AUTOMATIC TUBE CUTTING

MACHINE USING PLC

A REPORT

Submitted by

NANCYCHRISTY.E

LAKSHMI PRIYA.K

PRIYADHARSHINI.M

PRAKANYA.M

In a partial fulfilment of award of the degree

Of

BACHELOR OF ENGINEERING

In

ELECTRICAL AND ELECTRONICS ENGINEERING

MOUNT ZION COLLEGE OF ENGINEERING AND TECHNOLOGY

ANNA UNIVERSITY:CHENNAI 600 025

APRIL 2017

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 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certificate that this project report “AUTOMATIC TUBE CUTTING

MACHINE USING PROGRAMMABLE LOGIC CONTROL” is the
bonafide work of “NANCYCHRISTY.E (911713105032), PRAKANYA.M
(911713105036), LAKSHMIPRIYA.K (911713105021),
PRIYADHARSHINI.M (911713105038)” Who carried out the project work
under my supervision.

SIGNATURE SIGNATURE

Mrs. C.S.GAYATHRI Mrs. S.NAGAJOTHI

HEAD OF THE DEPARTMENT SUPERVISIOR

Department of EEE Department of EEE

Mount Zion College of Mount Zion College of

Engineering &technology Engineering & technology

Pudukkottai. Pudukkottai.

Submitted for viva examination held at Mount Zion College of

Engineering And Technology, Pudukkottai on.............................

Internal Examiner External Examiner

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 BHARAT HEAVY ELECTRICALS LIMITED
(A Govt. of India Undertaking)

High Pressure Boiler Plant, Tiruchirappalli -620 014, India.

MAINTENANCE & SERVICES DEPARTMENT

AN ISO 9001

CERTIFICATE

This is to certify that the project work entitled “AUTOMATIC TUBE CUTTING
MACHINE USING PROGRAMMABLE LOGIC CONTROL” is a bonafide work done
by the following students

NANCYCHRISTY.E (911713105032)

LAKSHMI PRIYA.K (911713105021)

PRIYADHARSHINI.M (911713105038)

PRAKANYA.M (911713105036) of Mount

Zion College Of Engineering And Technology.

The above project was carried out under my guidance during the period from
16.01.2017 to 16.02.2017 in the partial fulfilment of awarding B.E. degree in EEE.

They showed keen interest in their project work and completed successfully within
the prescribed time. They are very enthusiastic and hardworking candidates. This project is
bonafide to our organization.

I wish them all success in their future endeavors.

Signature

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 ACKNOWLEDGEMENT

We thank our honorable Head of the Department & Professor in Electrical

Engineering, Mrs.C.S.GAYATHRI, for giving us permission from college,
without which it would not have been possible by us to carry out our
project successfully.

We extend our heartfelt thanks to our college guide,

Mrs.S.NAGAJOTHI M.E., Professor in Electrical Engineering, who was
instrumental throughout our project enabling us to complete it with all his
extensive guidance and support.

It would be unfair if we fail to thank our external guide in BHEL

Trichirappalli, Mr.PRASANTH, Maintenance & Services, who guided us
throughout the project, sharing his invaluable time and directing us during
times of doubt.

Our project would not have been successful without the immense aid
from Mr.KEVIN-Senior Maintenance Engineer, Mr.R.SUGUMARAN
Assistant Engineer-I,

We thank the HRDC department of BHEL for giving us

permission to do our project in their prestigious organization.

Finally, we thank our family and friends for the report they extended
to us during the project.

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 ABSTRACT
The process of conversion of manual control into automatic control is
gaining importance in industries to cater their growing demand. Here in
our project we intend to convert a relay logic controlled electro-
hydraulic tube cutting machine into programmable logic controlled
machine thereby we tend to improve the efficiency of the machine by
increasing its production. BHEL is looking forward to build boilers of
large capacity, to meet the power demand of our country where in tubes
of large number are to be produced. Our project helps in increasing the
mass production of tube cutting machine using PLC. here we get the
basic relay logic diagram of the machine and convert them into PLC
ladder circuit. The limit switches of the relay PLC circuit thereby
improving the accuracy of the machine.

