INTERNSHIP REPORT ON PLC & IOT

Table of Contents

1. Introduction 1-4

2. Internship description 5-16

3. Skills learnt in the company 17-30

4. IOT (Internet of things) 31-34

5. Demonstration experiment 35-38

6. Conclusion 39

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

INTRODUCTION

GTTC was established in 1972 at Bangalore with the participation of the Karnataka State
Government, in collaboration with the Government of Denmark under the Bilateral
Development Co-operation Agreement. The excellent performance of GTTC Bangalore,
proactive Government of Karnataka which saw the need for expansion, got second unit of
GTTC started in 1992 with DANIDA assistance.
Proliferation of technology for development of the industries with supply of skilled
manpower is the key to meet the needs of the global requirement. With this Government of
Karnataka encouraged GTTC to start 10 more sub-centres to train in the area of tool and die
making in various parts of Karnataka.
GTTC is an autonomous society, and a recognised Scientific and Research Organisation by
the Government of India. Govt. Tool Room and Training Centre (GTTC), is serving industry
by way of precision tooling and providing in well trained craftsmen the area of tool and die
making.
Today, the GTTC has acquired mastery in Mould and Die making technology and have
blossomed into an epitome of precision and quality in the development and manufacture of
sophisticated moulds, dies and tools.
Fully aware of the rapid advancement in technology the world over, the GTTC is
periodically adding new technologies to the existing set of advanced equipment like CAD /
CAM, CNC machines for tooling, Precision Components, Laser for Industries, Rapid
prototyping, vacuum casting etc.
GTTC is concentrating on the Integrated Development of the related segments of industries
by way of providing international quality tools, trained personnel and consultancy in tooling
and related areas. In future, the focus would be more on turnkey projects in Tooling,
Aerospace components & their assemblies, and also to support the development of small and
medium scale enterprises.
TC graduates have underlined their presence around the world in various domains like Tool
& Die maker, Tool Designers, CNC programmers and Mechatronics and Electronics
technicians Diploma graduates of GTTC due to their excellence in skill are most sought after
in countries such as Australia, Canada, Singapore, Malaysia etc.
Alumni of graduates GTTC have been entrepreneurs in the Precision manufacturing area,
setting up cutting edge companies and providing employment to youngsters.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

AUTOMATION

Automation involves the use of technology to perform tasks with minimal human
intervention, aiming to increase efficiency, accuracy, and productivity in various sectors. In
industrial settings, automation often employs programmable logic controllers (PLCs) and
robotics to carry out repetitive and complex tasks. This can include activities such as
assembly line manufacturing, where robots perform precise and repetitive actions, leading
to higher production rates and improved product consistency. Automation extends beyond
manufacturing and into areas like information technology, where automated scripts and
algorithms streamline routine tasks, such as software deployment, system monitoring, and
data analysis. The integration of sensors, actuators, and control systems enables automation
to respond to real-time information, adjusting processes dynamically and optimizing overall
performance.
The advent of artificial intelligence (AI) and machine learning further enhances automation
by allowing systems to learn from data, adapt to changing conditions, and make decisions
without explicit programming. While automation brings numerous benefits, such as
increased efficiency and reduced labour costs, it also presents challenges, including
concerns about job displacement, the need for cybersecurity measures, and the initial
investment required for implementation. As technology continues to advance, automation is
likely to play an increasingly pivotal role in reshaping industries, improving workflows, and
driving innovation.

History of Automation

Automation has a rich history, evolving from the early mechanization of the Industrial
Revolution to the sophisticated technologies of today. The introduction of assembly lines by
Henry Ford in 1913 revolutionized manufacturing, setting the stage for increased efficiency.
The development of Programmable Logic Controllers (PLCs) in the 1960s allowed for more
flexible and programmable control systems. Robotics emerged in the 1970s, transforming
industries with automated tasks. With advancements in microprocessors and information
technology, automation expanded beyond the physical realm, incorporating software
automation and real-time monitoring.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

COMPANY PROFILE

Fig 1.1: Company Front View

It’s precision that makes the world go round” A premier Tool Room and Training
Centre established in 1992 at Mysore, Karnataka, India with assistance of the Government
of Denmark, has extensive facilities in Tool making and training. Government tool and
Training Centre (GTTC) is a modern tool room and training center with state-of-art
CAD/CAM equipment, machinery and inspection facilities to meet the complex needs of
discerning customers.
GTTC is committed to achieve customer satisfaction in quality and delivery of tool
engineering education, services and precision machining.
GTTC has acquired mastery in Tool Engineering and vast experience in conducting well
structured, practical oriented training programmers’ leading to post graduation, diplomas
and certificates.
Realizing the need to update and upgrade the skills of existing technical personnel in
industry, GTTC conducts a number of short-term programs in tool design, advanced
manufacturing techniques, design analysis and CNC programming for manufacture and
other aspect of manufacture.
The state-of-art sophisticated manufacturing facility consist of 3 to 5 axis high-speed CNC
machining centers, CNC jig grinding, CNC wire EDM, CNC co-ordinate measuring
machine and other supporting machineries and facilities.

