Industrial Training Report

Bharat Heavy Electricals Limited

BHEL, Haridwar Uttarkhand

Submitted to the department of Electronics & Communication in partial fulfilment of the requirements for the award of the degree of

Bachelor of TechnologyIn

Electronics & communication engineering

Submitted by

Nupur Goswami

1145031019

2014-15

Shri Ram Murti Smarak Women’s College of Engg. &Tech.

Bareilly-243202

CERTIFICATE

This is to certify that Mr./Ms. Nupur Goswami of B.Tech ( Electronics & Communication Engineering ) Roll

No. 1145031019 has completed her Industrial Training during the academic year 2013-14 as partial fulfilment

of B.Tech (Electronics & Communication Engineering) course.

The matter presented in this report has not been submitted by me in any otherUniversity/Institute for the award of any other degree.

Date:………………

Nupur Goswami

Signature of student

This is certifying that the above statement made by the student is correct to the best of my knowledge and

belief.

CO-ORDINATOR CO-ORDINATOR

(Ms. Neha Thakur) (Mr. Surendra Gangwar)

Assistant Professor ,EC Head of Department, EC

SRMSWCET,Bareilly SRMSWCET, Bareilly

Date-……………… Date-………………….

CO-ORDINATOR

(Mr. Mohit kumar)

Assistant Professor, EC

SRMSWCET, Bareilly

Date-………………

(ii)

Acknowledgement

It is my great pleasure to express my gratitude to MR. Raj Singh, Manager Training & Development Section,

BHEL, Haridwar Unit for his deep interest profile inspiration, valuable advice during the entire course of

vocational training.

I wish to express my gratitude to the Electronics & Communication department of BHEL for allowing me to

study various functions of their department.

It gives me an opportunity to understand the practical aspects of different functions of Electronics &

Communication department of BHEL. The present report bears the true justification of their investment.

My overriding dept continues to be the faculty members of our respected college for extending their unflinching

help & guidance.

For all this i would like to convey my wholehearted thanks to those entire people who helped me directly &

indirectly in completing my report.

Signature:

Nupur Goswami

(1145031019)

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ABSTRACT

Bharat Heavy Electricals Limited (BHEL) is an Indian integrated power plant equipment manufacturer and

operates as engineering and manufacturing company based in New Delhi, India. Established in 1964, BHEL

ushered in the indigenous Heavy Electrical Equipment industry in India. The company has been earning profits

continuously since 1971-72 and paying dividends since 1976-78.

It is engaged in the design, engineering, manufacture, construction, testing, commissioning and servicing of a

wide range of products and services for the core sectors of the economy, viz. Power, Transmission, Industry,

Transportation, Renewable Energy, Oil & Gas and Defence.

It is the 7th largest power equipment manufacturer in the world. In the year 2011, it was ranked ninth most

innovative company in the world by US business magazine Forbes. BHEL is the only Indian Engineering

company on the list, which contains online retail firm Amazon at the second position with Apple and Google at

fifth and seventh positions, respectively. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of 2010.

BHEL was established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment industry

in India. The company has been earning profits continuously since 1971-72 and paying since 1976-77. 74% of

the total power generated in India is produced by equipment manufactured by BHEL.

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TABLE OF CONTENTS

Chapter No. Description of Chapter Page no.

COVER PAGE i

CERTIFICATE ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

CONTENT TABLE v-vi

LIST OF FIGURES vii

LIST OF TABLES viii

ABBREVIATIONS ix

1. INTRODUCTION OF COMPANY 1-9

1.1 INTRODUCTION 1-2

1.2 BHEL HARIDWAR 2-3

1.3 BHEL PRODUCTION TREE 4-6

1.4 DIVISION OF BHEL INTO BLOCKS 8

1.5 MANUFACTURING DIVISIONS 9

2. INTRODUCTION TO CNC 10-11

2.1 ADVANTAGE OF CNC 11

3. CNC SYSTEMS 12-13

3.1 INTRODUCTION 12

3.2 CONTROL SYSTEM 13

3.2.1 OPEN LOOP SYSTEM 13

3.2.2 CLOSE LOOP SYSTEM 13

4. CONFIGURATION OF CNC SYSTEMS 14-16

4.1 INPUT DEVICES 15

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5 MACHINE CONTROL UNIT 17-23

5.1 MACHINE TOOL 17

5.2 DRIVING SYSTEM 18

6. SERVO DRIVE 24-33

7. INTERFACING 34-36

7.1 APPLICATIONS OF CNC MACHINES 36

8 . PLC PROGRAMMING 37-41

9 . PLC OPERATIONS 42-44

10. STRUCTURED PROGRAMMING 45-49

10.1. TIME CONTROL PROGRAM EXECUTIUON 46

10.2. EXAMPLE OF PLC PROGRAM 47-48

10.3. FLOW CHART 49

11. CONCLUSION 50

12. REFRENCES 51

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LIST OF FIGURES

Fig. no. Name of Fig. Page no.

1.1. BHEL MAIN GATE 3

3.1. OPEN LOOP SYSTEM 13

3.2. CLOSE LOOP SYSTEM 13

4.1. CNC MACHINE 14

4.2. SERIAL COMMUNICATION 16

5.1. BALL SCREW 18

5.2. BALL SCREW STRUCTURE 18

5.3. DC SERVO MOTOR 18

5.4. AC SERVO MOTOR 19

5.5. STEPPING MOTOR 20

5.6. TRANSDUCER

5.7. ROTATORY ENCODER 21

5.8. TACHOMETER 23

6.1. CONFIGURATION OF 3100 CNC 25

6.2. OPERATOR CONTROL PANEL 28

6.3. MACHINE PANEL OF 3100 30

8.1. PLC BLOCK DIAGRAM 38

8.2. HARDWARE 40

9.1. PROGRAM CONTROLLER 43

10.1. STRUCTURED USER OROGRAM 46

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LIST OF TABLES

FIG NO. NAME OF TABLE PAGE NO.