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 TABLE OF CONTANT

1. ABSTRACT 5
i. INTRODUCTION
6
ii. BHEL
7
b. Products 10
c. Machinery 12

CUTTING AND EDGE PREFERING

Cutting 18

Edge preferring 21

Electrical drawing 23

Relay Logic Control 25

PROGRAMABLE LOGIC CONTROL 29

Architecture 30
Types

Block diagram 37

SENSORS

Magnetic sensor 38

Photo reflective sensor 41

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 Optical fiber sensor 42

AUTOMATIC TUBE CUTTING

Block diagram 45

Working 49

Comparison between RLC and PLC 52

Ladder Diagram 53

CONCLUSION 55

REFERANCE 56

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 LIST OF TABLES

TABLE NO TABLE NAME PAGE NO

Table 2.1 BHEL Features

Table 3.2 Siemens S7-200
Table 5.2 Safety Equipment
Table 5.3 Difference between RLC & PLC

LIST OF FIGURES

FIGURE NO FIGURE NAME PAGE NO

1.1 Coil
1.2 Water wall panel
1.3 20 Torch
1.4 Straight Tube Butt Welding
2.1 Electrical diagram of tube cutting
machine
2.2 Electrical diagram of edge preparation
machine
3.1 PLC Architecture
3.2 Block diagram of PLC
4.1 Magnetic sensor
4.2 Photo reflective sensor
4.3 Optical fiber sensor
5.1 Block diagram of Automatic tube
cutting machine
5.2 Panel
5.3 Layout of Automatic tube cutting
machine
5.4 Ladder diagram
5.5 Flow chart

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 CHAPTER 1
INTRODUCTION

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 1.INTRODUCTION

Industrial automation is the use of control system, such as computers or

Robots, and information technologies for handling different processes and
Machineries in an industry to replace a human being. It is the second step
beyond Mechanization in the scope of industrialization. Earlier the
purpose of automation was to increase productivity(since automated
system can work 24 hours a day),and to reduce the cost associated with
human operators. However ,today the focus of automation has shifted to
increasing quality and flexibility in manufacturing process. In the
automobile industry installation of pistons into the engine used to be
performed manually with an error rate of 1-1.5%. presently, this task is
performed using automated machinery with an error rate of 0.00001%.

Advantages of industrial automation is lower operating cost. The

Maintenance cost associated with machinery used for industrial
automation is less because it does not often fail. If it fails, only computer
and maintenance engineers are required to repair it.

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1.1 BHEL PROFILE

BHEL is the largest engineering and manufacturing enterprise in India. In

the energy-related/infrastructure sector, today. BHEL was established
more then 40 years ago, ushering in the indigenous Heavy electrical
equipment industry in India. BHEL manufacture over 180 products under
30 majors product groups and caters to core sectors of the India economic
viz., power generation and transmission, industry, transportation,
renewable energy, etc. the wide network of BHEL’S manufacturing
divisions, four power sector regional efficiently and at competitive prices.
The high level of quality and reliability of its products is due to the
emphasis on design, engineering and manufacturing to international
standards by acquiring and adapting some of the best technology from
leading companies in the world, together with technologies developed in
its own R&D centres. BHEL’S operations are organised around three
business sectors, namely power, industry including transmission,
transportation and renewable energy and overseas business. This enables
BHEL to have a strong customer orientation, to be sensitive to his needs
and response quickly to the changes in the market.

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BHEL FEATURES:

 Installed equipment for over 90,000 MW of power generation -- for

Utilities, Captive and Industrial users.

 Supplied over 2,25,000 MVA transformer capacity and other

equipment operating in Transmission & Distribution network up to
400 kV (AC & DC).

 Supplied over 25,000 Motors with Drive Control System to Power

projects, Petrochemicals, Refineries, Steel, Aluminium, Fertilizer,
Cement plants, etc.

 Supplied Traction electrics and AC/DC locos to power over 12,000

kms Railway network.

  Supplied over one million Valves to Power Plants and other

Industries.

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BHEL TRICHY

At trichy, the High Pressure Boiler Plant of the Bharat Heavy

Electricals Limited (BHEL) was setup in 1963. Now, it is one of the
foremost manufacturing facilities within BHEL and it has 3 major plants
namely, High Pressure Boiler Plant, Seamless Steel Tube Plant and Boiler
Auxiliaries Plant. BHEL is the first state-owned company to acquire ISO
9000 certification during 1993 for all its operations. Further it has been
accredited to ISO 14001 Standard. It is having a very big Housing colony,
with all facilities including good educational facilities, on the NH-67, just
in front of the main factory. And it manufactures about 86% of the total
outcome of BHEL.