The computer integrated manufacturing facility in DNC network and supported by high end

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

software’s such as I-DEAS, for design and manufacturing, Uni-Graphics, pro-E, Master-
cam, Mechanical Desktop and Analysis package like C-Mold, Mold Flow and Pro-Cast.

The main objectives of Tool Room

 To conduct industry oriented technical program to youth with employable skills.

 To assist MSME units in technological upgradation byproviding quality tooling.
 To provide highly skilled work force to industries of various sectors.
The main activities of GTTC
 Offering hands onexperience in Long-term, Short-term and need based training
programs.
 Design and manufacturing of press tools, Dies for sheet metals and plastics parts,
jigs & fixtures etc.

 The center conducting many courses which is approved by Government of

Karnataka and all India Council for Technical Education (AICTE), New Delhi.

It offers courses like Computer Aided Design (CAD), Mechatronics, Automation, Robotics,
CNC Turning, CNC Milling, Design & Validation, 3D printing
Today’s highly increasing competitiveness over the industry demands high quality and most
consistent products with a competitive price. To address this challenge number of industries
considering various new product designs and integrated manufacturing techniques in
parallel with the use of automated devices.

Automation takes a step further mechanization that uses a particular machinery mechanism
aided human operators for performing a task. Mechanization is the manual operation of a
task using powered machinery that depends on human decision making.

The state-of-art sophisticated manufacturing facility consist of 3 to 5 axis high-speed CNC

machining centers, CNC jig grinding, CNC wire EDM, CNC co-ordinate measuring
machine and other supporting machineries and facilities.

The computer integrated manufacturing facility in DNC network and supported by high end
software’s such as I-DEAS, for design and manufacturing, Uni-Graphics, pro-E, Master-
cam, Mechanical Desktop and Analysis package like C-Mold, Mold Flow and Pro-Cast.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

INTERNSHIP DESCRIPTION

A Programmable Logic Controller (PLC) serves as the brain of industrial automation,

providing a robust and flexible solution for controlling and monitoring complex processes.
PLCs are programmable devices that execute specific tasks based on user-defined logic.
They have evolved from traditional relay control systems, offering greater efficiency,
reliability, and adaptability in industrial environments. PLCs operate by continuously
scanning input signals from sensors and switches, executing programmed instructions, and
then activating output devices such as motors or valves to control various aspects of a
manufacturing or processing system.
One of the key features of PLCs is their ability to be easily programmed and reprogrammed.
Engineers use specialized programming languages like ladder logic to define the behavior of
the control system. This adaptability allows for quick adjustments to accommodate changes
in production requirements or to introduce new functionalities, making PLCs a versatile tool
in dynamic industrial settings.
PLCs find widespread application in industries such as manufacturing, energy, and chemical
processing. Their reliability, real-time operation, and modularity make them essential for
tasks ranging from simple logic operations to complex automation processes. As technology
advances, modern PLCs integrate with other technologies, including the Internet of Things
(IoT) and artificial intelligence, further enhancing their capabilities and expanding their role
in the evolving landscape of industrial automation.

Fig : General PLC Diagram

Block diagram of PLC

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

The block diagram of a Programmable Logic Controller (PLC) provides a visual

representation of its fundamental components and their interactions within an industrial
control system. At its core lies the Central Processing Unit (CPU), the brain of the PLC,
responsible for executing programmed instructions. The CPU communicates with two
primary modules: the Input Module and the Output Module. The Input Module interfaces
with various sensors and input devices, converting physical signals, such as from switches
or sensors, into digital data that the PLC can interpret. This data is processed by the CPU
according to the programmed logic stored in the system's memory. Once processed, the CPU
sends signals to the Output Module, which interfaces with actuators and output devices,
converting digital signals from the CPU into physical actions, such as controlling motors,
valves, or indicators.
The system's memory plays a crucial role in storing the user-defined program, system data,
and temporary variables. This memory includes both volatile (RAM) and non-volatile
(ROM) storage. The programming device serves as the interface for engineers and
technicians to create, edit, and upload the control program into the PLC. Additionally, the
power supply ensures that the entire PLC system receives the necessary electrical power for
operation. Communication ports facilitate connectivity, allowing the PLC to exchange data
with external devices, such as Human-Machine Interfaces (HMIs), Supervisory Control and
Data Acquisition (SCADA) systems, or other PLCs, enabling seamless integration and data
exchange within the industrial automation environment. The block diagram showcases the
flow of information and signals within the PLC, emphasizing its ability to receive input,
process it based on programmed logic, and generate appropriate output signals to control
industrial processes and machinery.

