INDUSTRIAL INTERNSHIP TRAINING AT

BHARAT SANCHAR NIGAM LIMITED,

Thanjavur
REPORT
Submitted by

NIVETHA S
71382104029

In partial fulfillment of the requirements for the award of the degree of

BACHELOR OF ENGINEERING IN
ELECTRONICS AND COMMUNICATION ENGINEERING

SRI RAMAKRISHNA INSTITUTE OF TECHNOLOGY

(An Autonomous Institution)
COIMBATORE -641 010

June, 2023
 COURSE CODE: UIMC001-INTERNSHIP TRAINING

BONAFIDE CERTIFICATE

Certified that this Industrial Internship Training Report titled INDUSTRIAL

INTERNSHIP TRAINING BHARAT SANCHAR NIGAM LIMITED, THANJAVUR is the

bonafide work of Miss.NIVETHA.S who carried out the training work under my supervision.

Certified further, that to the best of my knowledge the work reported here in does not form part of

any other project report or dissertation on the basis of which a degree or award was conferred on an

earlier occasion on this or any other candidate.

[Dr. S.ANILA] [Dr. S. MARY PRAVEENA]

Head Internship Coordinator
Department of ECE Department of ECE

Submitted for the Industrial Internship Training Viva-Voce examination held on

Examiner Examiner Examiner Examiner

 COURSE CODE: UIMC001 INDUSTRIAL INTERNSHIP TRAINING

DECLARATION

I affirm that the Industrial Internship Training report titled “INDUSTRIAL INTERNSHIP

TRAINING At BHARAT SANCHAR NIGAM LIMITED, THANJAVUR” being submitted

in partial fulfillment of the requirements for the award of the Degree of BACHELOR OF

ENGINEERING IN ELECTRONICS AND COMMUNICATION ENGINEERING is the

original work carried out by me. It has not formed the part of any other project work submitted

for award of any degree or diploma, either in this or any other Institution.

NIVETHA.S
71382104029

I certify that the declaration made above by the candidate is true

Dr. S. MARY PRAVEENA

Department of ECE
 IIP - Grading Criteria
The Final Report and the Oral Presentation /viva voice will be graded by the Panel of Faculty Members based on the following scoring rubrics:
Name of Student: THARUN.I Reg.No.: 71382104041 Class: ECE
SCORING RUBRICS FOR INTERNSHIP REPORT
5 4 3 2 1
Organization/ Report format Excellent V. Good Good Satisfactory Poor
1Does the report contain all required parts? Doalfigures, graphs, tables
correctlydrawn,numbered,containtitles/captions,andstronglysupport 5 4 3 2 1
the text?
2Doesthereportofanacceptablelengthconsideringthesubjectmatter 5 4
3 2 1
presented?
Contents
3Doesthereportcontainawellwrittenbriefabstract.Doesthestudent
understand and clearly present in the report the type of the company 5 4
3 2 1
business he worked for, and how the department he worked in contributes
to the successful function of the whole company?
4 Does the student understand the main objective of his internship, and
3 2 1
the relation of his job functions to other functions in the company. 5 4
5DoesthestudentdescribehisInternshipexperiencewithmanydetails.?
Does the student make connections of how he has learned through his 5 4 3 2 1
Internship experience?
6 Does the student identify are as in which he has made a significant
contributiontotheorganization?Doesthepresentmaterialrelevanttothe 5 4 3 2 1
task performed?
7 Does the student provide concise and complete conclusions followed 5 4
3 2 1
from the report?
8.Areappropriatereferencecitationspresented,andareindustrialterms 5 4
3 2 1
and jargon, when used, adequately explained?
Style/Mechanics
9.Isthereportverywellwrittenandfreefromgrammar/spelling mistakes? 5 4 3 2 1
10. Are all sections in order, well-formatted, and readable? In addition,
constructive comments regarding the value of the program will be 5 4 3 2 1
considered.
A. Total Marks( Max 50)
 SCORING RUBRICS FOR IIP PRESENTATION/ VIVA VOCE
5 4 3 2 1
Presentation Excellent V. Good Good Satisfactory Poor
1.Doesthetopicintroduceclearlyandinaninterestingway?Wastheoutlineof 5 4 3 2 1
presentation given?
2.Werethepointsofthepresentationwell-organizedanddevelopedwithsufficient 5
andappropriatedetails?Wasthepresentationsummedupclearlyandeffectively, with 4 3 2 1
key points emphasized?
3. Is the length of presentation within the assigned time limits. Was the delivery 5
4 3 2 1
poised, controlled, and smooth?
Contents
4. Does the student made clear link and connection between ideas? 5 4 3 2 1
5. Is the material included is relevant to the overall purpose, and prepared with 5 4 3 2 1
appropriate amount?
6. The vocabulary of the presentation was appropriate for the topic. A variety of 5
phrases and sentence structures were used. The presentation content was 4 3 2 1
grammatically correct.
7.Visualaidswerecarefullypreparedandsupportedthepresentationeffectively. 5
They clarified and reinforced the spoken message. The aids added impact and interest 4 3 2 1
to the presentation.
Presenter
8.Doesthestudentspeakclearly,loudlyandatagoodpacetoensureaudience 5
comprehension, and the delivery was fluent and expressive? Was the student 4 3 2 1
language correct and fluent?
9. Does the student maintain good eye contact with the audience and is 5
4 3 2 1
appropriately animated (e.g., gestures, moving around, etc.)?
10. Does the student answer questions without/little difficulty? 5
4 3 2 1
Does the student demonstrate very good knowledge of the topic?
B. Total Marks (Max 50)

