are not
allowed to enter the workshop are without the overall safety kit including boots and
safety goggles. We are not allowed to enter to the workshop without boots and glasses
too.
The existing workshop doesnt have proper emergency exist or proper fire alarm
system or a fire protection system. Now the company is building a new workshop that
has all these facilities. The electric system and the pneumatic power system is
properly design for the safe of the workers as well as the customers.
But the office building is not that much of safe place as it is on 1st flow of the
building and it doesnt have an emergency exit. I suggest them to change the design of
the office to have a proper safety.
Chapter Four
Summary and Conclusions
4.1 Summary
During 12 weeks of my training experience in Techmast Automation (Pvt.)
Ltd, I was able to involve with site work, office works, and industrial visits.
As an automation company there we had lot of chance to study about the
pneumatic equipments which are widely used in the industrial automation field.
There is a full range of products which are used in automation are available in the
company. So we had a good understanding about the parts of the machines.
Page 49
There we had a chance to use and program the PLC units and we got a good
assistance from the staff. By practically using them we pick so many points that we
wont be able to learn from books.
I also had chance to involve some workshop practices too. Because lots of
pneumatic items are assembled hear. So they have use lathe machines, drilling
machines, tapping tools and etc. so I also involved into them and got a good
experience.
A newly building workshop is something like a work site for us. We went
there and have lot of welding practices as well as gas cutting. The construction thinks
like cladding boards and painting methods and the corrosion rsistance action taken
were observed.
Most importantly we had lot of chances to visit other industries and learn a lot
and find so many source persons.
4.2 Conclusions
At the University, we were taught many theories and given chances to do
several practical, experiments and tests to understand the concepts. But it is very
difficult to apply these things in the practical world without an experience.
In our training period I had lot of chances to visit other places and work with
various kinds of persons in different knowledge limits. So we have to be careful in
behaving with them and we should know how to manage the situation. Also in
practical case we can be confused and couldnt be able to understand the theoretical
aspect of the relevant case. So we should practice our theoretical things in a practical
manner. This training was very good opportunity for that.
Page 50
On the other hand if we no the practical situation of some thing then it is very
easy to understand the theoretical aspect of it. That means if we have seen the welding
process before then we can understand the theoretical things quickly.
Other thing is we cant learn every thing from the books. A experienced man
can have a good knowledge. In our training process we found so many persons like
that. We have learned lot of things from them.
In the industrial fields there are so many resources are available and we can
learn lot of things. Also the field is updating at very high speed. That means we can
keep in touch with the new technologies used there.
Most importantly we had lot of chances to visit other industries and learn a lot
and find so many source persons. So these sources are essential to identify the
situation of the current field and the role we have got to do in the future.
References
http://www.techmast-automation.com/aboutus.html
http://www.techmast-automation.com/products.html
http://en.wikipedia.org/wiki/Pneumatics
AIRTAC Pneumatic equipment catalog 2009A
Riko sensor manual
http://en.wikipedia.org/wiki/Time_switch
http://www.allaboutcircuits.com/vol_4/chpt_5/3.html
http://en.wikipedia.org/wiki/Programmable_logic_controller
http://en.wikipedia.org/wiki/Servomechanism
http://sourcing.indiamart.com/engineering/gears-gearboxes/gear-assembly/gearmotor/
Page 51
http://en.wikipedia.org/wiki/Pneumatic_actuator
Appendix A
Pneumatic Circuit of the Nail

Hammer Machine
Page 52
Page 53
Page 54
Appendix B
Relay Circuit Diagram of the

Glove Counting Machine
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Page 56
Appendix C
PLC Programs
Page 57
Page 58
Page 59
Appendix D
Quotation
Page 60
Page 61

Chapter One 1.0 Introduction To The Training Establishment

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Chapter One 1.0 Introduction To The Training Establishment

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Industrial Training Report

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Introduction to the Training Establishment

which provides automation products, consults and provides automation solutions in

Mechanical And Manufacturing Engineering

Industrial Training Report

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Design, Fabrication, Installation & Commissioning of custom-built automated

Vision of the company

Mission of the company

provide, innovative automation technologies, superior quality products and associated

Mechanical And Manufacturing Engineering

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Techmast Automation (Pvt.) Ltd basically consists with three different

Figure 1.1: Organization Structure

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Pneumatic systems are widely used in industrial automation world, because it

Simplicity of Design And Control

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the fluid of hydraulics directly transfers force.

Machines can be designed to be overload safe.

Classification of Pneumatic devices

system by cleaning and lubricating the gas.

give meaningful work output from the system.

the motion. Pneumatic cylinders are examples for pneumatic actuators

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Figure 2.1: Basic Classification of a Pneumatic System

Figure 2.2: Figure of FRL unit

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Figure 2.4: Figure of the inner parts of FRL unit

Flow Controller Units

Direction control valves.

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Figure 2.5: Figure of a spool

Figure 2.6: Figure of a the position of

2/2 way valves

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Figure 2.7: Figure of a 2/2 way valve

Figure 2.8: Figure of symbol

3/2 way valves

Figure 2.9: Figure of a 3/2 way

Figure 2.10: Figure of symbol

5/2 way valves

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Figure 2.11: Figure of a 5/2

Techmast Automation (Pvt.) Ltd | 2011