ACADEMIC INTERNSHIP

Report Title: Industrial Automation Project Report: PLC-Based Control System

Project Name: "Blinking Control System using PLC: Exploring Industrial

Automation"
Internship Organization: Tool Room & Training Centre , Guwahati

Submitted by:

1. BHARGAB GOGOI (ELECTRICAL ENGINEERING)

2. BIPLOP HAGJER (ELECTRICAL ENGINEERING)
3. KAUSTAV DEVGAN (ELECTRICAL ENGINEERING)
4. MITURAJ BAISHYA (ELECTRICAL ENGINEERING)
5. NITUMANI BHARALI (ELECTRICAL ENGINEERING)
6. PALLAB SONOWAL (ELECTRICAL ENGINEERING)

4TH SEMESTER

JORHAT ENGINEERING OLLEGE

2023
 DECLARATION

We the students of the 4th Semester, hereby declare that the

presented report of internship to the department of Electrical
Engineering of Jorhat Engineering College during the academic
year 2022-23, is uniquely prepared by us under the guidance of
the ”Tool Room and Training Centre, Amingaon, Guwahati"
after the completion of four weeks of work. The work done by
us is our own piece of work and authentic to the best of our
knowledge. This project work is submitted in partial fulfillment
of the requirements for the award of points in our B.Tech
course of Electrical Engineering. The results embodied in this
report have not been submitted to any other university or
another institute of higher learning for the award of any degree
as such.
 ACKNOWLEDGEMENT

Firstly, we would like to express our indebtedness appreciation to our

Departmental HOD Dr. Aditya Bihar Kandali. His constant guidance and
advice played the vital role in making the execution of the report.

Secondly, we would like to express our gratitude to all the faculty

members of Tool Room & Training Centre who helped us in all possible
ways to make our internship a success.

The internship opportunity we had with "Tool Room and Training

Centre, Amingaon, Guwahati " was a great chance for learning and
professional development. Therefore, we consider ourselves as a very
lucky individuals as we were provided with an opportunity to be a part
of it. We are also grateful for having a chance to meet so many
wonderful people and professionals who led us though this internship
period. We perceive as this opportunity as a big milestone in our career
development, we will strive to use gained knowledge in the best.
 TABLE OF CONTENTS

Sl No TOPIC PAGE NO
1 INSTITUTION INFORMATION 1
2 INTRODUCTION 2-3
3 SOFTWARE, HARDWARE & PROGRAM 3
4 DIFFERENT ELECTRICAL CIRCUITS 4-11
USING PLC
 Normally Closed (NC) & Normally
Open (NO)
 Latching
 Memory
 Comparator
 Counters
 Timers
5 PROJECT WORK 12-15
6 CONCLUSION 16
 INSTITUTION INFORMATION
About Tool Room & Training Centre, Guwahati
Tool Room & Training Centre, Guwahati has been established by Government of India to cater tooling
and training need of Industries of North Eastern Region. The State Government of Assam has provided
the land as well as initial building to the Tool Room. TRTC has been registered as Government of India
Society on 24th February 2000.It is situated at Amingaon Industrial Area, North Guwahati Road,
Guwahati-781031. It is a sprawling campus with Administrative Block, Training Block, Modern
Workshop, Knowledge Centre, Staff Quarters and Hostel.

The management of the affairs of the Centre rests with the Governing Council constituted by
Government of India. Additional Secretary and Development Commissioner (MSME), Government of
India, is the President of the Society and the Chairman of the Governing Council.
The training department provides quality training in the field of Design with CAD/CAM/CNC Machining
with latest high-tech software's , Machine Tool Operation, Precision Machining, Welding Technology, IT,
PLC etc. The production wing manufactures press tools, moulds, jigs & fixtures, gauges and other
precision components as per the needs of the industries.

In pursuit of excellence, Tool Room & Training Centre, Guwahati has been awarded with an IS/ISO
9001:2015, and IS/ISO 14001:2015 certifications.