Category A (max.50 marks ) B (max.50 marks) Total (A+B) (max 100 Marks)

GRADE POINT

Examiner Examiner Examiner Examiner

 ACKNOWLEDGEMENT

My heartfelt thanks are to the personalities for helping us to bring out this internship in a
successful manner.
I would like to express my sincere gratitude and hearty thanks to our beloved Principal
Dr. M. PAULRAJ, for providing guidance and an opportunity to bring out the excellence in the
Internship.
I wish to extend my gratitude to Professor & Head of the Department of In Electronics
and communication Engineering Dr. S. ANILA, for his conscientious guidance and
encouragement.
I like to give my sincere thanks to the Internship Coordinator Dr. S. MARY
PRAVEENA, Associate Professor, Department of Electronics and communication Engineering
for his guidance and support.
I would like to thank the respected Tutors of the Department of Electronics and
communication Engineering for their help to attend the Internship.
I thank my beloved parents for their constant support and blessings. Finally, I wish to
thank, our guide Mr.Senthil kumar, Telecom officer BHARAT SANCHAR NIGAM LIMITED for
allowing me to attend the Internship at BHARAT SANCHAR NIGAM LIMITED , BALAJI
NAGAR, THANJAVUR

1
 2. TABEL OF CONTENT

S.NO PAGE
TOPICS
NUMBER

1 ACKNOWLEDGEMENT 1

2 TABLE OF CONTENT 2

3 LIST OF FIGURES 4

4 LIST OF ABBREVATIONS 5

5 ABSTRACT 6

6 INTRODUCTION 7

i. Company’s Background 7

ii. Training Objectives 8

iii. Student’s Work Assignment 9

7 TELECOM NETWORK 9

i. Call setup 9
ii. Electronic Exchange 11
iii Carrier Room 12
7.3.1 Conventional Leased Line system 13
7.3.2 Managed Leased Line Network 15
ii. Main Distribution Frame 19
iii. 7.4.1 Function of MDF 20
iv. Power Plant 22
v. How a Telecom Exchange Work 22

2
8 Engine and Alternator 23

OMC 24

9 Switching 24

i. Stepper motor system 25

ii. PLC/Stepper motor communication 27
iii. Stepper motor Advantage and Disadvantage 28
10 3 PHASE INDUCTION MOTOR 29
i. 3 phase induction motor system 30
ii. PLC/3 phase induction motor communication 31
iii. 3 phase induction motor Advantages and Disadvantages 35
11 CONCLUSION 36
12 REFERENCES 37

3
4
 3. LIST OF FIGURES:

 Figure 6.1 - COMPANY’S BACKGROUNG

 Figure 6.2 – LOGO OF ARK TECH AUTOMATION SOLUTION Pvt Ltd
 Figure 6.3 – INFRASTRUCTURE OF ARK TECH
 Figure 7.1 – PROGRAMMABLE LOGIC CONTROLLER
 Figure 7.2 - CPU OPERATING CYCLE

