TRAINING / PROJECT

REPORT

By
VYOM DUTT RAI
18SE02CH057

Under the mentorship of

SOUMYADIP SARKAR, DESIGNATION

A Project / Training Report Submitted to

School of Engineering, P P Savani University

20 August, 2021

School of Engineering, P P Savani University

NH 8, GETCO, Near Biltech, Kosamba, Dist.: Surat - 394125
 Certificate

This is to certify that Training / Project work embodied in this report was carried
out by “VYOM DUTT RAI” at “ACADEMY OF SKILL DEVELOPMENT”. This Training /
Project work has been carried out under my mentorship.

Name & Signature of Institute Mentor

SOUMYADIP SARKAR

Date: 1 August 2021

Place: Academy Of Skill Development
 TABLE OF CONTENTS
1. Title page
Certificate by Mentor
Online Certificate
2. Figure
3. Abbreviation
4. Chapter 1 Introduction
5. Chapter 2 Project / Training Overview
6. Chapter 3 Learning Outcomes
7. Chapter 4 Concluding Remarks
 Certificate from the Mentor

This is to certify that [VYOM DUTT RAI] has successfully completed the project titled [4
Way Traffic Light Control System] under my supervision during the period from February
to May which is in partial fulfillment of requirements for the award of the B.Tech and
submitted to Department [CHEMICAL ENGINEERING] of [P P SAVANI UNIVERSITY]

____________________
Signature of the Mentor

Date: 01/08/2021
FIGURE
 ABBREVIATION

 PLC = Programmable logic controller

 SCADA= Supervisory control and Data acquisition
 CPU= Central processing unit
 DI=Digital input
 AI= Analogue input
 LD= Ladder Diagram
 SFC= Sequential flow chart
 INTRODUCTION

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 light fixtures.
PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for
multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. Programs to control machine operation are typically stored in battery-
backed or non-volatile memory.
A PLC is an example of a hard real time system since output results must be produced in response to input
conditions within a bounded time, otherwise unintended operation will result.
They were first developed in the automobile industry to provide flexible, ruggedized and easily
programmable controllers to replace hard-wired relays and timers. In 1968 GM Hydra-Mastic (the
automatic transmission division of General Motors) issued a request for proposals for an electronic
replacement for hard-wired relay systems based on a white paper written by engineer Edward R. Clark.

First PLC was developed in Modicon, which stood For Modular Digital Controller. One of the people who
worked on that project was Dick Morley, who is considered to be the "father" of the PLC.

Early PLCs were designed to replace relay logic systems. These PLCs were programmed in "ladder logic",
which strongly resembles a schematic diagram of relay logic.

Modern PLC systems today adhere to the IEC 61131/3 control systems programming standard that defines
5 languages: Ladder Diagram (LD), Structured Text (ST), Function Block Diagram (FBD), Instruction List
(IL) and Sequential Flow Chart (SFC).
 TRAINING OVERVIEW

FUNCTION OF PLC:-

a) PLC monitors inputs (PII) and variables.

b) Make decision based on stored program.
c) Control output to automate a process or machine.

BASIC ELEMENTS:-

Fig1. Major Component of common PLC

Input Module:-

Type of input module depends on type of input device i.e. DI, AI. Analog signals represent machine or
process condition as a range of voltage and current. Function of input circuitry is to convert the signals
provided by the switch and sensors into logic circuits that can be used by CPU.

Central Processing Unit (CPU):-

CPU evaluates the state of the input and other variables as it executes a stored program.CPU then sends
signals to update the status of output(PIQ) It consists of Microprocessor for implementing the logic and
controlling the communication among the modules.

Output Module:-
Output modules convert control signals from the CPU into digital or analog values that can be used to
control various output devices.

Programming Device: - It is used to enter or change the PLC user program or to monitor and change
stored values.

Operator Interface: - It is a device used in addition to simplify monitoring of the machine and process.

Advantage of PLC:-

 Smaller Physical Size than hard wire solution.

 Easier and faster to make change.

 Integrated diagnostic and override function.

 Application can be duplicated faster and less expensively.

 The control program can be watched in real time as it executes to find and fix problem.

Communication Capability: - A PLC can communicate with other controllers or computer equipment.

PLC Scan:- Once the program is downloaded in the CPU, the PLC is switched to ‘RUN’ mode and the PLC
executes the application program. The CPU regularly reads the status of the input devices and sends data to
the output devices as per the logical results after execution of the program.

S7 -300 consists of several modules:-

PLC Configuration

For Arranging Modules On A Single Rack:-

Following rules apply:

1. No more than eight modules (SM, FM, and CP) may be installed to the right of the CPU.
2. All modules that you have installed on one rack may not exceed a total current consumption
of 1.2 A (312 IFM: 0.8 A) from the S7-300 backplane bus.

PS CPU IM SM1 SM2 SM3 SM4 SM5 SM6 SM7 SM8

For Arranging Modules On A Multiple Rack :-

Following Rules Apply:-

 a) The interface module always uses slot 3 (slot 1: power supply; slot 2: CPU, slot 3:

Interface module).It is always on the left before the first signal module. b) No more than 8 modules
(SM, FM, and CP) are permitted per rack.

c) The number of modules (SM, FM, and CP) is limited by the permitted current consumption on the S7-
300 backplane bus. The total current consumption may not exceed 1.2 A per row (if 312 FM CPU is used: 0.8
A).

