Automation, embedded systems and Internet of things

CHAPTER 1
INTRODUCTION

Automation is the key to modernization and has been conceptually understood as a way to increase
efficiently and to improve productivity. The process of having machine follow a predetermined sequence of
operation with little or no human labor, using special equipment and devices that perform and control
manufacturing processes is known as automation. The goals of automation are Integration of various aspects
of manufacturing operations to reduce labor cost. The fundamental constituents of any automated process are a
power source, a feedback control mechanism, and a programmable command Automation is used for various
control systems for operating equipment’s such as machinery, processes in factories, boilers and heat-treating
ovens, switching on telephone networks, steering and stabilization of ships, aircraft and other applications
with minimal or reduced human intervention. The biggest benefit of automation is that it saves time; it is also
used to save energy and materials and to improve quality, accuracy and precision. Automation has been
achieved by various means including mechanical, hydraulic, pneumatic, electrical, electronic devices,
programmable logic controllers and computers, usually in combination. Programmable logic controllers are
computer based, solid-state, single processor devices that emulate the behavior of an electric ladder diagram
capable of controlling many types of industrial equipment and entire automated systems. PLCs are usually a
main part of automatic systems in industry. They are very efficient and reliable in applications involving
sequential control and the synchronization of processes and auxiliary elements in the manufacturing, chemical
and process industries. Besides having technological advantages of using PLC, it also decreases the prices in
the advanced level and complex control system.

The Internet of things (IoT) describes physical objects (or groups of such objects) with sensors, processing
ability, software and other technologies that connect and exchange data with other devices and systems over
the Internet or other communications networks. Internet of things has been considered a misnomer because
devices do not need to be connected to the public internet, they only need to be connected to a network and be
individually addressable. An IoT ecosystem consists of web-enabled smart devices that use embedded systems,
such as processors, sensors and communication hardware, to collect, send and act on data they acquire from
their environments
As its name suggests, Embedded means something that is attached to another thing. An embedded system can
be thought of as a computer hardware system having software embedded in it. An embedded system can be an
independent system or it can be a part of a large system. An embedded system is a microcontroller or

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 Automation, embedded systems and Internet of things

microprocessor based system which is designed to perform a specific task. For example, a fire alarm is an
embedded system; it will sense only smoke.

PROBLEM STATEMENT

Every product assembly line has different sector of work. The various machines are PLC powered, which
contains a proximity sensor to detect product. This PLC based machines will help in automating, which will
eliminate the use of Manpower ; thus, resulting in reduction of time consumption. The machines are designed
to perform a defined task based on the application in various industrial sectors.

OBJECTIVES

1. To understand the working mechanism of PLC.

2. To develop an appropriate ladder program using PLC.
3. To simulate the working of output with various conditions given at input.
4. To understand concept of embedded systems and internet of things

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 Automation, embedded systems and Internet of things
CHAPTER 2

ORGANIZATION: REXROTH BOSCH-DSU

The internship is carried out at Centre of competence in Industrial Automation technologies Dayananda
sagar University in collaboration with Bosch Rexroth. The brief description about internship organization
is given below.

BOSCH REXROTH

Bosch Rexroth AG is an engineering firm based in Lohr am Main in Germany. It is the result of a merger on 1
May 2001 between Mannesmann Rexroth AG and the Automation Technology Business Unit of Robert Bosch
GmbH, and is a wholly owned subsidiary of Robert Bosch GmbH.

Bosch Rexroth manufactures products and systems associated with the control and motion of industrial and
mobile equipment. In 2017, the company announced a partnership with Trumpf and Heraeus to build servo
valves using the former's TruPrint 5000 laser powder additive manufacturing machines to build a servo valve.
Bosch Rexroth's slogan is "The Drive & Control Company”.

The company has its roots in 1795, when the Rexroth family established an iron forge. Economical, precise,
safe, and energy efficient: drive and control technology from Bosch Rexroth moves machines and systems of
any size. In 1850 the Rexroth family took over an iron foundry in Lohr, where Bosch Rexroth still has its
headquarters to this day. Another key milestone occurred in 1954 when Rexroth showcased its new hydraulics
product line at Hannover Messe.

Over the years, a succession of innovations followed, from the introduction of drives and control systems, to
mobile electronics, to linear motion and assembly technology. In 1975 Rexroth became part of Mannesmann
AG, then in 2001 Mannesmann Rexroth AG and Bosch Automation Technology merged to form Bosch
Rexroth AG, and it has been part of the Bosch Group ever since. The company bundles global application
experience in the market segments of Mobile Applications, Machinery Applications and Engineering, Factory
Automation, and Renewable Energies to develop innovative components as well as tailored system solutions
and services. Bosch Rexroth offers its customer’s hydraulics, electric drives and controls, pneumatics, gear
technology, and linear motion and assembly technology all from one source.
Centre of Competence for Automation technology at Dayananda Sagar University in collaboration with Bosch
Rexroth was established in 2015 and is now upgraded to Industry 4.0. This Centre of Competence for
automation technologies is now identified as Centre of competence in Industrial Automation technology- A

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 Automation, embedded systems and Internet of things
joint Certificate Centre for training industry personnel.

Bosch Rexroth will now divert the industry customer training, enquiries or leads to Dayananda Sagar
University, SOE (School of Engineering, DSU) and this centre is now, also a regional Joint Certification
Centre. It serves as Centre of competence and skill development. This centre acts as the regional centre in
automation technologies to train the Faculty and Students of nearby colleges – Vocational institutes,
Polytechnics and Engineering in its Region. The technologies dealt in this Centre are Hydraulics, Pneumatics,
PLC (Programmable logic controllers), Sensors, AC Servo drives, and CNC Control systems. For the
accomplishment of repeated jobs automation is required. Automation can be achieved using Programmable
Logic Controllers (PLCs).

