MAHARASHTRA STATE BOARD OFTECHNICAL EDUCATION (MUMBAI)

Academic Year 2021-22

A
Report
On

Title: “Industrial Training at HBS Automation Systems”

Submitted by:

Mr. Prathamesh Prakash Bari

In partial fulfillment for the award of the Diploma Engineering

IN

Electronics & Telecommunication

At

Department OF Electronics &Telecommunication [FIRST Shift]

K. K. WAGH POLYTECHNIC, NASHIK

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 Maharashtra State Board of Technical Education
Certificate of Completion

Of Industrial Training

This is to certify that Mr.Prathamesh Prakash Bari with Enrollment No.190078004 has
successfully completed Industrial Training (22057) in HBS Automation Systems from
01/08/2021to 31/08/2021 for partial fulfillment towards completion of Diploma in
Electronics & Telecommunication from K.K.Wagh Polytechnic, Nashik.

Institute Code 0078.

Date:

Place: Nashik.

MS.M.N.Shsuryawamshi

Mentor HOD- E&TC Dept

Prof.P.T.Kadave

External Examiner PRINCIPAL

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 ABSTRACT

This Industrial training report presents the experience garnered during my 1 months of industrial training
undertaken at HBS Automation Systems.

My training was on the Automation through PLC of so many examples like Static Weigh Bride Electrical
Control Panel.

During this period, I acquired practical knowledge on how to Automatic any Machine or any System.

This report discusses the technical skills gained during the training period and justifying the relevance of the
scheme in equipping students with needed technical competence to thrive in the real world.

Industrial training is an important phase of a student life. A well planned, properly executed and evaluated
industrial training helps a lot in developing a professional attitude. It develop an awareness of industrial
approach to problem solving, based on a broad understanding of process and mode of operation of organization.
The aim and motivation of this industrial training is to receive discipline, skills, teamwork and technical
knowledge through a proper training environment, which will help me, as a student in the field of Electronics &
Telecommunication Technology, to develop a responsiveness of the self-disciplinary nature of problems.
Throughout this industrial training, During this period, we acquired practical knowledge on how to repair,
replace parts of electronic equipment’s and systems also assisted in providing the units the functionality they
need. This report discusses the technical skills gained during the training period and justifying the relevance of
the scheme in equipping students with needed technical competence to thrive in the real world. The industrial
training duration was four weeks. This commenced from 15th June to 15th July 2020.

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 Acknowledgement

I would like to express my deep sense of gratitude to Mr. Hari Shinde and all other employees for giving me an
opportunity to do training at HSB Automation Systems, Nashik.

We got the good knowledge of trouble shooting and manufacturing of electronic products (like: electronic
panels, CCTV panels, PLC’s etc.) manufactured inHSB Automation Systems. I feel very lucky to undergo
training in such organization. They have shown us right path that we could follow in the future to reach
maximum possible heights in my life.

Finally, I like to thank all the staff member of K. K. Wagh Polytechnic, Nashik for their very good support
during my training.

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What is Industrial Training:
Industrial training refers to the work experience that is relevant to professional development prior to the graduation. In
Industrial training students join the company which is relevant to their intrust and subject and they completed their
training in particular time frame e.g.4 Week, 6 Week etc. Main objective of industrial training is to provide the work
experience to student in particular field, and to provide a certificate for future In classroom students only learn theory and
they don’t know about practical terms. So in industrial training students and trainer also focus on practical terms.

With the help of industrial training students can learn how to work and approach in companies. You can also increase
your personality and behavior.

Importance of Industrial Training:

There is significant importance of industrial training in students’ life. After doing industrial training, you will not only
have the theoretical knowledge of the aspects, but you will learn everything practically by working in the real
environment of an industry. You cannot get the job in the job market only by your theoretical knowledge; no one is going
to listen to your theories. Companies only want you to work productively for them, which you can only do with the help
of industrial training. So, for gaining practical knowledge, industrial training is critical.