CENTRES

TOOL ROOM & TRAINING CENTRE, GUWAHATI, AMINGAON

TOOL ROOM & TRAINING CENTRE, JORHAT EXTENSION CENTRE
TOOL ROOM & TRAINING CENTRE, BAMUNIMAIDAN (CITY CENTRE), GUWAHATI

AIMS & OBJECTIVES

 To impart Long Term, Mid Term and Short Term Training to youngsters with the latest
technologies (and other allied engineering trades) both for fresher's and personnel already
engaged in this field.
 To provide qualitative service in the area of Development & Manufacturing of Quality Tools &
Components, Design, Project Consultancy & Skill Development Programme.
 To develop production facilities of moulds, jigs, fixtures, gauges & other sophisticated tools
preferable for Small Scale Industries.
 To Train manpower in the field of industrial engineering & other allied engineering trades both
for the fresher's and for personal already engaged in the field.
 To provide common facilities in precision machining.
 To provide consultancy facilities primarily for MSMEs units in the field of tool engineering aimed
at improvement in productivity.
 The aim of the Centre is to promote growth and development of Micro, Small & Medium
Enterprises through Technological and Skilled Manpower Support.

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 INTRODUCTION
PLC or Programmable Logic Controller
A Programmable Logic Controller (PLC) is an industrial digital computer which can control
automation process of some industries. These controllers can automate a specific process,
machine function, or even an entire production process. They are mostly used in industries in
assembly lines, machines, robotic devices, or any other activity that requires high reliability,
ease of programming, and process fault diagnosis. Dick Morley considered as the father of PLC
as he had invented the first PLC, the Modicon 084, for General Motors in 1968.

PLCs range from small devices with few to large rack-mounted modular devices with thousands
of I/O.

Programmable Logic Controllers are intended to be used by engineers without a programming

background. For this reason, a graphical programming language called Ladder Diagram (LD,
LAD) was first developed. It resembles the schematic diagram of a system built with
electromechanical relays and was adopted by many manufacturers and later standardized in
the IEC 61131-3 control systems programming standard. As of 2015, it is still widely used,
thanks to its simplicity.

As of 2015, the majority of PLC system adhere to the IEC 61131-3 standard that defines 2
textual programming languages.

 Structured Text
 Instruction List (IL)

As well as 3 graphical languages

 Ladder Diagram
 Functional Block Diagram (FBD)
 Sequential Function Chart (SFC)

Modern PLCs can be programmed in a variety of ways, from the relay derived ladder logic to
programming languages such as specially adapted dialects of BASIC and C.

WHY 24V DC IS USED IN PLC ?

1. Safety. As the supply is just 24 v DC no vast protective measures is to be taken.

2. Maintenance time is reduced as the maintenance can be done without the cut-off of the
input power
 3. Standardization. As earlier 24 V DC was used in RLC for controlling motor, relays,
contractor, etc. So if other voltage is used instead of 24 V DC the entire system is to be
altered which will turn out to be very expensive.
4. Reduced size of the machine as no complicated parts is to be used, the system become
compact in size.
5. By using DC power, the overall efficiency of the plant can be improved by reducing the
amount of energy lost in the form of heat during transmission.

Disadvantages of 24V DC
1. The major disadvantage of DC supply is that it cannot be used for longer distances. It
faces a reduction in signal capacity over long distances.
2. The 24V DC supply cannot be used for driving high current loads.

SOFTWARE, HARDWARE & PROGRAM

The main software we used in this process is ‘SIMATIC MANAGER’ (SIMATIC is a series of
programmable logic controller and automation systems, developed by Siemens. Introduced in
1958, the series has gone through four major generations, the latest being the SIMATIC S7
generation. The series is intended for industrial automation and production.)
Along with “SIEMENS S7-400 STAND ALONE PLC PANEL” for physical inputs and outputs

Program Creation

 Open SIMATIC MANAGER

 File -> New -> Project name<XYZ> -> OK
 Click MPI(1) -> Rack 400 _. UR2 (6ES7400-1JA01)
 PS400 -> Redundant PS400 -> PS407-10A (6ES7407-0KR02-0AA0)
 CPU 400 -> CPU-412-2PN (6ES7402-2EK06-0AB0) -> v6.0 ->OK
 SM400 ->
 DI400 -> DI16XUC24V/60A Interrupt
 DO400 -> DO16XDC24V/2A (6ES422-1BH11-0AA0)
 AI400 -> AI8X13BIT
 AO400-> AO8X13BIT
 Save
 Open SIMATIC MANAGER file ->
 Select Language (LAD)
 OK
The program is hence created for designing the different connections.