DAYANANDA SAGAR UNIVERSITY

DSU is a proud member of the Dayananda Sagar Institutions family. It is founded by Late Sri Dayananda Sagar
in the early sixties. Dayananda Sagar University created by an Act of the Karnataka State in 2014, built on this
adorable legacy and inspired by its own milestones, meeting the needs of quality higher education in this part of
the world. DSU has morphed into global education power house, spread over five campuses, catering to the
education needs of over 17,000 students. Operating under the aegis of the Mahatma Gandhi Vidya Peetha Trust
in Bengaluru, DSI has enabled the transformation of tens of thousands of young Indian and international
citizens into professionals in diverse specializations.

Research, Innovation and Incubation form the core of DSU. It has taken the next logical step: Laying the
foundation to transform the entrepreneurial dream of every young Indian and global citizen into a reality.
Enabling this transformation is the active support of industry leaders, industry bodies and a dedicated 4 lakh
square feet modern ready-to-move-in infrastructure.

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 Automation, embedded systems and Internet of things

CHAPTER 3

METHODOLOGY

INTRODUCTION TO PLC
A Programmable Logic Controller, or PLC, is a ruggedized computer used for industrial automation. These
controllers can automate a specific process, machine function, or even an entire production line. The PLC
receives information from connected sensors or input devices, processes the data, and triggers outputs based on
pre-programmed parameters. Depending on the inputs and outputs, a PLC can monitor and record run-time data
such as machine productivity or operating temperature, automatically start and stop processes, generate alarms
if a machine malfunctions, and more. Programmable Logic Controllers are a flexible and robust control
solution, adaptable to almost any application. PLCs have been gaining popularity on the factory floor and will
probably remain predominant for some time to come. Most of this is because of the advantages they offer. Are
flexible and can be reapplied to control other systems quickly and easily, computational abilities allow more
sophisticated control, reliable components make these likely to operate for years before failure. It is used to
reducing the human control allocation of human sequence given to the technical equipment that is called
Automation. It is used in batch process in chemical, cement, food and paper industries are sequential in nature,
requiring time or event based decisions

Fig 3.1 Rexroth PLC unit

THE ROLE OF PLC IN INDUSTRIAL AUTOMATION

Programmable Controllers are similar to industrial computers. PLCs can work as standalone units that can
continuously monitor and automate a process, specific machine function. PLCs can be networked; such a

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 Automation, embedded systems and Internet of things

network can control an entire production line. PLCs can be adapted to monitor and control many sensors and
actuators; they process electrical signals and use them to carry out pre-programmed commands for almost any
application. PLCs are used in industrial automation to increase reliability, system stability and performance,
minimizing the need for human operators and the chances of human error.

HARDWARE COMONENTS OF PLC

These PLC’s were designed by Rexroth Bosch group which consists of function modules, firmware, software,
on-board I/O and inline I/O. The Automation process programed (via Ladder Diagram) in the PC is transferred
to the PLC via Ethernet cable, which is the TCP (Transfer Communication Protocol), connected to the Profibus
of the PLC to CPU of the PC. This program is encoded, decoded and transmitted to the on-board by the
Profibus of the PLC. This decoded program carries out the automation process based on the inputs and outputs
given. The parts of PLC include profibus which acts as brain of PLC and is situated on top left side of PLC. It
also includes flashcard as memory of PLC and display board which tells about status of PLC. RS232 port is
used for communication between PLC and computer. There are inline modules present on top portion of PLC
and are of four colours-sky blue for digital input, Pink is for digital Output ,green is for analog input and yellow
for analog output. Onboard consists of the digital inputs 24 volts (red-16 in number), digital outputs 0 volts
(blue-16 in number), analog inputs (red-5 in number), Analog outputs (blue-2 in number), the power switch and
meter reading. There are 8 input pins present which are like backup for power source. Master PLC means the
functioning of PLC is independent of other machines and slave PLC means functioning is dependent on other
PLC’s.The Bosch Rexroth PLC is master PLC as the profibus is master

INTRODUCTION TO SOFTWARE

The software used to build the Logic for automation are ‘Indra Works Engineering Software’ and ‘Indra Logic
Software’. IndraWorks is the carrier system for integration of the Bosch Rexroth engineering tools. The PLC
and its associated software IndraWorks, which is a uniform engineering software, allows to solve all of the tasks
with one single software – from project planning and programming to visualization and diagnostics.
IndraWorks is universally available in all of the automation systems as integrated engineering software. Profits
are fast access to all functions and data of the control components and the increased understandability of
individual’s automation solution.

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 Automation, embedded systems and Internet of things
IndraLogic is a complete development environment for the PLC. The IndraLogic PLC software combines all
components from Rexroth to provide integrated solutions with motion and logic control. Using Indra logic, one
can implement all of the centralized and distributed control designs, customized to the industry-specific
requirements. The scalable control, visualization and I/O hardware platforms allow easy, flexible and integrated
automation of the applications. Combined with open communication interfaces, these hardware platforms
provide automation solutions that are also sustainable in the future and allow factory automation with any
degree of freedom. The 3rd generation Sercos [Serial Real-time Communications System] meets all
requirements for a future- oriented machine network – open, consistent and fast. From drives and controls to
I/O peripherals, all automation components are easily combined to form an understandable and capable overall
system. Indra Control L has different controller-based hardware such as CML10, CML20, CML45, etc.

PROCEDURE TO START PLC PROGRAMMING

Firmware environment: Indra works

Programming language (by Bosch Rexroth): Indra Logic language

1. Project Structure:

A project is put into a file named after the project. The first POU (Program Organization Unit)
created in a new project will automatically be named PLC_PRG. The process begins here, and other
POUs can be accessed fromthe same point (program function blocks and functions).

2. Project Set Up:

Firstly, configure PLC in order to check the accuracy of the addresses used in the project. Then
create the POUs needed to solve problem. Now program the POUs in the desired languages. Once
the programming is complete, compile the project and remove errors.