Main Purpose of Industrial Training;

Basically, the primary use of industrial training is getting better knowledge. Industrial training is vital for job oriented
opportunities and skills development. Students gain practical experience of working in the industry through practical
industrial training, and when they go for a job, they do not feel any difficulty to work in the industry. Students would learn
to come at a proper time, work with making appropriate worksheets through industrial training. Students do not feel the
pressure of working in the industry when they go for a job in reality.Industrial training is useful for students in many
aspects. This has been specially created to benefit the students of all streams. Significant importance of the industrial
training includes;

1. Students will become fully disciplined employees to work in the industry o company after completing graduation
and post-graduation.
2. Students become skillful employees who are always ready to work when they begin to put their first step in the
industry. It is because students become skillful by the practical industrial training at the institution and get the real
experience of working in the industry.
3. Students become mature in doing the tasks given to them in the actual industrial training.

Student Benefit:
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1. Practical Training of different hardware and software.

2. Expert Faculties.

3. Good track record of executing the turn-key solutions.

4. Fully equipped modern facility.

5. Want to acquire the essential knowledge in the field of industrial automation.

6. Want to upgrade the present level of automation to enhance productivity, quality and safety.

7. Want to minimize dependence on the supplier of automation systems.

8. Want to understand the facts of diversified automation hardware and software of leading manufactures.

9. Want to keep the peace with the latest technology.

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Company Profile:

HBS Automation Systems

HBS Automation Systems, Located in Nashik, established in the year 2012.

Having core competency in Design Engineering, execution and innovative
solutions of automation projects, received wide acceptance and as many
satisfied customers.

Registered Office:
Shop No.22, Sai Industrial Estate, Plot No.7, Additional
MIDC Area, Ambad, Nashik 422010, Maharashtra.
Ph: 0253 6614955, Email: [email protected]
www.hbsnashik.com, https://www.indiamart.com/hbsautomationsystems/

Contact Person: Hari Shinde

Contact No. : 8237031975,
Email: [email protected]

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Year of Establishment: Jan 2012
Type of Company: Proprietary
>Authorized System Integrator: RENU Electronics, Pune
Manufacturing Activity: Electrical Control Panel.
>Trading: PLC, HMI, SCADA, VFD, Servo
>Brands: Siemens, ABB, Mitsubishi
>Customize Software : DotNet Application development for DAQ, Utility
Softwares, Testing tools and mini SCADA.

Last Year Turnover: 1.25 CR

>Manpower: 4 Automation Engineer, 1 Software Engineer

>Work shop & office: 700 sqft (owned)

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Company Structure:
There are two floors.
1. First Floor: On the first floor there is a Workshop. All the Panel’s working is done here and also dispatch the
Panel from here.
2. Second Floor: On the second floor there is Main Office, Meeting Room, and other employee’s cabin.

Entry door of Company:

Company Safety Precautions:

In the HBS Automation Systems, if there is any human injury or damage of fire will occur there is a First aid
Box and Fire Cylinder is available.

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 Actual Training Details:
In Industrial Training we did 2 Panels with Company’s Engineer’s.
1. Panel 1: CCTV Control Panel
2. Panel 2: Water Level Control Pannel

Panel 1: CCTV Control Panel

1. Panel’s Power and Control Wiring:

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2. Instruments Used:
1) PLC:

Description:

Model No. - FL005-0808P

Power - 24 V DC

Digital Input and Outputs – 8

Serial Ports -2 ports - 1 RJ45 / RS232 & 1 RS485

USB Port - 1 port - USB Micro (Device)

In this Panel we used 8x8 PLC. (8 Inputs and 8Outputs).

A programmable logic controller (PLC) or programmable controller is an industrial digital computer which has
been ruggedized and adapted for the control of manufacturing processes, such as assembly lines,
or robotic devices, or any activity that requires high reliability, ease of programming and process fault
diagnosis.
PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a housing integral with the
processor, to large rack-mounted modular devices with a count of thousands of I/O, and which are often
networked to other PLC and SCADA systems.
They can be designed for many arrangements of digital and analog I/O, 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.
PLCs were first developed in the automobile manufacturing industry to provide flexible, rugged and easily
programmable controllers to replace hard-wired relay logic systems. Since then, they have been widely adopted
as high-reliability automation controllers suitable for harsh environments.
A PLC is an example of a "hard" real-time system since output results must be produced in response to input
conditions within a limited time, otherwise unintended operation will result.

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 2) SMPS:

Description:

Model No. – G41-60-12

Input – 230 V AC, 1.0 A, 50/60 Hz

Output – 24 V DC, 5.0 A ( SMPS 1 )

12 V DC, 5.0 A ( SMPS 2 )

In this Panel as per requirement we used 2 SMPS.