1.1 BHEL PRODUCTION TREE 5-6

1.2 PRODUCTION OF BHEL AND THEIR ROUTING 7

10.1 SPINDLE ON 45

(viii)

ABBREVATIONS

• DPU DATA PROCESSING UNIT

• CLU CONTROL LOOP UNIT

• USB UNIVERSAL DATA BUS

• PLC PROGRAMALE LOGIC CONTROLLER

• ROM READ ONLY MEMORY

• HEEP HEAVY ELECTRICAL EQUIPMENT PLANT

• CEEP CENTRAL FOUNDRY FORGE PLANT

• OHT OVER HEAD TANK

• EMRP ELECTRICAL MACHINES REPAIR PLANT

• ASSCP AMORPHOUS SOLAR CELL PLANT

• CNC COMPUERIESED NUMERICAL CONTROL

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CHAPTER 1

INTRODUCTION OF BHEL

1.1.Introduction:-

In 1956, India took a major step towards the establishment of its heavy engineering industry

when Bharat Heavy Electrical Ltd., the first heavy electrical manufacturing unit of the country was

setup at Bhopal. It progressed rapidly and three more factories went into production in 1965. The

main aim of establishing BHEL was to meet the growing power requirement of the country.

B.H.E.L appeared on the power map of India in 1969 when the first unit supplied by it was commissioned

at the Basin Bridge Thermal Power Station in Tamil Nadu. Within a decade, BHEL had

commissioned the 100 unit at Santaldih West Bengal.

BHEL had taken India from a near total dependence on imports to complete self-reliance in this vital area of

power plant equipment BHEL has supplied 97% of the power generating equipment. BHEL has

already supplied generating equipment to various utilities capable of generating over 18000 MW

power. Today BHEL can produce annually; equipment capable of generating 6000MW. This

will grow further to enable BHEL to meet all of India’s projected power equipment requirement. As well as

sizeable portion of export targets.

Probably the most significant aspect of BHEL’s growth has been it’s diversification. The constant

reorientation of the organization to meet the varied needs in time with time a philosophy that has led to the

development of a total capability from concepts to commissioning not only in the field of

energy but also in industry and transportation.

In the world power scene, BHEL ranks among the top ten manufactures of power plant equipment and in terms

of the spectrum of products and services offered, it is right on top. BHEL’s technological excellence and

turnkey capabilities have won it worldwide recognition. Over 40 countries in the world over have

placed orders with BHEL covering individual equipment to complete power stations on a turnkey basis.

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In1978-79 export earnings reached Rs. 122 crores, the highest for any one-year. BHEL has its headquarters

at New Delhi.Its operations are spread over 11 manufacturing plants and number of engineering and

service divisions located across the country/ the service divisions includes a network of regional

branch offices throughout India.

BHEL today is the largest Engineering Enterprise of its kind in India with excellent track record of

performance, making profits continuously since 1971-72. BHEL's vision is to become a world-class engineering

enterprise, committed to enhancing stakeholder value. The company is striving to give shape to its aspirations

and fulfill the expectations of the country to become a global player. BHEL business operations cater to core

sectors of Indian Economy.

Power

Industry

Transportation

Transmission

Defences

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1.2. BHEL-HARIDWAR

At the foothills of the majestic Himalayas, on the bank of the Holy Ganges in Ranipur, Uttarakhand is located

Heavy electrical equipment plant (HEEP) of B.H.E.L.

BHEL, completely owned by the Government of India is an integrated engineering complex consisting of

several plants of India, where about 70,000 workers are employed in the design and manufacturing of heavy

electrical equipment.

At present, 70 % of country’s electrical equipment is generated at BHEL Haridwar. BHEL is the largest

engineering and manufacturing enterprise in India in the energy-related / infrastructure sector, today.

BHEL is ushering in the indigenous Heavy Electrical Equipment industry in India-a dream that has

been more than realized with a well-recognized track record of Performance.

Fig1.1 BHEL HARIDWAR MAIN GATE

A widespread network comprising of 14 manufacturing companies, which have international

recognition for its commitment towards quality. With an export presence in more than 60 countries,

BHEL is truly India’s ambassador to the world. BHEL’s vision is to become world class engineering

enterprise, committed to enhancing stakeholder value.

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The greatest strength of BHEL is its highly skilled and committed 50,000 employees. Every employee is given

an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career

planning, a positive work culture and participative style of management all these have engendered development

of a committed and motivated workforce setting new benchmarks in terms of productivity, quality and

responsiveness. At Haridwar, against the picturesque background of Shivalik Hills, 2 important manufacturing

units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry Forge Plant

(CFFP). The hum of the construction machinery working started under Shivalik Hills during early 60s and

sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration – Heavy Electrical Equipment Plant.

Consequent upon the technical collaboration between India and USSR in 1959, BHEL’s prestigious unit, Heavy

Electrical Equipment plant (HEEP), was established in October, 1963, at Hardwar. It started manufacturing

thermal sets in 1967 and now thermal sets of 210, 250 and 500 MW, including steam turbines, turbo-generators,

condensers and all associated equipments, are being manufactured. This unit is capable of manufacturing

thermal sets up to 1000 MW. HEEP-manufactured gas turbines, hydro turbines and generators, etc., are not only

successfully generating electrical energy within and outside the country, but have also achieved a historic record

of the best operational availability.

POWER & WATER SUPPLY SYSTEM:

- 40 MVA sanctioned Electric Power connection from Grid (132 KV / 11KV / 6.6 KV) (Connected load –

around 185 MVA)

- 26 deep submersible Tube Wells with O.H. Tanks for water supply.

- A 12 MW captive thermal power station is located in the factory premises.

MAIN PRODUCTS:

- Steam Turbines

- Gas Turbines

- Turbo Generators

- Heat Exchangers

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1.3.BHEL- Haridwar Organization/Production Tree

BHEL – Haridwar is divided into various sections/blocks for effective organization and management. Each

block manufactures a specific set of machinery and equipments which are described as below :

TABLE 1.1

Sr. No. Block Major Facilities Products 1. Block –I (Electrical

Machines) Machine Shop, Stator Winding [THRI & LSTG], Rotor Winding [THRI & LSTG], Core Assembly, Exciter Section, over speed balancing, Test Bed, babbiting, Micalastic impregnation [LSTG & THRI]

Turbo Generator, Brushless Exciters

2. Block – II (Fabrication Block)

Stator Frame[THRI & LSTG], Markings, welding ,Cutting, straightening, gas cutting press, , grinding, assembly, heat treatment, cleaning & Shot blasting, machining, fabrication of pipe coolers, painting

Large size fabricated assemblies/ components for power equipments

3. Block –III (Turbines & Auxiliary Block)

Machining, facing wax melting, broaching, assembly preservation & packing, test stands/ station, painting grinding, milling, polishing etc.