3. Project testing

Once all errors have been removed, activate the simulation, log in to the simulated PLC and "load"
project in the PLC in Online mode. Now open the window with PLC Configuration and test project
for correct sequence. To do this, input variables are entered manually and outputs are observed.

4. Debugging
In case of a programming error one can set breakpoints. If the process stops at such a breakpoint, the
values of all project variables at this point can be examined in time. By working through sequentially
(single step) the logical correctness of program is checked.

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PROBLEM SOLVING

1. Design of Alarm system by sensing various conditions at Input.

CASE 1: If one input is ON nothing happens

INPUT1 is input which is given Input address as %IX0.1-- (true)

OUTPUT 1 is output which is given Output address as %QX0.0--(false)

Fig 3.2 ladder logic 1

CASE 2: If any two inputs are ON, a red light goes ON

INPUT2 is input which is given Input address as %IX0.2 --(true)

INPUT3 is input which is given Input address as %IX0.3 --(true)
REDLIGHT is output which is given Output address as %QX0.1 -- (true)

CASE 3: If any three inputs are ON, an alarm sirens sound

INPUT6 is input which is given Input address as %IX0.6 --(true)
INPUT7 is input which is given Input address as %IX0.7 --(true)
INPUT8 is input which is given Input address as %IX0.8 --(true)
SIREN is output which is given Output address as %QX0.3--(true)

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 Automation, embedded systems and Internet of things
CASE 4:If all are ON, the fire department is notified

INPUT9 is input which is given Input address as %IX1.2 –(true)

INPUT10 is input which is given Input address as %IX1.3 –(true)
INPUT11 is input which is given Input address as %IX1.4 –(true)
INPUT12 is input which is give Input address as %IX1.5–(true)
FIRE DEPT is output which is given Output address as %QX0.4–(true)

Fig 3.3 ladder logic 2

2. In certain process control application a fan is to run only when all of the following conditions are met:
1.Input A is OFF
2.Input B is ON or i/p C is ON, or both B &C are ON
3.Inputs D &E both are ON
4.One or more of inputs F, G, or H is ON

Fig 3.4 ladder logic 3

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FUNCTIONAL BLOCKS USED IN LADDER DIADRAM

The Function Block Diagram (FBD) is a graphical language for programmable logic controller design that can
describe the function between input variables and output variables. A function is described as a set of
elementary blocks. Input and output variables are connected to blocks by connection lines. The PLC
programming is done in IndraLogic software. The programming is carried out using ladder diagram. The main
functional blocks used in ladder diagram are timers, counters and reset blocks. These provide application in
pulse counting, frequency reading, time measurement etc.

DIFFERENT TYPES OF TIMERS

1. On-Delay Timer (Ton): When input (IN) goes high, output (Q) will go high only after
the pre-set time has elapsed. When input goes low, output will also go low immediately.
2. Off-Delay Timer (Toff): When input (IN) becomes high, simultaneously output (Q)
becomes high. When input becomes low, output becomes low after the pre-set time (PT) is
elapsed.
3. Pulse Timer (TP): If input (IN) is low, output (Q) is low. When input goes high, output
will remain high till the pre-set time (PT) & after that it will be reset even if input is high

Fig. 3.5 Different types of timers

PROBLEMS

1. There are 3 mixing devices on a processing line A,B,C. After the process begin mixer-A is to start after
7 seconds elapse, next mixer-B is to start 3.6 second after A. Mixer-C is to start 5 seconds after B. All
then remain ON until a master enable switch is turned off. Write PLC ladder diagram, timing diagram
and realize the same

In the below attached screenshot, the system is Ladder Programmed by using timer

 INPUT is input which is given Input address as %IX0.1

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 Automation, embedded systems and Internet of things
 MIXER A is output which is given Output address as %QX0.1

 MIXER A in the next step becomes the input and the address is %IX0.2

 MIXER B is output which is given Output address as %QX0.2

 MIXER B is input in next step which is given input address as %IX0.3

 MIXER C is output which is given output address as %QX0.3

 T1,T2 and T3 are the timers

Fig 3.6 ladder logic 4

2 Design a PLC ladder diagram to realize the following Timer operation. Write timing diagrams. i) Limited ON
time

Fig 3.7 ladder logic 5

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DIFFERENT TYPES OF COUNTERS

 Down Counter (CTD): When input (CD) has the rising edge, counter value (CV) is
decremented by 1. So, when the counter value becomes equal to the pre-set value (PV) which is
zero, output (Q) becomes high. Some initial value is given to Load which is been shifted to CV.
 UP Counter (CTU): When input (CU) has the rising edge, counter value (CV) is incremented by
1. When CV becomes equal to the pre-set value (PV) which is loaded with some initial value
except zero,output (Q) becomes high. Reset is used to reset the counter value to zero.

 Up-Down Counter (CTUD): It can act as Up Counter as well as Down Count

Fig. 3.8 Different types of counters

RESET BLOCK

The reset block is used to reset the output coil depending on the input given to the reset block so that output for
that particular input in remains off state. It can reset the accumulated value and status bit of a timer or counter.
Either direct input can be given to the reset block or using enable blocks e.g., AND logic block, OR logic block,
XOR logic block etc.