 Figure 7.3 - PLC ARCHIETECTURE

 Figure 7.4 - PLC PROGRAMMING SOFTWARE
 Figure 7.5 - PLC SOFTWARE PROGRAMMING USING LOGIC LADDER
 Figure 7.6 - PLC PROGRAMMING USING FLOW CHART
 Figure 7.7 –PLC SOFTWARE
 Figure 7.8 – PROGRAMMABLE RUNG
 Figure 7.9 - SCHNEIDER ELECTRIC SOFTWARE
 Figure 7.10 - PROGRAMMABLE MEMORY
 Figure 8.1 – HUMAN MACHINE INTERFACE
 Figure 9.1 – STEPPER MOTOR
 Figure 9.2 – STEPPER MOTOR SYSTEM
 Figure 9.3 – APPLICATION IN INDUSTRY
 Figure 10.1 – 3PHASE INDUCTION MOTOR
 Figure 10.2 - CIRCUIT DIAGRAM OF PLC
 Figure 10.3 – BLOCK DIAGRAM OF PLC
 Figure 10.4 – NETWORK DIAGRAM
 Figure 10.5 – PIN DIAGRAM

5
 4. LIST OF ABBREVIATIONS

 PLC- Programmable Logic Unit

 PIC- Pulse Input Signal

 BCD- Binary Coded Decimal

 ASCII- American Standard Code for Information Interchange

 SCADA- Supervisory Control And Data Acquisition

 DCS- Distributed Control System

 AUTOM- Automation

 TRIAC- Triode for Alternating Device

 LD- Ladder Diagram

 D/A- Digital to Analog Converter
 VFD - Variable Frequency Drive
 HMI – Human Machine Interface

6
 5. ABSTRACT:

The report presents the summary of the various tasks taken up in the BHARAT
SANCHAR NIGAM LIMITED, Thanjavur, during the Industrial Internship period at the
former industry. The detailed explanation of telecom is taken in both Technical and Non-
technical and activities are presented in the report. In addition to the above mentioned
works, some activities such as live sessions of PLC were also taken up and successfully
completed during the period of internship. The manufacturing and working process of
various equipment and machines which run on Industrial Computers that run on inputs
and sensors were studied. The focus for this detailed steady is provided by their
applications and various types of demo program.

7
 6. INTRODUCTION

6.1 COMPANY PROFILE

Bharat Sanchar Nigam Limited (BSNL) is a central public sector undertaking

headquartered in New Delhi, India. It is under the ownership of the Department of
Telecommunications, Ministry of Communications, Government of India. It was
incorporated on 1 October 2000 by the Government of India. Its top official is
designated as Chairman and Managing Director who is a central government civil
servant of the Indian Communication Finance Service cadre or a central government
engineer of the Indian Telecommunications Service cadre. It provides mobile voice
and internet services through its nationwide telecommunications network across
India. It is the largest government-owned-wireless telecommunications service
provider in India

Type Central Public Sector Undertaking

Industry Telecommunications Founded
Founded September 15,2000; 22 years ago
Headquarters New Delhi, India
Area served India
Key people Ashwini Vaishnaw(Cabinet Minister for Communications)
Pravin Kumar Purwar, ICFS (Chairman & MD)
Services Fixed line telephone,Mobile phone, Broadband
Internet television,IPTV
Revenue ₹18,595 crore (US$2.3 billion) (2020-21)
Operating income Decrease ₹15,499 crore (US$1.9 billion) (2020)
Net income Decrease ₹7,441 crore (US$930 million) (2021)[2]
Total assets Increase ₹133,840 crore (US$17 billion) (2020-21)[2]
Total equity Increase₹32,500 crore (US$4.1 billion) (2020-21)[2]
Owner Department of Telecommunications, Ministry of Communications ,
Government of India
Number of employees 60,104(As on 31 March,2023)
Divisions Bharat Fiber,BSNL Broadband,BSNL Mobile,

8
 Bharat Net,BSNL Towers Limited
Website bsnl.co.in
Subsisidiaries Mahanagar Telephone Nigam Limited

Fig 6.1 Logo of BSNL Fig 6.2 Headquarters of BSNL, New

Delhi, India

HISTORY OF BSNL
Bharat Sanchar Nigam Limited is India's government enterprise and its history can be
traced back to the British India. The foundation of telecom network in India was laid
by the British sometime during the 19th century. During the British era, the first
telegraph line was established between Calcutta and Diamond Harbour in 1850. The
British East India Company started using the telegraph in 1851 and until
1854telegraph lines were laid across the country. In 1854, the telegraph service was
opened to the public and the first telegram was sent from Mumbai to Pune. In 1885,
the Indian Telegraph Act was passed by the British Imperial Legislative Council.
After the bifurcation of Post and Telegraph department in the 1980s, the creation of
Department of Telecom eventually led to the emergence of the government owned
telegraph and telephone enterprise which led to the foundation of BSNL.

