Report of the Internship

ON

PLC AUTOMATION

Company Name: BRIZTECH INFOSYSTEMS SYSTEMS PVT. LTD.

Location: Lalpur, Ranchi (Jharkhand)

BY

Name: ROHIT KUMAR

Roll No.: 12637706

DIPLOMA IN ELECTRICAL ENGINEERING

GARHWA POLYTECHNIC COLLEGE
GARHWA (JHARKHAND)
(2024)
CERTIFICATE

This to certify that ROHIT KUMAR, Roll No.: 12637706 the work
presented in the INTERNSHIP REPORT entitled PLC AUTOMATION in
partial-fulfillment of the requirement for award of the degree of DIPLOMA in
ELECTRICAL Engineering of BRIZTECH INFOSYSTEMS SYSTEMS
 PVT. LTD., Lalpur, Ranchi is an authentic work carried out under my
supervision and guidance.

To the best of my knowledge, the content of this INTERNSHIP REPORT is

original.

__________________
Tanweer Zafar
Guide of Briztech
Infosystems PVT. LTD.
Lalpur, Ranchi

CERTIFICATE OF APPROVAL

The foregoing INTERNSHIP REPORT entitled PLC AUTOMATION is hereby

approved as a creditable work on the topic and has been present ROHIT KUMAR ,
Roll No.: 12637706 in satisfactory manner to warrant its acceptance as
prerequisite to the degree for which it has been submitted.
It is understood that by this approval, the undersigned do not necessarily endorse
any conclusion drawn or opinion expressed therein, but approve the INTERNSHIP
REPORT for the purpose for which it is submitted.

(Internal Examiner) (External

Examiner)

Head of Department
DIPLOMA IN ELECTRICAL ENGINEERING
GARHWA POLYTECHNIC COLLEGE
GARHWA (JHARKHAND)

ACKNOWLEDGEMENT

We take this opportunity to thank all who have contributed towards shaping this
INTERNSHIP REPORT. I would like to express my sincere thanks to my guide
and Head Prof. (Prof. Name), Department of ELECTRICAL Engineering.
whose invaluable suggestions helped me in development of this INTERNSHIP
REPORT. As my supervisor, he has constantly encouraged me to remain focused
on achieving my goal.

I would also like to thank all faculty and technical staff members of the
Department who have been kind enough to advise and help in their respective
roles. I have been fortunate to have wonderful support structure among the
graduate students. I am really thankful to my friends. My sincere thanks to
everyone who has provided me with kind words, new ideas, useful criticism, or
their invaluable time, I am truly indebted.

Bearing in mind previous I am using this opportunity to express my deepest

gratitude and special thanks to the Instructor of BRIZTECH INFOSYSTEMS
PVT. LTD. who in spite of being extraordinarily busy with her/his duties, took
time out to hear, guide and keep me on the correct path and allowing me to carry
out my project at their esteemed organization and extending during the training.

Student Name

CONTENTS

• Introduction of PLC

• History of PLC
 • PLC modules

• PLC switch

• RELAY

• LADDER DIAGRAM

• RUNG

• SOFTWARES USED

• RS LOGIX MICRO

• RS LINX CLASSIC

• RS EMULATOR 500

• PLC LADDER PROGRAMMING EXAMPLES

• EXAMPLE 1 –TRAFFIC LIGHT WITH TON TIMER

• EXAMPLE 2-CONVEYOR AUTOMATION USING COUNT UP COUNTER

• EXAMPLE 3- SEAL IN LADDER PROAGRAM FOR WATER MOTOR

• CONCLUSION
INTRODUCTION OF PLC

Introduction :- PLC stands for Programmable Logic Controllers. They are basically used to control
automated systems in industries. They are one of the most advanced and simplest forms of
control systems which are now replacing hard-wired logic relays at a large scale.
Programmable Logic Controllers (PLC) Programmable logic controllers are
the most widely used electronic devices in the control of production and assembly process in
most automated factories due to its simplicity and
versatility.
A programmable logic controller (PLC) is a user-friendly, microprocessor-based, specialized
computer carrying out control
functions of many types and levels of complexity in industrial applications.
It would be appropriate to think of the PLC. As a special purpose computer. Nevertheless, a
programmable logical Controller has many characteristics similar To those of a general-purpose
computer.
It has
• a power supply,
• main processor,
• memory,
• inputs and outputs,
• possibly some peripheral equipment.