BHEL provides customers worldwide with complete custom-

designed Boiler Island Solutions for power and process steam generation
covering design, engineering, manufacture, erection and commissioning of
boilers, boiler house auxiliaries and all associated systems and sub-
systems. In addition to Concept-to- Commissioning expertise for all types
of steam generators, BHEL has the unique advantage of world class, state-
of-the-art manufacturing facilities for the entire gamut of components and
systems for the boiler island - including boilers, auxiliaries such as fans,
air pre-heaters and electrostatic precipitators, piping and piping systems,
valves, soot blowers, gravimetric feeders, controls & instrumentation etc.

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1.2 PRODUCT
Coil :
Coil is a popular name of an inductor.
Coil(chemistry), a tube used to cool and condense steam from a
distillation.
Coil spring, used to store energy, absorb shock, or maintain a force
between two surfaces.
Electromagnetic coil formed when a conductor is wound around a core or
form to create an inductor or electromagnet.
Ignition coil, an electromagnetic induction coil used in internal
combustion engines to create a pulse of high voltage for a spark plug.

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WATER WALL PANEL :
A wall panel is piece of material, usually flat and cut into a rectangular
shape, that serves as the visible and exposed covering for a wall. wall
panels are functional as well as decorative, providing insulation and
soundproofing, combined with uniformity of appearance, along with some
measure of durability or ease of replace cability. While there is no set size
limit for a piece of material fulfilling these functions, the maximum
practical size of wall panel has been suggested to be 24 feet by 8 feet, to
allow for transportation.
Use of water wall panel can reduce construction cost by providing a
consistent appearance to the panelled surface without requiring the
application of paint or other finishing material. Wall panel may be finished
on only one side, if the other side is going to be against a brick or concrete
wall, or a comparable structure.

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1.3 MACHINERI
20 Torch:

The WP-20 series TIG torch is the best selling water-cooled TIG torch for
general applications. The WP-20 torch body is small, versatile, powerful
and provides cool operation up to 250 amps dc supply. The power cable,
water and gas hoses are small, light weight and flexible. The WP-20 series
torch accepts the industry standard “13N” series parts and is the basis for
adding a wide variety of options and accessories to specific application.

WP-20 specifications:

250 amp AC/DC (100% duty cycle )

Water cooled body with 70 degree heat angle.

Electrode capacity 020” (0.5mm)to 1/8”(3.2mm).

Torch body weight 3 (85g).

Handle diameter ¾”(19.0mm)

Water flow 1qt/min(0.946 l/min)

Maximum pressure 50 psi (3.448 BAR)

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STRIGHT TUBE BULT WELDING:
Welding is a process of joining two or more pieces of the same or
dissimilar to achieve complete coalescence. This is accomplished by
fabrication of vastly different components including critical structures
like water wall panel, heat exchanger, pressure vessels, etc. Welding
can be done with or without the application of filler materials called
electrode . welding joins different metals/alloys with the help of
number of processes in which heat is supplied either electrically or by
means of gas torch . In order to join two or more pieces of metal
together by one of the welding processes ,the most essential in many
processes . in the course of time ,temperature difference in a body is
reduced by heat flowing from different region of higher temperature
of those of lower temperature. This process takes place in all
substances such assistant liquids and gases and also in solids .In
comparison to other process of joining the metal, STB process can
give 100%of strength and efficiency . straight tube Butt welding metal
inert gas welding process is widely used process in STBW process.
Today it is a well established semi automatic process, which can be
easily automated with a wide range of application.
Here the straightened and short blasted tubes of 24 meters in lengths
are automatically fed to mechanically welded by TIG and GMAW
process of welding.

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Specification:

This machine is meant for butt-welding of straight tube with edge

prepared ends.

*welding of tubes of similar or dissimilar materials in steel (like

carbon steel to alloy steel ,alloy stainless steel)

* welding of tubes of various outer diameters and thicknesses.

*torches have to employed.

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Automatic Feeding and Welding of Tubes in STBW Machine

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Welding of Tube Joints in Straight Tube Butt Welding (STBW)
machine.