Fig 2.2: Block diagram of PLC

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

A Programmable Logic Controller (PLC) is composed of several key components, each

playing a specific role in the control and automation of industrial processes. Here are the
main components of a typical PLC:
1.Central Processing Unit (CPU):

The CPU is the core of the PLC, responsible for executing the control program. It interprets
the logic written by the user, processes input signals, and generates output signals based on
the programmed instructions. The CPU also manages communication with other devices.
2.Input Modules:

Input modules interface with external sensors, switches, and other devices to collect
information about the state of the process. These modules convert physical signals from the
input devices into digital signals that the PLC's CPU can process.
3.Output Modules:

Output modules connect to actuators, motors, valves, and other devices to control the
industrial process. They convert digital signals generated by the CPU into physical actions
or outputs that affect the controlled system.
4.Memory:

PLCs have two types of memory: RAM (Random Access Memory) and ROM (Read-Only
Memory). RAM is used for temporary storage of variables and data during program
execution, while ROM stores the user-defined control program and other fixed data.
5.Programming Device:

The programming device is used by engineers and technicians to create, edit, and download
control programs into the PLC. It can be a computer running specialized programming
software, a handheld programming device, or even a built-in programming interface on the
PLC itself.
6.Power Supply:

The power supply provides the necessary electrical power for the entire PLC system. It
ensures that the CPU, input modules, and output modules receive the correct voltage for
proper operation.

7. Communication Ports:
Communication ports allow the PLC to connect and exchange data with other devices, such

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

as Human-Machine Interface (HMI) panels, Supervisory Control and Data Acquisition

(SCADA) systems, or other PLCs. This facilitates data exchange and integration within the
broader automation system.

8.I/O Interface:
The Input/Output (I/O) interface manages the interaction between the input and output
modules and the rest of the PLC system. It ensures that data flows sothly between the CPU
and the external devices.
9.Clock/Timer:
Some PLCs include an internal clock or timer that helps in scheduling and sequencing
operations within the control program.
These components work together to form a cohesive system that can monitor, control, and
automate various industrial processes. The flexibility and modularity of PLCs allow for
customization to suit specific applications and industries.

PLC Programming Language (PLC)

 Ladder Logic (LAD)

 Functional Block Diagram (FBD)

 Statement List (STL)

 Sequential List (SFC)

 S7- Graph

 Continuous Function Chart (CFC)

Simatic S7-1200 Memory card

 Load memoryexpansion

 Distribution of program

 Firmware update

 Documentation

 Memory card binding

 Unliked DBs

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

 Module exchange without PG

 designed to detect and manage abnormal conditions that may arise during its

operation.

Fig : S7-1200 Memory Card

 The CPU scans the user program.

 Reading/uploading a program from CPU is possible.

 Changed programcan be downloaded into

the CPU Stop Mode

 The CPU does not scan the user program.

 Reading/uploading a program from CPU is possible.

Changed program can be downloaded into the CPU

Error modes
 designed to detect and manage abnormal conditions that may arise during its
operation.
 These error modes serve as critical diagnostic tools
 When errors occur, the PLC enters a designated error-handling mode,
providing diagnostic information

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

PROGRAMMING LANGUAGE USED IN A PLC

Ladder Logic is a graphical programming language commonly used in Programmable Logic

Controllers (PLCs) for designing and implementing control logic in industrial automation.
The name "Ladder Logic" comes from its visual representation, which resembles a ladder.
The language is designed to mimic relay logic diagrams used in traditional control systems,
making it familiar to individuals with a background in electrical systems.

Key elements of Ladder Logic:

1.Rungs:
Ladder Logic programs are organized into rungs, each resembling a horizontal step on a
ladder. Each rung represents a specific control function or operation.

2.Contacts and Coils:

Contacts and coils are the fundamental building blocks of Ladder Logic. Contacts represent
input conditions, such as sensors or switches, while coils represent output devices, like
motors or valves.

1.Logic Symbols:
Ladder Logic uses standard logic symbols such as AND gates, OR gates, and NOT gates to
create logical relationships between input conditions (contacts) and output actions (coils).

2.Power Rails:
The vertical sides of the ladder diagram represent the power rails. These rails typically
symbolize the positive and negative sides of the power supply, and they provide power to
the various components in the rungs.

3.Series and Parallel Connections:

Series and parallel connections are created by arranging contacts and coils on the rungs.
Series connections (represented horizontally) imply an AND relationship, and parallel
connections (represented vertically) imply an OR relationship.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Example of a simple Ladder Logic rung:

Fig 2.5: ladder logic

Ladder Logic is known for its simplicity, clarity, and ease of understanding, making it a
widely used programming language in industrial automation. Engineers and technicians can
quickly interpret ladder diagrams, facilitating the design, maintenance, and troubleshooting
of control systems.