Stem turbines, hydro turbines, gas turbines, turbine bladders, special tooling.

4. Block –IV (Feeder Block) 1. ACM

Rotor Bar Manufacturing [THRI & LSTG]

Rotor Bars [Field Bars]

2.CSM Stator bar manufacturing

Stator bars and exciter bars

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5. Block – V Fabrication, pneumatic hammer for forgings, gas fired furnaces, hydraulic manipulators

Fabricated parts of steam turbine, water box, storage tank hydro turbine parts, hydro turbines assemblers & Components

6. Block – VI (Fabrication)

Welding, drilling, shot blasting, CNC flame cutting ,CNC deep drilling, Shot basting, sheet metal work, assembly

Fabricated parts of steam turbine water box, stronger tanks, hydro turbine parts, Hydro turbines assemblies & components,

7. Block- VI (Stamping & Die Manufacturing)

Machining, turning, grinding, jig boring stamping presses, de varnishing, degreasing & de rusting, varnishing sport welding, painting.

Wooden packing, spacers etc.

8. Block- VII (wood working)

Wood Cutting, machines, grinding , packing

Wooden packing, spacers etc.

9. Block – VIII Drilling ,turning, saw, cutting, welding, tig welding

LP Heater ejectors glad, steam cooler oil coolers, ACG collers, oil tanks, bearing covers.

BHEL has:-

Installed equipment for over 90,000MW of power generation for Utilities, captive and

Industrial users.

Supplied over 25000 Motors with Drive Control System to power projects, Petrochemicals Refineries,

Steel, Aluminum, Fertilizer, Cement plant, etc.

Supplied Traction electrics and AC/DC locos over 12000 kms Railway network.

Supplied over one million Values to Power Plants and other Industries

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RATINGS PRODUCTS OF BHEL HARIDWAR AND THEIR CAPACITY TABLE 1.21

.

Thermal/nuclear set 210MW-1000MW

2

.

Hydro set 115MW

3

.

Generator according to requirement

4

.

gas turbine 60MW-200MW

5

.

heat exchangers, condensers Upto 800MW

6

.

AC/DC electrical machine 5kW-2000kW

(a)AC (250 kW-1600kW )

(b)DC (7kW-1000kW)

BHEL has turnkey capabalities for executing power projectors from concept to commissioning. it possesses the

technology and capability to produce thermal power plant equipment upto 1000MW rating and gas turbine generator

sets upto a unit rating of 240MW.Cogeration and combine cycle plants have been introduced to achieve higher plant

efficiencies. To make efficient use of the higher ash content crash coil manufacturers 235MW nuclear turbine

generator sets and has commenced the generation of 500 MW nuclear turbine generator head discharge

combinations are also engineered and manufactured is equally competitive.

1.4.BHEL is divided into many blocks:

1).Block-1:-In block one turbo generator, generator, exciter motors (A.C&D.C) are manufactured &

assembled

2). Block-2:-In block two large size fabricated assemblies\component for power equipment are manufactured &

assembled.

3) Block-3:-In block -3 steam turbine, hydro turbines, and gas turbines, turbines blade are manufactured

& assembled.

4) Block-4:-In block -4winding for turbo generator, hydro generator, insulation of A.C&D.C motors

insulating component for turbo generator, hydro generator motors are manufactured & assembled.

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5) Block-5:-In block -5 fabricated parts of steam turbine water box, hydro turbine turbines

parts are manufactured & assembled.

6) Block-6:-In block -6 fabricated oil tanks hollow guide blades, rings, stator frames rotor spiders are

manufactured & assembled.

7) Block-7:-In block -7 all types of dies including stamping dies, stamping for generators

&motors are manufactured & assembled.

8) Block-8:-In block-8 LP heaters, ejectors, steam coolers, oil coolers, ACG coolers, oil tanks are manufactured

& assembled.

1.5.MANUFACTURING DIVISIONS

Heavy Electrical Plant, Piplani, Bhopal

Electrical Machines Repair Plant (EMRP), Mumbai

Transformer Plant P.O. BHEL, Jhansi.

Bharat Heavy Electrical Limited : Central Foundry Forge Plant., Ranipur, Hardwar

Heavy Equipment Repair Plant, Varanasi.

Insulator Plant, Jagdishpur, Distt. Sultanpur.

Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad

High PressureBoiler Plant & Seamless Steel Tube Plant, Tiruchirappalli.

Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.

Industrial Valves Plant, Goindwal.

Electronics Division :

Electronics Systems Division.

Amorphous Silicon Solar Cell Plant (ASSCP).

Electro porcelains Division.

BANGALORE

Component Fabrication Plant, Rudrapur.

Piping Centre, Chennai.

Heavy Electrical Equipment Plant,

Regional Operations Division, New Delhi

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1.5.1.TRANSMISSION-

BHEL also supplies a wide range of transmission products and systems upto 400kV class. These include high

voltage power, distribution transformers, instrument transformers, dry type transformer,SF6 switch gear,

capacitor and insulator,etc.Series and shunt compensation systems have been also developed and introduced to

minimize transmission losses.

1.5.2.TRANSPORTATION-

A high percentage of trains operated by the Indian Railways are equipped with BHEL’s traction and control

equipment including the metro at Calcutta and Delhi.the company supplies broad gauge.

Electrical locomotive to Indian Railway and diesel shunting locomotives to various industries 5000/6000 hp

AC/DC locomotive developed and manufactured by B.H.E.L. have been leased to Indian Railway, battery

powered road.

1.5.3.INTERNATIONAL OPERATIONS-

B.H.E.L.’s product series and projects have been exported to countries ranging from United states in the west

and New Zealand in the east and for India over 3000MW.a few notable ones are a 15o MW gas turbine to

Germany ,utility boiler and open cycle gas turbine plant to Malaysia, Tripoli west, power station in Libya and

Turkey .in Cyprus, hydro generator to New Zealand and hydro power plant to Thailand, Oman, Greece and

Egypt.