A Programmable Logic Controller, or PLC, is more or less a small computer with a built-in
operating system (OS). This OS is highly specialized and optimized to handle incoming events in
real time, i.e., at the time of their occurrence.

The PLC has input lines, to which sensors are connected to notify of events (such as
temperature above/below a certain level, liquid level reached, etc.), and output lines, to which
actuators are connected to affect or signal reactions to the incoming events (such as start an
engine, open/close a valve, and so on).

The system Is user programmable. It uses a language called “Relay Ladder” or RLL (Relay Ladder
Logic). The name of this language implies that the control logic of the earlier days, which was
built from relays, is being simulated.

Some other languages used include:-

• Sequential Function chart
• Functional block diagram
• Structured Text
• Instruction List
• Continuous function chart

A programmable logic controller, PLC, or programmable controller is a digital computer used for
automation of typically industrial electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or light fixtures. PLCs are used in many machines, in
many industries.

PLCs are designed for multiple arrangements of digital and analog inputs and outputs,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and
impact. Programs to control machine operation are typically stored in battery-backed-up or non-
volatile memory. A PLC is an example of a “hard” real-time system since output results must be
produced in response to input conditions within a limited time, otherwise unintended operation
will result.

Before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles
was mainly composed of relays, cam timers, drum sequencers, and dedicated closed-loop
controllers. Since these could number in the hundreds or even thousands, the process for
updating such facilities for the yearly model change-over was very time consuming and
expensive, as electricians needed to individually rewire the relays to change their operational
characteristics.

Digital computers, being general-purpose programmable devices, were soon applied to control
industrial processes. Early computers required specialist programmers, and stringent operating
environmental control for temperature, cleanliness, and power quality. Using a general-purpose
computer for process control required protecting the computer from the plant floor conditions.
An industrial control computer would have several attributes: it would tolerate the shop-floor
environment, it would support discrete (bit-form) input and output in an easily extensible
manner, it would not require years of training to use, and it would permit its operation to be
monitored. The response time of any computer system must be fast enough to be useful for
control; the required speed varying according to the nature of the process.[1] Since many
industrial processes have timescales easily addressed by millisecond response times, modern
(fast, small, reliable) electronics greatly facilitate building reliable controllers, especially because
performance can be traded off for reliability.
MODULAR PLC
HISTORY OF PLC

The PLC or Programmable Logic Controller has revolutionized the automation industry. Today
PLCs can be found in everything from factory equipment to vending machines, but prior to New
Year’s Day 1968 the programmable controller didn’t even exist. Instead what existed was a
unique set of challenges that needed a solution. In order to understand the history of the PLC
we must first take some time to understand the problems that existed before programmable
controllers.
Before the Programmable Controller Before the days of the PLC the only way to control
machinery was through the use of relays. Relays work by utilizing a coil that, when energized,
creates a magnetic force to effectively pull a switch to the ON or OFF position. When the relay is
de-energized, the switch releases and returns the device to its standard ON or OFF position. So,
for example, if I wanted to control whether a motor was ON or OFF, I could attach a relay
between the power source and the motor. Then I could control when the motor is getting power
by either energizing or de-energizing the relay. Without power, of course, the motor would not
run, thus I am controlling the motor. This type of relay is known as a power relay. There could be
several motors in one factory that need to be controlled, so what do you do? You add lots of
power relays. So factories started to amass electrical cabinets full of power relays. But wait,
what switches the coils in the power relays ON and OFF before the power relay turns the motor
ON, and what if I want to control that? What do you do? More relays. These relays are known as
control relays because they control the relays that control the switch that turns the motor ON
and OFF. I could keep going, but I think you get the picture of how machines were controlled
pre-PLC, and, more importantly, I think you start to see some of the problems with this system
of electromechanical control via relays.