Fig 3.9 Reset block used in ladder diagram

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PROBLEMS

1. Three conveyors feed a main conveyor. The count from each feeder conveyor is fed into an input register in
the PLC. Construct a PLC program to obtain the total count of parts on the main conveyor. Use a time to
update the total every 15 seconds. Design, construct, and test PLC circuits for this process.In the below
attached screenshot, the system is Ladder Programmed by using counter

 INPUT1 is input which is given Input address as %IX0.1

 C1,C2 and C3 are the up counters and T1 is timer

 UPDATE is OUTPUT which is given Output address as %QX0.1

 INPUT 2 is input and the address is %IX0.2

 INPUT 3 is input which is given input address as %IX0.3

 Enable box ADD is added at the output to get the result

Fig 3.10 ladder logic 6

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 Automation, Embedded Systems and Internet of Things

2.In certain process control application when the count reaches 25, a paint spray is to run for 40 seconds.
Design, construct, and test PLC circuits for this process

Fig 3.11 ladder logic 7

3. In certain process control application o/p is ON if the count is less than 34 or more than 41. Implement the
same using PLC ladder diagram

Fig 3.12 ladder logic 8

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 Automation, Embedded Systems and Internet of Things

4.A conveyor is supposed to have exactly 45 parts on it. You have three indicating lights to indicate the
conveyor count status: less than 45, yellow: exactly 45, green: and more than 45, red. The count of parts on the
conveyor is set at 45 each morning by an actual count of parts. There are two sensors on the conveyor, one is
actuated by parts entering the conveyor, and the other is actuated by parts leaving. Design a PLC program to
carry out this process.

Fig 3.13 ladder logic 9

5.Design a ladder program for star/delta logic

By pressing the start push button, main contactor and star contactor are switched on simultaneously. After the
release of start push button, NO contact across the start P.B. acts as a hold on (latching) contact and maintains
the flow of current. As there is a On Delay Timer in series with the delta contactor, it gets switched on
after the time delay specified. So after the pre-set time the delta contactor is switched on and star
contactor is switched off as the NC contact of delta contactor becomes NO. Finally, the motor is operated
through main and delta contactor. Stop push button/Emg. Stop push button is used to switch off the motor or
stop the entire operation

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Fig 3.14 exercise template for star/delta logic

Fig 3.15 description of variables

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Fig 3.16 ladder logic 10

6. Tank filling device simulator consists of 3 tanks that are equipped with signal encoders. The tank
filling device simulator is switched on using the S1 pushbutton “Start”. For switching the device
simulator off, the S2 pushbutton “Stop” is used. For the "Max" (full) notifications, the signal encoders
S3, S5 and S7 are used. For the "Min" (empty) notifications, the signal encoders S4, S6 and S8 are
used. The storage tanks can be arbitrarily filled and emptied by hand. For the filling, the valves Y1, Y2
and Y3 are used. A control is to secure that after an "Min" (empty) notification occurred, only 1 tank
can be filled. The filling of the tank continues until the corresponding "Max" (full) notification has
occurred.

Fig 3.17 description of variables

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Automation, embedded systems and Internet of things

Fig 3.18 exercise template for tank filling device simulator

Fig 3.19 ladder logic 11

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SENSORS AND PROCESS CONTROL INSTRUMENTATION

Automation is process that involves various parameters that affect the functioning of the machine. The
fundamental among them are listed below.
Fundamental Process Parameters
 Temperature
 Flow
 Pressure
 Level

These four parameters affect every machining and production sectors. Thus they are considered as the
fundamental parameters of the processing activity.
The sensors that perform the task of sensing and measuring the fundamental process parameters can be
listed as follows.
1. Temperature transducers
 Thermometer - it provides mechanical output as the temperature reading.
 Bi-metallic strip or thermostat - it provides mechanical output.
 Thermocouple - it provides electrical output in mV.
 Thermistor - it provides electrical output in k ohm.
 Resistance temperature detector (RTD) - it provides electrical output in ohm.
2. Flowrate sensors
 Venturi sensors
 Oriffice
 Flow nozzle
 Rotameter
3. Pressure sensor
 Diaphragm
 Bellows
 U-tube manometer - it provides mechanical output.
4. Level sensors
 Capacitance based level sensor

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FEEDBACK CONTROL SYSTEM

The feedback is an electric signal which is transferred from the output to the controller, so the controller
would be able to calculate how the output is different from the required value. The controller would know
the past state of the system output with the help of this feedback signal. The controller would calculate the
error and it would vary the system input to get the required output. The closed-loop system is also called a
feedback system because it fed back the output into the input so that the errors can be cleared and the
required output quality can be maintained. The feedback control is to remove the measured disturbances.
The feedback controls are automated and it should do the sensing, calculating, and manipulating to be
performed by the equipment, and that each element must communicate with the other elements in the
control system.

In a control system, a feedback loop is an important tool, the feedback loop will consider the system
output and this will help the system to alter its operation in order to get the required output. In order to
do this task, a system should have controllers, compensators, and feedback structures to the system. The
feedback control system is composed of sensors, controllers, process systems, etc. The major components
of a feedback control system are input, the process which is being controlled, output, sensing elements,
controllers, and actuating devices. The feedback control would only need minimal knowledge of the
process that is to be controlled. The feedback control can be considered as the easy way to automate the
control of a process. The sensors in the control system would measure the actual value of the controlled
variable. So after measuring the value it will be transmitted to the feedback controller. The controller
would compare the measured value to the desired value and the difference between these values is
considered as error. So if there is an error then the controller would send a proportional output to the
control value. The controller would send a signal to the plant and sets the process variable, according to
the set point. So in case if there is a disturbance that affects the process variable of the plant then the
sensor in the feedback section would detect this and sends a signal to the controller.

Fig 3.20 feedback control system

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CONTROLLER AND ITS TYPES

In control systems, a controller is a mechanism that seeks to minimize the difference between the actual
value of a system (i.e. the process variable) and the desired value of the system
Types of controller
 Proportional controller: the output is directly proportional to the error signal. For a proportional
controller, there are two conditions and these are written below: The deviation should not be large;
i.e. there should not be a large deviation between the input and output and the deviation should not be
sudden.
 Proportional and Integral Controller-As the name suggests it is a combination of proportional and an
integral controller the output is equal to the summation of proportional and integral of the error
signal.
 proportional and derivative controller-output is directly proportional to the summation of
proportional of error and differentiation of the error signal

ADC and DAC an analog-to-digital converter is a system that converts an analog signal, such as a sound
picked up by a microphone or light entering a digital camera, into a digital signal. An ADC works
by sampling the value of the input at discrete intervals in time. In electronics, a digital-to-analog
converter is a system that converts a digital signal into an analog signal. We use hold circuit in DAC.

