VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Belagavi - 590018

Internship Training Report

On

“PLC FUNDAMENTALS”
In

Submitted by

MD FAROOQUE AHMAD
USN - 1AY22ME408

DEPARTMENT OF MECHANICAL ENGINEERING

ACHARYA INSTITUTE OF TECHNOLOGY

(Affiliated to Visvesvaraya Technological University, Belagavi)
2022-2023

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 ACHARYA INSTITUTE OF TECHNOLOGY
Acharya Dr. Sarvepalli Radhakrishnan Road, Soladevanahalli, Bengaluru – 560107
(Affiliated to Visvesvaraya Technological University, Belagavi)

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the Internship Training Report entitled “PLC FUNDAMENTALS” is a carried out

by Md Farooque Ahmad, USN NO -1AY22ME408 is a Bonafide student at Acharya Institute

of Technology in partial fulfillment for the award of degree of Bachelor of Engineering in

Mechanical Engineering of Visvesvaraya Technological University, Belagavi during the

year 2022 - 2023. It is certified that all corrections/suggestions indicated for Internal

Assessments have been incorporated in the report deposited in the departmental library.

The Internship Training Report has been approved as it satisfies the academic requirements

in respect of Internship Report prescribed for the Bachelor of Engineering Degree.

Signature of Coordinator Signature of HOD Date:

Prof. Vinod Kumar C S Dr Manjunatha B

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 ABSTRACT

I completed an online internship in PLC fundamentals through Udemy to gain hands-on

knowledge of Programmable Logic Controllers.

The course provided in-depth understanding of:

•PLC components like power supply, CPU, I/O modules

•PLC programming languages like Ladder Logic, Function Block, Instruction List

•PLC installation, configuration, programming, troubleshooting

•Key topics like addressing, scan cycle, ladder logic circuits, control systems, analog I/O
handling, data manipulation, sequencers, HMI integration

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 ACKNOWLEDGEMENT

I thank Udemy for giving me the opportunity to complete an online internship in PLC fundamentals.
Through this internship, I have gained valuable skills and knowledge about PLC hardware, software
programming and applications. The course modules, simulations and hands-on exercises have enabled
practical learning for me. This experience has prepared me well for career roles in PLC and automation
engineering.

I am deeply indebted to Dr. Rajath Hegde. M. M Principal, Acharya Institute of Technology, Bengaluru.
who has been a constant source of enthusiastic inspiration to steer us forward.

I heartily thank Dr. Manjunatha. B, Head of the Department, Department of Mechanical Engineering,
Acharya Institute of Technology, Bengaluru, for his valuable support and for rendering us resources for
this activity.

I especially thank Prof Vinod Kumar CS, Associate Professor, Department of Mechanical Engineering who
guided me with valuable suggestions in completing this Internship at every stage.

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 TABLE OF CONTENTS
 Introduction 07

 Background About PLCs 08

 Overview of PLCs 09

 PLC Programming 12

 Advantages 13

 Disadvantages 14

 Application 15

 Limitation 16

 Learning Outcomes 17

 Conclusion 18

 Biodata 19

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INTRODUCTION

Udemy is a leading global marketplace for online learning, offering over 180,000 courses
in topics like business, technology, design and more. I recently completed the "PLC
Fundamentals " course offered on Udemy to gain skills in Programmable Logic
Controllers (PLCs) and industrial automation.

This course is created by Paul Lynn, an experienced PLC programmer and instructor with
over 10 years of experience in the automation industry. Through comprehensive video
lectures and simulation-based exercises, this course provides training on fundamentals
of PLCs including how they work, programming using ladder logic and function block
diagram languages, wiring, addressing, HMI integration and troubleshooting.
Over a 2-week schedule, the course covers key PLC concepts like installation,
inputs/outputs, logic gates, timers and counters, analog i/o, data manipulation
techniques, PID control and industrial communications. Learners have to apply the
concepts by developing PLC programs for real-world automation scenarios using
simulation software.
By completing this intensive bootcamp-style course on Udemy, I was able to gain
essential knowledge and practical skills to confidently develop, test and debug PLC
programs for industrial applications. The hands-on learning has prepared me well for
implementing automation solutions using Programmable Logic Controllers. I highly
recommend this course on Udemy for anyone looking to get started with PLC
programming and industrial automation.