Innovative Improvements

1970s:-
With inexpensive microprocessors becoming available in the late 1970s, PLC manufacturers
began developing graphical programming devices. These devices enabled PLCs to be digitally
programmed with graphical representations for normally open and closed relay contacts,
pushbuttons, switches, relay coils, motor starters, valves, timers, and more. Unfortunately,
these programming devices were prohibitively expensive, often costing more than the PLC they
were designed to program. The programming devices were also only compatible with a single
manufacturer’s controllers, further reducing their utility.

1980s :-

Third-party software packages that worked with multiple PLC hardware platforms came
available in the 1980s to alleviate the high cost of early programming devices. These third-party
software packages also offered vastly improved documentation and reporting capabilities over
the OEM programming devices. This led PLC manufacturers to develop and market their own
competing programming packages, as well as purchase many of the third-party software
companies.

The 1980s also saw the introduction of the IEC 61131-3 Standard for Programmable Controllers,
which is the standard all PLC software is held against. The IEC brings consistency to PLC software
programs by defining various standards for data types, naming conventions, program flow, and
other programming elements. More specifically, the standard ensured functions and function
blocks looked the same and had the same defined inputs and outputs, making it easier for
engineers or maintenance personnel to understand the program. The IEC also established five
PLC compliant programming languages, consisting of LD function block diagrams (FBD),
sequential function chart (SFC), structured text (ST), and IL.
1990s :-
In the 1990s, manufacturers began requesting for machinery to include interactive terminals
that allowed them to monitor their PLC software. In addition, the terminals would allow
operators to quickly see what was wrong with their machines preventing them from having to
spend hours troubleshooting. This idea led to the development of the human-machine interface
(HMI).
Initially, HMIs were merely a digital replacement for physical pushbuttons and were considered
too expensive for applications that had less than 20 pushbuttons. However, with continued
development and growing demand for machine monitoring, HMIs gained the ability to translate
the machine data being recorded by PLCs and display it in the form of system status, alarms,
cycle times, reports, production counts, and more

By the end of the 1990s, PLCs were becoming smaller, faster, more powerful, and equipped with
significantly more memory. As the world moved into the twenty-first century, these
advancements in PLC technology would help pave the way forward.
manufacturers to implement a new era of internet connectivity, big data, and even forms of
artificial intelligence on the factory floor.

PLC SWITCH

A switch will be in its “normal” (resting) state when the stimulus value is less than the threshold
value. Conversely, a switch will be in its “actuated” state when the stimulus value exceeds the
threshold value.
Determination of a switch’s status, therefore, is a matter of comparing
the stimulus quantity to the threshold “trip” setting. One cannot simply look at the schematic
diagram to tell what the switch is doing – one must compare the switch’s setting versus against
a known stimulus value in order to tell whether it will be in its resting state or not.
Likewise, if we happen to know the switch’s present status in a system,
we may qualitatively determine the stimulating quantity by comparing the present status
against the “normal” (resting) status.

If a switch is in its resting state, then the stimulating quantity must be less than the trip
threshold. If a switch is in its actuated (non-normal) state, then the stimulating quantity must be
greater than the trip threshold

The example showcases these determinations.

In this next example, we see a pictorial representation of multiple switches wired to the
discrete input channels of a programmable logic controller (PLC), with red LED indicators
denoting the real-time status of each input on the PLC:

PLC Example with Switches :-

We may determine a switch’s degree of stimulation by comparing its present status with its
“normal” status.
If a switch happens to be in the same state as its normal state (i.e. resting), we know its stimulus
must be less than the threshold (trip) value.
Consider, If a switch happens to be in the opposite state as its normal state (i.e. actuated), we
know its stimulus has exceeded the threshold (trip) value.