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 CHAPTER 2

CUTTING AND EDGE PREFERING MACHINE

2.TUBE CUTTING AND EDGE PREFERING MACHINE

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2.1 CUTTING
Cutting machine producing high quality cuts on a variety of
tubular shapes. Complete automation from mill length bundle to
finished part, high production rates, and reusable inexpensive easy to
maintain tooling.
Tube cutting is a metal forming process used to permanently form
pipes or tubing into the shape of a die. Factors involved in the tube
cutting process is the tube thickness, length and lubricants needed by
the pipe. A tube can be cut in multiple length .Feed rate (diameter
and length) are set by using hydraulic servo valve. Blade speed is set
by using encoder. Parameter setting and cutting operation are
convert to automatic from manual by using PLC.
The tubing is held in clamping dies. A horizontal blade makes an initial cut
through a portion of the tube wall so that the vertical blade encounters less
resistance and pierces the tube wall without dimpling

It is most suitable for carbon steels and alloy steels, including stainless steels.

Each tube diameter requires its own set of clamping dies. The clamping dies are
hardened and ground to precise tolerances. They are relatively inexpensive and
can be resharpened for use for up to 3 million cuts. Four clamping die sections
are assembled into two sections, allowing them to open and close to feed and
clamp the tubing and to provide clearance for the horizontal and vertical .

During the cutting process, the horizontal blade removes only a small amount of
material, but this is necessary to create the notched area for the vertical blade to
enter. the initial penetration of the vertical blade directs

The slug to the inside of the tube. This slug folds in under the blade and is
pushed through the bottom of the tube. Depending on wall thickness and
diameter, the end cut may have some burr and sharp edges.
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EFFECT ON CUTTING:
One side effect of cutting the work piece is the wall thickness changes;
the wall along the inner radius of the tube becomes thicker and the
outer wall becomes thinner. To overcome this, the tube may be
supported internally or externally to preserve the cross section.

advantages:

 Cuts square and rectangular shapes, as well as round.

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  Cuts tubing from straight lengths or from coiled stock.
 Can be integrated with secondary operations.
 The cut is square and distortion-free.
 Overall length tolerances of 0.010 in. are attainable.
 Has quick-change tooling.
 Can be integrated with bundle loaders for high-volume cutting.
 Production rates up to 7,000 are possible cuts per hour

disadvantages:

 Range of materials it can cut is limited to 0.125 to 6.50 in. dia. and
wall thicknesses from 0.020 to 0.250 in.
 Material loss occurs with each cut.
 Cannot cut austenitic stainless steels, exotic alloys, soft coppers, or
aluminium.
 On certain sizes, burr and sharp edges are present.

EDGE PREFERING:

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Chamfering is a term commonly used in mechanical and
manufacturing engineering. Chamfer does not go to end of the piece.
After complete the chamfering , the tube can easily welding.

* The machine is to be designed and constructed for measuring,

cutting and edge preparation automatically from tube feed to
discharge.

* The edge preparation involves cutting, facing, chamfering, boring to

correct size of ID, depending on job requirement.
This machined parts requires finishing operation in which small amount of
material is removed to bring the part to required tolerance. Example of this
surface finishing operation is chamfering, grinding and deburning. These
surface finishing operation constitute a significant amount money and effort in
industry. Automation of these operation is very important and crucial in
industry.
Automation plays an increasingly important role in the world economy and in
daily experience. Presently, manual finishing accounts for 12% of the total
labour cost and 10%– 30% of the manufactured parts need rework after the
manual finishing process. By automating chamfering process, tolerances could
be held to less than 0.07 mm (0.003 in), the finishing costs could be reduced as
much as 50%, and the rework rates could be nearly eliminated. Chamfering is
required for the variety of the reasons: to guarantee component fit( support of
the assembly process), prevention of nicks during work piece transportation,
improvement of tool life during hard finishing process, enhance part
appearance.

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2.3 ELECTRI DRAWING
Tube cutting machine:

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Edge preparing machine:

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2.4 RELAY LOGIC CONTROL:
Relays
Relays are the basic devices used in Relay Logic Control. A relay is
a simple device that uses a magnetic field to control a switch.

When a voltage is applied to the input coil, the resulting current

creates a magnetic field. The magnetic field pulls a metal switch (or reed)
towards it and the contacts touch, closing the switch. The contact that
closes when the coil is energized is called normally open. The normally
closed contacts touch when the input coil is not energized. Relays are
normally drawn in schematic form using a circle to represent the input
coil. The output contacts are shown with two parallel lines. Normally open
contacts are shown as two lines, and will be open (non-conducting) when
the input is not energized. Normally closed contacts are shown with two
lines with a diagonal line through them. When the input coil is not
energized the normally closed contacts will be closed. Relays are used to
let one power source close a switch for another power source, while
keeping them isolated.