Addressing for input and output

For Input:-I:0.00.1

For Output: -O0:0.0/0,0:0.0/1

INPUT/OUTPUT DEVICES

INPUTS OUTPUTS
Switches Relays
Pushbuttons Lamps
Limit Switches Contactors
Proximity Sensors Alarm Hooters
Photo Sensors LED
Contactors Solenoid Valves
Condition Sensor Control Relays
Pressure Switches Counter
Level Switches Printer

Table 2.1: I/O Devices

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Hardware overview
1.PLC Processor (CPU)
At the heart of every PLC system is a processor. It is arguably the most crucial PLC
hardware component. Sometimes the PLC processor is also referred as the PLC controller
or PLC CPU (Central Processing Unit). Whatever you choose to call this piece of PLC
hardware.
The PLC processor is the workhorse of the PLC system responsible for all the logic
computation and number crunching. The PLC processor can be embedded into the PLC unit
or come as a separate PLC module. Generally fixed PLC types have their processor
embedded in the PLC itself. While modular and distributed PLC types have their PLC
processors as a separate module.
The PLC processor contains 3 fundamental components:

 PLC CPU (Central Processing Unit)

 PLC Memory

 PLC Programming port

2.PLC Hardware Mounting Systems

The hardware mounting system of a PLC provides the means to physically connect the
various hardware components of the PLC system. PLC hardware mounting systems can
vary from one PLC manufacturer to another and can also vary depending on the type of
PLC used.
The 3 main PLC mounting systems used in industrial automation projects are:

 Rack mounted PLC

 Rail mounted PLC

 Panel mounted PLC

2. PLC Power Supply

The main purpose of a PLC power supply is to convert the available power supply voltage
into a voltage that is usable by the PLC processor (CPU) and other PLC modules. The most
common

PLC power supply input voltages are 120VAC, 240VAC, AC voltage range (like 85-

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

265VAC) and 24VDC. While the most common PLC power supply outputs are 24DC and
5VDC.

There are 3 main types of PLC power supplies:

 Integrated PLC power supply
 PLC power supply module
 Remote PLC power supply

3.PLC Input and Output Hardware Interface

In an industrial PLC system the PLC input and output modules are a common interface
between the field devices and the PLC processor (CPU). The PLC inputs and outputs are
generally connected to the field devices via a terminal strip. Communication modules
with fieldbus protocols like Ethernet IP, Profinet etc. can also be used as a PLC input and
output interface. In a PC (Personal Computer) the input and output interface is the
connection between the peripheral devices and the PC. The keyboard and mouse are
examples of input devices and the USB port is an example of the input interface. The
monitor is an example of an output device and the monitor port is an example of the output
interface.
In a PLC, the inputs are connected to PLC input devices like pushbuttons, limit switches,
proximity sensors, temperature transmitters, pressure transmitters, level transmitters,
encoders etc. And the PLC outputs are connected to PLC output devices such as relays,
motor contactors, VFDs (Variable Frequency Drives), solenoid valves, proportional vales,
indication lights, sirens etc.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Fig 2.6: PLC Inputs and Outputs

Types of PLC Input and Outputs

The 2 main types of PLC input and output signals are analog and digital (discrete). Analog
and digital inputs both measure external field conditions and report it back to the PLC
processor (CPU). And analog and digital outputs both send command signals from the PLC
processor (CPU) in order to activate field devices. So what’s the difference?
The main difference between PLC analogue I/O and digital I/O are:

 Signal Format

 Signal Wiring

 Signal Processing

PLC Input and Output Hardware Connection

There are various PLC input and output connection methods. Some connection methods are
more tedious than others. In general connection of field devices to PLC inputs and outputs
is a labor intensive exercise, especially when there are large volumes of PLC I/O.
The most common PLC input and output hardware connection methods are:

 Hardwire connection with terminals

 Fieldbus network connection

4.PLC Communication Hardware Interface

PLCs can communicate to multiple devices by using a communication interface. The

communication interface has communication ports which allows cable connection to
devices such as other PLCs, remote I/O drops, fieldbus devices, touch screens,
programming PCs and servers. Multiple communication interfaces may be required for
larger and more complex applications.
The PLC communication interface can exist as either embedded communication ports on the
PLC processor or as communication modules. If there is a need for multiple communication
interfaces then it’s quite common to see both embedded communication ports on the PLC
processor and extra communication modules slotted into the rack.

PLC communication ports commonly use either a Serial based communication protocols or

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Ethernet based communication protocols. Serial communication ports on a PLC usually use
D-sub connectors or terminal connectors, while Ethernet communication ports usually use
RJ45 connectors.

Fig 2.7: PLC hardware

PLC Communication Ports

some popular Ethernet based protocols used for PLC communication include Ethernet IP,
Profinet, Ether cat, Modbus TCP/IP and BACnet IP. With Serial communication ports,
some of the common protocols are Device Net, Profibus DP, Modbus RTU, CAN open,
BACnet MS/TP, MPI, Direct Net, RS-485, RS-422 and RS-232.
PLC communication ports that have serial protocols are now considered “old school” by
some. However, they are readily available, generally cheaper and are still useful in certain
applications. However they are generally slower and cannot handle the same data
bandwidth as modern day industrial Ethernet based protocols.
3.PLC Programming Device
The last, but by no means the least, is the PLC programming device. Programmable Logic
Controllers need to be programmed somehow. There are 2 devices that can do it.