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Background about PLCs

Programmable Logic Controllers (PLCs) are digital computers used for automation of
electromechanical processes in industries like manufacturing, energy, transportation,
mining, etc. PLCs were first introduced in the 1970s and have evolved over generations
to become the backbone of industrial automation systems.
A PLC works by interfacing with sensors and actuators on the shop floor to monitor and
control different machines and processes via programs developed using ladder logic or
function block diagram languages. The core components of a PLC system include the
central processing unit (CPU), memory, power supply, input/output (I/O) modules and
programming device.
The CPU executes the PLC program stored in memory in a continuous scan cycle to take
inputs from sensors, execute program logic, and update outputs to actuators. The input
and output modules connect the PLC to devices like switches, valves, drives etc. on the
field. PLCs offer benefits like ease of programming, flexibility, modularity, reliability and
communication capabilities.
With the increasing complexity of industrial processes, PLCs play a crucial role in
automation today. Learning PLC programming skills is very important for anyone
looking to start a career in industrial automation. The objective of this internship
program was to gain comprehensive knowledge of PLC working principles,
programming, applications, and practical skills through hands-on learning modules.

Fig no - 1

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Overview of PLC basics:

PLC Basics

Central Processing Unit (CPU)

 Microprocessor-based controller that executes the PLC program.

 Fetch-Decode-Execute cycle: Retrieves program instructions, decodes them, and
executes logic.
 Scan time: Time taken for one execution of the program. Typically, in
milliseconds.
 Different types of CPUs are available based on memory, speed, I/O capacity.
 System and application memory for storing programs, OS, variables etc.

Memory

 System Memory - Stores operating system, boot project

 User Memory - Stores PLC program and values
 Types: RAM, ROM, EEPROM
 RAM - Fast, temporary storage, erased when PLC turned off.
 ROM - Permanent storage, cannot be modified.
 EEPROM - Retains data even if power is switched off.

Power Supply

 Converts the AC input voltage to necessary DC levels to power different

components.
 Should provide ample power for entire I/O, modules, field devices.
 Can have backup provisions like batteries, uninterrupted supplies.
 Indicator LEDs for power status, overload protection

I/O Modules

 Analog Input - Measure continuous signals like temperature, pressure, level

 Analog Output - Send control signals to actuators and drives.
 Digital Input - Read discrete on/off signals from limit switches, buttons.

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Programming Devices

 Handheld programmers used for small projects.

 Computer-based software like STEP 7, RS Logix, Unity Pro for large programs
 Supports programming languages like Ladder Logic, FBD, SFC
 Used for programming, testing and troubleshooting.

System Wiring

 Field devices like sensors and switches connected to input modules.

 Actuators like drives and valves connected to output modules.
 Point-to-point, multi-core cabling between PLC and devices
 Fieldbus networks like AS-i, Profibus used for connecting multiple devices.
 Proper grounding, shielding and cable trays important.

Sensors

 Proximity Sensors - Optical, inductive, capacitive, ultrasonic types

 Photoelectric Sensors - Diffused, retro-reflective modes
 Limit Switches - Detect mechanical position.
 Encoders - Measure rotary or linear position
 Temperature Sensors - Thermocouples, RTDs, thermistors

Actuators

 Solenoid Valves - Control flow of fluids

 Motor Starters - Control motors
 Servo/Stepper Motors - Provide precise motion
 Pneumatic/Hydraulic cylinders - Linear motion

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  PLC, components:

A PLC or Programmable Logic Controller is a digital computer used for automating

industrial processes. The main components of a PLC include the CPU (Central Processing
Unit), memory, power supply, input/output modules and programming device. The CPU
executes the logic program stored in memory and processes inputs and outputs from
field devices via the I/O modules.