SIGNAL CONDITIONING DEVICES

Signal conditioning is the manipulation of an analog signal in such a way that it meets the requirements
of the next stage for further processing.
 Filters-In signal processing, a filter is a device or process that removes some unwanted components
or features from a signal.
 Amplification-Signal amplification performs two important functions: increases the resolution of the
input signal, and increases its signal-to-noise ratio. Commonly used amplifiers used for signal
conditioning include sample and hold amplifiers, peak detectors, log amplifiers, antilog amplifiers,
instrumentation amplifiers and programmable gain amplifiers.
 Current-to-voltage converters scale and convert current signal input to the desired output voltage
range.
 Voltage-to-frequency converters accept a voltage signal and convert its analog level to a signal with a
corresponding frequency.

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 Automation, embedded systems and Internet of things

 Frequency-to-voltage converters accept a signal and convert its frequency to a corresponding analog
voltage level
 Analog-to-Digital Converter - An analog-to-digital (ADC) converter is a device that accepts, as
input, an analog signal and at the output, produces an equivalent digital signal. Digital-to-Analog
Converter A digital-to-analog (DAC) converter produces the reverse operation of an ADC.

PROBLEM SOLVING
The Ladder logic for the automation process can be built up using various platforms. Another platform
for creating the ladder logic has been the virtual labs.

1. There are two machines, each with its own start-stop button. Only one may run at a time. Develop the
Ladder logic.

Fig 3.21 ladder logic 12

2. A motor and a lubricating pump are on at the same time. When both are switched off, the scenario of
‘cost motor down’ is observed. The lubricating pump must supply the lubrication oil to the motor during
the ‘cost down time’ of 20 seconds. Develop a Ladder logic for the above description

Fig 3.22 ladder logic 13

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EMBEDDED SYSTEM AND IOT

An embedded system is a microcontroller or microprocessor based system which is designed to

perform a specific task. For example, a fire alarm is an embedded system; it will sense only smoke. An
embedded system has three components

 It has hardware.

 It has application software.

It has Real Time Operating system (RTOS) that supervises the application software and provide
mechanism to let the processor run a process as per scheduling by following a plan to control the
latencies.

1. RISC Processor
RISC stands for Reduced Instruction Set Computer Processor, microprocessor architecture with a simple
collection and highly customized set of instructions. It is built to minimize the instruction execution time
by optimizing and limiting the number of instructions. Examples of RISC processors are SUN's SPARC,
PowerPC

2. CISC Processor
The CISC Stands for Complex Instruction Set Computer, developed by the Intel. It has a large collection
of complex instructions that range from simple to very complex and specialized in the assembly language
level, which takes a long time to execute the instructions. So, CISC approaches reducing the number of
instruction on each program and ignoring the number of cycles per instruction. It emphasizes to build
complex instructions directly in the hardware because the hardware is always faster than software.
Examples of CISC processors are VAX, AMD, Intel x86.

3.ARM PROCESSOR
ARM processors are a family of central processing units (CPUs) based on a reduced instruction set
computer (RISC) architecture. ARM architectures represent a different approach to how the hardware for
a system is designed when compared to more familiar server architectures like x86. Acorn Computers
first developed the Arm processor in the 1980s. Until recently, the name Arm was treated as an
acronym, ARM, which at first stood for Acorn RISC Machine and then for Advanced RISC
Machine. Due to their low costs, minimal power consumption, and lower heat generation than their
competitors, ARM processors are desirable for light, portable, battery-powered devices,

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including smartphones, laptops and tablet computers, and other embedded systems.

MICROPROCESSOR AND MICROCONTROLLER

Microprocessor is a controlling unit of a micro-computer, fabricated on a small chip capable of
performing ALU (Arithmetic Logical Unit) operations and communicating with the other devices
connected to it.Microprocessor consists of an ALU, register array, and a control unit. ALU performs
arithmetical and logical operations on the data received from the memory or an input device. Register
array consists of registers identified by letters like B, C, D, E, H, L and accumulator. The control unit
controls the flow of data and instructions within the computer.

A microcontroller is a compact integrated circuit designed to govern a specific operation in an embedded

system. A typical microcontroller includes a processor, memory and input/output (I/O) peripherals on a
single chip. Sometimes referred to as an embedded controller or microcontroller unit (MCU),
microcontrollers are found in vehicles, robots, office machines, medical devices, mobile radio
transceivers, vending machines and home appliances, among other devices. They are essentially simple
miniature personal computers (PCs) designed to control small features of a larger component, without a
complex front-end operating system (OS).

INTERNET OF THINGS
The Internet of things (IoT) describes physical objects (or groups of such objects) with sensors,
processing ability, software and other technologies that connect and exchange data with other devices and
systems over the Internet or other communications networks. Internet of things has been considered
a misnomer because devices do not need to be connected to the public internet, they only need to be
connected to a networkand be individually addressable. The connected “smart home” is a prime example
of the Internet of Things in action.
An IoT system consists of sensors/devices which “talk” to the cloud through some kind of connectivity.
Once the data gets to the cloud, software processes it and then might decide to perform an action, such
as sending an alert or automatically adjusting the sensors/devices without the need for the user. But if the
user input is needed or if the user simply wants to check in on the system, a user interface allows them to
do so. Any adjustments or actions that the user makes are then sent in the opposite direction through the
system: from the user interface, to the cloud, and back to the sensors/devices to make some kind of
change.