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Rules of PLC :

1. The input can be connected in series as well as parallel. But output cannot be
connected in series but only in parallel.
2. Input address can be repeated multiple times as an input, but output address
cannot be repeated multiple times as an output.
3. Input address cannot be used as output, but output address can be used as
input.

Different Electrical Circuits Using PLC

1. Normally Closed (NC) & Normally Open (NO) :

Logic is developed in every control circuit and automation system based on the open or
closed state of switches, sensors, or relays. As a result, understanding the idea of NO/NC
is required. The words normally open (NO) and normally closed (NC) are used to
describe the states of switches, sensors, or relay contact
contactss when their coils are not
energized. It is referred to as the backbone of process automation.

A NO contact, also known as a normally open contact, is one that remains open until a
specified condition is reached. Consider a limit switch as an example. A limit
l switch
contains at least one NO contact. The limit switch’s NO contact stays open until the
actuator is pressed. When the actuator is pressed, the contact closes and the current
begins to flow. NO contacts in proximity switches remain open until they detect an item;
similarly, in pressure switches, the contact remains open until the predetermined
pressure level is met.

NO Switch: It is represented in the form Ia.b, where a is any +integer

integer and b is the
number of bit ranging from 0 to 7.

Symbol:

By function, an NC contact, also known as a usually closed contact, is the total opposite
of a NO contact. It remains closed until a specific condition is reached. In this situation,
let us look at how the limit switch works. When the NC contact of a limit switch
s is
pressed in a circuit, it breaks the circuit or current flow. Similarly, unless the coil of a
relay is stimulated, its contacts remain closed
closed.

NC Switch: It is represented in the form Ia.b, where a is any +integer and b is the
number of bit ranging
ing from 0 to 7.

Symbol:

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PLC output usually refers to the physical devices connected to the programmable logic
controller. Outputs are generally isolated from the CPU of the PLC through light. This isolation is
the reason that if the output is destroyed, the PLC can still function. Usually, the output can be
corrected, and a new output card can be placed on the PLC. Alternatively, the output can be
corrected, and the PLC output can be programmed for another output address. These output
devices allow the PLCC to perform an action and control the inputs if feedback is from the
output.

Output: It is represented in the form Qa.b, where a is any +integer and b is the number of
bit ranging from 0 to 7.

Symbol:

Some of the Solution Circuits which we created for some problems are provided follows.

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2. Latching:

The latching is used where the output must be activated even after the entry ceases. A
simple example of such a situation is a motor, which is started by pressing a button
switch. Although the switch contacts do not remain closed, it is required that the motor
continue to run until a stop button switch is pressed. The latching used to stay the
motor run until the push button is pressed again. Circuits that are characteristic given
the previous conditions are often needed in logic control. In this series the output is
latched by using the output contact itself, so even though the input has changed, the
output condition is fixed:

When there is an exit, another set of contacts associated with the exit is closed. These
contacts form an OR logic gate system with the input contacts. Therefore, even if the A
input is opened, the circuit will keep the output energized. The only way to release the
output is to activate the normally closed contact B.

Some of the Solution Circuits which we created for some problems are provided
follows.

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3. Memory:

Memory is the element that stores information, programs, and data in a PLC. The user
memory of a PLC includes space for the user program as well as addressable memory
locations for storage of data. Data are stored in memory locations by a process
called writing. Data are retrieved from memory by what is referred to as reading.

Bit memory is the simplest and most basic form of PLC memory, as it can store only one
binary value (0 or 1) per address. Bit memory is used for storing discrete inputs and
outputs, such as switches, sensors, relays, and solenoids. Bit memory is fast and easy to
use, as it can be directly accessed by the PLC logic.

Byte memory is a form of PLC memory that can store eight bits (or one byte) per
address. Byte memory is used for storing binary-coded decimal (BCD) values, such as
timers, counters, or numeric displays. Byte memory is more versatile and efficient than
bit memory, as it can store more information per address, and it can handle basic
arithmetic operations. However, byte memory is still limited and cumbersome, as it can
only store values from 0 to 255, and it requires conversion functions to handle other
data formats, such as hexadecimal or ASCII.