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CHAPTER 2

INTRODUCTION TO CNC

Numerical control for machines .tools were introduced in 1950’s by Prof.John T Parsons. The first NC machine

was built at the Massachusetts institute of Technology in 1953 by joint efforts of US Air Force, the MIT and

parson’s cooperation. NC is control by numbers .NC is control recorded information called part program, which

is set of coded instructions given as numbers for automatic control of am machine in a pre-determined

sequence.

Numerical control can be defined as a technique of controlling a machine tool by the direct insertion of

numerical data at some point of the system .The functions that are controlled on the machine tool are

displacement of the slide members, spindle speeds ,tool selection etc.At first ,the numerical control was used to

produce geocentrically complex parts ,but later used for added efficiency in medium batch production of turned

and milled parts presently, Numerical control is employed in all sectors of production .

Rapid development in the field of electronics such as integrated circuit, large scale integrated circuits and

development of minicomputer lead to the development of minicomputers based CNC systems. Further

development and the electronic “chip” revolution have ushered in the current generation “compact and

powerful” Microprocessor based CNC systems.

Development of computer numerically controlled (CNC) machines is an outstanding contribution to the

manufacturing industries. It has made possible the automation of the machining process with flexibility to

handle small to medium batch of quantities in part production.

Initially, the CNC technology was applied on basic metal cutting machine 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 setup on the same machine, CNC machines capable of performing multiple operations were developed.

To start with, this concept was applied to develop a CNC machining centre for machining prismatic components

combining operations like milling, drilling, boring and taping. Further, the concept of multi-operations was also

extended for machining cylindrical components, which led to the development of turning centers.

Computer Numerical Control (CNC) is a specialized and versatile form of Soft Automation and its

applications cover many kinds, although it was initially developed to control the motion and operation of

machine tools.

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Computer Numerical Control may be considered to be a means of operating a machine through the use of

discrete numerical values fed into the machine, where the required 'input' technical information is stored on a

kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc.

The machine follows a predetermined sequence of machining operations at the predetermined speeds

necessary to produce a workpiece of the right shape and size and thus according to completely predictable

results. A different product can be produced through reprogramming and a low-quantity production run of

different products is justified.

2.1.ADVANTAGE OF CNC MACHINES

Higher flexibility

Increased productivity

Consistent quality

Reduced scrap rate

Reliable operation

Reduced non productive time

Reduced manpower

Shorter cycle time

High accuracy

Reduced lead time

Just in time (JIT) manufacture

Automatic material handling

Lesser floor space

Increased operation safety

Machining of advanced material

The definition of CNC given by Electronic Industry Association (EIA) is as follows:

“ A system in which actions are controlled by the direct insertion of numerical data at some point.

The system must automatically interpret at least some portion of this data.”

In a simple word, a CNC system receives numerical data, interpret the data and then control the action

accordingly.

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CHAPTER 3

CNC SYSTEMS

3.1.INTRODUCTION

Numerical control (NC) is a method employed for controlling the motions of a machine tool slide and its

auxiliary functions with input in the form of numerical data. A computer numerical control (CNC) is a

microprocessor-based system to store and process the data for the control of slide motions and auxiliary

functions of the machine tools. The CNC system is the heart and brain of a CNC machine which enables the

operation of various machine members such as slides, spindles, etc. as per the sequence programmed into it,

depending on the machining operations.

The main advantage of a CNC system lies in the fact that the skills of the operator hitherto required in the

operation of a conventional machine is removed and the part production is made automatic.

The CNC systems are constructed with a NC unit integrated with a programmable logic controller (PLC) and

some times with an additional external PLC (non-integrated). The NC controls the spindle movement and the

speeds and feeds in machining. It calculates the traversing path of the axes as defined by the inputs. The PLC

controls the peripheral actuating elements of the machine such as solenoids, relay coils, etc. Working together,

the NC and PLC enable the machine tool to operate automatically. Positioning and part accuracy depend on the

CNC system's computer control algorithms, the system resolution and the basic mechanical machine accuracy.

Control algorithm may cause errors while computing, which will reflect during contouring, but they are very

negligible. Though this does not cause point to point positioning error, but when mechanical machine

inaccuracy is present, it will result in poorer part accuracy.

Computer Numerical Control (CNC) is a specialized and versatile form of Soft Automation and its

applications cover many kinds, although it was initially developed to control the motion and operation of

machine tools.

Computer Numerical Control may be considered to be a means of operating a machine through the use of

discrete numerical values fed into the machine, where the required 'input' technical information is stored on a

kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The

machine follows a predetermined sequence of machining operations at the predetermined speeds

necessary to produce a work piece of the right shape and size and thus according to completely predictable

results. A different product can be produced through reprogramming and a low-quantity production run of

different products is justified.

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3.2.Control Systems

3.2.1. Open Loop Systems :

Open loop systems have no access to the real time data about the performance of the system and therefore no

immediate corrective action can be taken in case of system disturbance. This system is normally applied only to

the case where the output is almost constant and predictable. Therefore, an open loop system is unlikely

to be used to control machine tools since the cutting force and loading of a machine tool is never a constant. The

only exception is the wirecut machine for which some machine tool builders still prefer to use an open loop

system because there is virtually no cutting force in wirecut machining.

FIG 3.1Block Diagram of an Open Loop System

3.2.2.Close Loop Systems:

In a close loop system, feedback devices closely monitor the output and any disturbance will be corrected in the

first instance. Therefore high system accuracy is achievable. This system is more powerful than the open loop

system and can be applied to the case where the output is subjected to frequent change. Nowadays, almost all

CNC machines use this control system.

FIG 3.2 Block Diagram of a Close Loop System

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CHAPTER 4 CONFIGURATION OF THE CNC SYSTEM

Fig.1 shows a schematic diagram of the working principle of a NC axis of a CNC machine and the interface of a

CNC control.