RELAY
A relay Is an electrically operated switch that is used to turn ON / OFF a high power circuit by
using a low power signal.

An electromagnetic relay consists of an electromagnet, an armature, set of input terminals and

set of control terminals. While, a solid-state relay consists of semiconductor based mechanism
for switching of the circuit.
An electrically operated switch which is used for switching a high power circuit with the help of
a low power circuit is known as relay. Hence, in simple words, a relay is nothing but an
electrically operated switch.

A typical relay consists of a set of input terminals and a set of operating contact terminals.
Where, the input terminals are provided for inputting a single or multiple control signals.

Based on construction and design, there are two types of relays namely electromagnetic relays
and solid-state relays. An electromagnetic relay consists of a coil wound around a soft iron core,
where the iron core provides a path of low reluctance for the flow of magnetic flux. It also
consists of a movable armature and a set of contacts. On the other hand, the solid-state relays
do not consists of any moving part, they use semiconductor devices instead of electromagnets.

The relays are used in such applications where it is required to control the operation of an
electrical or electronic circuit by a low power electric signal or where a number of circuits have
to be controlled by one electric signal. Some practical applications of relays are in electronic
circuits, home appliances, signalling and control in railways, motor control circuits, power
generation and transmission systems, etc.

Relays are used wherever it is necessary to control a high power or high voltage circuit with a
low power circuit, especially when galvanic isolation is desirable. The first application of relays
was in long telegraph lines, whereas the weak signal received at an intermediate station could
control a contact, regenerating the signal for further transmission. High-voltage or high-current
devices can be controlled with small, low voltage wiring and pilots switches. Operators can be
isolated from the high voltage circuit. Low power devices such as microprocessors can drive
relays to control electrical loads beyond their direct drive capability. In an automobile, a starter
relay allows the high current of the cranking motor to be controlled with small wiring and
contacts in the ignition key.

Electromechanical switching systems including Strowger and crossbar telephone exchanges

made extensive use of relays in ancillary control circuits. The Relay Automatic Telephone
Company also manufactured telephone exchanges based solely on relay switching techniques
designed by Gotthilf Ansgarius Betulander. The first public relay based telephone exchange in
the UK was installed in Fleetwood on 15 July 1922 and remained in service until 1959.

The use of relays for the logical control of complex switching

systems like telephone exchanges was studied by Claude Shannon, who formalized the
application of Boolean algebra to relay circuit design in A Symbolic Analysis of Relay and
Switching Circuits. Relays can perform the basic operations of Boolean combinatorial logic. For
example, the Boolean AND function is realised by connecting normally open relay contacts in
series, the OR function by connecting normally open contacts in parallel. Inversion of a logical
input can be done with a normally closed contact. Relays were used for control of automated
systems for machine tools and production lines. The Ladder programming language is often
used for designing relay logic networks.
Early electro-mechanical computers such as the ARRA, Harvard Mark II, Zuse Z2, and Zuse Z3
used relays for logic and working registers. However, electronic devices proved faster and easier
to use.

Because relays are much more resistant than semiconductors to nuclear radiation, they are
widely used in safety-critical logic, such as the control panels of radioactive waste-handling
machinery. Electromechanical protective relays are used to detect overload and other faults on
electrical lines by opening and closing circuit breakers.

For protection of electrical apparatus and transmission lines, electromechanical relays with
accurate operating characteristics were used to detect overload, short-circuits, and other faults.
While many such relays remain in use, digital protective relays now provide equivalent and
more complex protective functions.

Ladder Diagram

Ladder Diagram is a graphical programming language that you use to develop software for
programmable logic controllers (PLCs). It is one of the languages that the IEC 61131 standard
specifies for use with PLCs. A program in ladder diagram notation is a circuit diagram that
emulates circuits of relay logic hardware. The underlying program uses Boolean expressions that
translate readily to switches and relays.