The two most common PLC programming devices are handheld programming devices and
personal computers (PC). Both are used to develop the PLC program (like ladder logic)
and then transfer it into the PLC memory. The PLC programming devices connect to the
PLC using a cable and transfer the PLC program using either an Ethernet or Serial based
communication protocol.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Handheld programming devices are propose built to develop PLC program. But they have
limited programming memory, have a very basic display, simple keyboard input functions
and are slow and tedious to use. They are generally limited to programming small
applications with low numbers of I/O.
SKILLS LEARNT IN THE COMPANY

PROGRAMMING IN PLC:

PLC programs are typically written in a special application on a personal computer, then
downloaded by a direct-connection cable or over a network to the PLC. The program is
stored in the PLC either in battery-backed-up RAM or some other non-volatile flash
memory. Often, a single PLC can be programmed to replace thousands of relays.
Ladder Logic is a programming language that represents a program by a graphical diagram
based on the circuit diagrams of relay-based logic hardware. It is primarily used to develop
software for Programmable Logic Controllers (PLCs) used in industrial control applications.
The name is based on the observation that programs in this language resemble ladders, with
two vertical rails and a series of horizontal rungs between them. Ladder logic is widely used
to program PLCs, where sequential control of a process or manufacturing operation is
required. Ladder logic is useful for simple but critical control systems, or for reworking old
hardwired relay circuits. As programmable logic controllers became more sophisticated it
has also been used in very complex automation systems.

Fig 3.1: Simple Ladder Logic

If a path can be traced between the left side of the rung and the output, through asserted
(true or "closed") contacts, the rung is true and the output coil storage bit is asserted (1) or
true. If no path can be traced, then the output is false (0) and the "coil" by analogy to
electromechanical relays is considered "de- energized. Ladder logic has contacts that

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

make-or-break circuits to control coils. Each coil or contact corresponds to the status of a
single bit in the programmable controller's memory. Unlike electromechanical relays, a
ladder program can refer any number of times to the status of a single bit, equivalent to a
relay with an indefinitely large number of contacts.

So-called “contacts” may refer to physical (Hard) inputs to the programmable controller
from physical devices such as pushbuttons and limit switches via an integrated or external
input module, or may represent the status of internal storage bits which may be generated
elsewhere in the Each rung of ladder.

COMMUNICATION OF PLC WITH PC

We will use S7-1200 PLC. The model that we will be using is 1215C direct current (DC).
The advantage of S7-1200 is the price and the integrated IO. As shown in the below figure
this PLC have 14 digital inputs (DI) and 10 digital outputs (DQ) and 2 analog inputs (AI)
and 2 analog outputs (AQ). It has also high-speed counters (HSC) and pulse generators
(PWM).

Fig 3.2: Siemens S7-1200 PLC

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Fig 3.3: CPU DC/DC/DC 6ES7 214-1BG40-0XB0

How to open TIA portal

Double click on TIA Portal and create a new device. Say configure a device and add new
device in that controller option select Simatic S7-1200 within that CPU select
(CPU1214ACDCRelay) and select 6ES72141BG400XBO double click on that and add.
The new device will be the PLC.

Fig 3.3: Create a new project and add S7-1200PLC Set IP Address

After Creating a new PLC, the first step is to set its IP address. To set the IP address, you
need to open the property dialog of the PLC. If you click on the PLC image you need to go
to profinet interface, Ethernet address. If you click on the Ethernet ports on the PLC image
you can see directly the entry Ethernet address.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Fig 3.4: Set IP Address

Download Configuration

Click on save Project and Click on the icon for compile options to check for the errors and
if there is no error then download start search then save and stop all then click on load then
finish.

Simple Program:

Let suppose we wire a lamp to the first digital output of the PLC. In the configuration of the
PLC, we give that output a name or a tag. The name can also be given in the PLC tags table.
The following animations illustrate how to create a tag and write a small program in order
to blink lamp.

Fig 3.6: Blink an output with a frequency of 1Hz

In this example we use the tag or variable clock 1Hz in order to turn on and off the lamp
output, with a frequency of 1Hz.

Plc instructions

There are various instructions which are useful for making ladder logic for PLC
Programming. These are as follows:

o XIC (Examine if closed)

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

use the XIC instruction in your ladder program to determine if a bit is ON. When the
Instruction executed, if the bit addressed is on (1), then the instruction is evaluated as true.
When the instruction is executed, if the bit addressed is off (0), then the instruction is
evaluated

as false. XIC (Examine if closed):

Input Output

0 1

1 1

Examples of devices that turn on or off include:

 A push button wired to an input (addressed as I: 0/4).

 An output wired to a pilot light (addressed as O: 0/2).
 A timer controlling a light (addressed as T4:3/DN).

o XIO (Examine if open)

Use the XIO instruction in your ladder program to determine if a bit is OFF. When the
Instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as
true. When the instruction is executed, if the bit addressed is on (1), thenthe instruction is
evaluated as false.
Examples of devices that turn on or off include:

 Motor overload normally closed (N.C.) wired to an input (I: 0/10).

 An output wired to a pilot light (addressed as O: 0/4).