RELAY LOGIC:
Relay logic is a method of controlling industrial electronic circuits
by using relays and contacts. The schematic diagrams for relay logic
circuits are often called line diagrams, because the inputs and outputs are
essentially drawn in a series of lines. A relay logic circuit is an electrical
network consisting of lines, or rungs, in which each line or rung must have
continuity to enable the output device. A typical circuit consists of a
number of rungs, with each rung controlling an output. This output is

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controlled by a combination of input or output conditions, such as input
switches and control relays. The conditions that represent the inputs are
connected in series, parallel, or series-parallel to obtain the logic required
to drive the output. Relay logic diagrams represent the physical
interconnection of devices. Electrical devices are shown in their normal
conditions. Modern control systems still include relays, but these are rarely
used for logic.

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Ladder Logic
Ladder logic is the main programming method used for PLCs. As
mentioned before, ladder logic has been developed to mimic relay logic.
By selecting ladder logic as the main programming method, the amount of
retraining needed for engineers and trades people was greatly reduced.

Relay logic design

In many cases, it is possible to design a relay logic diagram directly
from the narrative description of a control event sequence. In general, the
following suggestions apply to designing a relay logic diagram:

1. Define the process to be controlled.

2. Draw a sketch of the operation process. Make sure all the
components of the system are present in the drawing.
3. Determine the sequence of operations to be performed. List the
sequence of operational steps in as much detail as possible. Write
out the sequence in sentences, or put them in table form.
4. Write the relay logic diagram from the sequence of operations.

Disadvantage of Relay Logic

 Fault identification is difficult

 Mass production is not possible.
 External wiring is complex and more.
 Rewiring is required to change logics.

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 CHAPTER 3
PROGRAMABLE LOGIC CONTROLLER

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 3.PROGRAMMABLE LOGIC CONTROLER
REQUIREMENT OF A PLC

 Able to receive standard AC supply.

 Able to output standard AC supply of adequate current rating to
energies relays/ solenoids.
 Programmable to perform discrete operation. Also to be easily
reprogrammable to suit different application.
 Programmed to perform and easy to understand its operation using
standard terminology.
 Able to handle other types of electrical signals including other
voltage signals.
 Easily upgradeable with latest cards.
 Shall be modular types, having multiples of basic units.
 Shall be able to communicate to Distributed Control System at a
remote location.
 Redundancy in power supply. CPU shall be available for critical
process.

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 3.1 ARCHITECTURE:

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3.2 TYPES
There are different PLCs from many manufacturers such as

 Mitsubishi
 Siemens
 Panasonic
 ABB
 Motorola

We select Siemens S7 200 range of PLC for tube cutting process.

SIMATIC S7-200 CPUs:

SIMATIC S7-200

The fields of application of the SIMATIC S7-200 extend from

replacement of relays and contactors up to more complex automation tasks
in stand-alone mode, in networks, and within distributed configurations.
The S7-200 also increasingly provides access to areas in which special
electronics was previously developed for economic reasons. In addition to
the comprehensive basic functionality of the five different CPUs, the
modular system technology of the SIMATIC S7-200 offers a wide range
of scalable and specific expansion modules for an extremely high range of
functionalities in accordance with requirements. The S7-200 has been
proven worldwide in applications covering all sectors as a result of its
wide range of exceptional features.

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CPU NAME NO. OF I/O MAX NO. OF I/O
CPU 221 6 inputs/ 4 outputs 10- not expandable
CPU 222 8 inputs /4 outputs 94- +2 expandable
CPU 224 14 inputs /10 outputs 224 +7 expandable
CPU 224XP 14 inputs /10 outputs - 2 224 +7 expandable
analog input/ 1 analog
output
CPU 224XPsi 14 inputs /10 outputs - 2 224 +7 expandable
analog input/ 1 analog
output (current sinking
digital output)
CPU 226 24 inputs /16 outputs 256 +7 expandable

In our project, the total number of I/O is 83. Thus we select the
CPU 222 with maximum of 94 I/O keeping in mind to be economical.
BENEFITS:
SIMATIC S7-200 delivers consistently economical solutions. The
entire system family features 
 powerful performance, 
 optimum modularity and 
 Open communications.
 Small and compact
 Ideal for any applications where space is tight
 Basic and advanced functionality in all CPU models
 Large program and data memory
 Outstanding real-time response – being in total command of the
entire process at any time means increased quality, efficiency and
safety
 Easy-to-use STEP 7-Micro/WIN engineering software – ideal for