Some of the Solution Circuits which we created for some problems are provided
follows.

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4. Comparator:

Comparators are used for comparing two values. Say, If we want to compare two
physical quantities (temperature, pressure etc.). We can use the equal instruction to
determine, if a first comparison value is equal to a second comparison value or not.

There are many comparator operations like equal (==), not equal (<>), less than (<),
greater than (>), less than or equal (<=), greater than or equal (>=). All these comparator
operations might be used in different logic scenarios while writing a ladder logic
program.

Because they are used for comparing two the value of input variables, there will be two
operators which are being compared. these input variables could be of any data type i.e.
integer, real, boolean, character, string et cetera. And the output will be a boolean data
type which denotes true or false, or “0” or “1”.

Equal operator (==):The equal operator is used to check if two operands are equal or
not. The input operands’ datatype could be any of the possible data types in the
language we are using.

Not equal comparator operator: This operator is used to compare two operands. When
they are not equal it produces positive RLO with High logic and when they are equal it
returns false or “0”.

Greater-than “>” comparator operation: The greater than comparator operator is used
for checking if operand 1 is greater than operand 2 or not.

Less-than “<” comparator operation: The less than comparator operator is used for
checking if operand 1 is less than operand 2.

Greater-than or equal comparator operator “>=”: A run in a ladder logic program that
uses greater-than or equal “>=” operator. The output shows true when the two
operands are equal or greater.

Less-than or equal comparator operator “<=”: A run in a ladder logic program that uses
less than or equal “<=” operator. The output shows true when the two operands are
equal or less

. Some of the Solution Circuits which we created for some problems are provided
follows.

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 5. Counters:

This instruction is denoted by the ‘‘C‘‘ in LD programming. And it is part of the

mathematical function. The role of the counter in PLC is to control and to operate the
device in the sequential order. This sequential order can be in ascending order or
descending order.
Basically, PLC counter operates into four modes such as up mode, down mode,
bidirectional mode, and the quadrature mode.

Counters in PLC are classified into three main different parts.

 Up Counter (operates up mode)

 Down Counter (operated in down mode)
 Up/Down Counter (operates in bidirectional and quadrature mode)

Up Counter: Up counter counts from zero to the preset value. Basically, it increases the pulse or
number. Up counter is known as the ‘‘CTU’ or ‘CNT’ or ‘CC’ or ‘CTR’.

Down Counter: The down counter counts from the preset value to zero. It decreases the pulse
or number. Down counter is shortly known as the ‘‘CTD’ or ‘CD’.

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Up-Down Counter: The up-down
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. Up-down
down counter is known as ‘‘CTUD’. For the bidirectional and quadrature operation
mode, the up-down
down counter is selected depending on the status (high or low) of the specified
count input terminal.

. Some of the Solution Circuits

cuits which we created for some problems are provided follows.

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 6. Timers:

PLC timers are internal PLC instructions that can be used to delay input and output
signals in the PLC program.
These timers operate like relay timers but you cannot hold a PLC timer in your hand and
they do not need to be connected to wires to operate.
A timer is a PLC instruction measuring the amount of time elapsed following an event.
Timer instructions come in two basic types: on-delay timers and off-delay timers. Both
“on-delay” and “off-delay” timer instructions have single inputs triggering the timed
function.
The accuracy and repeatability of the timer are extremely high because the PLC
processor generates delays. A timer starts counting at time-based intervals and
continues until the accumulated value equals the preset value. When the accumulated
value is equal to the preset time, the output will be energized. Then the timer sets the
output.

There are five main types of PLC timers:

 Pulse timer (S_PULSE).
It makes the timer on for a period when input is made on and restart the timer if input is
made off and on again, during which output is received.
 Extended Pulse timer (S_PEXT)
It makes the timer on for an entire period when input is made on and continues the
timer even if input is made off, during which output is received.
 On-delay timer (S_ODT)
It makes the timer after a period when input is made on and restart the timer if input is
made off and on again, after which output is received.
 Retentive on-delay timer (S_ODTS)
It makes the timer on after a period when input is made on and continues the timer
even if input is made off, after which output is received.
 Off-delay timer (S_OFFDT)
It makes the timer on after the input is made off. For the time which input in on and
timer is running output is gained, after that the output is off.

