TRAINING REPORT SUBMITTED IN FOR THE AWARD OF DEGREE

OF BACHELOR OF TECHNOLOGY IN APPLIED ELECTRONICS AND INSTRUMENTATION

Submitted by:

BHANU MADAN 1209883

SETH JAI PRAKASH MUKUND LAL INSTITUTE OF ENGINEERING AND TECHNOLOGY RADAUR 135133
Affiliated to Kurukshetra University, Kurukshetra Department of APPLIED ELECTRONICS AND INSTRUMENTATION

TRAINING REPORT SUBMITTED IN FOR THE AWARD OF DEGREE

OF BACHELOR OF TECHNOLOGY IN APPLIED ELECTRONICS AND INSTRUMENTATION

Submitted by:

BHANU MADAN 1209883

SETH JAI PRAKASH MUKUND LAL INSTITUTE OF ENGINEERING AND TECHNOLOGY RADAUR 135133
Affiliated to Kurukshetra University, Kurukshetra Department of APPLIED ELECTRONICS AND INSTRUMENTATION

Acknowledgement It gives me immense pleasure in expressing my profound sense of gratitude and indebtedness to my esteem guide Er. Tapsi Arora of Safe eSolution Pvt. Ltd. for her guidance, valuable suggestions and constructive criticism in the preparation of this training work. I am very grateful to H.O.D Mr. RAJAT KAPILA OF AEI Dept., JMIT for giving me the great vision for the training. I am also thankful to all the faculty members of Instrumentation department for the encouragement and helpful guidance. I would like to express my cooperation to friends who constantly helped me in successful completion of my bachelor training work. My esteemed parents have always encouraged me in all endeavors. It is all because of their blessings and good wishes for which I owe a debt of gratitude to them. They also stood by me in difficult times and showed me the right path. I am grateful to God for showering his blessing and helping me in every aspects of my life.

ABOUT THE ORGANISATION

Safe eSolution Pvt. Ltd. is global provider of innovative web & Desktop Software solutions offerings services in Govt. Sector, Education, Finance, and Manufacturing, hotel Industry technology consulting, Data Integration, Data Digitization, Web Marketing, Search Engine Optimization and Business Intelligence solutions since 2006. Safedot Innovative Automation a joint ventures of Safedot eSolution Pvt. Ltd and Innovative Automation. A global software company and Innovative Automation is provider of industrial automation Services. Safedot Innovative Automation is an initiation by a team of dynamic entrepreneurs to provide all kind of automation support at one place. Our highly talented Team of engineers with extensive experience delivers successful solutions to the clients in diverse industries. We believe in delivering total solutions to improve the performance of process control industry and in providing after sales support thats second to none. Automation team has successfully handled a wide range of projects that improves plant profitability by: Increasing production/throughput. Improving Yields and product upgrade. Minimizing Energy requirements. Reducing product variability. Improving process stability.

AUTOMATION Automation is the use of control systems and information technologies reducing the need for human intervention. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly reduces the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience. Automation has had a notable impact in a wide range of highly visible industries beyond manufacturing. Once-ubiquitous telephone operators have been replaced largely by automated telephone switchboards and answering machines. Medical processes such as primary screening in electrocardiography or radiography and laboratory analysis of human genes, sera, cells, and tissues are carried out at much greater speed and accuracy by automated systems. Automated teller machines have reduced the need for bank visits to obtain cash and carry out transactions. In general, automation has been responsible for the shift in the world economy from agrarian to industrial in the 19th century and from industrial to services in the 20th century. Advantages of Automation Replacing human operators in tasks that involve hard physical or monotonous work. Replacing humans in tasks that should be done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc) Making tasks that are beyond the human capabilities such as handling too heavy loads, too large objects, too hot or too cold substances or the requirement to make things too fast or too slow.