1. SMPS 1(24V): For PLC’s number of inputs.
2. SMPS 2(12V): ForPower to the PLC or to run the PLC.
A switched-mode power supply (switching-mode power supply, switch-mode power supply, switched power
supply, SMPS, or switcher) is an electronic power supply that incorporates a switching regulator to convert
electrical power efficiently. Like other power supplies, an SMPS transfers power from a DC or AC source
(often mains power) to DC loads, such as a personal computer, while
converting voltage and current characteristics. Unlike a linear power supply, the pass transistor of a switching-
mode supply continually switches between low-dissipation, full-on and full-off states, and spends very little
time in the high dissipation transitions, which minimizes wasted energy. A hypothetical ideal switched-mode
power supply dissipates no power. Voltage regulation is achieved by varying the ratio of on-to-off time (also
known as duty cycles). In contrast, a linear power supply regulates the output voltage by continually dissipating
power in the pass transistor. This higher power conversion efficiency is an important advantage of a switched-
mode power supply. Switched-mode power supplies may also be substantially smaller and lighter than a linear
supply due to the smaller transformer size and weight.
Switching regulators are used as replacements for linear regulators when higher efficiency, smaller size or
lighter weight are required. They are, however, more complicated; their switching currents can cause electrical
noise problems if not carefully suppressed, and simple designs may have a poor power factor.

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 3) MCB:

Description:

Model No. – 5SL 1P and 5SL 2P

In this Panel we used one 2 Pole MCB and two 1 Pole MCB.
1. 2 Pole MCB is used for Phase and Neutral.
2. 1 Pole MCB’s are used after every SMPS for 12 V and 24 V.
A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from
damage caused by excess current from an overload or short circuit. Its basic function is to interrupt current flow
after a fault is detected. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be
reset (either manually or automatically) to resume normal operation.
Circuit breakers are made in varying sizes, from small devices that protect low-current circuits or individual
household appliance, up to large switchgear designed to protect high voltage circuits feeding an entire city. The
generic function of a circuit breaker, or fuse, as an automatic means of removing power from a faulty system is
often abbreviated as OCPD (Over Current Protection Device).

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 4) Relay Card:

Description:

Model No. – Omron

RLCH8R14

Channel - 8

In this Panel we used 8 Pole Relay. The output of PLC is given to the Relay Card. (For every output of PLC one
uses one relay is used).

A relay is an electrically operated switch. It consists of a set of input terminals for a single or multiple control
signals, and a set of operating contact terminals. The switch may have any number of contacts in
multiple contact forms, such as make contacts, break contacts, or combinations thereof.
Relays are used where it is necessary to control a circuit by an independent low-power signal, or where several
circuits must be controlled by one signal. Relays were first used in long-distance telegraph circuits as signal
repeaters: they refresh the signal coming in from one circuit by transmitting it on another circuit. Relays were
used extensively in telephone exchanges and early computers to perform logical operations.
The traditional form of a relay uses an electromagnet to close or open the contacts, but other operating
principles have been invented, such as in solid-state relays which use semiconductor properties for control
without relying on moving parts. Relays with calibrated operating characteristics and sometimes multiple
operating coils are used to protect electrical circuits from overload or faults; in modern electric power systems
these functions are performed by digital instruments still called protective relays.

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 5) Fan:

Description:

Model No. – REC – 220038 A2 W

Input - 230 V AC, 50 Hz, 0.10 A

In this panel we used axial flow fan. This fan is used to keep cool the instruments which are used in Panel.
A fan is a powered machine used to create flow within a fluid, typically a gas, such as air. A fan consists of a
rotating arrangement of vanes or blades, which act on the air. The rotating assembly of blades and hub is known
as an impeller, rotor, or runner. Usually, it is contained within some form of housing, or case.[1] This may direct
the airflow, or increase safety by preventing objects from contacting the fan blades. Most fans are powered
by electric motors, but other sources of power may be used, including hydraulic motors, hand cranks,
and internal combustion engines.
Axial-flow fans have blades that force air to move parallel to the shaft about which the blades rotate. This type
of fan is used in a wide variety of applications, ranging from small cooling fans for electronics to the giant fans
used in wind tunnels. Axial flow fans are applied in air conditioning and industrial process applications.
Standard axial flow fans have diameters of 300–400 mm or 1,800–2,000 mm and work under pressures up to
800 Pa. Special types of fans are used as low pressure compressor stages in aircraft engines. Examples of 

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 6) Limit Switch:

Description:

Model No. – KLS001X-OA

Input - 230 V AC, 50 Hz, 10 A

Contact – 1 NO, 1 NC

In this Panel we used Limit Switch. When the Panel’s door is closed then the Tube light which in the Panel is
normally off. Nut when we open the door then limit switch released and the Tube Light is turn on.