CNC system

Fig.4.1. Schematic diagram of a CNC machine tool

A CNC system consists of the following 6 major elements:

a. Input Device

b. Machine Control Unit

c. Machine Tool

d. Driving System

e. Feedback Devices

f. Display Unit

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NCPLC

Servo Drive Servo Motor

Spindle Head

Work piece

Table

Encoder

Position Feedback

TachoGeneratorVelocity

Feedback

Tape ReaderTape Punch

Other Devices

MachineElements

Inputs

Outputs

LeadScrew

Command value

• Proximity switches• Limit switches• Relay coils• Pressure switches• Float switches

4.1.Input Devices

a. Floppy Disk Drive

Floppy disk is a small magnetic storage device for CNC data input. It has been the most

common storage media up to the 1970s, in terms of data transfer speed, reliability, storage

size, data handling and the ability to read and write. Furthermore, the data within a

floppy could be easily edited at any point as long as you have the proper program to read it.

However,this method has proven to be quite problematic in the long run as floppies have

a tendency to degrade alarmingly fast and are sensitive to large magnetic fields and as well

as the dust and scratches that usually existed on the shop floor.

b. USB Flash Drive

A USB flash drive is a removable and rewritable portable hard drive with compact

size and bigger storage size than a floppy disk. Data stored inside the flash drive are

impervious to dust and scratches that enable flash drives to transfer data from

place to place. In recent years, all computers support USB flash drives to read and

write data that make it become more and more popular in CNC machine control

unit.

c. Serial communication

The data transfer between a computer and a CNC machine tool is often accomplished

through a serial communication port. International standards for serial communications are

established so that information can be exchanged in an orderly way. The most common

interface between computers and CNC machine tools is referred to the EIA Standard RS-232.

Most of the personal computers and CNC machine tools have built in RS232 port and a

standard RS-232 cable is used to connect a CNC machine to a computer which enables the

data transfer in reliable way. Part programs can be downloaded into the memory of a

machine tool or uploaded to the computer for temporary storage by running a

communication program on the computer and setting up the machine control to interact with the

communication software.

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Direct Numerical Control is referred to a system connecting a set of numerically

controlled machines to a common memory for part program or machine program

storage with provision for on-demand distribution of data to the machines. (ISO

2806:1980) The NC part program is downloaded a block or a section at a time into the

controller. Once the downloaded section is executed, the section will be discarded to

leave room for other sections. This method is commonly used for machine tools that do not

have enough memory or storage buffer for large NC part programs.

Distributed Numerical Control is a hierarchical system for distributing data between a

production management computer and NC systems. (ISO 2806:1994) The host computer is

linked with a number of CNC machines or computers connecting to the CNC

machines for downloading part programs. The communication program in the host

computer can utilize two-way data transfer features for production data communication

including: production schedule, parts produced and machine utilization etc.

FIG 4.2. Serial communication in a Distributed Numerical Control system

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CHAPTER 5

MACHINE CONTROL UNIT

Machine Control Unit (MCU)

The machine control unit is the heart of the CNC system. There are two sub-units in the machine control unit:

the Data Processing Unit (DPU) and the Control Loop Unit (CLU).

a. Data Processing Unit

On receiving a part programme, the DPU firstly interprets and encodes the part programme into internal

machine codes. The interpolator of the DPU then calculate the intermediate positions of the motion in terms

of BLU (basic length unit) which is the smallest unit length that can be handled by the controller. The calculated

data are passed to CLU for further action.

b. Control Loop Unit

The data from the DPU are converted into electrical signals in the CLU to control the driving system to

perform the required motions. Other functions such as machine spindle ON/OFF, coolant ON/OFF, tool

clamp ON/OFF are also controlled by this unit according to the internal machine codes.

5.1.Machine Tool

This can be any type of machine tool or equipment. In order to obtain high accuracy and repeatability, the

design and make of the machine slide and the driving lead screw of a CNC machine is of vital importance. The

slides are usually machined to high accuracy and coated with anti-friction material such as PTFE and Turcite in

order to reduce the stick and slip phenomenon. Large diameter recirculating ball screws are employed to

eliminate the backlash and lost motion. Other design features such as rigid and heavy machine structure; short

machine table overhang, quick change tooling system, etc also contribute to the high accuracy and high

repeatability of CNC machines.

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FIG 5.1. Ball Screw in a CNC machine FIG 5.2Ball screw structure

5.2.Driving System

The driving system is an important component of a CNC machine as the accuracy and repeatability depend very

much on the characteristics and performance of the driving system. The requirement is that the driving system

has to response accurately according to the programmed instructions. This system usually uses electric motors

although hydraulic motors are sometimes used for large machine tools. The motor is coupled either directly or

through a gear box to the machine lead screw to moves the machine slide or the spindle. Three types of

electrical motors are commonly used.

a. DC Servo Motor

This is the most common type of feed motors used in CNC machines. The principle of operation is based on the

rotation of an armature winding in a permanently energized magnetic field. The armature winding is

connected to a commutator, which is a cylinder of insulated copper segments mounted on the shaft. DC current

is passed to the commutator through carbon brushes, which are connected to the

machine terminals.

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The change of the motor speed is by varying the armature voltage and the control of motor torque is

achieved by controlling the motor's armature current. In order to achieve the necessary dynamic behaviour it

is operated in a closed loop system equipped with sensors to obtain the velocity and position feedback signals.

FIG 5.3 DC Servo Motor

b. AC Servo Motor

In an AC servomotor, the rotor is a permanent magnet while the stator is equipped with 3-phase

windings. The speed of the rotor is equal to the rotational frequency of the magnetic field of the stator, which is

regulated by the frequency converter. AC motors are gradually replacing DC servomotors.

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The main reason is that there is no commutator or brushes in AC servomotor so that maintenance is virtually not

required. Furthermore, AC servos have a smaller power-to-weight ratio and faster response.

FIG 5.4 AC Servo Motor

c. Stepping Motor

A stepping motor is a device that converts the electrical pulses into discrete mechanical rotational

motions of the motor shaft. This is the simplest device that can be applied to CNC machines since it can

convert digital data into actual mechanical displacement. It is not necessary to have any analog-to-

digital converter nor feedback device for the control system. They are ideally suited to open loop systems.