For 160 years, BSNL had operated the public telegram service. In 2010 the telex
network between its 182 offices was replaced with the "Web Based Telegram Messaging
System" which relied on internet connections rather than telex lines (which are more
reliable where power outages are more common). This led to a decline in service, and the
company applied the title "diminished service" to telegrams in 2010. Finally on 15 July
2013 the public telegram service was shut down completely

9
 7. TELECOM NETWORK
This section includes brief introduction of how a call is processed when we dial a call
from basic telephone to another basic telephone or from basic to mobile or vice versa.

7.1 CALL SETUP:

 PLC programming is extremely valuable to modern industry for its ability

to minimize the monotony of simplistic work tasks, to simplify wiring and
reduce material costs
 PLC Programming create dynamic, complex routines that outdated methods
such as mechanical relay-based control simply cannot handle, and
especially cannot handle in a cost-effective manner.
 The PLC enables cost-effective solutions to even the smallest and largest of
manufacturers seeking solutions to complex assembly, process control,
testing and manufacturing applications. 

10
 Fig 7.1 Programming Logic Controller

7.2 How does a PLC work?

11
 Fig 7.2 - CPU Operating Cycle

 A PLC’s most important components are its CPU, its I/O modules, and its rack
and power supply.
 The CPU is the brain of the PLC; it handles the mathematical heavy lifting
required to run an automated system at an extreme speed.
 The I/O modules connect the field inputs (the sensory feedback to the
machine) and the outputs (the devices to produce mechanical motion and
other actions) to the rack.
 The rack connects the processor and the I/O modules to pass data between the
two; the power supply supplies the energy to do this. As per the diagram
above, each scan cycle sees the PLC do internal diagnostic checks, check the
inputs, execute the program logic, then update output bits accordingly.
 This process continues as long as the PLC is in run mode.
7.3 PLC Architecture:

12
 Fig 7.3 PLC Architecture

 The term PLC architecture refers to the design specification of the various PLC
hardware and software components and the how they interact with one another to
form the overall PLC system.
 The architecture of a PLC is based on the same principles of that used in
standard computer architecture. However, PLC architecture does differ
because the design is based around providing high reliability, immunity to
harsh industrial environment, ease of maintenance and access to large
amounts of peripheral inputs and outputs.
 If a PLC system is described as having closed architecture it refers to a
proprietary system of hardware and software components that cannot (or is
difficult to) connect to other manufacturers components and software.

 However if a PLC system is described as having open architecture it refers to

the PLC system as having off the shelf components that adhere to a common
standard and are easily connected to other manufacturer’s hardware and
software components. 

13
  The heart of the PLC system is the CPU (Central Processing Unit). It is made
up of a control unit and processor.

 The CPU control unit manages the interaction between the various PLC
hardware components while the CPU processor handles all the number
crunching and program (eg ladder logic) execution.

 Data flow is from the input devices, through the CPU processor and then to

the output devices.
 The CPU processor also exchanges data with the program and data memory.
Once all the data is gathered the program is processed in a cyclic fashion.
 The resulting data flows to the output interface for conditioning and execution
of the output devices.
 The CPU also controls and exchanges data with the communication interface
and devices.

7.4 SOFTWARE PROGRAMS OF PLC:

Programmable logic controllers use a variety of software programming languages for

control. These include:

 Sequential function chart (SFC)

 Function block diagram (FBD)
 Ladder diagram (LD)
 Structured text (ST)
 Instruction list (IL)
 Relay ladder logic (RLL)
 Flow Chart
 C
 BASIC

The IEC 61131-3 programming environment provides support for five languages

specified by the global standard: Sequential Function Chart, Function Block Diagram,
Ladder Diagram, Structured Text, and Instruction List. This allows for multi-vendor
compatibility and multi-language programming.

14
SFC is a graphical language that provides coordination of program sequences, supporting
alternative sequence selections and parallel sequences.

LD is a graphic language for discrete control and interlocking logic. It is completely
compatible with FBD for discrete function control

ST is a text language used for complex mathematical procedures and calculations less
well suited to graphical languages.

IL is a low-level language similar to assembly code. It is used in relatively simple logic
instructions.

Relay Ladder Logic (RLL), or ladder diagrams, is the primary programming language
for programmable logic controllers (PLCs). Ladder logic programming is a graphical
representation of the program designed to look like relay logic.

Flow Chart is a graphical language that describes sequential operations in a controller

sequence or application. It is used to build modular, reusable function libraries.

C is a high level programming language suited to handle the most complex computation,
sequential, and data logging tasks. It is typically developed and debugged on a PC.