Limit switches are used to automatically detect or sense the presence of an object or to monitor and indicate
whether the movement limits of that object have been exceeded. The original use for limit switches, as implied
by their name, was to define the limit or endpoint over which an object could travel before being stopped. It was
at this point that the switch was engaged to control the limit of travel.

A standard limit switch used in industrial applications is an electromechanical device that consists of a
mechanical actuator linked to a series of electrical contacts. When an object (sometimes called the target) comes
in physical contact with the actuator, the actuator plunger’s movement results in the electrical contacts within
the switch to either close (for a normally open circuit) or open (for a normally closed circuit) their electrical
connection. Limit switches use the mechanical movement of the actuator plunger to control or change the
electrical switch’s state. Similar devices, such as inductive or capacitive proximity sensors, or photoelectric
sensors, can accomplish the same result without requiring contact with the object. Hence, limit switches are
contact sensors in contrast to these other types of proximity sensing devices. Most limit switches are mechanical
in their operation and contain heavy-duty contacts capable of switching higher currents than those of alternative
proximity sensors.

In the Left Corner of upper side of Panel we can see the Limit Switch.

7) Terminal Block:

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 Description:

Model No. – KLS001X-OA

Input - 230 V AC, 50 Hz, 10 A

Contact – 1 NO, 1 NC

In this Panel we used terminal blocks are:

1. 3 Block: Used for Phase, Neutral and Earthing (This like Input of MCB)
2. 3 Block: Used for Phase, Neutral and Earthing (This like to Output of MCB)
3. 2 Block: Used for 12 V from SMPS
4. 9 Block: Used for 24 V and the Input of PLC
5. 15 Block: Used for PLC’s Output through Relay
6. 3 Block: Used for Communication of PLC to Computer
Single feed products represent the basic type of terminal block, and are used for wire-to-wire connection. Single
feed terminal blocks have one input and one output contact: two distinct wires are fed into either side of the
terminal block and are connected within its housing.

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 8) 3 Pin:

Description:

Model No. – 6A 3 PIN PLUG TOP

Input - 230 V AC, 50 Hz, 6A

In this Panel we used 3 pin plug top which is 6 A, 240 V of capacity.

It is used for to connect the supply from MSEB.

9) 3 Pin Socket Box:

Description:

Model No. – 6A 3 Pin Socket

Input - 230 V AC, 50 Hz, 6A

In this Panel we used 3 pin socket which is 6 A, 240 V of capacity.

When the Panel is on site that time if any problem in Panel at that time we want to used Laptop ( but battery of
laptop is discharge ) to solve this problem then to charge Laptop or any other requirement we given the Extra
Socket with Panel.

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 10) Tube light:

In this Panel we used small LED tube light.

If the on the site there is darkness and at that time if any problem in Panel then we can’t check out the problem
in darkness. So this tube light is given into the Panel which is control by a Limit Switch.

11) Base Plate:

In this Panel we want to used this Base Plate for implementing all the components which are we want to used in
Panel.

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 12) Din Rail:

In this Panel we used the Din rail for hold the components on it. This din rail is fix on the base plate.
As the following picture components hold on it.

13) Cable Tray:

In this Panel we used cable tray as shown in above figure. In the panel so many wire are used that wires for
could not short circuit and to see the Panel like good the cable tray is used in the Panel.
Size – 25 x 25, 25 x 45, 25x 60

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 14) Screw:

M4 M6
In this Panel to fit base plate and other components we used M6 and M4 Screws.

15) Wires:
In this Panel for wiring means connecting the components to each other as per requirement we used 0.5 Sqmm
Wire of Poly cab. This wires are color of Blue, Brown, and Green.

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 16) Tools:
In the industry for making Panel as per requirement we used the tools from this board.

