PRACTICAL SUMMER TRAINING REPORT

Submitted by:xyz V Semester (Electronics and Communication) Institute of Technology and Management
1

Training

at
MARUTI SUZUKI INDIA LTD.

ACKNOWLEGMENT

I take this opportunity to express my sincere thanks and deep gratitude to all those who extended their whole hearted cooperation and have helped me in completing this project successfully. First of all, I would like to thank Mr. AD BURMAN general manager (people development),HR for giving me an opportunity to do my training in this prestigious organization. Id also like to express my sincere gratitude towards Mr. Vinay Aggarwal, Mr. RP Kala, Mr. Amar Singh for their guidance & help which enabled me to get the required data & information required to finish my assignments Thei r inspiring suggestions and timely guidance enabled me to perceive the various aspects of the projects in a new light. I would also like to thank all senior members and workers of KB Engine Plant Maintenance for having guided and encouraged me throughout the duration of the project. In all I found a congenial work environment in MSIL and the completion of the projects will mark a new beginning for 3 me in the coming years.

OVERVIEW OF THE COMPANY

In 1982,Government of India entered into a joint venture with Suzuki Motor Corporation of Japan.Plant was established at Gurgaon in Haryana.

Brief Introduction

Maruti Suzuki India Limited is publicly listed automaker in India.It is a leading four-wheeler automobile manufacturer in South Asia.

Suzuki Motor Corporation of Japan holds a majority stake in the

company.It is the first company in India to mass produce and sell more than million cars. Manufacturing plant,located some 25km south of New Delhi in Gurgaon,has an installed capacity of 3,50,000 units per annum,with a capability to produce about half a million. Untill recently,18.28% of the company is owned by the Indian government,and 54.2% by suzuki of Japan.

Organization

Chairman

Mr. R.C. Bhargava Managing Director and CEO Mr. Kenichi Ayukawa Directors Mr. Manvinder Singh Banga Mr. Amal Ganguly Director and Managing Executive (production)Mr.Tsuneo Ohashi Over more than 8000 employees work in Maruti Suzuki India Ltd.

Description of PLCS
This training introduces the basic hardware and software components of a Programmable Logic Controller (PLC). It details the architecture and basic instruction set common to all PLCs. Basic programming techniques and logic designs are covered. This training describes the operating features of the PLC, the advantages of the PLC over hard-wired control systems, practical applications, troubleshooting and maintenance of PLCs. A PLC contains a programmable microprocessor that is programmed using a specialized computer language. Typically, the program for the automated process is written on a computer and then is downloaded onto the programmable logic controller directly through a cable connection. The program is stored in the PLC.

Programmable Logic Control

( Definition according to NEMA standard ICS3-1978)

Programmable Logic Controllers

A digitally operating electronic apparatus which uses a programming memory for the internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.

PLC Origin
Developed

to replace relays in the late 1969.

PLCs began in 1970s and has become the most common choice for manufacturing controls.
The PLC was invented in response to the American automotive manufacturing industry(primarily General motors). Costs dropped and became polpular in 1980s. Now used in many industrial designs.
10

Advantages of PLCs:This type of controller has made a significant contribution to factory automation. Earlier automation systems had to use thousands of individual relays, timers and sequencers, which had to be replaced or rewired whenever the automated process needed to change. In many cases, a programmable logic controller allows all of the relays and timers within a factory system to be replaced by a single controller. Modern PLCs deliver a wide range of functionality, including basic relay control, motion control, process control and complex networking.They can also be used in the Distributed Control Systems(DCS).

Thus it can be described in points that the major advantages of PLC are:1.Less wiring 2.Wiring between devices and relay contacts are done in the PLC program. 3. Easier and faster to make changes. 4.Trouble shooting aids make programming easier and reduce downtime. 5.Reliable components make these likely to operate for years before failure.
12

Disadvantages:Too much work required in connecting wires. Difficulty with changes or replacements. Difficulty in finding errors, requiring skillful work force.

13

1968 1969

Programmable concept developed Hardware CPU controller, with logic

instructions, 1 K of memory and 128 I/O points Use of several (multi) processors within a PLC - timers and counters; arithmetic operations; 12 K of memory and 1024 I/O points Remote input/output systems introduced Microprocessors - based PLC introduced
14

1974

1976 1977

Programmable Controller Development

1980

Intelligent I/O modules developed

Enhanced communications facilities Enhanced software features (e.g. documentation) Use of personal microcomputers as programming aids 1983 Low - cost small PLCs introduced 1985 on Networking of all levels of PLC, computer and machine using SCADA software.
15

Leading Brands Of PLC

AMERICAN 1. Allen Bradley 2. Gould Modicon 3. Texas Instruments 4. General Electric 5. Westinghouse 6. Cutter Hammer 7. Square D EUROPEAN 1. Siemens 2. Klockner & Mouller 3. Festo 4. Telemechanique
16