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IOT APPLICATIONS
 Smart Homes
 Smart City
 Self-driven Cars
 IoT Retail Shops
 Farming
 Wearables
 Smart Grids

SENSORS AND ITS TYPES

A sensor is a device that measures physical input from its environment and converts it into data that can
be interpreted by either a human or a machine. The input can be light, heat, motion, moisture, pressure
or any number of other environmental phenomena. The output is generally a signal that is converted to a
human-readable display at the sensor location or transmitted electronically over a network for reading or
further processing. Sensors play a pivotal role in the internet of things (IoT). They make it possible to
create an ecosystem for collecting and processing data about a specific environment so it can be
monitored, managed and controlled more easily and efficiently. IoT sensors are used in homes, out in
the field, in automobiles, on airplanes, in industrial settings and in other environments

1. ULTRASONIC SENSOR

An ultrasonic sensor is an electronic device that measures the distance of a target object by
emitting ultrasonic sound waves and converts the reflected sound into an electrical signal. Ultrasonic
sensors have two main components: the transmitter (which emits the sound using piezoelectric crystals)
and the receiver (which encounters the sound after it has traveled to and from the target). An ultrasonic
sensor emits a sound pulse in the ultrasonic range. This sound pulse propagates at the speed of sound
through air (about 344 meters per second) until the sound pulse encounters an object. The sound pulse
bounces off the object and is returned in reverse to the sensor where this "echo" is received. By
measuring the time it takes for the sound pulse to travel from sensor to object and back to the sensor.
The distance to the object can be calculated very accurately. This measuring principle is also called
"Time of Flight", or transit time measurement. The distance can be calculated with the following
formula: Distance L = 1/2 × T × C, where L is the distance, T is the time between the emission and
reception, and C is the sonic speed. Ultrasonic sensors are used primarily as proximity sensors. They can
be found in automobile self-parking technology and anti-collision safety systems. Ultrasonic sensors are
also used in robotic obstacle detection systems, as well as manufacturing technology.

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2. GAS SENSOR

A gas sensor is a device which detects the presence or concentration of gases in the atmosphere. Based
on the concentration of the gas the sensor produces a corresponding potential difference by changing the
resistance of the material inside the sensor, which can be measured as output voltage. Based on this
voltage value the type and concentration of the gas can be estimated. It works on the principle of
transforming the gas adsorption effects on the surface of the active material into a detectable signal.
3. LIGHT SENSORS

A light sensor is a photoelectric device that converts light energy (photons) detected to electrical
energy. Different types of light sensors are available, mainly Photoresistors, Photodiodes, and
Phototransistors. Light sensors work by the photoelectric effect.

4. SOIL MOISTURE SENSOR

The soil moisture sensor is one kind of sensor used to gauge the volumetric content of water within the
soil. As the straight gravimetric dimension of soil moisture needs eliminating, drying, as well as sample
weighting. These sensors measure the volumetric water content not directly with the help of some other
rules of soil like dielectric constant, electrical resistance, otherwise interaction with neutrons, and
replacement of the moisture content. The applications of moisture sensor include the following-
Agriculture, Landscape irrigation, Research, Simple sensors for gardeners.

5. HUMIDITY SENSOR

A humidity sensor is an electronic device that measures the humidity in its environment and converts its
findings into a corresponding electrical signal. Humidity sensors vary widely in size and functionality;
some humidity sensors can be found in handheld devices (such as smartphones), while others are
integrated into larger embedded systems (such as air quality monitoring systems). Humidity sensors are
commonly used in the meteorology, medical, automobile, HVAC and manufacturing industries. Relative
humidity sensors usually contain a humidity sensing element along with a thermistor to measure
temperature.
6. RASPBERRY PI

Raspberry Pi is a series of small single-board computers (SBCs) developed in the United Kingdom by
the Raspberry Pi Foundation in association with Broadcom. There are three series of Raspberry Pi, and
several generations of each have been released. Raspberry Pi SBCs feature a Broadcom system on a

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chip (SoC) with an integrated ARM-compatible central processing unit (CPU) and on-chip graphics
processing unit (GPU), while Raspberry Pi Pico has a RP2040 system on chip with an integrated ARM-
compatible central processing uniThere have been many generations of the Raspberry Pi line: from Pi 1
to 4, and even a Pi 400. There has generally been a Model A and a Model B of most generations. Model
A has been a less expensive variant, and tends to have reduced RAM and fewer ports (such as USB and
Ethernet). The Pi Zero is a spinoff of the original (Pi 1) generation, made even smaller and cheaper

MULTISIM
Laboratory Virtual Instrument Engineering Workbench is a system-design platform and development
environment for a visual programming language from National Instruments. Labview is a graphical
programming environment engineers use to develop automated research, validation, and production test
systems.Multisim is industry standard SPICE simulation and circuit design software for analog, digital
and power electronics in education and research

Fig 3.23 half wave rectifier using multisim

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INDUSTRIAL VISIT TO BWSSB WATER TREATMENT PLANT

Fig 3.24 water treatment plant

An industrial visit was done to ‘Bangalore water supply and sewage board (BWSSB) was organised.
The plant in-charge briefed the on plant’s history and highlighted that it is water purification plant with
5 stages of purification and pumping along with conventional and latest technology as its unique and
exclusive mode. It is spread across 25 acres.

Water treatment process begins by chlorinating of water to the required level. As chlorine is a
dangerous gas it is stored in big tanks and any leakage of chlorine is absorbed and detected by chlorine
leak absorption system. In case of any leakage of chlorine gas in any space, the alarm notifies the
respective department. The department has to arrest the leakage within a time span of 5 minutes else
there would be serious consequences. The air direction indicator is installed at the top of the building
to know the direction of gas flow. If there is chlorine leakage, the gas flows in the direction of wind
flow. This helps the people and staff around to know the gas flow direction and they can run in the
opposite direction of wind flow and assemble at the safe assembly point.

