15EC390L INDUSTRIAL TRAINING

REPORT OF

SEMESTER VI
Submitted by
Name: G DEVA KUMAR
Reg no: RA1711004010060
To
 DEPARTMENT OF
ELECTRONICS AND COMMUNICATION ENGINEERING
SRM Institute of Science and Technology
(Deemed to be University u/s 3 of UGC Act, 1956)
S.R.M. NAGAR, KATTANKULATHUR – 603203.
KANCHEEPURAM DISTRICT
TABLE OF CONTENTS
SL Topic Page No
No

1 Abstract 3

2 About the company 4

3 Services by the company 5

4 Training schedule 6

5 Reference 14

6 Summary 14

7 Photocopy Training Certificate 15

2
 Abstract
BHEL is engaged in the design, engineering, manufacturing, construction, testing, commissioning
and servicing of a wide range of products, systems and services for the core sectors of the
economy, viz. power, transmission, industry, transportation, renewable energy, oil & gas and
defence.

This project report pertains to 2 Weeks of industrial training under the course name of Industrial
Training that I had underwent at BHEL, Hyderabad as part of curriculum of degree in Bachelor
of technology in Electronics and Communication engineering as required by SRM Institute of
Engineering and Technology, Chennai. I ponder upon my decision and always get a thought that
I have made a very good decision by doing my internship at BHEL.

I learnt a lot of things over there as my workplace about CNC machines Development of Computer
Numerically Controlled (CNC) machines is an outstanding contribution to the manufacturing
industries. It has made possible the automation of the machining processes with flexibility to
handle small to medium batch quantities in part production.

Initially, the CNC technology was applied on basic metal cutting machines like lathes, milling
machines, etc. Later, to increase the flexibility of the machines in handling a variety of
components and to finish them in a single set-up on the same machine, CNC concept was applied
to develop a CNC machining center for machining prismatic components combining operations
like milling, drilling, boring and tapping. Further, the concept of multi-operations was also
extended for machining cylindrical components, which led to the development of turning centers.

About the company

BHEL is largest engineering manufacturing enterprises in India in the energy related/
infrastructure sector, today BHEL was established more than 50 Years ago, ushering in the
indigenous Heavy Electricals Equipment in India- a dream that has been more than realized with

3
a well- recognized track record of performance. The company has been earning profit
continuously since 1971-72 and paying dividends since 1976-77 and thus because of such a
prosperous history.

Over 65% of power generated in India comes from BHEL-supplied equipment.Overall it has
installed power equipment for over 90,000 MW.BHEL's Investment in R&D is amongst the largest
in the corporate sector in India.Net Profit of the company in the year 2011-2012 was recorded as
6868crore having a high of 21.2% in comparison to last year.BHEL has already attained ISO 9000
certification for quality management, and ISO 14001 certification for environment management.

It is one of India's nine largest Public Sector Undertakings or PSUs, known as the NAVRATNAS
or 'The Nine Jewels’.

The power plant equipment manufactured by BHEL is based on contemporary technology

comparable to the best in the world.

The wide network of BHEL's 14 manufacturing divisions, 4 Power Sector regional centre, over
100 project sites, 8 Service Centre and 18 regional offices, enables the company to promptly serve
its customers and provide them with suitable products, systems and services efficiently.Thus I
selected BHEL for internship.

Services by BHEL
BHEL has a vast network of Service Centers throughout the country to render the after sales
services to our esteemed customers. BHEL has exported products such as Transformers,
Capacitors, Bushings, Switchgear, Insulators, Motors, High-pressure Valves and Oil field
equipment to many countries.

POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power plant business as of
31.03.2001, BHEL supplied sets account for nearly 64737 MW or 65% of the total installed
capacity of 99,146 MW in the country, as against nil till 1969-70.

4
POWER TRANSMISSION & DISTRIBUTION (T & D)
BHEL offer wide ranging products and systems for T & D applications. Products manufactured
include power transformers, instrument transformers, dry type transformers, series and stunt
reactor, capacitor tanks, vacuum and SF circuit breakers gas insulated switch gears and insulators.

TELECOMMUNICATION
BHEL also caters to Telecommunication sector by way of small, medium and large switching
system.

RENEWABLE ENERGY
Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources
of energy include: wind electric generators, solar photo voltaic systems, solar lanterns and battery-
powered road vehicles.

INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of the world, ranging
for the United States in the west to New Zealand in the far east.

TECHNOLOGY UPGRADATION AND RESEARCH &

DEVELOPMENT
To remain competitive and meet customers' expectations, BHEL lays great emphasis on the
continuous up gradation of products and related technologies, and development of new products.

HUMAN RESOURCE DEVELOPMENT INSTITUTE

The most prized asset of BHEL is its employees. The Human Resource Development Institute and
other HRD centers of the Company help in not only keeping their skills updated and finely honed
but also in adding new skills, whenever required .

HEALTH, SAFETY AND ENVIRONMENT MANAGEMENT

BHEL, as an integral part of business performance and in its endeavor of becoming a world-class
organization and sharing the growing global concern on issues related to Environment.

PRINCIPLES OF THE "GLOBAL COMPACT"

Business should support and respect the protection of internationally proclaimed human rights and
make sure they are not complicit in human rights abuses.

5
Training schedule
FUNCTION OF A MACHINE TOOL:
The purpose of a machine tool is to cut away surplus material, usually metal from the material
supplied, to leave a work piece of require shape and size, produced to a high degree of accuracy
and surface finish. The machine tool must possess certain capabilities in order to fulfill these
requirements.

It must be:
 Able to hold the work piece and the cutting tool securely.
 Endowed with sufficient power to enable the tool to cut the work piece material at
economic rates.
 Capable of displacing the tool and work piece relatively to one other to produce the
required work piece shape: the displacement must be controlled with a degree of precision,
which will ensure desired accuracy of surface finish and size.

FUNCTION OF A CONTOL SYSTEM:

Automatic control systems in one form or another can be applied to machine tool, in order to
control the overall machine functions. The following are some of the more important functions,
which can be controlled:

 Displacement of slide members

 Angular rotation of circular tables
 Stop/start of the main spindle
 Change the spindle speed
 Reverse spindle
 Change feed rate of slide members
 Rotate tool turret
 Change tool
 Cutting fluid, ON/OFF
 Lock table in position.
ELEMENTS OF A CNC MACHINE TOOL:
In a CNC machine tool there are three major groups of elements
 Control and electronics
 Electric drives (electromechanical drives)
 Mechanical elements (table, Slide, tool holder, etc.)

6
In addition, there can be hydraulic and pneumatic systems, which are integrated with the CNC
machine tool. The primary function of the drive is to cause motion of the controlled machine tool
member (spindle, slide, etc.) to conform as closely as possible to the motion commands issued by
the CNC system.

In order to maintain a constant material removal rate, the spindle and the tool movements have to
be coordinated such that the spindle has a constant power and the slide has a constant torque.

INPUT ELEMENTS:
Some of the commonly employed input elements are push-button, foot switch, proximity switch,
float switch, relay contact, photo transistor switch, selector switch, pressure switch, limit switch
and flow switch.

OUTPUT ELEMENTS:
 Output Elements that are commonly used are:
 Indicating Lamps
 DC control relays (electromagnetic): A control relay (CR) is an electromagnetic device
excited through an ac or dc electric coil. The dc relays are used as interface between the
CNC-PLC and the ac or dc power switching devices.
 Power contractors: Contractors (C) are also electromagnetic devices which are excited
with ac voltages (110V or 220V used for ON/OFF functions of induction motors, induction
coils, drive power circuits, etc. Power contractors are designed to switch currents up to
several hundreds of amperes at 440 V ac three-phase.
 DC and AC solenoids
 Electromagnetic clutch and brake
 Solid state relay
 Overload (OL) Relays: Bi-metallic thermal overload relays are very commonly used as
overload protection devices for various ac motors such as hydraulic pump motor, coolant
pump motor, lubrication motor, blower induction motor, or any other power ac circuit. The
overload (OL) relay, when connected in series with the power circuit, will open out when
the current increases beyond a preset value.

7
  Miniature Circuit Breaker (MCB): An MCB is a protective device, which will provide both
overload and short circuit protection when connected in a circuit. Hence an MCB will
replace a fuse and a bi-metallic overload relay. When an MCB trips, it has to be reset
manually. Compact MCBs with auxiliary trip contact are used in the electrical control
panel for CNC machines.
 DESIGN OF MODERN CNC MACHINES: The design & construction of computer
numerically controlled (CNC) machines differs greatly from that of conventional machine
tools.