BASIC is a high level language used to handle mathematical, sequential, data capturing
and interface functions.

15
 FIG 7.4 PLC Programming software

7.5 HOW TO PROGRAM USING LOGIC LADDER:

The procedure for programming a PLC for a certain application depends on the
type of standard manufacturer software tool and the type of control application. But in
order to give a basic guidance to the students, this article provides a simple approach
of designing control application in PLC programming software, as given below. But
this way of programming doesn’t exactly fit into all the types of programming tools
and control applications.

16
Step 1: Analyse and Get the Idea of Control Application

The primary step to program the PLC is to get the idea for which you are going to
develop an application-based program. If you are driving a line follower robot by the use
of DC motor when the push button is pressed. This status must be displayed by the LED
light when the motor gets turn on. The motor is also attached with a sensor (Here it is
considered as another switch) that detects obstacles, so when this turned on, the motor
should be turned off. And correspondingly, if the motor switched off, the buzzer should
be turned on.

FIG 7.5 PLC programming using logic ladder

Step 2: List All the Conditions and Get the Design using Flowchart

The variables of the above project are M: Motor, A: Input Switch 1, B: Input
Switch 2, LED and Bu: Buzzer, and the designing of the logic is easy with the
implementation of flow chart, which is given below for the above application.

17
 FIG 7.6 PLC programming using flowchart

Step 3: Open and Configure the PLC Programming Software

Open the programming software installed in the PC that comes with PLC
hardware. Select the hardware model of the PLC in the software and configure it with
appropriate input and output modules. Select the ladder language (LD) from the list of the
programming languages, and choose the hardware processor and give a name for the
program.

FIG 7.7 PLC Software

18
Step 4: Add the required rungs and address them

Add the required rungs based on the control application logic and give the address
to the each and every input and outputs.  The ladder logic diagram of the above discussed
example is given below.

FIG 7.8 Programmable Rung

Step 5: Check the Errors and Simulate It

Locate the Online section in the menu bar and select Online. Check for the errors
and make necessary changes after selecting Offline. Again, go online and select the Run
option to simulate it.

Step 6: Download the Program to PLC CPU Memory

After the successful simulation of the program, download the program to CPU by
selecting the download option through a network or communication cable.

19
7.6 SCHNEIDER ELECTRIC SOFTWARE FOR PLC:

 As the brain and nerves of many applications in the industrial world, PLC and
I/O modules must be working at optimal levels to maintain peak performance
in a production facility. At Schneider Electric Industrial Repair Services, they
have the skills to reliably refurbish programmable logic controls (PLC) and
associated input-output modules (I-O or I/O) so that these critical components
function as they should.

 Schneider electric software provides a wide variety of automation products

effective for both simple machines and complex systems. DMC is a Schneider
Electric Alliance Partner with a team of engineering experts available to assist
you with selecting and implementing the proper controls for your solution.

FIG 7.9 Schneider electric software

20
  So Machine is all-in-one software for automating machines and smaller systems.
Engineers can use it for both PLC and HMI development to minimize
development time and cost.
 The highly skilled and experienced technicians that perform PLC and I/O repair
work are backed by engineers that design programs to fully exercise the memory
and functions of each PLC or I/O module tested ensuring the equipment is
restored to proper working order.
 Schneider Electric’s repair service replaces component parts identified as
defective during visual inspection and static testing, as well as components
identified as likely unreliable due to age or indications from our extensive repair
historical database.
 I was really excited to start my PLC Programming which was first ever
engineering cum experiment which I really learnt a lot and Schneider Electric
goes down in a logical Sequence

7.7 Types of PLC modules:

The 3 distinct types of PLC architecture available for use in industrial

automation are known as fixed, modular and distributed. The terminology
surrounding PLC types can vary between PLC manufacturers, especially when
talking about fixed PLCs. There is also crossover between PLC types with some
fixed type PLCs having modular type features and some modular type PLCs having
distributed type features.

21
 FIG 7.10 Programmable memory

TYPES OF MODULES:

 Fixed
 Module
 Distributed

When considering PLC architecture types we can generally say that fixed PLCs are
used for smaller sized, less complex application. Modular PLCs are generally used for
medium sized, more complex applications. Whereas distributed PLCs are used for large
sized, extensive application spread across multiple location.