Leading Brands Of PLC:JAPANESE 1. Toshiba 2. Omron 3. Fanuc 4. Mitsubishi

17

APPLICATIONS:-

18

PLC Size
- it covers units with up to 128 I/Os and memories up to 2 Kbytes. - these PLCs are capable of providing simple to advance levels or machine controls. 2. MEDIUM - have up to 2048 I/Os and memories up to 32 Kbytes. 3. LARGE - the most sophisticated units of the PLC family. They have up to 8192 I/Os and memories up to 750 Kbytes. - can control individual production processes or entire plant. 1. SMALL
19

Tank Used to Mix Two Liquids

MOTOR

A
FS

FLOAT SWITCH

SOLENOIDS

SOLENOID

C
TIMER

1 -MINUTE

20

Tank Used to Mix Two Liquids

A tank is used to mix two liquids. The control circuit operates as follows:

When the start button is pressed, solenoids A and B energize. This permits the two liquids to begin filling the tank.
When the tank is filled, the float switch trips. This deenergizes solenoids A and B and starts the motor used to mix the liquids together. The motor is permitted to run for one minute. After one minute has elapsed, the motor turns off and solenoid C energizes to drain the tank.
21

Continued.
When the tank is empty, the float switch de-energizes solenoid C. A stop button can be used to stop the process at any point.

If the motor becomes overloaded, the action of the entire circuit will stop.
Once the circuit has been energized it will continue to operate until it is manually stopped.
22

Major Components of a Common PLC

POWER SUPPLY

From SENSORS
Pushbuttons, contacts, limit switches, etc.

I M N O P D U U T L E

PROCESSOR

O U T P U T

M O D U L E

To OUTPUT
Solenoids, contactors, alarms etc.

PROGRAMMING DEVICE

23

24

Major Components of a Common PLC

POWER SUPPLY Provides the voltage needed to run the primary PLC components

I/O MODULES Provides signal conversion and isolation between the internal logiclevel signals inside the PLC and the fields high level signal.

25

Major Components of a Common PLC

PROCESSOR

Provides intelligence to command and govern the activities of the entire PLC systems.

PROGRAMMING DEVICE
used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine.

26

I/O Module
The I/O interface section of a PLC connects it to external field devices.

The main purpose of the I/O interface is to condition the various signals received from or sent to the external input and output devices. Input modules converts signals from discrete or analog input devices to logic levels acceptable to PLCs processor.
Output modules converts signal from the processor to levels capable of driving the connected discrete or analog output devices.
27

DC INPUT MODULE:IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

USE TO DROP THE VOLTAGE TO LOGIC LEVEL

FROM INPUT DEVICE

Current Limiting Resistor

OPTOISOLATOR

Buffer, Filter, hysteresis Circuits

TO PROCESSOR

28

AC INPUT MODULE:IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

CONVERTS THE AC INPUT TO DC AND DROPS THE VOLTAGE TO LOGIC LEVEL

FROM INPUT DEVICE

Rectifier, Resistor Network

OPTOISOLATOR

Buffer, Filter, Hysteresis Circuits

TO PROCESSOR

29

DC / AC OUTPUT MODULE:IS NEEDED TO: Prevent voltage transients from damaging the processor. Helps reduce the effects of electrical noise

FROM PROCESSOR

TTL Circuits

OPTOISOLATOR

Amplifier RELAY TRIAC XSISTOR

TO OUTPUT DEVICE

30

OUTPUTS

INPUTS
CONTACTOR

MOTOR

LAMP PUSHBUTTONS

PLC

31

Allen-Bradley 1746-1A16 L1 L2

I= Input
I:2
Module slot # in rack

P. B SWITCH

Module Terminal # Address I:2.0/0

LADDER PROGRAM INPUT MODULE WIRING DIAGRAM

32

CONTACTOR

L2

L1

N.O

MOTOR C

L2 L1 FIELD WIRING

SOLENOID VALVES LAMP BUZZER

OUTPUT MODULE WIRING

L1

O:4

L2

CONTACTOR

0
33

LADDER PROGRAM

Discrete Input:A discrete input also referred as digital input is an input that is either ON or OFF are connected to the PLC digital input. In the ON condition it is referred to as logic 1 or a logic high and in the OFF condition maybe referred to as logic o or logic low.
Normally Open Pushbutton Normally Closed Pushbutton Normally Open switch Normally Closed switch Normally Open contact Normally closed contact
34

IN

OFF Logic 0

PLC Input Module

24 V dc

IN

OFF Logic 1

PLC Input Module

24 V dc

35

PLC Operation
Basic Function of a Typical PLC:
Read all field input devices via the input interfaces, execute the user program stored in application memory, then, based on whatever control scheme has been programmed by the user, turn the field output devices on or off, or perform whatever control is necessary for the process application. This process of sequentially reading the inputs, executing the program in memory, and updating the outputs is known as scanning.