Economy improvement. Sometimes and some kinds of automation implies improves in economy of enterprises, society or most of humankind. For example, when an enterprise that has invested in automation technology recovers its investment; when a state or country increases its income due to automation like Germany or Japan in the 20th Century or when the humankind can use the internet which in turn use satellites and other automated engines. Disadvantages of Automation: Technology limits. Current technology is unable to automate all the desired tasks. Unpredictable development costs. The research and development cost of automating a process is difficult to predict accurately beforehand. Since this cost can have a large impact on profitability, it's possible to finish automating a process only to discover that there's no economic advantage in doing so. Initial costs are relatively high. The automation of a new product required a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches. The automation of a plant required a great initial investment too, although this cost is spread in the products to be produced.

PLC BASICS HISTORY In the 1960s and 1970s, industry was beginning to see the need for automation. Industry saw the need to improve quality and increase productivity. Flexibility had also become a major concern. Industry needed to be able to change processes quickly to meet the needs of the consumer. Old ways There was always a huge wiring panel to control the system. Inside the panel there were masses of electromechanical relays. These relays were all hardwired together to make the system work. Hardwiring means that an electrician has to install wires between the connections of the relays. An engineer would design the logic of the system and electricians would be given a blueprint of the logic and would have to wire the components together. Earlier ways The only way to see everything was correct was to run the system. Troubleshooting was done by running the actual system. This was a very time-consuming process. No product could be manufactured while the wiring was being changed and system had to be disabled for wiring changes. This means that all the production personnel associated with that production line were without work until the system was repaired. The control system was based on mechanical relays.

Mechanical devices are usually the weakest links in the systems. Mechanical devices have moving parts that can wear out. If one relay failed, the electrician might have to troubleshoot the whole system again. The system was down again until the problem was found and corrected. Another problem with hardwired logic is that if a change must be made, the system must be shutdown and the panel rewired. If a company decided to change the sequence of operations (even a minor change), it was a major expense and loss of production time while the system was not producing parts.

Need for PLC Due to the disadvantages of the hardwired control panels industry saw the need to replace them and introduce PLCs. Increased competition to manufacturers to improve both quality and Productivity. Flexibility, rapid changeover and reduced downtime became important. Industry realized that a computer could be used for logic instead of hardwired relays. Computer could take the place of huge, costly, inflexible, hardwired control panels. If changes in the system logic or sequence of operations were needed, the program of the computer could be changed instead of rewiring. Imagine eliminating all the downtime associated with wiring changes.

Imagine being able to completely change how a system operated by simply changing the software in the computer. Advantages of PLC High reliability Small space requirements Computing capabilities Reduced costs Ability to withstand harsh environments Expandability What is a PLC ? A programmable logic controller, also called a PLC or programmable Controller, is a computer-type device used to control equipment in an industrial facility. The kinds of equipment that PLCs can control are as varied as industrial facilities themselves. Conveyor systems,food-processing machinery, auto assembly lines.

How PLC helps in removing complexity?

In a traditional industrial control system, all control devices are wired directly to each other according to how the system is supposed to operate. In a PLC system, however, the PLC replaces the wiring between the devices. Thus, instead of being wired directly to each other, all equipment is wired to the PLC. Then, the control program inside the PLC provides the wiring connection between the devices. The control program is the computer program stored in the PLCs memory that tells the PLC whats supposed to be going

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on in the system. The use of a PLC to provide the wiring connections between system devices is called soft wiring. Lets say that a push button is supposed to control the operation of a motor. In a traditional control system, the push button would be wired directly to the motor. In a PLC system, however, both the push button and the motor would be wired to the PLC instead. Then, the PLCs control program would complete the electrical circuit between the two, allowing the button to control the motor.