Important parts and aspects of CNC machine’s to be considered in their designing:

 Machine Structure
 Guide Ways
 Feed Drives
 Spindle & Spindle Bearings
 Gauging
 Tool Monitoring
 Controllers, Software & Operator Interface
 Measuring Instruments
 MACHINE STRUCTURE: The Machine structure is the load carrying & supporting
member of the Machine tool. All the motors, drive mechanism & other functional
assemblies of machines tools are aligned to each other & rigidly fixed to the Machine
structure. The Machine structure is subjected to static of dynamic forces & it is, therefore,
essential that the structure does not deform or vibrate beyond the permissible limits under
the action of these forces.

 GUIDE WAYS : Guide ways are used in Machine tools to:

 Control the directions or lines of action of the carriage or the table on which a
tool or a work piece is held.
 To absorb all the static & dynamic forces.

8
 FEED DRIVES: On a CNC Machine the function of feed drives is to cause motion of
the slides as per the motion commands. Since the degree of accuracy requirement is
high, the feed drive should have high efficiency & response. The fed drive consists of :
(a) servomotor.
(b) Mechanical transmission system.
 SPINDLE / SPINDLE BEARINGS: Material removal using single point or multi-point
work piece requires rotational speeds of the order of 30-6000 rpm and even higher. All
work or tool carrying spindles rotating at these speeds are subjected torsional and radial
deflections. They are also subjected to thrust forces depending on the nature of the metal
cutting operation being performed. To intorsional strain on the spindles they are designed
to be as stiff as possible with a minimum over hang. Also, the final drive to the spindle
should be located as near as possible the bearings.
 GAUGING: Gauging on a Machine tool is basically used for work piece inspection, for
defining tool off-sets & for tool breaking detection.
 TOOL MONITORING SYSTEMS: A tool monitoring system monitors the tools wear &
tool breakage.
 CONTROLS, SOFTWARE & USER INTERFACE: CNC controls are the heart of the
CNC MACHINEs. The early CNC controls were developed for simple applications in
turning, machining centers & grinding. The new generation computer numerical controls
allow simulations control of more axes, interpolate positions faster, and use more data
points for precise control. These processors perform multi tasks run one programming &
simulating a second – which maximizes the Machine use.
 MEASURING SYSTEMS: On all CNC Machine, an electronic measuring system is
employed on each controlled axis to monitor the movement & to compare the position of
the slide & the spindle with the desired position.
Measuring systems are used on CNC Machines for:
(i) Monitoring the positioning of a slide on a slide way.
(ii) Orienting the spindle table & measuring the speed of the spindle.

9
ADVANTAGES OF CNC MACHINES:
CNC machines offer the following advantages in manufacturing:

 Higher flexibility
 Increased productivity
 Consistent quantity
 Reduced scrap rate
 Reliable operation
 Reduced non-productive time
 Reduced manpower & Inspection
 Shorter cycle time
 Higher accuracy
 Reduced lead time
 Just-in-time (JIT) manufacture

10
  Automatic material handling
 Lesser floor space
 Increased operational safety
 Machining of advanced materials
 Elimination of operator errors

Flexibility in changes of component design

PROGRAMMABLE LOGIC CONTROLLERS(PLC):
All industrial processes need some form of control system if they are to run safely and
economically. In recent years a specialist control computer, called a programmable controller, has
evolved and revolutionized control engineering by combining computing power and immense
flexibility. A control computer, which is the heart of the automation system, for which the inputs
come from a vast number of devices. Some of these are analog (flows, temperature, pressures and
similar analog signals) and most will be single bit on/off digital signals. A PLC monitors inputs,
makes decisions based on its program, and controls outputs to automate a process or machine.

Programmable Control:
In programmable control systems, the construction of the controller and the wiring are independent
of program definition. Sensor contacts and operating coils on machine tool, for instance, are
connected directly to the controller.

The program defining the control operation is written directly into the memory of the controller
with the aid of a programmer. This program determines the sequence in which sensor contacts are
to be scanned, according to which logic function (AND, OR) they are to be gated and which
outputs the result are to be assigned to i.e. in which order the operating coils are to be energized
or de-energized.