36

While the PLC is running, the scanning process includes the following four phases, which are repeated continuously as individual cycles of operation:
PHASE 1

Read Inputs Scan

PHASE 2

Program Execution
PHASE 3

Diagnostics/ Comm
PHASE 4

Output Scan
37

PHASE 1 Input Status scan

A PLC scan cycle begins with the CPU reading the status of its inputs. PHASE 2 Logic Solve/Program Execution The application program is executed using the status of the inputs PHASE 3 Logic Solve/Program Execution Once the program is executed, the CPU performs diagnostics and communication tasks
38

PHASE 4 - Output Status Scan

An output status scan is then performed, whereby the stored output values are sent to actuators and other field output devices. The cycle ends by updating the outputs.

39

As soon as Phase 4 are completed, the entire cycle begins again with Phase 1 input scan. The time it takes to implement a scan cycle is called SCAN TIME. The scan time composed of the program scan time, which is the time required for solving the control program, and the I/O update time, or time required to read inputs and update outputs. The program scan time generally depends on the amount of memory taken by the control program and type of instructions used in the program. The time to make a single scan can vary from 1 ms to 100 ms.
40

Replacing Relay By PLC

FIRST STEP- We have to translate all of the items we are using into symbols that PLC understands Contact Symbol

Coil Symbol
41

SECOND STEP- We must tell the PLC where everything is located. In other words we have to give all devices an address. FINAL STEP- We have to convert the schematic into logical sequence of events.

42

LADDER DIAGRAM AND PROGRAMMING

LOAD- The load (LD) instruction is normally a open contact a load(contact) symbol LOAD BAR- The load bar is normally a closed contact a load bar(normally closed contact) symbol
43

OUT- The out instruction is sometimes also called as output energize instruction. The output instruction is like a relay coil an out(coil) symbol OUT BAR- The out bar is normally a closed relay symbol. an out bar(normally closed relay)symbol
44

45

46

47

48

49

PLC Communications
Common Uses of PLC Communications Ports
Changing

resident PLC programs - uploading/downloading from a supervisory controller (Laptop or desktop computer). Forcing I/O points and memory elements from a remote terminal.
Linking

a PLC into a control hierarchy containing several sizes of PLC and computer.
Monitoring

data and alarms, etc. via printers or Operator Interface Units (OIUs).
50

Serial Communications
PLC communications facilities normally provides serial transmission of information.

Common Standards
RS 232 -

Used in short-distance computer communications, with the majority of computer hardware and peripherals. Has a maximum effective distance of approx. 30 m at 9600 baud.

51

Local Area Network (LAN)

Local Area Network provides a physical link between all devices plus providing overall data exchange management or protocol, ensuring that each device can talk to other machines and understand data received from them. LANs provide the common, high-speed data communications bus which interconnects any or all devices within the local area. LANs are commonly used in business applications to allow several users to share costly software packages and peripheral equipment such as printers and hard disk storage.
52

RS 422 / RS 485 Used

for longer-distance links, often between several PCs in a distributed system. RS 485 can have a maximum distance of about 1000 meters.

53

PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

M a n u f a c t u r e r A lle n B r a d l e y G o u l dM o d ic o n G e n e r a lE l e c t r ic M it s u b i s h i S q u a r eD T e x a sI n s t r u m e n t s N e t w o r k D a t a H i g h w a y M o d b u s G E N e tF a c t o r yL A N M e ls e c N E T S Y / N E T T I W A Y

54

Selecting a PLC
Criteria: Number of logical inputs and outputs. Memory Number of special I/O modules Scan Time Communications Software

A Detailed Design Process

1. Understand the process 2. Hardware/software selection 3. Develop ladder logic 4. Determine scan times and memory requirements

Troubleshooting
1. Look at the process 2. PLC status lights HALT - something has stopped the CPU RUN - the PLC thinks it is OK (and probably is) ERROR - a physical problem has occurred with the PLC 3. Indicator lights on I/O cards and sensors 4. Consult the manuals, or use software if available. 5. Use programming terminal / laptop.

List of items required when working with PLCs:

1. Programming Terminal - laptop or desktop PC. 2. PLC Software. PLC manufacturers have their own specific software and license key. 3. Communication cable for connection from Laptop to PLC. 4. Backup copy of the ladder program (on diskette, CDROM, hard disk, flash memory). If none, upload it from the PLC. 5. Documentation- (PLC manual, Software manual, drawings, ladder program printout, and Seq. of Operations manual.)

Examples of PLC Programming Software:

1. Allen-Bradley Rockwell Software RSLogix500 2. Modicon - Modsoft 3. Omron - Syswin 4. GE-Fanuc Series 6 LogicMaster6 5. Square D- PowerLogic 6. Texas Instruments Simatic 7. Telemecanique Modicon TSX Micro