22
7.8 Advantages and Disadvantages of PLC:

Advantages:
 Troubleshooting is Easier and Faster.
 -Easy to develop Programs by offline simulation
 -Less amount of Space Needed
 -Less Maintenance
 -Easy to Monitor Inputs and Outputs by HMI devices and from PC's

Disadvantages:
 Cost of PLC is high
 PLC'S are designed by semiconductors, which are depends on thermal
characteristics

7.9 Real time Applications:

Glass industry:

PRCs controllers have been in use in the glass industry for decades. They are used
largely to control the material ratio as well as to process flat glasses. The technology has
been advancing over the years and this has created an increased demand for the PLC
control mode for use in the glass industry.

Paper industry:

In the paper industry, PLCs are used in various processes. These include
controlling the machines that produce paper products at high speeds. For instance, a PLC
controls and monitors the production of book pages or newspapers in offset web printing .

23
Cement Manufacturing

Manufacturing cement involves mixing various raw materials in a kiln. The

quality of these raw materials and their proportions significantly impact the quality of the
final product. To ensure the use of the right quality and quantities of raw materials, the
accuracy of data regarding such process variables is of the essence.

Other examples of PLC programming applications that are in use in various

industries today include water tank quenching systems in the aerospace sector, filling
machine control system in the food industry, – industrial batch washing machine
control and closed loop textile shrinkage systems.

8. HUMAN MACHINE INTERFACE:

Today, in every process human is interacting with machines and moreover there is
an increase in human productivity with the interaction between persons and equipment.

“Human Machine Interface is a software application that presents information to

an operator or user about the state of a process, and to accept and implement the
operators control instructions. Typically information is displayed in a graphic format.”

Fig.8.1 Human Machine Interface

24
 Human Machine Interfaces (HMI) enables workers to perform duties with the help
of concise automation equipment via an interface instead of switches and levers. As a
tool for convergence of visual computing and automation control systems, industrial
automation with human machine interface systems usually consists of LCD panels, often
with touch screen capability, mounted on the control consoles of industrial automation
equipment. In industrial automation, human machine interface systems face challenges of
creating scalable HMI product families with varying performance levels, scalable
graphics resolutions and different display type.

8.1 HMI IN PLC WORKING:

Most modern control systems employ a PLC (Programmable Logic Controller) as a means to
control motors, pumps, valves and various other equipment are used in a process. Computer
based HMI (Human Machine Interface) products provide the means by which process personnel
interact with the PLC control system. A well designed combination of PLC’s and HMI’s can be a
solid foundation for your process automation needs.

9. STEPPER MOTOR:

 Engineers rely on motion-control devices to improve efficiencies and

production rates on automated factory floors, or at least maintain them. One
family of such devices, stepper motors, is widely used because of their simple
implementation, attractive price/performance ratio, and high torque at low
speeds.

 In the past, stepper motors couldn’t keep up with servo motors in demanding
applications, but recent advances have greatly upgraded stepper-motor
performance, expanding the areas in which they can make positive differences.
Stepper motors are often used in demanding applications, such as this
packaging machine.

25
 Fig.9.1 Stepper Motor

 Stepper motors generally include a motor, drive, and controller. The motor, a

brushless dc version, moves in equally sized fixed steps during rotation, and
only rotates one step at time. Stepper motors have simple designs and controls,
and don’t require tuning or adjustment. They provide excellent torque at speeds
under 1,000 rpm and are one-half to one-third the cost of comparable servo
systems. Their output torque decreases as their speed (rpm) increases, making
them difficult to operate. Not only that, it’s tough to get useful work out of
them at speeds above 1,000 rpm for dc-powered applications and above 1,500
rpm for ac-powered ones.

9.1 STEPPER MOTOR SYSTEM:

The three main elements of a stepper-motor setup are the motor, controller, and
drive. These three components are used along with a programmable logic controller
(PLC) or a PC, either of which provides supervisory control and coordination among
multiple stepper motors. Most systems are connected to a PLC for supervisory
control.

26
 FIG 9.2 Stepper motor system

CONTROLLER:

The controller accurately regulates the step position, the speed at which the

motor moves from step to step, and the torque generated by the motor. It generates
control signals used by the drive. Stepper controllers can be either open- or closed-
loop. Open-loop controllers do not require feedback from the motor, assuming the
motor is at the commanded step position and producing the desired torque. Closed-
loop controllers use feedback based on the motor load, resulting in performance closer
to a servo motor.
DRIVER:

The drive amplifies and modifies signals from the controller to regulate the

magnitude and direction of the current flow into the motor windings. Thus, it drives
the stepper motor to its desired positions, and holds it there with the desired amount of
torque.