 PLC system wiring, power supply:

In a PLC system, the CPU, memory and I/O modules are mounted together on a rack or
chassis. The power supply provides the necessary DC power levels to the PLC
components derived from the AC mains supply. Field devices like sensors, switches and
actuators are wired to the respective input and output modules on the PLC rack. The
wiring can be point-to-point through multi-core cables or over fieldbus networks.

 Inputs and outputs, sensors, actuators:

The input modules connect the PLC to sensors which provide data about the process
conditions. Common industrial sensors used with PLCs include proximity sensors,
photoelectric sensors, limit switches, pressure transmitters, temperature sensors etc. The
output modules connect the PLC to actuators like motors, valves, drives etc. which act
on the process based on the PLC program logic.

Fig no - 2

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PLC Programming

Ladder Logic Programming

 Uses ladder diagram with two vertical rails representing power rails.
 Left rail (hot) is positive voltage.
 The right rail (neutral) is zero voltage.
 Horizontal rungs between rails like rungs on a ladder
 Inputs, outputs and other instructions placed on rungs.
 Outputs turned ON when certain logic conditions are met.

Ladder Elements:

 Contacts - Act like switches, used for inputs.

 Coils - Act like relays, used for outputs.
 Power flow - Current flows from left to right when contacts are closed.
 Basic Instructions:
 Normally open and normally closed contacts
 Output coils - Energize or de-energize.
 Series and parallel contact combinations
 Timers, counters, math functions etc.

Benefits:

 Graphical and visual programming

 Resembles relay control circuits.
 Easy for technicians to understand logic.
 Widely used in industrial automation

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Advantages of PLCs:

 Flexible and Customizable Programming - PLC logic can be modified, and

programs changed easily compared to hardwired relay circuits. New functionality

can be added by changing the software program.

 Easy Troubleshooting - PLCs have built-in diagnostic indicators and functions

that help identify issues. Program flow can be monitored in real-time for

debugging.
 Reliable and Robust - PLCs are designed for harsh industrial environments. They

have stable operating temperatures and immunity to vibrations, noise and

shocks.

 Compact Size - Miniature PLCs take up very less space compared to relay panels
and provide high density I/O configuration.

 Communication Capabilities - PLCs can communicate with HMIs, SCADA, other

controllers using protocols like Ethernet IP, Modbus, Profibus.

 Cost Effective - For small I/O count, PLCs are more cost effective than relay
systems. Development, testing and maintenance costs are low.

 Easy to Scale and Expand - Modular PLCs allow easy expansion by adding more
I/O modules. Programs can also be scaled efficiently.

 Reduced Downtime - Reliability, diagnostics capabilities and easy

troubleshooting reduce downtime and maintenance costs.

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Disadvantages:

 Higher Initial Cost - For large I/O counts, initial PLC cost may be high compared

to relay systems.
 Skill and Expertise Needed - Proper training required to program and implement

PLC systems.
 Processor Limitations - Complex programs and large memory requirements may

exceed PLC processor and memory capacity.

 Damage Risk - Harsh environments, noise and temperatures can damage PLC

electronics if not properly protected.

 Vendor Specific - PLC programming software and hardware often proprietary to

the vendor and non-interchangeable.

 Failures - Processor or I/O module failures can lead to complete shutdown of

automated systems.
 Licensing Costs - For some advanced PLC programming software, licensing costs
are high.

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Application of PLC

 Motor Control - PLCs are widely used for controlling motors in industries. A PLC

system with motor starter outputs can control motor operation for applications like
conveyors, pumps, compressors, lift mechanisms etc. PLC programming involves

wiring diagrams, safety interlocks, jog/run controls, speed control and monitoring.
 Process Control - PLCs are ideal for continuously monitoring and controlling process

variables like flow, temperature, pressure, level etc. using analog I/O modules. PLCs
can implement PID control loops for efficient process control. Useful for applications

like heating systems, batch production, distillation columns etc.