Aeration is the first step in water treatment process. Raw water is made to fall over series of steps.
Water mixes with atmospheric air and gets aerated hence absorbs oxygen for the reduction of taste and
odour.it also helps in removal of dissolved gases like carbon dioxide and metals like iron, hydrogen
etc.First chorine gas is diffused into the water. Difussing the gas into the water, from the bottom of
water level, helps in proper mixing of Cl with water and avoids its spreading into air. Adding of Cl
removes the dirt materials in the water by sedimenting the dirt, and kills the micro-organisms. Then
alum is added to water. Alum helps in coagulation of smaller dirt material over the water surface.in the
next step both chlorine and alum is added again to ensure proper mixing of these elements in raw water
and this guarantees removal of dirt particles. The water is then let to flow over certain distance and

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carried on to Dissolved Air Floatation (DAF) block.DAF is a water treatment process that clarifies
waste water by removal of oils or solids.this is achevied by dissolving air in water under pressure and
then reelasing it at atmospheric pressure.the released air forms tiny air bubbles which stick to
suspended matter where it may be removed by skimming device.the flow of water to certain distance
allows the dirt to float over the water surface. Then the dirt over the water surface is removed and the
clear water is carried forward for the further treatment.

The flow of this water over a certain distance allows the dirt to float over the water surface. the dirt
over the water surface is removed and the bottom clear water is carried forward for the further
treatment. Next stage of treatment is bed treatment, wherein, the water is placed in the sand beds over
large surface regions over a period of time. This process filters all the remaining dirt particles. there
are totally 24 beds, each bed comprising of 25 MLD water for treatment. This process gives
completely purified water, after completion of which the purified water is passed on to the supply
chamber.

When the sand becomes dirty the filters/bed must be cleaned and washed by forced movement of water
and compressed air. This process is called back washing. The cleaned water is now diverted to pump
house where it gets supplied to the consumers.

NATIONAL CONFERENCE ON ARTIFICIAL INTELLIGENCE AND MACHINE

LEARNING FOR ELECTRONICS, CONTROL AND AUTOMATION

1.Speaker - Mr. Sunil T Shambhatnavar

Artificial intelligence (AI) refers to the simulation of human intelligence in machines that are
programmed to think like humans and mimic their actions. The term may also be applied to any
machine that exhibits traits associated with a human mind such as learning and problem-solving.

The ideal characteristic of artificial intelligence is its ability to rationalize and take actions that have
the best chance of achieving a specific goal. A subset of artificial intelligence is machine
learning (ML), which refers to the concept that computer programs can automatically learn from and
adapt to new data without being assisted by humans. Deep learning techniques enable this automatic
learning through the absorption of huge amounts of unstructured data such as text, images, or video.

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CHARACTERISTICS OF AI

 AI adds intelligence to existing products

 AI adapts through progressive learning algorithms to let the data do the programming.
 AI achieves incredible accuracy through deep neural networks.
 AI automates repetitive learning and discovery through data.
TYPES
 Artificial narrow intelligence (ANI) – it has a narrow range of abilities;
 Artificial general intelligence (AGI) - it is on par with human capabilities;
 Artificial superintelligence (ASI) - it is more capable than a human
APPLICATIONS

 AI in healthcare. The biggest bets are on improving patient outcomes and reducing costs.
Companies are applying machine learning to make better and faster diagnoses than humans.
One of the best-known healthcare technologies is IBM Watson. It understands natural
language and can respond to questions asked of it. The system mines patient data and other
available data sources to form a hypothesis, which it then presents with a confidence scoring
schema. Other AI applications include using online virtual health assistants and chatbots to
help patients and healthcare customers find medical information, schedule appointments,
understand the billing process and complete other administrative processes. An array of AI
technologies is also being used to predict, fight and understand pandemics such as COVID-
19.

 AI in business. Machine learning algorithms are being integrated into analytics and
customer relationship management (CRM) platforms to uncover information on how to
better serve customers. Chatbots have been incorporated into websites to provide immediate
service to customers. Automation of job positions has also become a talking point among
academics and IT analysts.

 AI in education. AI can automate grading, giving educators more time. It can assess students
and adapt to their needs, helping them work at their own pace. AI tutors can provide
additional support to students, ensuring they stay on track. And it could change where and
how students learn, perhaps even replacing some teachers.

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 AI in finance. AI in personal finance applications, such as Intuit Mint or TurboTax, is

disrupting financial institutions. Applications such as these collect personal data and provide
financial advice. Other programs, such as IBM Watson, have been applied to the process of
buying a home. Today, artificial intelligence software performs much of the trading on Wall
Street.

INTERNET OF THINGS

The Internet of things (IoT) describes physical objects (or groups of such objects) with sensors,
processing ability, software and other technologies that connect and exchange data with other devices
and systems over the Internet or other communications networks. Internet of things has been
considered a misnomer because devices do not need to be connected to the public internet, they only
need to be connected to a network and be individually addressable

2.SPEAKER: Mr. Jayaprakash. K

DIGITAL TWIN

A digital twin is a digital representation of a physical object, process or service. A digital twin can be a
digital replica of an object in the physical world, such as a jet engine or wind farms, or even larger
items such as buildings or even whole cities. As well as physical assets, the digital twin technology can
be used to replicate processes in order to collect data to predict how they will perform.

The life of a digital twin begins with experts in applied mathematics or data science researching the
physics and operational data of a physical object or system in order to develop a mathematical model
that simulates the original. The developers who create digital twins ensure that the virtual computer
model can receive feedback from sensors that gather data from the real world version. This lets the
digital version mimic and simulate what is happening with the original version in real time, creating
opportunities to gather insights into performance and any potential problems. A digital twin can be as
complex or as simple as you require, with differing amounts of data determining how precisely the
model simulates the real world physical version. The twin can be used with a prototype to offer
feedback on the product as it is developed or can even act as a prototype in its own right to model what
could occur with a physical version when built.