MOTOR:

The stepper motor has several coils that must be energized in a specific

sequence to make the motor rotate through each step. Typical stepper motors move
1.8 degrees per step, which equates to 200 steps per 360-degree revolution. Some
stepper motors move in smaller steps to provide more precise positioning. For
example, at 0.9 degrees per step, there are 400 steps per 360-degree revolution .

27
 FIG 9.3 Application in Industry

Manufacturing processes because of their repeatability, high torque at low speeds,

and minimal required maintenance. Common linear-positioning applications include
conveyers, rail positioning, and X-Y tables.

Stepper motors also work well in rotary-motion applications, thanks to their

versatile mounting options, repeatability, and reliability. Common rotary-motion
applications are indexing tables, cut-to-length machines, and labellers.

9.2 PLC/Stepper-Motor Communication:

 Whether opting for separate components or a combo unit, a PLC or PC is still

needed to provide supervisory control and coordination. Most stepper motors
are paired with a PLC, a design we’ll now examine in detail.
 Automated machines and processes are commonly controlled by PLCs. In
addition to real-time control, PLCs also coordinate all of the controlled
devices, such as motors, valves, and cylinders, and provide functions
including data collection and storage, as well as remote access.
 Interfaces between PLCs and stepper-motor controllers can be either via
individual inputs and outputs hardwired between the two, or through a digital
data link. Hardwired signals require a lot of wiring and corresponding
installation labour, which opens up the possibility of wiring errors.

28
  Digital data links, such as the Ethernet protocol Modbus TCP, only require a
single cable between the PLC and the stepper-motor controller, simplifying
installation. Several stepper-motor controllers can be connected in an Ethernet
network, further reducing wiring.
 Digital communications are more flexible and let new functions be added
simply by reprogramming the PLC and stepper-motor controller, rather than
running new wires. The full gamut of stepper-motor controller functions,
including control, monitoring, and diagnostics, is typically available via the
digital data link, all through a single Ethernet cable.

9.3 ADVANTAGES AND DISADVANTAGES OF PLC:

ADVANTAGES:
1. Stable. Can drive a wide range of frictional and inertial loads.
2. Needs no feedback. The motor is also the position transducer.
3. Inexpensive relative to other motion control systems.
4. Standardized frame size and performance.
5. Plug and play. Easy to setup and use.
6. Safe. If anything breaks, the motor stops.
7. Long life. Bearings are the only wear-out mechanism.
8. Excellent low speed torque. Can drive many loads without gearing.
9. Excellent repeatability. Returns to the same location accurately.
10. Overload safe. Motor cannot be damaged by mechanical overload.

DISADVANTAGES:
1. Low efficiency. Motor draws substantial power regardless of load.
2. Torque drops rapidly with speed (torque is the inverse of speed).
3. Low accuracy. 1:200 at full load, 1:2000 at light loads.
4. Prone to resonances. Requires micro stepping to move smoothly.
5. No feedback to indicate missed steps.
6. Low torque to inertia ratio. Cannot accelerate loads very rapidly.
7. Motor gets very hot in high performance configurations.
8. Motor will not "pick up" after momentary overload.
9. Motor is audibly very noisy at moderate to high speeds.
10. Low output power for size and weight.

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 10. 3 PHASE INDUCTION MOTOR

A 3-phase induction motor is an electric motor that runs on three-phase power. It is a type
of alternating current (AC) motor, and it is one of the most commonly used motors in
industrial settings.

The 3-phase induction motor is a type of asynchronous motor, meaning that it does not
run at a synchronous speed. It relies on the difference in frequency between the stator and
rotor currents to produce torque. The stator is the stationary part of the motor that
contains the windings, and the rotor is the rotating part of the motor.

Fig 10.1 3 Phase Induction Motor

The 3-phase induction motor has a number of advantages, including high efficiency, low
cost, and good performance at both high and low speeds. It is also relatively simple to
construct and maintain.

Overall, the 3-phase induction motor is a reliable and efficient motor that is widely used
in a variety of industrial and commercial applications.

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10.1 3 PHASE INDUCTION MOTOR SYSTEM

A 3-phase induction motor is an electric motor that uses three alternating currents of
different phases to generate a rotating magnetic field. The three phases are used to create
a rotating magnetic field that turns the motor's rotor, which is made up of a series of
conductive windings or bars.

The motor's stator, which is made up of a series of stationary magnetic poles, is

connected to a 3-phase power source. When the current flows through the stator, it
generates a magnetic field that rotates at a specific frequency. This rotating magnetic
field then magnetizes the rotor, causing it to turn at the same frequency as the stator field.