The soft wiring advantage provided by programmable controllers is tremendous. In fact, it is one of the most important features of PLCs. Soft wiring makes changes in the control system easy and cheap. If you want a device in a PLC system to behave differently or to control a different process element, all you have to do is change the control program. In a traditional system, making this type of change would involve physically changing the wiring between the devices, a costly and timeconsuming process. Lets say that two push buttons, PB1 and PB2, are connected to a PLC. Two pilot lights, PL1 and PL2, are also connected to the PLC. The way these devices are connected now pressing push button PB1 turns on pilot light PL1 and pressing push button PB2 turns on pilot light PL2. Lets say that you want to change this around so that PB1 controls PL2 and PB2 controls PL1. In a traditional system, you would have to rewire the circuit so that the wiring from the first push button goes to the second pilot light and vice versa. However, because these devices are connected to a PLC, making this change is as simple as making a small change in the control program.

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About Inputs and outputs of PLC The input/output (I/O) system is the section of a PLC to which all of the field devices are connected. If the CPU can be thought of as the brains of a PLC, then the I/O system can be thought of as the arms and legs. The I/O system is what actually physically carries out the control commands from the program stored in the PLCs memory. I/O modules are devices with connection terminals to which the field devices are wired. Together, the rack and the I/O modules form the interface between the field devices and the PLC. When set up properly, each I/O module is both securely wired to its corresponding field devices. This creates the physical connection between the field equipment and the PLC. All of the field devices connected to a PLC can be classified in one of two categories: Inputs Outputs Inputs are devices that supply a signal/data to a PLC. Typical examples of inputs are push buttons, switches, and measurement devices. Basically, an input device tells the PLC, that something is happening out hereyou need to check this out & see how it affects the control program. Outputs are devices that await a signal/data from the PLC to perform their control functions. Lights, horns, motors, and valves are all good examples of output devices. These devices stay unaffected, until the PLC says now you need to turn on or youd better open up your valve a little more, etc.

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WHAT IS A CONTROL PROGRAM? The control program is a software program in the PLCs memory. Its what puts the control in a programmable controller. The user or the system designer is usually the one who develops the control program. The control program is made up of things called instructions. Instructions are, in essence, little computer codes that make the inputs and outputs do what you want in order to get the result you need. There are all different kinds of instructions and they can make a PLC do just about anything (add and subtract data, time and count events, compare information, etc.). All you have to do is program the instructions in the proper order and make sure that they are telling the right devices what to do and when to do. If you want the system to act differently, just change the instructions in the control program. Different PLCs offer different kinds of instructions. Thats part of what makes each type of PLC unique. However, all PLCs use two basic types of instructions: Contacts Coils Contacts are instructions that refer to the input conditions to the control program, that is, to the information supplied by the input field devices. Each contact in the control program monitors a certain field device. The contact waits for the input to do something in particular (e.g., turn on, turn off, etc.this all depends on what type of contact it is). A contact is a computer code that monitors the status of an input coil is a computer code that monitors the status of an output. Coils are instructions that refer to the outputs of the control program that is, to what each particular output device is

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supposed to do in the system. Like a contact, each coil also monitors a certain field device. However, unlike a contact, which monitors the field device and then tells the PLC what to do, a coil monitors the PLC control program and then tells the field device what to do. Coil makes the field device to on or off depending upon the PLC instructions. Lets say that turning on the switch is supposed to turn on the light. In this situation, the PLCs control program would contain a contact that examines the input device the wall switch for an on condition and a coil that references the light. When the switch turns on, the contact will energize, meaning that it will tell the PLC that the condition its been looking for has happened. The PLC will relay this information to the coil instruction by energizing it. This will let the coil know that it needs to tell its referenced output the light to turn on. EXAMPLE
On or Off

Contact On or Off?

Contact

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INTRODUCTION TO ZELIO SOFT STARTING THE PROGRAM When the Zelio Soft Program is launched, the following window appears:

Click on Create a new program to start or choose a New in the file menu if the program has already been launched.

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PROGRAMS IN ZELIO SOFT 1. Make a remote control switch which has only one input and one output. Solution:Let I1=Input Q1 - Output

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SIMULATION OF THE PROGRAM

In Simulation Mode, we give a pinch of pulse to Input I1 by right clicking on it. The output glows. When we again right click on I1, the output Q1 is switched off.