The control program can be modified by changing the contents of the controller’s memory. The
circuit wiring is not affected.

Bus System:

11
A bus system is a path for the transmission of signals. In the programmable controller, it is
responsible for the signal exchange between processor and input/output modules. The bus
comprises of several parallel signal lines:

The address bus, which selects the address on the individual modules.

The data bus, which carries data e.g. from input or to output modules.

The control bus, which transfers control and timing signals for the synchronization of the CPU’s
activities within the programmable controller.

The processor of the programmable controller scans the inputs for “voltage present “and “voltage
not present” and depending on the stored program and result of the scanning operation, the
actuators are switched “ON” or “OFF”.

Characteristic Functions of a PLC:

A PLC is defined “a digital electronic device that uses a programmable memory to store
instructions and implement specific functions such as logic sequence, timing, counting and
arithmetic to control machines and processor”.

As this is a very broad definition it is more useful to examine the essential characteristics of the
PLC that portray its unique aspects.

Some of the most important characteristics include the following:

It is field programmable by the user. This characteristic allows the user to write and change
programs in the field without rewiring or sending the unit back to the manufacturer for this
purpose. It contains pre-programmed functions.

PLC’s contain least logic, timing, counting and memory function that the user can access through
some type of control oriented programming language.

It scans memory and I/O in a deterministic manner. This critical feature allows the control engineer
to determine precisely how the machine or process will respond to the program.

12
It provides error checking and diagnostics. A PLC will periodically run internal tests of its
memory, processor and the I/O system to ensure that what it is doing to the machine or process in
what it was programmed to do.

It can be monitored. A PLC will provide some form of monitoring capability either to indicating
lights that show the I/O status or by an external device that can display program execution status

Input / Output modules:

Input / Output modules transfer information between the CPU and such process peripherals as
sensors, actuators and transducers. Inputs, giving an interface for field signals (such as push
buttons, limit switches and proximity switches) into the system, to provide the data necessary for
the processor to make its control decisions; and Outputs, to switch the machine/process loads (for
example, solenoids, contractors and motor starters) under direction from the processor. There are
two types of input/output modules available viz. Analog and Digital.

STEP–5 PROGRAMMING LANGUAGE:

The user programs are written in STEP 5, the programming language for SIMATIC S5
programmable controllers. STEP = Siemens Technical Education Program

With STEP 5, three methods of representation can be used to translate a problem into a user
program for the SIMATIC S5 programmable controller.

The step 5 operations set is divided into basic operations, supplementary operations and system
operations.

INTERFACING MACHINE ELEMENTS TO CNC/PLC:

Interconnecting the individual elements of both the machine and the CNC system using cables
and connectors is called interfacing.

Extreme care should be taken during interfacing. Proper grounding in electrical installation is
most essential. This reduces the effects of interference and guards against electronic shocks to
personnel. It is also essential to properly protect the electronics equipment.

13
Cable wires of sufficiently large cross-sectional area must be used. Even though proper grounding
reduces the effect of electrical interference, signal cables required additional protection. This is
generally attained by using shielded cables. All the cable shields must be grounded at control only,
leaving the other end free. Other noise reduction techniques includes using suppression devices,
proper cable separation, ferrous metal wire ways, etc. electrical enclosures should be designed to
provide proper ambient conditions for the controller. Power supply to the controller should match
with the supplier’s specification.

Reference

The following content has been taken from the

1. www.bhel.com/home.php
2. www.economictimes.indiatimes.com/bharat-heavy-electricalsltd/
infocompanyhistory/companyid-11831.cms
3. https://en.wikipedia.org/wiki/Bharat_Heavy_Electricals
4. BHEL Annual Report 2013-14 (English) from www.bhel.com

Summary
This training has proved to be quite faithful. This gave me, a chance to have an encounter with
such heavy CNC machines. The architecture of B.H.E.L. ,the way the various units are linked and
the way the working of the whole plant is controlled, makes the student realize that engineering is
not just the structural description but more of planning and management. It has provided an
opportunity to learn that optimization of technology used at proper place and time can save a

lot of labour.

The training has proved to be immensely helpful as it has helped me to have an exposure of the
practical implementation of the theoretical knowledge that I have gained till date.

14
Internship Certificate

15