However, stepping motors are not commonly used in machine tools due to the following drawbacks: slow

speed, low torque, low resolution and easy to slip in case of overload. Examples of stepping motor application

are the magnetic head of floppy-disc drive and hard disc drive of computer, daisy-wheel type printer, X-Y tape

control, and CNC EDM Wire-cut machine.

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FIG 5.5 Stepping Motor

Feedback Device

In order to have a CNC machine operating accurately, the positional values and speed of the axes need to be

constantly updated. Two types of feedback devices are normally used positional feedback device and velocity

feedback device.

a. Positional Feed Back Devices

There are two types of positional feedback devices: linear transducer for direct positional measurement and

rotary encoder for angular or indirect linear measurement.

Linear Transducers –

A linear transducer is a device mounted on the machine table to measure the actual displacement of the

slide in such a way that backlash of screws; motors, etc would not cause any error in the feedback data. This

device is considered to be of the highest accuracy and also more expensive in comparison with other measuring

devices mounted on screws or motors.

FIF 5.6 Linear Transducer

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Rotary Encoders –

A rotary encoder is a device mounted at the end of the motor shaft or screw to measure the angular

displacement.

This device cannot measure linear displacement directly so that error may occur due to the backlash of screw

and motor etc. Generally, this error can be compensated for by the machine builder in the machine

calibration process.

FIG 5.7 Incremental and Absolute Rotary Encoder

b. Velocity Feedback Device

The actual speed of the motor can be measured in terms of voltage generated from a tachometer mounted at the

end of the motor shaft.DC tachometer is essentially a small generator that produces an output voltage

proportional to the speed. The voltage generated is compared with the command voltage corresponding to the

desired speed.

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The difference of the voltages can is then used to actuate the motor to eliminate the error.

FIG 5.8 Tachogenerator

Display Unit

The Display Unit serves as an interactive device between the machine and the operator. When the machine is

running, the Display Unit displays the present status such as the position of the machine slide, the spindle

RPM, the feed rate, the part programmes, etc. In an advanced CNC machine, the Display Unit can show the

graphics simulation of the tool path so that part programmes can be verified before the actually

machining. Much other important information about the CNC system can also displayed for maintenance and

installation work such as machine parameters, logic diagram of the programmer controller, error massages and

diagnostic data.

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CHAPTER 6

SERVO DRIVE

A servo drive consists of a servo amplifier and a servo motor. The main task of a servo amplifier (also called

amplifier, servo controller, or just controller) is the control of the motor current. In addition, ESR servo

amplifiers offer a broad spectrum of functionality

While most of the electrical drives are operated at constant speed, a servo drive has a rather "hectic" life. Often

it has to accelerate to the rated speed within a few milliseconds only to decelerate a short time later just as

quick. And of course the target position is to be reached exactly with an error of a few hundredths of a milli

-meter.

Compared to other controlled drives servo drives have the advantage of high dynamics and accuracy, full stall

torque, and compact motors with high power density.

Servo drives are used where high dynamics (i. e. fast acceleration and deceleration) and good accuracy at

reaching target positions are important. The good control behaviour allows the optimal adaptation to the

application (e. g. positioning without overshoot). But also the smooth run (due to sinusoidal commutation) and

the possibility of exact synchronisation of two or more drives open a wide field. Because of their wide speed

range servo drives can be used in a huge number of applications.

Servo drives run in large, highly automated installations with several dozens of axes as well as in machines with

only a few axes which perhaps operate independently.

Servo motor

Servo motors are electric motors that are designed specially for high dynamics. Servo motors by ESR

distinguish themselves by a compact design with high power density and a high degree of protection (up to IP

65). They come as AC servo motors (brush less) or DC servo motors (with brushes for the commutation). The

high power density is achieved by permanent magnets made of neodymium-iron-boron (NdFeB), samarium-

cobalt (SmCo), or ferrite material. The servo motor is equipped with a position sensor which provides the

controller with position and speed information.

As a standard, the AC servo motors are equipped with resolvers. In combination with the digital servo

amplifiers sincos encoders (absolute encoder, single-turn or multi-turn) and high-resolution incremental

encoders may be used as well, in case higher accuracy or dynamics is required.

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The DC servo motors can be equipped with tacho generators and/or incremental encoders. For dimensioning

the motor the following data are important: the mass of the parts to be moved, the cycle time of the application,

and the friction torque. With these data the rated and peak torque (maximum acceleration or deceleration) and

the rated speed can be calculated. If required, gears are used to match the moment of inertia of the motor to the

moment of inertia of the application.

Servo amplifier

The servo amplifier (also called amplifier, servo controller, or just controller) controls the current of the motor

phases in order to supply the servo motor with exactly the current required for the desired torque and the desired

speed. The essential parts of a servo amplifier are the power section and the control loops.

The power section consists of a mains rectifier, a DC-bus, and a power circuit which supplies the individual

motor phases with current.

The control loops (analogue or digital) drive the power circuit and by constantly comparing setpoint with actual

values ensure that the motor keeps exactly to the desired motions even under varying load.

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SYSTEM 3SINUMERIK SIEMENS

Z -

X -

Z+

X+

POWER ON

Emergency Stop

Cycle

Fig.6.1 Typical numerical control configuration of Hinumerik 3100 CNC system

Tape Puncher Tape Reader

Power Supply NC PLC1

Logic Unit

MachineControlPanelExpansion

MachineControlPanel

LSM2

LSM1

PLC 2, external

LSM-Logic Sub

module

Operator Control Panel

Fig.4 shows a typical Hinumerik 3100 CNC system's operator control panel. The operator control panel

provides the user interface to facilitate a two-way communication between the user, CNC system and the

machine tool. This consists of two parts:

• Video Display Unit (VDU)

• Keyboard

Video Display Unit (VDU)

The VDU displays the status of the various parameters of the CNC system and the machine tool. It displays all

current information such as:

• Complete information of the block currently being executed

• Actual position value, set or actual difference, current feed rate, spindle speed

• Active G functions

• Main program number, subroutine number

• Display of all entered data, user programs, user data, machine data, etc.

• Alarm messages in plain text

• Soft key designations

In addition to a CRT, a few LEDs are generally provided to indicate important operating modes and status.