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This is Ferrule Machine. This machine is used to label the Wire, Panel and Components.
Sleeve – 3.2 mm, 3.5 mm, 4.20 mm.

Examples:

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3. How we Start the work?
Ans.
Step 1: As per requirement the engineer’s give order of requiring components, Panel’s body and Base plate.
Step 2: When the order was collected from the delivery boy, we sanitized that material. We check the material
is Ok or not.

Step 3: After the check out of material we start working from Panel’s door. First we put Gaskets on border of
the Panel. For Safety from Water and Dust.

[We learn Parallel Working from this. (Means after

putting gasket on Panel no. 1 then the gasket was
applied to the all Panels)]

Step 4: After putting gasket on all Panel, We attach the Fan on every
Panel’s Body. Connect the door with Panel’s Body.

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 After applying Gasket and attach the Fan:

Step 5:After above work we ready the Base Plate. In this work we drill on the base plate as arrangement of all
components; and attach Din rail and Cable tray on base plate.

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Step 6: We attach the base plate in the Panel’s Body. And also attach the components on Din rail. And start
Wiring as per power and control wiring.

Step 7:After the wiring completed we set the all wires and components to see Panel good.

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Step 8: After arranging we cover the cable tray by its cover.

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Step 9: After completing all work it’s time to upload the Program in the PLC through FlexiSoft Software throup
Communication Cable. The Program is made in this software. After uploading Program we can check the
program is running or not through that software.

Step 10:After uploading Program it’s time to Testing.

Methods of Testing:
1. Continuity Testing:

This test is done by Multimeter. First set knob on Continuity Testing Mode. In this testing we connect the
multimeter’s terminal like shown in above figure. By this testing we get the conclusion that all wires are
connected properly and all wire are Ok to flow the current through them.

2. Final Testing:
After Continuity Testing if all is Ok then turn On the supply and check the voltage is properly coming or not as
per requirement.

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Step 11:After all the work and the Testing the Panel is Ok. And then Panel is ready for going at the Site, means
it’s time to Dispatch the Panel. In this step we clean the Panel, Rapped the Panel and finally it is ready to
dispatch. The dispatcher is keep the Panel whenever it send to the site.
( The dispatcher is any honest Transport System )

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By this below motor we put the Panel from first to ground floor.

Working of Panel:

Weigh-in-motion is a technology that can be used for various private and public purposes (i.e. applications)
related to the weights and axle loads of road and rail vehicles. WIM systems are installed on the road or rail
track or on a vehicle and measure, store and provide data from the traffic flow and/or the specific vehicle. 
Internal Structure Working of Panel:
1. First we apply 230 V MSEB supply to Panel because from any other supply we cannot run the Panel.
2. The 230 V supply is applied to MCB 1 through terminal box. MCB we used for the other components safety.
3. From the MCB 1 the supply is go to SMPS which is used to convert AC into DC. After SMPS the 230 V
supply is converted into 24 V ( SMPS 1 ) and 12 V ( SMPS 2 ).
4. Before the 230 V supply is given to the SMPS 2 the 230 V is given to Tube light, Limit Switch, Fan through
Fuse. The Fan is continuously ON to maintain temperature of Panel. And the Tube Light is operated by motion
of Limit Switch.
5. The 12 V DC is given to the PLC’s power terminal and 24 V DC is given to the PLC’s 8 inputs through MCB
2 for 24 V and MCB 3 for 12 V.
6. After the inputs are given to PLC, The PLC outputs are given to the relay card. Means from the PLC’s
program instructions that are operated by relay switch. ( Means for example, I want turn ON Lamp 3 which is
connected to the output terminal Y03 of PLC; then for turn ON lamp 3 we want to turn ON relay 3 which is
connected to the output terminal Y03 of PLC).
7. And the output of PLC through relay is given to the Terminal Box. At the site as per requirement the site
engineer complete the connections.
8. To communicate the PLC we used communication cable which is connected from PLC to Terminal Box. And
the other connection as per requirement the site engineer complete the remaining connections.

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Photos of working

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Certificate

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Conclusion:
After all the work and the Testing the Panel is Ok. And then Panel is ready for going at the Site.

References :
1. [email protected]
2. www.hbsnashik.com,
3. https://www.indiamart.com/hbsautomationsystems/

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