 Robotic Control - PLCs provide the precision control capabilities needed for robotic

motion control. Multi-axis coordinated robotic movements for pick-and-place,

palletizing, welding etc. can be programmed on a PLC using dedicated motion

instructions.
 Tank Level Monitoring - Monitoring fluid levels in process tanks and vessels is a

common application. PLCs automate the level monitoring using level sensors like
ultrasonic, capacitive, float switches etc. and control valves for inlet/outlet flows.

 Packaging Machines - High speed packaging machines rely heavily on PLCs for
control of motors, sensors, clutches and actuators. PLC I/O modules and program

handle sequence control, registration control, operation monitoring and safety

interlocks.

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Limitation of PLC

1. Processing Limitations

 PLCs have limited processing power and speed compared to a computer.

Complex math operations and extensive data handling can lead to scan time
delays.

 Large programs with many loops and functions, can exceed the memory capacity
and processing capability of a PLC CPU.

 For highly complex processes like motion control, machine vision, PLCs may not
offer sufficient performance.

2. Programming Complexity

 While ladder logic is easy to learn, large programs with many rungs and functions
can become complex and hard to troubleshoot.

 Structured Text language is better for complex programs but requires advanced
programming skills.
 Difficult to program applications with complex mathematical computations.

3. Communication Limitations

 Most PLCs have a limited number of communication ports and protocols. Adding

networks can get complex.

 Data exchange with numerous devices can be inefficient and slow over PLC

communication links.
 Handling large data communication loads from SCADA, MES can be challenging.

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Learning Outcomes

I learned a lot of useful skills about Programmable Logic Controllers (PLCs) from this

course. Now I know the basic parts that make up a PLC system - the processor, memory,
input/output modules and how they are all connected. I can read circuit diagrams to see

how sensors, switches, valves and motors are wired to the PLC.
The most important thing I learned is how to make ladder logic programs on the

computer to control machines and processes. I practiced using contacts, coils, timers,
counters and other functions to write programs. This is like creating simple circuits with

logic gates. Now I can program PLCs to do things like start and stop motors, monitor
tank levels, control conveyor belts and more.

I also learned how to find and fix problems with the PLC programs and hardware. The
course gave me good experience in testing programs and troubleshooting issues when

the PLC does not work right. I got better at reading technical manuals and datasheets
too. This will really help me in future PLC and automation jobs.

Overall this was a very useful course to learn all about PLCs. I feel more confident now
to use PLCs for real equipment control and automation. This is the first step for me in

becoming a skilled PLC programmer.

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Conclusions

I learned a lot about PLCs from doing this online internship course on Udemy. The

videos, projects and tests taught me the basics of how PLCs work and how to program

them. I now know how to connect sensors, motors and switches to a PLC and write
ladder logic programs to control machines.

The course gave me good experience in using PLC simulation software to test programs.
I also learned how to find and fix problems with PLC hardware and software. Doing real-

world examples as class projects was very useful to improve my skills.

The instructor answered all my questions quickly during the course. I am happy I took

this internship because now I can confidently work on PLC and automation projects. This
will really help me in getting jobs as a PLC programmer. I would recommend this

internship to anyone who wants to learn PLC programming correctly from the basics.
Udemy is a great platform for online PLC training.

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Brief Biodata

 Name Md Farooque Ahmad

 USN 1AY22ME408
 Email id mdm.22.beme@acharya.ac.in
 Contact no 9122618452

Personal Details

 Date of Birth 02/03/2001

 Place of Birth Darbhanga
 Father Name Md Imtayaz Ahmad
 Mother Name Nasreen Kamal
 Sex Male
 Nationality- Indian
 Language Known English, Hindi, Urdu.

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