With Simulink® PLC Coder™, you can use ladder import to import ladder diagrams created with
Rockwell Automation® IDEs, such as RSLogix™ 5000 and Studio 5000 into the Simulink
environment as a model. You can create ladder diagrams in the Simulink environment as a
model.

After importing or creating the ladder diagram models, you can:

• Edit the imported Ladder Diagram model from within Simulink by using the plcladderlib
library.

• After importing the ladder diagram code into Simulink, simulate it.

• Generate C code from the imported ladder diagram and integrate the code into your
existing C language-based simulation environments.
• Generate ladder diagram code from the imported ladder diagram and integrate the code
into your Rockwell

• Automation IDE. You cannot generate structured text code from the Ladder Diagram
blocks.

• Generate PLC test-bench code for the imported ladder diagram and verify the code in
your Rockwell Automation IDE.

Ladder diagrams are used to formulate PLC logic expressions in graphical Ladder diagrams are
used to formulate PLC logic expressions in graphical form. They use symbols to represent
conditional, input and output expressions. Ladder diagrams are similar to relay control circuits
and are used due to their ease of programming compared to text based programming
languages.

Early control system designers were accustomed to relay logic control circuits and ladder
diagrams closely mimic these. They preferred to use ladder diagrams for PLC programming
instead using text based programming languages of the day like C, BASIC, Pascal and FORTRAN.

Factory maintenance staff already understand how to read relay control circuits. They can use
their knowledge of relay control circuits to help troubleshooting control system problems that
implement PLC programming with ladder diagrams.

Ladder Diagram (LD) is the official name given in the

International PLC programming standard IEC-61131. But, these days the terms ladder diagram,
ladder logic diagram, ladder drawing, ladder control, ladder circuit, control logic diagram and
logic diagram (to name a few) are all used to describe relay logic circuits and ladder logic
programming.
So don’t get too caught up in the specific definition of each of these expressions, they kind of
generally all mean the same thing. At the end of the day most people will know what you are
talking about anyway. Personally, I use the term ladder logic for PLC programming and relay
logic for relay control circuits.. They use symbols to represent conditional, input and output
expressions. Ladder diagrams are similar to relay control circuits and are used due to their ease
of programming compared to text based programming languages.

Early control system designers were accustomed to relay logic control circuits and ladder
diagrams closely mimic these. They preferred to use ladder diagrams for PLC programming
instead using text based programming languages of the day like C, BASIC, Pascal and FORTRAN.

Factory maintenance staff already understand how to read relay control circuits. They can use
their knowledge of relay control circuits to help troubleshooting control system problems that
implement PLC programming with ladder diagrams.

Ladder Diagram (LD) is the official name given in the international PLC programming standard
IEC-61131. But, these days the terms ladder diagram, ladder logic diagram, ladder drawing,
ladder control, ladder circuit, control logic diagram and

logic diagram (to name a few) are all used to describe relay logic circuits and ladder logic
programming.
So don’t get too caught up in the specific definition of each of these expressions, they kind of
generally all mean the same thing. At the end of the day most people will know what you are
talking about anyway. Personally, I use the term ladder logic for PLC programming and relay
logic for relay control circuits.

RUNG

In PLC ladder logic programming, the horizontal line is called Rung. Basically, the ladder logic is
composed of a set of rungs. Each rung represents a single line with specific functions.

Let’s see here, simple representation of the rung in ladder logic.

Rung and Rail LD PLC
If you have seen the above diagram, the horizontal lines represented as R1, R2 … Rn are the
rungs. Each rung can have multiple inputs, outputs, and other programming instructions.
That is how the input and output modules connect and communicate through the rungs.
The rungs are drawn as horizontal lines and connect the rails to the logic expressions. If they
were in a relay logic circuit they would represent the wires that connect the power supply to the
switching and relay components. Each rung is numbered in ascending sequential order.