Thus it works like a remote control switch.

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2. Make a program of Car parking which counts each car on its entry. No timer is to be used. Solution: Let I1-Sensor outside I2-Sensor inside I3-Sensor inside I4-Sensor outside Q1-Entry Gate open/close Q2-Exit Gate open/close CC1-Counter at the entry gate CC2-Counter at the exit gate.

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SIMULATION OF CAR PARKING

In the above picture, one car has entered as CC1=1. The exit gate is open as Q2 is glowing. In the next step, the car will exit, exit gate Q2 will be closed and the counter CC1=0.

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TWIDO It has 200 Inputs/Outputs Softwares used for Twido are: 1. Twido Suite- For Simulation 2. Twido Soft - Requires hardware for Simulation.

ADDRESSING Input %I0.0.0 The first zero specifies the base controller. The second zero specifies the Rack number. The last zero specifies the pin number. Output %Q0.0.0

Twido Compact All in one product, screw terminal connection 10 compact bases, 10, 16, 24 and 40 I/O, including 6 expandable bases using 4 to 7 digital (different connection methods) or analog I/O modules, together with options: display, real-time clock, memory Supply 24 V DC or 100 240 V AC Modbus, CANopen, Ethernet (integrated on 40 I/O)

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TWIDO SUITE

How to Start the Program You can either start the TwidoSuite Application Launcher: program via the

From the Start Programs Schneider Electric TwidoSuite Application Launcher path OR From the desktop Application Launcher shortcut that has been installed with the program:

Application Launcher Options The Application Launcher constitutes the launch center for the TwidoSuite software suite. The TwidoSuite application comes in several language pairs available from the Schneider Electric download site:

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English-French English-German English-Spanish English-Italian English-Chinese(simplified)

Depending on which language pair you installed, it lets you run TwidoSuite in English (default language) or the other installation language. Use the Application Launcher to start TwidoSuite in:

Programming Mode Monitoring Mode PLC Firmware Update

Additional Features-Use the additional features to:

See whats new?

, .

View the Video Demo

NOTE: By default the Video Demo is shown at TwidoSuite startup. To disable this feature uncheck the box "Show video at startup" at the bottom of the video screen. TwidoSuite Application Launcher The following figure shows an example of the TwidoSuite Application Launcher for the English-French installed language pair.

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Creating a new project in Twido

Click on Create a new project. Give a name to the project. Specify the directory to which the project has to be saved. Then click on Create which is at the bottom left of the screen.

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AC Drive

All electric on motors require a control system. This can be a simple ON/OFF or a complex control system. Over the years, various methods have been tried to exert some control over motors. Some of the types of adjustable speed control that have been used are: Mechanical:- Mechanical methods involve using devices such as brakes, clutches, and gearing to control motor speed. These methods are not particularly efficient. Hydraulic Transmission Control Physically the configuration includes a torque converter. This method is not used widely today: Advantages: infinite speed control and moderate cost Disadvantages: complex installation and high maintenance

Electro-mechanical speed control: - A combination of mechanical and electrical controls is used. This method of control has fallen from current favor, because it is very inefficient:

Advantages: simple and moderate cost, easy to maintain. Disadvantages: discrete incremental control only. Uses wound-rotor motors, which are usually non-stock, creating higher expenses and more maintenance problems. Eddy current:-

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A magnetic clutch is used to adjust motor output speed in infinite increments. It is a simple idea, and it works. However, it is very inefficient and a lot of energy is lost through heat. Advantages: Simple Disadvantages: Poor efficiency and requires cooling, either by water or air.

Electronic speed control (AC Drives) :

Direct electronic controls are used most often to control speed: Advantages: most efficient speed control, low maintenance, most flexible of all control schemes. Disadvantages: can be more expensive at initial purchase, but saves money over time.