Video display units may be of two types:

1. Monochrome or black and white displays

2. Color displays

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Operator's and machine panel

SYSTEM 3

SINUMERIK SIEMENS

Z -

X -

Z+

X+

POWER ON

Emergency Stop

Cycle

Control elements and indicators of the operator's panel

Program in progressFeed holdPosition not yet reached(Machine in motion)Alarm

Basic displayTool compensationZero offset

TestPart program

CRT

LED-indicatorFor assignmentOf keys

Change to actual value display

Change of display

Leaf forwards

Leaf backwardsRight-Left Cursor

Reset changeover

Assignment of keysCancel word

Alter word

Enter wordChange over to customer display

Operator guidance Yes,No

Delete inputStart

Fig.6.2 Operator control panel of Hinumerik 3100 system

Address Keys/Numerical keyboard

Keyboard

A keyboard is provided for the following purposes:

• Editing of part programs, tool data, and machine parameters.

• Selection of different pages for viewing.

• Selection of operating modes, e.g. manual data input.

• Selection of feed rate override and spindles speed override.

• Execution of part programs.

• Execution of other toll functions.

Machine Control Panel (MCP)

It is the direct interface between operator and the NC system, enabling the operation of the machine through the

CNC system. Fig.5 shows the MCP of Hinumerik 3100 system.

During program execution, the CNC controls the axis motion, spindle function or tool function on a machine

tool, depending upon the part program stored in the memory. Prior to the starting of the machine process,

machine should first be prepared with some specific tasks like,

• Establishing a correct reference point

• Loading the system memory with the required part program

• Loading and checking of tool offsets, zero offsets, etc.

For these tasks, the system must be operated in specific operating mode so that these preparatory functions can

be established.

(29)Control elements of the machine control panel

Modes of operation

Generally, the CNC system can be operated in the following modes:

• Manual mode

• Manual data input (MDI) mode

• Automatic mode

• Reference mode

• Input mode

• Output mode, etc.

Z -

X -

Z+

X+

POWER ON

Emergency Stop

Cycle

Mode selector Switch

Spindle speed override

Feedrate/rapid traverse override

Rapid traverse activate

Direction keysSpindle

OFF ON

FeedHold/Start

Cycle start

NC ON Key operated switch for input inhibit

Block search

Single block

Dry RunBlock Delete

Rapid TraverseOverride active

Manual encoder active inX-and Z-axis resp.

Fig.6.3 Machine control panel of Hinumerik 3100 system

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Manual mode:

In this mode, movement of a machine slide can carried out manually by pressing the particular jog button (+

or -). The slide (axis) is selected through an axis selector switch or through individual switches (e.g., X+, X-,

Y+, Y-, Z+, Z-, etc.). The feed rate of the slide movement is prefixed. CNC system allows the axis to be jogged

at high feed rate also. The axis movement can also be achieved manually using a hand wheel interface instead

of jog buttons. In this mode slides can be moved in two ways:

• Continuous

• Incremental

Continuous mode: In This mode, the slide will move as long as the jog button is pressed.

Incremental mode: Hence the slide will move through a fixed distance, which is selectable. Normally, system

allows jogging of axes in 1, 10, 100, 1000, 10000, increments. Axis movement is at a prefixed feed rate. It is

initiated by pressing the proper jog+ or jog- key and will be limited to the no of increments selected even if the

jog button is continuously pressed. For subsequent movement the jog button has to be released and once again

pressed.

Manual Data Input (MDI) Mode

In this mode the following operation can be performed:

• Building a new part program

• Editing or deleting of part program stored in the system memory

• Entering or editing or deleting of:

------ Tool offsets (TO)

------ Zero offsets (ZO)

------ Test data, etc.

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Teach-in

Some system allows direct manual input of a program block and execution of the same. The blocks thus

executed can be checked for correctness of dimensions and consequently transferred into the program memory

as part program.

Playback

In setting up modes like jog or incremental, the axis can be traversed either through the direction keys or via the

hand wheel, and the end position can be transferred into the system memory as command values. But the

required feed rates, switching functions and other auxiliary functions have to be added to the part program in

program editing mode.

Thus, teach-in and playback operating method allows a program to created during the first component prove

out.

Automatic Mode (Auto and Single Block)

In this mode the system allows the execution of a part program continuously. The part program is executed

block by block. While one block is being executed, the next block is read by the system, analyzed and kept

ready for execution. Execution of the program can be one block after another automatically or the system will

execute a block, stop the execution of the next block till it is initiated to do so (by pressing the start button).

Selection of part program execution continuously (Auto) or one block at a time (Single Block) is done through

the machine control panel.

Many systems allow blocks (single or multiple) to be retraced in the opposite direction. Block retrace is allowed

only when a cycle stop state is established. Part program execution can resume and its execution begins with the

retraced block. This is useful for tool inspection or in case of tool breakage. Program start can be effected at any

block in the program, through the BLOCK SEARCH facility.

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Reference Mode

Under this mode the machine can be referenced to its home position so that all the compensations (e.g., pitch

error compensation) can be properly applied. Part programs are generally prepared in absolute mode with

respect to machine zero. Many CNC systems make it compulsory to reference the slides of the machine to their

home positions before a program is executed while others make it optional.

Input Mode and Output Mode (I/O Mode)

In this mode, the part programs, machine setup data, tool offsets, etc. can be loaded/unloaded into/from the

memory of the system from external devices like programming units, magnetic cassettes or floppy discs, etc.

During data input, some systems check for simple errors (like parity, tape format, block length, unknown

characters, program already present in the memory, etc.). Transfer of data is done through a RS232C or

RS422C port.

Other Peripherals

These include sensor interface, provision for communication equipment, programming units, printer, tape

reader/puncher interface, etc.

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CHAPTER 7

INTERFACING

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 shock to personnel. It is also essential to

properly protect the electronic equipment.

Cable wires of sufficiently large cross-sectional area must be used. Even though proper grounding reduces the

effect of electrical interference, signal cable requires additional protection. This is generally achieved by using

shielded cables. All the cable shields must be grounded at control only, leaving other end free. Other noise

reduction techniques include using suppression devices, proper cable separation, ferrous metal wire ways, etc.