Rungs serve the same function as steps on a step ladder. The only difference between rungs on
an extension ladder and step ladder is that rungs on an extension ladder are half as deep to
allow the fly section to slide up and down. Rung locks serve to lock the fly section into place so
that it doesn’t collapse. In order to drop the fly section, the rung locks hinge upward so they
slide over the base rungs.

SOFTWARE USED FOR LADDER PROGRAMMING

1.RS Logix Micro Software

2. RS Linx Classic

RSLinx Classic for Rockwell Automation Networks and Devices is a

Comprehensive factory communication solution, providing Allen-Bradley
Programmable controller access to a wide variety of Rockwell Software and
Allen-Bradley applications. These range from device programming and
Configuration applications such as RSLogix and RSNetWorx, to HMI
(Human-Machine Interface) applications such as RSView32, FactoryTalk View
SE (Site Edition), and FactoryTalk View ME (Machine Edition), to your own
Data acquisition applications using Microsoft Office, web pages, or Visual
Basic®. RSLinx Classic also incorporates advanced data optimization
Techniques and contains a set of diagnostics. The API (Application
Programming Interface) supports custom applications developed with the
RSLinx Classic SDK.
3. RS Emulator 500

PLC Programming

Example 1.

Traffic signal using Ton timer

Ton timer

The TON, also known as Timer ON, an instruction is used to keep track of time of occurrence of
certain events. The conditions preceding the TON instruction will allow the timer to start
counting up to a specified value. Once this value is reached, the program will set specific
internal bits notifying the programmer as well as other instructions within the PLC that the
timer has finished counting.

Data Types Allowed for TON (Components of Timer)

The TON leverages a specific data structure, called the Timer, present in most PLC systems.

Timer – The high-level instruction specification of all the inner structures.

.PRE – Integer specifying up to which value the timer will count.(preset)

.ACC – Integer specifying the current time value of the timer.(accumulator)

.EN – Boolean value which is set to HIGH when the timer is energized.(enable)

.TT – Boolean value which is set to HIGH when the timer is in the process of counting.

.DN – Boolean value which is set to HIGH when the timer is finished counting.(done)

List of Inputs and Outputs

I:1/0 = Start (Input)

I:1/1 = Stop (Input)

B3:0/0= Latched Coil Bit (Bit)

T4:0 = Timer to update output sequence (Timer)

O:2/0 = North-South Green Light (Output)

O:2/1 = North-South Yellow Light (Output)

O:2/2 = North-South Red Light (Output)

O:2/3 = East-West Green Light (Output)

O:2/4 = East-West Yellow Light (Output)

O:2/5 = East-West Red Lig

EXAMPLE 2

Conveyor belt Automation using Count Up Timer

EXAMPLE 3

SEAL IN MOTOR LADDER PROGRAM

Conclusion

This report covered the preview of our learning path and study materials. The use of PLC has
many advantages. And Ladder Programming is very beneficial It can help to reduce the time it
takes to produce the programming needed in the work environment. RS Logix Micro software
is the most amazing range of computer aided programming tool. It is now considered to be the
best according to industry standards that can be obtained for a wide array of designing of PLC
automation and other industrial purposes.

Automation is the key to scaling up production, bringing efficiency and cost-effectiveness to the
manufacturing process. Across all industries and diverse sectors, manufacturers use PLC in
industrial automation to monitor and automate their system processes. With sophisticated
technology and flexible programming, compact PLC in India are in demand for the reason that
they are faster, cheaper and powerful-thus contributing to performance efficiency. Besides
driving efficiency in automation processes, the benefits of PLC include:

Reliability- reduces manual errors and drives system efficiency.

Performance efficiency and precision in manufacturing.

Flexibility- Micro PLC in India such as NX-ERA Xpress offer remote I/O capabilities that connect
external devices such as sensors, actuators.

Cost effectiveness- PLC manufacturers in India such as Alan Bradely offer cutting edge
technology at cost effective prices, enabling companies to improve operations and minimize
downtime.