Addressing

Slot Based Addressing: - Slot-based addressing is the default setting, that is, STEP-7 assigns each slot
number a defined module start address.

Absolute Addressing: - With user-defined addressing, you can assign any module address from the
address area managed by the CPU. For the S7-300, user-defined addressing is only possible with CPUs 315,
315-2 DP, 316-2 DP, and 318-2 DP.

Addressing Of Digital Module:-The address of an input or output of a digital module consists of a byte
address and a bit address.

Addressing Of Analog Modules:-

 The address of an analog input or output channel is always a word address.

 The channel address depends on the module start address.

 Insert the first analog module into slot 4 so that it has default start address 256.

 The start address of every subsequent analog module will be incremented by 16 per slot An analog
I/O module has the same start addresses for its input and output.

Practical Module Specification:-

Power Supply Module “- PS 307 10A

CPU :- CPU 312, CPU 313C

Interface Module :- IM 360

Digital Input Module :- SM 321 DI (16 x AC 120 V)

Digital Output Module :- SM 322 :- ( 16 x DC 24V)

Analog Input Module: - SM 331:- (AI4 x 0/4 - 20 mA

INPUT/OUTPUT HARDWARE

Contactor & Relays

Contractor :- A contactor is an electrically controlled switch used for switching an electrical power circuit.

A contactor has three components:-

 The contacts are the current carrying part of the contactor. This includes power contacts, auxiliary
contacts, and contact springs.
 The electromagnet (or "coil") provides the driving force to close the contacts .

 The enclosure is a frame housing the contacts and the electromagnet. Enclosures are made of
insulating materials such as Bakelite, Nylon 6, and thermosetting plastics to protect and insulate the
contacts and to provide some measure of protection against personnel touching the contacts.

Relay: - Relay is an electrical switch, which is turn ON /OFF under another switch.

Relay is of two types –

I) Controlling type: - Controlling Relay takes lower amount of current & voltage and control higher
amount of current & voltage.

Controlling Relay is two types –

a. EMR (Electromagnetic Relay).

b. SSR (Solid State Relay).

II) Protection type: - Protection Relay detects the isolated faults in the generation, transmission &
distribution system. Protection Relay is two types –

a. OLR (Overload Relay).

b. Microprocessor.
Toggle Switch: - A Toggle Switch is an electromechanical switch which uses a lever or baton as an actuator.
Toggle switches are available in many sizes and configurations and offer a wide range of uses. They are
popular for their ease of operation and generally offer 1-3 positions to open or close a circuit.

Different types of toggle switch-

 SPST single pole single throw

 SPDT single pole double throw
 DPST double pole single throw
 DPDT double pole double throw
 SPCO single pole change over
 QPDT quarter pole double throw

Limit Switch: - A limit switch is an electromechanical device that consists of an actuator, mechanically
linked to a set of contacts. When an object comes into contact with the actuator, the device operates the

contacts to make or break anelectrical connection.

Benefits:-

i. Can be used in any industrial environment.

ii. Can switch load with high inductance.

Limitation:-

i. Restricted to equipment operating at lower speed.

ii. Must make direct contact with target. iii. Moving mechanical parts will wear out.

Sensor:-Sensor is a part of controlling circuit not a switch . Sensor is two types –

a) Analog ( Thermocouple, Thermo resistor, RTD).

b) Digital ( Inductive, Capacitive, Optical).

Timer:- A Timer is a device that provides time delay between two events or process.

Timer is two types -

 Mechanical Timer: - It is a mechanical switching device. It’s max time range 0.1sec –30sec. It has no
coil part only having contact part. Contact part changes its state by mechanical force.
  Electrical Timer:-It is an electrical switching device. It’s timer max range 0.1sec – 30min. It has one
relay coil, two contact parts, and two NO & two NC part. Contact part changes its state by the help of
electricity.
Types of PLC Timer :-

I) Pulse Timer.
II) Extended Pulse Timer.
III) On-delay Timer.
IV) Retentive On-delay Timer.
V) Off-delay Timer.
 LEARNING OUTCOMES

During my training with the ACADEMY OF SKILL DEVELOPMENT under IICHE, I was able to

 Learn how to code in PLC and SCADA.

 Perform simulations in given environments.

 Put these skills in practise and to complete AUTOMATIC BOTTLE FILLING SYSTEM and
4 WAY TRAFFIC CONTROL SYSTEM using PLC in projects.

 Learn the importance of automation in industries and got familiar with the challenging
tasks ahead.

 Understand how difficult and challenging the learning process via online platforms
is during the pandemic.
 CONCLUSION

It was a wonderful learning experience from Automatic skill development for two months
through online lectures. On the whole, this internship was a useful experience. I have gained
new knowledge, skill and met many new people. I achieved several of my learning goals. I
learned two of the programming languages PLC and SCADA used in the automation in
industries. I hope this experience will surely help me in my future and also in shaping my
career. The internship is also good to find out what my strength and weakness are. This
helped me to what skill and knowledge I have to improve in coming time. At last internship
has given me a new rights and motivation to pursue a carrier in industrial background.