Input Output
 A
0 1

1 0

timer controlling a light (addressed as T4:3/DN)

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

o Output Energize (OTE)

Use the OTE instruction in your ladder program to turn on a bit when rung conditions are
evaluated as true. An example of a device that turns on or off is an output wired to a pilot
light. (Addressed as O:0/4).

OTE instructions are reset when:

• The SLC enters or returns to the REM Run or REM Test mode or Power is restored.

• The OTE is programmed within an inactive or false Master Control Reset (MCR) zone.

Training example:
Q: Once the photoelectric sensor detects 10 products, the robotic arm will begin to pack
up. When the action is completed, the robotic arm and the counter will be reset.

Sol:

Number of PLC Inputs Required:-

X0 – Photoelectric sensor for counting products. X0 = ON when products are detected.
X1 – Robotic arm action completed sensor.
X1 = ON when packing is completed

Number of PLC Counter Required:-

C0 – Counter: 16-bit counting up (general purpose)

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Number of PLC Outputs Required:-

Y0 – Robotic arm for packing

Plc ladder diagram for above question

Working:

 Once the photoelectric sensor detects a product, X0 will go from OFF to ON

once, and C0 will count for one time.
 When the present value in C0 reaches 10, the Normally Open contact C0 will
be closed. Y0 = ON, and the robotic arm will begin to pack.
 When the packing is completed, the robotic arm action completed sensor will
be enabled. X1 will go from OFF to ON and RST instruction will be executed.
Y0 and C0 will be reset for the next packing task.
Timers and counters:

Timers are used to perform the timing operations. Time base is the minimum value of time
in Second that can be taken by the timer. Preset value is the total number of the seconds for
which the timing operation has to be done Accumulator starts increasing the time in seconds
up to the preset value. Up to the preset value of the accumulator the enable bit of timer is
high & the timer runs. When accumulator reaches the preset value thenthe timer stops and
the done bit of the timer becomes high.

Types of Timers
 TP – Pulse Timer

 TON – On delayTimer

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Pulse Timer

The first timer is called the pulse timer, because it is used to generate a pulse of a specific
length. It takes two inputs and has two outputs. So far, we have only seen function blocks
where the inputs and outputs where Boolean. This is still true for the IN and Q of the TP
block. Built is a little different with the PT and ET. They both take variables of the
datatype TIME.
PT stands for Preset Time and is an input to the block. This is where you put the time you
want to pulse at Q to be. As soon as the input IN is true, the output Q will be set for PT
time. ET stands for Elapsed Time. This is the time Q has been active.

Fig 3.7: Pulse Timer

TON – On delay Timer

The next type of timer is the On Delay Timer or just referred to as TON. But instead of
setting the time for the pulse, it is used to set a delay for the pulse. When the input is on the
timer will start counting. After the time PT has elapsed the output Q will be set. This is also
the reason for its name. It turns on the output after a delay.

The on-delay timer has the same input and output pins as the pulse timer. And again, it still
has the ET to see how much time has elapsed.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Fig 3.8: TON Timer

TOF- OFF delay Timer

The functionality of the off-delay timer (TOF) is very similar to the TON. But with one big
difference. It turns off the output after a delay.
In the moment the input is set to true, the output will be set. As long as the input stays true
the output will stay on until the PT time has elapsed. After that time the output will be turned
off.

Fig 3.9: TOF Timer

TONR-On delay with Reset Timer

The ON delay with Reset Timer (TONR) instruction counts time when the enabling
input is ON. When the current value (Txxx) is greater than or equal to the preset time
(PT), the timer bit is ON. The current value of the Retentive On-Delay timer is maintained
when the input is OFF.

COUNTERS

Counters are used to count the number of operations. Its function is same as the timer
accepts that the timer counts the number of seconds and the counter counts the number of
operations or pulses. At each operation the value of the accumulator increases and when the
value of the accumulator comes to the preset value ofthe counter then the counter stops.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

 CTU (Counter Up)

 CTD (Counter Down)

 CTUD (Counter Up and Down)

 CTU (Count Up)

 The CTU is an instruction that counts false-to-true rung transitions. Rung transitions
can be caused by events occurring in the program (from internal logic or by external
field devices) Such as parts traveling past a detector or actuating a limit switch. When
rung conditions for a CTU instruction have made a false-to-true transition The
accumulated value is retained when the rung conditions again become false. The
accumulated count is retained until cleared bya reset (RES) instruction that has the
same address as the counter reset.

Fig 3.10: up counter

CTD (Count Down)

The CTD is an instruction that counts false-to-true rung transitions. Rung transitions can be
caused by events occurring in the program such as parts traveling past a detector or
actuating a limit switch.

Fig 3.11: down counter

When rung conditions for a CTD instruction have made a false-to-true transition, the
accumulated value is decremented by one count, provided that the rung containing the

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

CTD instruction is evaluated between these transitions. The accumulated counts are retained
when the rung conditions again become false. The accumulated count is retained until
cleared by a reset (RES) instruction that has the same address as the counter reset.