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 both beginners and experts
 Integrated R-S 485-interface or use as system bus 
 Extremely fast and precise operational sequence and process
control  
 Complete control of time-critical processes by time interrupts

HIGHLIGHTS:
 Memory card for data logging, recipe management, saving of STEP
7-Micro/WIN project, and storage of documentation in various
formats
 PID auto-tune function 
 2 built-in serial ports for extended communication options, e.g. with
other manufacturers’ devices(CPU 224 XP, CPU 226)
 CPU 224 XP with built-in analog inputs/output

SIMATIC S7-200 Signal modules:

There are expansion modules from 4/4 to 32/32 I/Os, analog modules from
4/0, 8/0, and 0/4 up to 4/1 I/Os, as well as performance modules for
switching loads: 5A DC or 10A relays
Digital modules:
Digital input/output modules support the link-up of the control with digital
process
Digital output modules can be used to output digital signals from the
control to the process.
 Modular building block system
 Expansion modules can be scaled according to requirements
 Digital expansion modules from 4/4 to 32/32 inputs/outputs
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Analog modules:
12-bit resolution and various input and output range enable sensors and
actuators to be connected without the need for additional amplifiers. There
are analog modules from 4/0, 8/0, 0/4 to 4/1 to in/outputs, all with
extremely short conversion times

SIMATIC S7-200 Function modules:

Description
SIMATIC S7-200 has a consistently modular design. In addition to
expansion and communication modules, the modular system provides a
range of specific expansions for positioning, weighing technology
and temperature measurement.
Positioning Module EM 253:
The EM 253 is a function module for simple positioning tasks (1 axis). It
can be connected to stepper motors and servo motors from the Micro
Stepper to the high-performance servo drive via a high-frequency pulse
input.
The EM 253 positioning module is mounted in the same manner as an
expansion module and connected to the S7-200 expansion bus via the
integrated connection cable.
The configuration data are read out of the CPU automatically on
connection
The module has the following features:
 5 digital inputs for signals from the process
 24 pulse outputs for direct activation of the drive
(forwards/backwards or speed/direction)

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  2 control outputs (DIS; CLR).
 12 status LEDs
Communication
The SIMATIC S7-200 Micro PLC provides a full range of communication
capabilities.
 In the freely programmable mode up to 115.2 kbaud, with user-
specific protocols such as ASCII (this supports interconnections with
a modem, printer, barcode reader, PC, third-party PLC and any other
device). Up to 32 SIEMENS frequency converters can be controlled
without additional hardware by using USS protocol instructions.
 The S7-200 CPUs can be accessed nearly anywhere in the world by
modem via wired network or radio.
 With the EM 277 expansion module, you can implement
PROFIBUS capability of individual machines equipped with S7-
200.
Continuous 24 Volts Supply: With Every Switched Mode Power
Supply Unit:
Full range of switched mode power supply units provides a
controlled 24vdc power supply and other input voltages. Unique spectrum
of DC-UPS and expansion modules extends our power supply range to
protect the 24 Volt supply against mains problems and problems on the dc
side.

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Micro Panels
 SIMATIC TD 100C
 SIMATIC TD 200
 SIMATIC TD 300C
 SIMATIC TD 400C
 SIMATIC OP73micro
 SIMATIC TP 177micro
Human-machine interface for SIMATIC S7-200:
The Micro panel speaks the "language" of the SIMATIC S7-200
controller, which means that all contacts and variables can be read or set
without the need for add-ons.
Whether you choose text display for simple applications, or graphics-
capable touch or operator panels, micro panel ensures that you have
complete control of the machine-oriented HMI.
Software for SIMATIC S7-200 controllers:
Engineering Software STEP 7-Micro/WIN:
The STEP 7-Micro/WIN programming software features time-saving and
powerful tools – and that means great cost savings in your day-to-day
work. Operation of the programming software is the same as standard
Windows applications. Micro/WIN contains all the necessary tools for
programming the entire S7-200 range of controllers. You have the
powerful SIMATIC instruction set at your disposal and you can program
in accordance with IEC 1131. A host of functions such as Trend Charts
and wizards make programming even easier.
STEP 7 Micro/WIN is also used for configuring the text displays inside
Micro Panel product range.