The rotor is connected to a load, such as a pump or fan, which is turned by the motor's
rotation. The speed of the motor's rotation is controlled by the frequency of the power
supply, and the amount of torque the motor can produce is determined by the strength of
the magnetic field.

Fig.10.2 Circuit Diagram of PLC

3-phase induction motors are widely used in industrial and commercial applications due
to their reliability, efficiency, and low cost. They are also commonly used in residential
and small business applications, such as air conditioning units and washing machines.

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10.2 PLC/3 Phase Induction-Motor Communication:

Step 1: Decide the inputs and outputs.

Inputs
 Safety Switch
 Start Pushbutton Switch
 Stop Pushbutton Switch
 MCCB feedback
 Contactor feedback
 Overload relay feedback
Outputs
 Contactor Coil which drives an induction motor
 

Step 2: Decide the PLC

Fig.10.3 Block diagram of PLC

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Step 3: Prepare power and control drawings.

There are MCCB, Contactor, and Overload Relay in the power drawing. We have used
the feedback as NO contact from MCCB, Contactor, and Overload Relay and connected
it to inputs I0.0, I0.1, and I0.2.

There is a safety switch, start pushbutton, and stop pushbutton which is connected to I0.3,
I0.4, and I0.5.

The output Q0.0 is driven to a 24V DC relay and the relay’s NO contact will be used as
the main driver to conduct a contactor coil in the control.

Step 4: Prepare a PLC program

Network1: This network is showing the ready status of the motor, if the MCCB is ON
and the safety switch is in a normal position then the motor is ready to start.
 

Network2: This network shows the start logic for the motor. If there is no error and the
motor is ready to start then when the operator presses the start button from the local panel
it will activate the driver to start the motor.
 

Network3: Whenever the operator presses the stop pushbutton it will deactivate the
driver.
 

Network4: This network stops the driver in the case of contactor malfunction.

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Fig 10.4 Network Diagram

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Network5: This network shows the error status or trip status of the motor due to
excessive current from the overload relay.

Network6: Whenever the operator presses the safety switch or power MCCB goes off
then it will deactivate the driver in this network.

Network7: The status of the driver is transferred to the coil which is the main output of
the PLC.

Fig 10.5 Pin Diagram

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10.3 ADVANTAGES AND DISADVANTAGES OF 3 PHASE
INDUCTION MOTOR

ADVANTAGES
High efficiency: Three-phase induction motors have a high efficiency, typically around
90%. This means that they waste very little energy as heat, which makes them more cost-
effective to operate.

Low maintenance: These motors do not have brushes or commutators, which means
they do not require regular maintenance such as brush replacement. This makes them
very reliable and easy to maintain.

High power factor: Three-phase induction motors have a high power factor, which
means they can effectively use the power supplied to them. This makes them more
efficient and can help to reduce energy costs.

Wide range of sizes and types: Three-phase induction motors are available in a wide
range of sizes and types, making them suitable for a variety of applications.

DISADVANTAGES
Limited starting torque: These motors have limited starting torque, which means they
may not be suitable for applications that require a high starting torque.

Dependence on three-phase power: Three-phase induction motors can only be used

with three-phase power, which may not be available in all locations.

Requires starter: These motors require a starter to get them up and running, which can
add to the initial cost.

Sensitive to voltage imbalance: Three-phase induction motors are sensitive to voltage

imbalances, which can cause them to operate less efficiently or even fail.

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11. CONCLUSION:

I have attended the internship program conducted in ARKTECH SOLUTIONS

PRIVATE LIMITED, Coimbatore. It was great experience in ARK workshop,
Coimbatore. Life is all about learning and we learnt the basics and yet to learn. This
internship training gives a clear idea how a company works. We students should come
out of our student’s life and we should learn to adapt to the industrial situation. In period
of training, I got some ideas and I was excited to work in a company. Making a report on
the work helped me recollect and present my work. So, I conclude by saying that any my
period of 2 weeks at the workshop was well informative and satisfactory.
I hereby thank the management and the principal for giving me the opportunity of
attending the industrial internship training.
Thanks to ARK TECH Workshop for the guidance and teachings.

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12. REFERENCES:

 www.instrumentationtools.com

 www.automationtools.com

 www.autoprimer.com

 www.isre.org

 www.educba.com

 www.soildtech.com

 www.softwaretestingmentoe.com

 www.browerstack.com

 www.arktech.com

 www.grantaautomation.com

 www.automationworld.com

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