CTUD (Counter Up and Down)

An up-down counter is a combination of an up-counter and a down-counter. It can count in

directions, increasing as well as decreasing. The up-down counter counts the value from
zero to the preset value or from the preset value to zero. In other words, this counter can be
act as down counter or up counter. CD input is used to get counter enable bool input. S input
is used to get the set input, once S input changes from 0 to 1, counter accumulator value
changes to 999, which is counter’s higher limit. PV is word input where you can give preset
value with the format of C#. R input is the reset Bool input’s output is used to get counter
enable output. CV and CV_BCD used to get the counter’s accumulator value in integer
format and BCD format. Up-down counter is known as ‘CTUD’.

Fig 3.12: up & down counter

MEMORY TYPES IN SIEMENS PLC

In general, the S7 PLC memory is composed of 4 parts

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Fig 3.13: types of memory

Load Memory

Stores any data downloaded from the PC to the PLC, this means that any PLC program
downloaded to the PLC is stored in the Load Memory. Integrated RAM in CPU, External
memory card are part of load memory (Hard disk is the best example).

There are two types of Load Memory

 Internal Load Memory.

 External Load Memory.

`
Working Memory

It’s part of memory where it can store the executive part of the PLC program, it looks like
the RAM in the Computer, and in this case, the load memory is the hard disk.
Running relevant code blocks and running relevant data blocks will present. When PLC
executes the instruction related codes, related values will store in work memory (PC RAM
is the best example).

```System memory

It’s part of the memory where it can store the addressing part of the PLC program like
Inputs, Outputs, Timers, Counters, and Bit memory.

Retentive Memory

It’s part of the memory where it can store data permanently, for instance, if you want to keep the
data in specific bit memory stored permanently where in the case of electricity cut off this bit
memory is not impacted.

Different types of blocks

In the Siemens PLC programming software, these blocks are as follow:

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

 Organization Block (OB)

 Function Block (FB)

 Function (FC)

 Data Block (DB)

Fig 3.14: siemens PLC programming block structure

 Organization Block
Data blocks are called by the OS cyclically and are the interface between the user program
and the OS. In this organization block, the PLC control unit is informed by means of block
call commands as to which program blocks it has to process.

 Function Block

For each call (instance), the function block needs an assigned memory area. When a
function block is called a data block for ex can be assigned to it as instance DB. The data in
this instance DB is then accessed by means of the variables of the FB. Different Memory
areas have to be assigned to an FB if it is called several times.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

 Function (FCs)
A function does not have an assigned memory area. The local data of a function is lost after
the function is processed. Users can create a part of the logic in the Function (FC) block of
the PLC.
These are some common examples of Function (FC) like

a. Control Valve Open/Close

b. Mathematical Calculation or Conversion

c. Operation of a Particular Area of the entire plant, etc.

Data Block (DC)

DBs are used to provide memory for the data variables. There are two types of data blocks:
global DBs where all OBs, FBs and FCs can read the stored data or themselves can write
data into the DB and instance DBs that are assigned to certain FB.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

IOT (internet of things)

The internet of things, or IoT, is a network of interrelated devices that connect and
exchange data with other IoT devices and the cloud. IoT devices are typically embedded
with technology such as sensors and software and can include mechanical and digital
machines and consumer objects.

Increasingly, organizations in a variety of industries are using IoT to operate more

efficiently, deliver enhanced customer service, improve decision-making and increase the
value of the business.

With IoT, data is transferable over a network without requiring human-to-human or human-
to- computer interactions.

A thing in the internet of things can be a person with a heart monitor implant, a farm animal
with a biochip transponder, an automobile that has built-in sensors to alert the driver when
tire pressure is low, or any other natural or man-made object that can be assigned an
Internet Protocol address and is able to transfer data over a network.

Fig 4.1: internet of things

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Working of IoT

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.

IoT devices share the sensor data they collect by connecting to an IoT gateway, which acts
as a central hub where IoT devices can send data. Before the data is shared, it can also be
sent to an edge device where that data is analyzed locally. Analyzing data locally reduces
the volume of data sent to the cloud, which minimizes bandwidth consumption.

Sometimes, these devices communicate with other related devices and act on the
information they get from one another. The devices do most of the work without human
intervention, although people can interact with the devices -- for example, to set them up,
give them instructions or access the data.

The connectivity, networking and communication protocols used with these web-enabled
devices largely depend on the specific IoT applications deployed.

IoT can also use artificial intelligence and machine learning to aid in making data collection
processes easier and more dynamic.

Importance of IoT

IoT helps people live and work smarter. Consumers, for example, can use IoT-embedded
devices -- such as cars, smartwatches or thermostats -- to improve their lives. For example,
when a person arrives home, their car could communicate with the garage to open the door;
their thermostat could adjust to a preset temperature; and their lighting could be set to a
lower intensity and colour.
In addition to offering smart devices to automate homes, IoT is essential to business. It
provides organizations with a real-time look into how their systems really work, delivering