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3.3 Block diagram of PLC:

Power supply

(AC or DC)

Low voltage

Input card Out put

CPU card

Memory

Program Data

Programming and
communication port

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 CHAPTER 4
SENSORS

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 4.SENSORS:
4.1 Magnetic sensor:

Magnetic sensor differ from most other detectors in they do not directly
measure the physical property of interest. Device that monitor properties
such as temperature , pressure, strain, or flow provide an output that
directly reports the desired parameter. Magnetic sensors on other hand,
detect changes, or disturbance, in magnetic fields that have been created
or modified, and form than device information on properties such as
direction, presence, rotation, angle, or electrical currents. The output signal
of these sensor requires some signal processing for translation into the
desired parameter.

Types:

Low field sensing

Medium field sensing

High field sencing

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Figure 1, conventional sensors detect a physical property directly (A);
Magnetic sensors detect changes in magnetic fields and from them derive
information on physical properties (B).

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F45 | P a g e
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4.2 Photo reflective sensor:

This is a reflective sensor combines a GaA1As infrared light emitting

diode with a high sensitive Darlington phototransistor in a mini package.

Diagram:

Features:

* Compact

* high performance

*high output

* easy to mount on PSB

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*Widely application

Application ideas:

* Timing sensors

* edge sensors

* Micro floppy disc drivers

*level sensor of liquids

4.3 Optical fibre sensor:

The fibre optic sensor is a sensor that uses optical fibre either at sensing
element, or as means of relaying signal from a remote sensor to the
electronics that process the signals. Fibre have many uses in remote
sensing. Depending on their application, fibre may be used because of
their small size, or because no electrical power is needed at remote
location, or because many sensor can be multiplexed along the length of
the fibre by using light wavelength shift for each sensor, or by sensing the
time delay as light passes along the fibre through each sensor.

Fibre optic sensor also immune to electromagnetic interference, and do

not contain electricity so they can be used in places where there is high
voltage electricity or flammable material. Fibre optic sensors can be
designed to withstand high temperatures as well.

Optical fibres can be used as sensor a to measure strain, temperature,

pressure and other quantities by modifying a fibre so that the quantity to be

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measured modulates the intensity, phase, polarization, wavelength or
transit time of light in a fibre.

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 CHAPTER 5
AUTOMATIC TUBE CUTTING USING PROGRAMABLE LOGIC
CONTROLLER

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5. Automatic tube cutting machine
5.1Blockdiagram:

LSW-01 - Tool Return LSW -09 – Pressure Die

Reverse Stop
LSW-02 – Safety Plate
LSW-03 – Safety Plate
LSW-04 –Moving Arm Safety
Auxiliary
LSW -05 – Clamp Forward Stop
LSW-06 – Clamp Reverse Stop
LSW 07 – Vertical Clamp up
LSW-08 – Vertical Clamp down
LSW – 10 – cut Home position
LSW- 11 – Pressure Die Forward Stop
LSW – 12 – Pressure Die Forward
Stop
LSW – 13 – cut Home Slow Pre limit
Switch
LSW-14 – Slide Bar End

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PARTS OF CUTING MACHINE:
Base clamp:

It locks the job with the machine. It is the first operation of the bending
process.

Pressure die:

It is used to hold the job firmly while cutting process is on to avoid

unwanted movements of job.

Booster die:

It’s a part of pressure die which helps the job to move forward a little to
attain a smooth cut. The name of the part indicates its function. Booster is the
control element of pressure die. It is in the ratio B: P=1:10 limit switches are
present to serve the position of die.
Former:

It holds the clamping Die and rotates to make the cut of desired length.

Base plate:

It’s the place where the job is fed for the cutting process. It move with
the arm while cutting is process is progressing.

Base:

It is the place where all the cutting process takes place.

Clamping die:

It is used to clamp the object tightly so that cut is made correctly at the
spot.

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Carrier or Carriage

It is used to hold the job for automatic feeding and measurement and
marking.

Limit switch:
A limit switch is an electromechanical device. It is placed in the control
circuitry of a machine system. They are commonly employed as input devices
to indicate the presence or absence of a particular condition in a system or
process that is being monitored and/or controlled. In motorized
electromechanical systems, limit switches provide the function of making and
breaking electrical contacts and consequently electrical circuits. A limit switch
is configured to detect when a system's element has moved to a certain position.
A system operations triggered when a limit switch is tripped. Limit switches are
widely used in various industrial applications, and they can detect a limit of
movement of an article and passage of an article by displacement of an
actuating part. The limit switches are designed to control the movement of a
mechanical part. A mechanical limit switch interlocks a mechanical motion or
position with an electrical circuit. These limit switches are primarily used with
reciprocating actuators, or where position memory or manual reset is required.
Spring-return limit switches automatically reset when actuating force is
removed.

