Summer Internship Report on

In-Plant Training at

Steel Authority of India Limited

India

By,
Ankit Renee Topno
Roll No. 07EC 3503
Printed Circuit Board(PCB)

A printed circuit board, or PCB, is used to mechanically support and electrically

connect electric components using conductive pathways, tracks
or traces eteched from copper sheets laminated onto a non-conductive substrate.

Manufacture of PCB

1. Film Generation: 2. Shear Raw Material:

Generated from your Industry standard 0.059"

design files, we create an thick, copper clad, two
exact film representation sides. Panels will be
of your design. We will sheared to accommodate
create one film per layer. many boards

4. Electroless
Copper: 3. Drill Holes:

Apply thin Using NC

copper deposit machines and
in hole barrels. carbide drills.
Manufacture of PCB

5. Apply Image: 6. Pattern Plate:

Apply photosensitive Electrochemical

dryfilm (plate resist) to process to build
panel. Use light source copper in the holes
and film to expose and on the trace
panel. Develop area. Apply tin to
selected areas from surface.
panel.

8. Solder mask: 7. Strip & Etch:

Apply solder mask Remove dryfilm,

area to entire board then etch
with the exception of exposed copper.
solder pads. The tin protects
the copper
circuitry from
being etched.
Manufacture of PCB

9. Solder coat: 10. Fabrication:

Apply solder to Apply white letter

pads by immersing marking using screen
into tank of solder. printing process.
Hot air knives level .Route the perimeter
the solder when of the board using NC
removed from the equipment.
tank.
 Programmable Logic Controller (PLC)

A programmable logic controller (PLC) or programmable controller is a Digital

Computer used for automation of electromechanical processes, such as control
of machinery on factory assembly lines, amusement rides, or lighting fixtures.
PLCs are used in many industries and machines. The PLC is designed for
multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
PLCs offer numerous advantages over hardwired systems. They are:.

Parameter Conventional Control PLC-Based Control Panel

Panel
Tool used for Hard wiring is used. Software programs are used.
automation
Space requirements It requires a large amount of These are compact systems
space to house the relays and can be installed in much
and the connecting wires. smaller space.
Power consumption The power consumption is The power consumption is
higher. The approximate much lower. The
power requirement for a approximate power
contactor consisting of 500 requirement for a PLC
I/O devices is 220 volts x controlling 500 I/O devices
0.2 amps x 500 = 22 KVA. is 0.1 KVA. This is because
PLCs do not require
hardwiring and actual
circuits for controlling
operations.
Programmable Logic Controller (PLC)

Installation The installation process is The installation process is

difficult because the much easier, and the
individual relays first needcontrols can be easily
to be made using programmed using ladder
electronic circuits and thenlogic and tested in a
connected using simulated environment. In
hardwiring. Each relay addition, the installation of
needs to be tested PLCs can be made
individually for proper modular. In other words,
functioning. different parts of a process
can be automated in
different phases.
Maintenance Regular wear and tear of Because the software
relay and hardwire takes program is not subject to
place. As a result, wear and tear, not much
extensive and constant effort is required for
maintenance of the system normal maintenance. Only
is required. the cables connecting the
real-world devices to the
PLC need to be
maintained.
Flexibility It is not very adaptable to It is very adaptable to
changes. Any change in the change. To change a
process requires shutting process, a modification in
down of the entire system the program is required.
and the addition or The modified program can
removal of the concerned be tested outside the
relays. system; and after the
robustness of the program
is checked, the program
can be installed in the
system without having to
shut down the entire
system.
Programmable Logic Controller (PLC)

Block Diagram of the Standard Components of a PLC

Physical Layout of a PLC Rack

Programmable Logic Controller (PLC)

Block Diagram of the Standard Components of a PLC

Physical Layout of a PLC Rack

Programmable Logic Controller (PLC)

PLC programs are typically written in a special application

(Unity Pro ) on a personal computer, and 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

IEC 61131-3 currently defines five programming languages for

programmable control systems:
•FBD (Function block diagram),
•LD (Ladder diagram),
•ST (Structured text, similar to the Pascal programming language)
• IL (Instruction list, similar to assembly language) and
• SFC (Sequential function chart).
 ZERO SPEED SENSOR DEVELOPMENT FOR CONVEYOR BELTS
AT UNDERGROUND MINES