insights into everything from the performance of machines to supply chain and logistics

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

operations.

IoT enables machines to complete tedious tasks without human intervention. Companies
can automate processes, reduce labor costs, cut down on waste and improve service
delivery. IoT helps make it less expensive to manufacture and deliver goods, and offers
transparency into customer transactions.

IoT is one of the most important technologies and it continues to advance as more
businesses realize the potential of connected devices to keep them competitive.

Architecture of IoT

Sensing Layer

The sensing layer is the first layer of the IoT architecture and is responsible for collecting
data from different sources. This layer includes sensors and actuators that are placed in the
environment to gather information about temperature, humidity, light, sound, and other
physical parameters. These devices are connected to the network layer through wired or
wireless communication protocols.

Network Layer

The network layer of an IoT architecture is responsible for providing communication and
connectivity between devices in the IoT system. It includes protocols and technologies that
enable devices to connect and communicate with each other and with the wider internet.
Examples of network technologies that are commonly used in IoT include WiFi, Bluetooth,
Zigbee, and cellular networks such as 4G and 5G. Additionally, the network layer may
include gateways and routers that act as intermediaries between devices and the wider
internet, and may also include security features such as encryption and authentication to
protect against unauthorized access.

Data processing Layer –

The data processing layer of IoT architecture refers to the software and hardware
components that are responsible for collecting, analyzing, and interpreting data from IoT
devices. This layeris responsible for receiving raw data from the devices, processing it, and

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

making it available for further analysis or action.The data processing layer includes a
variety of technologies and tools, such as data management systems, analytics platforms,
and machine learning algorithms. These tools are used to extract meaningful insights from
the data and make decisions based on that data.Example of a technology used in the data
processing layer is a data lake, which is a centralized repository for storing raw data from
IoT devices.

Application Layer

The application layer of IoT architecture is the topmost layer that interacts directly with the
end-user. It is responsible for providing user-friendly interfaces and functionalities that
enable users to access and control IoT devices. This layer includes various software and
applications such as mobile apps, web portals, and other user interfaces that are designed to
interact with the underlying IoT infrastructure. It also includes middleware services that
allow different IoT devices and systems to communicate and share data seamlessly. The
application layer also includes analytics and processing capabilities that allow data to be
analyzed and transformed into meaningful insights. This can include machine learning
algorithms, data visualization tools, and other advanced analytics capabilities.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

Fig 4.2: datonis architecture

DEMONSTRATION EXPERIMENT

#include <Servo.h>

// Define pins
const int trigPin = 9;
const int echoPin = 10;
const int servoPin = 3;

// Create Servo object

Servo myServo;

// Variables for calculating distance

long duration;
int distance;

// Setup function
void setup() {
// Initialize serial communication
Serial.begin(9600);

// Set pin modes

pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);

// Attach servo to pin

myServo.attach(servoPin);

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

// Initial position of the servo

myServo.write(0);
}

// Function to calculate distance using ultrasonic sensor

int calculateDistance() {
// Send a pulse from the trigger pin
digitalWrite(trigPin, LOW);
delayMicroseconds(2);
digitalWrite(trigPin, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin, LOW);

// Read the pulse from the echo pin

duration = pulseIn(echoPin, HIGH);

// Calculate distance in cm
distance = duration * 0.034 / 2;
return distance;
}

// Main loop
void loop() {
// Calculate the distance
int dist = calculateDistance();
Serial.print("Distance: ");
Serial.print(dist);
Serial.println(" cm");

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

// Check if an object is within 10 cm range

if (dist <= 10) {
myServo.write(90); // Open the lid
delay(2000); // Wait for 2 seconds
} else {
myServo.write(0); // Close the lid
}

// Small delay to avoid rapid opening/closing

delay(500);
}
// Calculate distance in cm
distance = duration * 0.034 / 2;
return distance;
}

// Main loop
void loop() {
// Calculate the distance
int dist = calculateDistance();
Serial.print("Distance: ");
Serial.print(dist);
Serial.println(" cm");

// Check if an object is within 10 cm range

if (dist <= 10) {
myServo.write(90); // Open the lid
delay(2000); // Wait for 2 seconds
} else {

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

myServo.write(0); // Close the lid

}

// Small delay to avoid rapid opening/closing

delay(500);
}

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

CONCLUSION

The internship was successfully completed at Government Tool Room and Training
Centre, and Knowledge was gained about PLC and IoT. It was a great experience as we
learnt a lot through hands on working. In this one month of training, I acquired
knowledge about automation and I got some information about PLC and how we work
on it. I learned the programming on PLC and also learned about the basics of IoT and
the programming involved with it.
The report has discussed the programming with PLC and ladder logic made from it.

 Programmable Logic History- This section discussed the history and

advancement of control technology.
 PLC components- This section defined what programmable logic
is and described all hardware associated with it.

 PLC programming- This section covered various techniques of PLC Programming

 IoT-This section contains basic introduction of IoT system.

DEPT OF ECE, MRIT MANDAYA

INTERNSHIP REPORT ON PLC & IOT

DEPT OF ECE, MRIT MANDAYA