Benefits of AC Drives:-Energy savings, particularly for fans and pumps. -Extended equipment life through reduced mechanical stress (belts, bearings). -Elimination of excessive motor inrush current which in turn, extends useful motor life. -Solid state device which has no moving parts or contacts to wear out

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AC Drive Applications:Air Conditioning Fans, Pumps, Compressors Cement Industry : Fans, Kilns, Conveyors Chemical Industry : Pumps, Fans, Mixers, Processing lines, Cranes and harbors Food and Beverage : Mixers, Conveyors, Centrifuges, Ovens, Bottling tables Marine Applications Positioning : Material Handling Conveyors, Hoists,

Metal Industry : Roller tables, Processing lines, Cranes Mining and Mineral Processing : Conveyors, Dredgers, Crushers Oil and Gas Industry : Fans, Pumps, Centrifuges, Compressors Plastic and Rubber Industry Mixers, Extruders, Conveyors, Processing lines Power Plants : Pumps, Fans, Conveyors Printing: Printing Machinery, Winders

Working of AC Drives:AC motor speed is controlled by frequency. An AC drive is a device for controlling the speed of an AC motor by controlling the frequency of the voltage supplied to the motor. It does this by first converting 3 phase 50 Hz AC power to DC power. Then, by various switching mechanisms, it inverts this DC power into a pseudo sine wave 3 phase adjustable frequency alternating current for the connected motor.

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There are two general types of solid state frequency control systems available: six step and pulse width modulator (PWM) control. All of square D AC drives use the pulse width modulator method of frequency control .The two main section of a PWM drive are the converter and the inverter.
AC Lines DC Bus + Motor Loads

Converter
Constant Frequency

Inverter
Adjustable Frequency

Three phase 60 Hz AC power is coming into the converter. The converter typically uses a rectifier (which is a solid state device that changes AC to DC) to change the incoming 60 Hz AC into a rectified DC voltage.

The DC voltage coming out of the converter is ratherDC Voltage rough. AC line Voltage Different types of filtering can be used to smooth (Rectified) out the Rectifier (non-rectified) DC so that it is of a more or less constant voltage value. rectified

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This filtering takes place between the converter and inverter stages. This smoothed DC is sent on to the inverter.
DC Voltage (Non-inverted) V V

AC Voltage (Inverted)

Inverter t t

The inverter section produces an AC output that is fed to the motor. Positive and negative switching occurs within the Inverter that produces groups of voltage pulses. The output frequency of a PWM drive is controlled by applying positive pulses in one half cycle, and negative pulses in the next half cycle. The pulses within each group have varying widths that correspond to voltage values.

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D .C . MOTOR DRIVES INTRODUCTION:The thyristor D.C. drive remains an important speed-controlled industrial drive, especially where the higher maintenance cost associated with the D.C. motor brushes (c.f. induction motor) is tolerable. The controlled (thyristor) rectifier provides a lowimpedance adjustable d.c. voltage for the motor armature, thereby providing speed control. Until the 1960s, the only really satisfactory way of obtaining the variable-voltage D.C. supply needed for speed control of an industrial D.C. motor was to generate it with a D.C. generator. The generator was driven at high speed by an induction motor, and the Weld of the generator was varied in order to vary the generated voltage. The motor/generator (MG) set could be sited remote from the D.C. motor, and multi-drive sites (e.g. steelworks) would have large rooms full of MG sets, one for each variable-speed motor on the plant. Three machines (all of the same power rating) were required for each of these Ward Leonard drives, which was good business for the motor manufacturer. For a brief period in the 1950s they were superseded by grid-controlled mercury arc rectifiers, but these were soon replaced by thyristor converters which were cheaper, higher efficiency (typically over 95%), smaller size, reduced main- tenancy, and faster response to changes in set speed. The disadvantages of rectified supplies are that the waveforms are not pure D.C., that the overload capacity of the converter is very limited, and that a single converter is not capable of regeneration.

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Though no longer pre-eminent, study of the D.C. drive is valuable for several reasons: The structure and operation of the D.C. Drive are reflected in almost all other drives, and lessons learned from the study of the D.C. drive.