There are certain disadvantages with the automation techniques equipped for the conveyor
belts used in the mines. These disadvantages are believed and aimed to be removed by
using PLC and microcontroller based systems. Intrinsically safe devices are required for the
automation and these devices should be fitted in a flameproof enclosure.
Components Used:
The entire setup consists of the main components for signal sensing, generation and
automation process. The main components are-
•PROXIMITY INFRARED SENSOR
•OPTO-ISOLLATOR
•MICROCONTROLLER UNIT
•PLC
 ZERO SPEED SENSOR DEVELOPMENT FOR CONVEYOR BELTS
AT UNDERGROUND MINES

PROXIMITY INFRARED SENSOR

The setup consists of a toothed rotor connected with rotor shaft of conveyor belt. As the belt rotates, it makes the
rotor rotates. When the toothed part of the rotor cuts or comes in front of the IR source it results a LOW level of pulse
generator and when the gap between the teeth comes in front of the IR source the pulse level switches to HIGH. This
continuous change from LOW to HIGH or vice-versa results in a pulse train which is specific for a specified speed of the
conveyor belt. For different speeds of the conveyor belt, the RPM of the rotor varies and this results in different pulse
trains. These pulse trains are fed to the COUNTER of the microcontroller unit. When the counter counts less than a
specific predetermined level .the “zero speed” is indicated.
 
 
OPTO-ISOLATOR (OP-07)
An opto-isolator is a semiconductor device that allows signal to be transferred between circuits or
systems while keeping those circuits or systems electrically isolated from each other. In its simplest form, it consists of
an LED and a photosensor for signal reception. The transmitter takes the electrical signal and converts it into a beam
of modulated visible light. This beam of modulated visible light travels across a transparent gap and is picked up by the
receiver which converts the modulated light back into an electric signal. The electric output waveform is identical to
the input waveform but the input output amplitude varies. In this particular project , the pulse train is fed into an
opto-isolator before feeding it into the microcontroller unit. This opto-isolator(OP-07) converts the signal into 24v DC,
so that it can be used for longer cable works.
ZERO SPEED SENSOR DEVELOPMENT FOR CONVEYOR BELTS
AT UNDERGROUND MINES

Schematic Diagram for

Zero Speed Sensor of
Conveyor Belt
CCD CAMERA

Modular line scan camera model LC1912 has been used as a basic sensor for
measuring the strip width.
The LC1912 line scan camera is a precision, electro-optical instrument that is
housed in a compact, light-weight and extremely rugged enclosure. It contains a
linear array image sensor comprised of discrete elements which scan repeatedly
along a single line. The linear image sensor containing a discrete photo diode is
connected to a CCD shift register.
The LC1912 camera senses light from a scene and converts it into an analog
video signal. The amplitude of the video signal is a linear function of the incident
illumination from the scene. The LC912 camera with 2048 photo-element arrays
have been used in the width meter.
CAMERA CONTROLLER
RS1910 is a modular camera controller and a power supply enclosed in a rugged
aluminum case. It provides all the power and timing signals required for the
camera to function. This rugged unit contains a high quality linear power supply
which provides clean, stable, regulated DC power to the camera. Internally
generated timing signals are output to the camera in RS422 differential format for
superior noise immunity.
CCD CAMERA

Cross-sectional view of
CCD Camera
Computerized Training Management System

PURPOSE OF CTMS
A CTMS was implemented at RDCIS.CTMS stands for computerized
training management system. The CTMS is a record system. It is the central
repository for personnel and payroll data. CTMS supplies information and
statistics on all trainees.
  CTMS reports data on all trainees who are being
trained under RDCIS, maintains data on former and current trainees; and
stores historical personnel data for inquiry and analysis

SOFTWARE - Oracle Database 10g/Express Edition, Visual Basic 6

Interconnection – ADODB
 Computerized Training Management System
College
College_id(primary key)

Entity Relationship Diagram

Guide

guide_id(pk)
Trainee
Project

Trainee_id(pk)
Project_id(primary key)

Dept

Dept_id(pk)

Qualification

Qualification_id(pk)

Branch

Branch_id(pk)