Panel:

A control panel is a flat, often vertical, area where control or

monitoring instruments are displayed.

They are found in factories to monitor and control machines.

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Older control panels are most often equipped with push button analog
instruments whereas nowadays in many cases touch screens are used for
monitoring and control.

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F54 | P a g e
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Saw blade:
Saw blade is used to cut the tube. Sawing is one of the most versatile and
widely adapted methods for cutting tubing .each sawing application is unique,
but, generally, sawing is suitable for low-volume production. The most
important consideration in sawing is applying the correct blade to the tube to
be cut. In all sawing applications, the number of teeth required on the blade is
based on the number of teeth that contact the tube on the maximum arc of the
cut.

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5.2 working:
The tubing is held in clamping dies. A horizontal blade makes an initial cut
through a portion of the tube wall so that the vertical blade encounters less
resistance and pierces the tube wall without dimpling

It is most suitable for carbon steels and alloy steels, including stainless steels.

Each tube diameter requires its own set of clamping dies. The clamping dies are
hardened and ground to precise tolerances. They are relatively inexpensive and
can be re sharp for use for up to 3 million cuts. Four clamping die sections are
assembled into two sections, allowing them to open and close to feed and clamp
the tubing and to provide clearance for the horizontal and vertical .

During the cutting process, the horizontal blade removes only a small amount of
material, but this is necessary to create the notched area for the vertical blade to
enter. the initial penetration of the vertical blade directs

The slug to the inside of the tube. This slug folds in under the blade and is
pushed through the bottom of the tube. Depending on wall thickness and
diameter, the end cut may have some burr and sharp edges.

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Machine layout:

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Safety equipment

Safety equipment Function

Emergency STOP switch
Protection cover
Key-switch for setup operation
Electrical overload protection
Light barrier
(magazine area, optional for H)
Protection barriers/ doors
(optional)
All functions of the saw and auxiliary
equipment are stopped immediately
The automatic mode is only possible
when the
protection cover is closed
The operation in setup mode is only
possible
with the key.
Motors are turned off in cases of
overload
Reverse drive of the pushers and the
introduction of material is prevented.
Material bar is processed.
May only be opened when no function
is active in this machine area.
Interruption of all functions in the area
of the
protection barrier/ door.
Closing of the barrier or the door must
be acknowledged.

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5.3 differance between RLC and PLC:
SL NO RLC PLC
01 Hard ware and fixed Flexible and logic can be
logic. altered.

Program stored with in

the memory.

02 Required more space, Required less spacing,

more component, more less component, less
wiring. wiring.

03 Interlock alteration of Interlock operation

site is difficult. simple and easy.

04 Addition of component Addition of component

in site is very difficult. may not be required.

05 Power supply Power supply

requirement in more. requirement is less.

06 More maintenance, more Less maintenance, less

time for fault diagnosis time for fault diagnosis
and high down time. and less down time.

07 External cabling more. External cabling can be

reduced by using local
I/O

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 5.4 ladder diagram

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5.5 Flow Chart

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F63 | P a g e
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 CHAPTER 6

CONCLUSION

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 6.Conclusion:

Keeping in mind, the demerits of existing relay logic control and to

increase the mass production of the tube cutting machine, we have proposed in
our project, the conversion of the existing relay logic control to programmable
logic control (PLC). The CPU 222 provides extra I/O modules which can be
utilized in future for expansion, if required. As a result, the accuracy and speed
of operation of the machine improves thereby increasing the mass production
capability of the machine to meet the demand.

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 CHAPTER 7

REFERANCE

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7. REFERANCE:

 Profile Cutting Machine, Retrieved July 29, 2015.

 P. Balashanmugam, G.Balasubramanian,2015, Design and Fabrication of

 Typical Pipe Cutting machine.
 Profile Cutting Performed by an Industrial Robot, Retrieved July 29,
2015
 Profile Cutting with A CNC Machine, Retrieved July 26, 2015.

 Relay Circuit, Retrieved July 26, 2015.

 A PLC, Retrieved July 25, 2015.

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