. Some of the Solution Circuits which we created for some problems are provided follows.

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 PROJECT WORK
Blinker Control
In pursuit of exploring the capabilities and applications of PLCs, we embarked on a
project to develop a scaled-down and simplified version of a blinker control system. For
our project, we selected the Siemens S7-400 PLC, a state-of-the-art automation
platform known for its robustness and performance. With its powerful processing
capabilities and advanced programming features, the S7-400 offered an ideal platform
for our blinker control system.

We have designed a versatile blinker control system that allows us to control the
blinking rate of the bulb and it comprises of three distinct modes of operation, each
activated by a dedicated switch:

 Switch 1 (Bulb On/Off Mode): When Switch 1 is turned on, the bulb remains
continuously illuminated until the switch is turned off. This mode serves as a
simple ON/OFF control for the bulb, allowing manual activation and
deactivation.(Under condition that Switch 2 & 3 are off)

 Switch 2 (Slow Blinking Mode): Upon activating Switch 2, the bulb enters a slow
blinking mode. The PLC program is designed to regulate the blinking interval,
creating a gentle and periodic illumination effect with the use of TIMERS. The
blinking continues until Switch 2 is turned off. (Under condition that Switch 3 is
off)

 Switch 3 (Fast Blinking Mode): Switch 3 initiates the fast blinking mode, causing
the bulb to blink at a higher frequency compared to the slow blinking mode.
Similar to the slow blinking mode, the fast blinking mode persists until Switch 3 is
deactivated. (This mode is independent of Switch 1 &2)

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Ladder Logic Diagram for our Project is as follows:

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Hardware Configuration:

In our blinker control system project, we have employed a PLC relay in

conjunction with a 100W bulb to control the lighting output. The PLC relay acts as
an intermediary device, facilitating the communication between the Siemens S7-
400 PLC and the bulb, which is the end-device.

Components Used:

 Siemens S7-400 PLC: The heart of our control system, the Siemens S7-400
PLC, is a high-performance programmable logic controller renowned for its
reliability and robustness in industrial automation applications.
 PLC Relay: The PLC relay serves as an interface between the output of the
PLC and the connected load, which is the 100W bulb in our case. It ensures
that the higher voltage output from the PLC does not directly drive the
bulb, providing electrical isolation and protection.
 100W Bulb: The 100W bulb represents the load that we control using the
blinker control system. It simulates the light output, demonstrating the
practicality of the PLC-based control in a real-world scenario.

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Wiring Configuration:

The PLC relay is wired to the output of the PLC at address Q0.0. The PLC's output
module, associated with address Q0.0, provides the necessary control signal to the
relay. When the output is energized by the PLC, the relay activates, allowing the
electrical current to flow through the connected load (the 100W bulb). As a result, the
bulb lights up according to the predefined control logic implemented in the PLC
program.

Result:

The inclusion of timers in our PLC design for the blinker control system has
significantly enhanced its versatility and control capabilities. By utilizing
timers to regulate the ON/OFF cycles of the bulb, we can precisely adjust
the blinking rates according to the desired application and production
requirements. This integration showcases the power and adaptability of
PLCs, enabling us to explore the full potential of industrial automation and
its positive impact on cost-effectiveness and efficiency in modern
industries.

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 CONCLUSION
Throughout our PLC internship, we gained extensive knowledge about
industrial automation, including PLC usage and hardware setup. The
most thrilling part was successfully finishing the "Blinking Control"
project. This project provided us with a deeper understanding of PLC
programming and its practical application in industrial automation.

Building the blinker control system allowed us to implement multiple

control modes for the blinking rate, showcasing the versatility of PLCs
in adapting to diverse requirements. This hands-on experience has
deepened our appreciation for how PLC-based systems can
significantly impact cost-effectiveness and operational efficiency in
industrial settings.

As we conclude our PLC internship, we are excited about the prospects

of pursuing a career in industrial automation. The knowledge gained
during this internship has equipped us with a solid foundation to
contribute effectively to the evolving landscape of industrial
engineering. We look forward to applying our expertise to innovative
projects and making a positive impact in the realm of PLCs and
automation.

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