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CHARACTERISTICS

1. Reprogrammable and smart

Digital Twin shows the errors or malfunctioning of the system during the testing process itself, just
as a real-time data. This malfunctioning can be rectified in prior due to this data, by reprogramming
the operation or redesigning the product

2.Connect and collect

Digital twin uses IoT for connectivity amongst the systems and also among different controlling
aspects of the system. The usage of IoT in the process as the main source of connectivity provides
ease in huge range, for collecting the information about the systems, such as its processing,
mechanical aspects, etc

3.Processing
Digital twin provides the platform to know and analyse the actual outcomes of the hardware and
software factors, inbuilt in the system, in advance to the manufacture of the product.
The terms simulation and digital twin are often used interchangeably, but they are different things.
A simulation is designed with a CAD system or similar platform, and can be put through its
simulated paces, but may not have a one-to-one analog with a real physical object. A digital twin,
by contrast, is built out of input from IoT sensors on real equipment, which means it replicates a
real-world system and changes with that system over time. Simulations tend to be used during the
design phase of a product's lifecycle, trying to forecast how a future product will work, whereas a
digital twin provides all parts of the business insight into how some product or system they're
already using is working now.
BENEFITS
1.Improved performance

Real-time information and insights provided by digital twins let you optimize the performance of
your equipment, plant, or facilities. Issues can be dealt with as they occur, ensuring systems work at
their peak and reduce downtime.

2.Predictive capabilities

Digital twins can offer you a complete visual and digital view of your manufacturing plant,
commercial building, or facility even if it is made up of thousands of pieces of equipment. Smart

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sensors monitor the output of every component, flagging issues or faults as they happen. You can
take action at the first sign of problems rather than waiting until equipment completely breaks
down.

3.Remote monitoring

The virtual nature of digital twins means you can remotely monitor and control facilities. Remote
monitoring also means fewer people have to check on potentially dangerous industrial equipment.

4.Accelerated production time

You can accelerate production time on products and facilities before they exist by building digital
replicas. By running scenarios, you can see how your product or facility reacts to failures and make
the necessary changes before actual production

APPLICATIONS
1.Construction.

. Construction teams create digital twins to better plan residential, commercial, and infrastructure
projects while providing a real-time picture of how existing projects are progressing. Architects also
use digital twins as part of their project planning by combining 3D modeling of buildings with
digital twin technology. Commercial building managers use digital twins to monitor live and
historical temperature, occupancy, and air-quality data within rooms and open spaces to improve
occupant comfort.

2.Manufacturing

Digital twins are used across the whole manufacturing lifecycle, from designing and planning to
maintaining existing facilities. A digital twin prototype allows you to monitor your equipment at all
times and analyze performance data that shows how a particular part or the entirety of your plant is
functioning.

3.Energy

Digital twins are widely used in the energy sector to support strategic project planning and optimize
the performance and lifecycles of existing assets, such as offshore installations, refining facilities,
wind farms, and solar projects.

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DIGITAL FORCES FOR DEVELOPMENT

The following factors can be listed as the major driving digital forces of the technological
development in all spectrums of industrial workspace:
 Internet of Things

 Software analytics

 Machine Learning

 Spatial elemental network

PRODUCT CYCLE

Any manufacturing unit should undergo the following process to come up with a product, bring it to
the customer and maintain a continuous flow in the product manufacturing.

Fig 3.25 product lifecycle

A manufacturing industry should always first ensure the concept with which the product exists and
works, by preparing a prototype. The product must then be analyzed and configured based on its
appearance; followed by structuring the product manufacturing process. The manufacturing should
be executed and the sales of the products must be channelized. The production should be
appropriately configured and followed based on the usage of the product. This maintains the
optimum circulation in the import of the raw materials and delivery of the final product. The
product hardware and software must be upgraded accordingly from time to time, based on the
market needs. This keeps up the demand of the product.

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CHAPTER 3
CONCLUSION

Manufacturing Execution CCCCONCLUSIOCCC

. The automation of the design of industrial control processes has a history of strong innovations.
In this report the concept of Programmable logic controllers and its applications are discussed. PLC
applications are typically highly customized systems so the cost of a packaged PLC is less compared
to the cost of a specific custom-built controller design. Development of small modular structure in
comparison with earlier structures have increased the flexibility of PLC configurations, PLC
computing, scan time, data processing, network communication, graphics display, and other
functions. The PLC programming tools are constantly developing, so it can be used more widely in
the applications of numerical control technology, control of machining center which will be more
flexible and reliable. This report focuses on automation, Programmable Logic Controllers (PLC) and
implementation of the prototype, “Ladder Programming using PLC”. This PLC based machine will
help in automating the embossing, which will eliminate the use of manpower; thus, resulting in
reduction of time consumption. The session provided hands-on practice on building up the ladder
logic for PLC automation. The internship has been helpful in having exposure to basics of
Automation, Embedded systems and Internet of Things. The knowledge taken up in the internship
supports one to take up projects and further be innovative in project building ideas. The introduction
to new software and various other control systems allows one to take lead in any of the field of
interest by exercising over it, with the usage of gained information.The demonstration to the Internet
of things with the Thing Speak platform allowed to know about IoT. It also gave us the knowledge of
embedded systems

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REFERENCES

[1]http://www.boschrexroth.com/en/xc/

[2]http://www.dsu.edu.in/index.php/innovation-labs/automative

system

[3]Programmable logic controller – Wikipedia

[4] Industrial automation using PLC – Slide Share

[5]https://www.quora.com

[6] indraworks.software.informer.com

[7] https://ieeexplore.ieee.org

[8] https://www.techtarget.com/iotagend

[9]https://en.wikipedia.org/wiki/Embedded_system

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