Electrical enclosures should be designed to provide proper ambient conditions for the controller.

MONITORING

In addition to the care taken by the machine tool builder during design and interfacing, basic control also

includes constantly active monitoring functions. This is in order to identify faults in the NC, the interface

control and the machine at an large stage to prevent damages occurring to the work piece, tool or machine. If a

fault occurs, first the machining sequence is interrupted, the drives are stopped, the cause of the fault is stored

and then displayed as an alarm. At the same time, the PLC is informed that an NC alarm exits. In Hinumerik

CNC system, for example, the following can be monitored:

• Read-in

• Format

• Measuring circuit cables

• Position encoders and drives

• Contour

• Spindle speed

• Enable signals

• Voltage

• Temperature

• Microprocessors

• Data transfer between operator control panel and logic unit

• Transfer between NC and PLC

• Change of status of buffer battery

• System program memory

• User program memory

• Serial interfaces

DIAGNOSTICS

The control will generally be provided with test assistance for service purposes in order to display some status

on the CRT such as:

• Interface signals between NC and PLC as well as between PLC and machine

• Flags of the PLC

• Timers of the PLC

• Counters of the PLC

• Input/output of the PLC

For the output signals, it is also possible to set and generate signal combinations for test purposes in order to

observe how the machine react to a changed signal. This simplifies trouble shooting considerably.

MACHINE DATA

Generally, a CNC system is designed as a general-purpose control unit, which has to be matched with the

particular machine to which the system is interfaced. The CNC is interfaced to the machine by means of data,

which is machine specific. The NC and PLC machine data can be entered and changed by means of external

equipment or manually by the keyboard. These data are fixed and entered during commissioning of the machine

and generally left unaltered during machine operations.

Machine data entered is usually relevant to the axis travel limits, feed rates, rapid traverse speeds and spindle

speeds, position control multiplication factor, Kv factor, acceleration, drift compensation, adjustment of

reference point, backlash compensation, pitch error compensation, etc. Also the optional features of the control

system are made available to the machine tool builder by enabling some of the bits of machine data.

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7.1. Applications of CNC Machines

CNC machines are widely used in the metal cutting industry and are best used to produce

the following types of product:

• Parts with complicated contours

• Parts requiring close tolerance and/or good repeatability

• Parts requiring expensive jigs and fixtures if produced on conventional

machines

• Parts that may have several engineering changes, such as during

the development stage of a prototype

• In cases where human errors could be extremely costly

• Parts that are needed in a hurry

• Small batch lots or short production runs

Some common types of CNC machines and instruments used in industry are as

following:

• Drilling Machine

• Lathe / Turning Centre

• Milling / Machining Centre

• Turret Press and Punching Machine

• Wirecut Electro Discharge Machine (EDM)

• Grinding Machine

• Laser Cutting Machine

• Water Jet Cutting Machine

• Electro Discharge Machine

• Coordinate Measuring Machine

• Industrial Robot

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CHAPTER 8

PLC PROGRAMMING

Programmable Logic Controller (PLC)

A PLC matches the NC to the machine. PLCs were basically introduced as replacement for hard wired relay

control panels. They were developed to be reprogrammed without hardware changes when requirements were

altered and thus are reusable. PLCs are now available with increased functions, more memory and large

input/output capabilities. Fig.7 gives the generalized PLC block diagram.

In the CPU, all the decisions are made relative to controlling a machine or a process. The CPU receives input

data, performs logical decisions based upon stored programs and drives the outputs. Connections to a computer

for hierarchical control are done via the CPU.

The I/O structure of the PLCs is one of their major strengths. The inputs can be push buttons, limit switches,

relay contacts, analog sensor, selector switches, proximity switches, float switches, etc. The outputs can be

motor starters, solenoid valves, position valves, relay coils, indicator lights, LED displays, etc.

The field devices are typically selected, supplied and installed by the machine tool builder or the end user. The

voltage level of the field devices thus normally determines the type of I/O. So, power to actuate these devices

must also be supplied external to the PLC. The PLC power supply is designated and rated only to operate the

internal portions of the I/O structures, and not the field devices. A wide variety of voltages, current capacities

and types of I/O modules are available.

The principle of operation of a PLC is determined essentially by the PLC program memory, processor, inputs

and outputs.

The program that determines PLC operation is stored in the internal PLC program memory. The PLC operates

cyclically, i.e. when a complete program has been scanned, it starts again at the beginning of the program. At

the beginning of each cycle, the processor examines the signal status at all inputs as well as the external timers

and counters and are stored in a process image input (PII). During subsequent program scanning, the processor

the accesses this process image.

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To execute the program, the processor fetches one statement after another from the programming memory and

executes it. The results are constantly stored in the process image output (PIO) during the cycle. At the end of a

scanning cycle, i.e. program completion, the processor transfers the contents of the process image output to the

output modules and to the external timers and counters. The processor then begins a new program scan.

Fig.6 System with peripheral devices

Fig.8.1. Generalized PLC block diagram

Programming Units

Tape Reader

PrintersTape Puncher

Processor Logic memory

Storage memory

PowerSupply

Inputs

Outputs

Power Supply

Programmer Field Devices

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What does ‘PLC’ mean?

A PLC (Programmable Logic Controllers) is an industrial computer used to monitor inputs, and depending

upon their state make decisions based on its program or logic, to control (turn on/off) its outputs to automate a

machine or a process.

PROGRAMMABLE LOGIC CONTROLLER

“A digitally operating electronic apparatus which uses a programmable memory for the internal

storage of instructions by implementing specific functions such as logic sequencing, timing,

counting, and arithmetic to control, through digital or analog input/output modules, various

types of machines or processes”.

Traditional PLC Applications

*In automated system, PLC controller is usually the central part of a process control system.

*To run more complex processes it is possible to connect more PLC controllers to a central computer.

Disadvantages of PLC control

- Too much work required in connecting wires.

- Difficulty with changes or replacements.

- Difficulty in finding errors; requiring skillful work force.

- When a problem occurs, hold-up time is indefinite, usually long.

Advantages of PLC control

* Rugged and designed to withstand vibrations, temperature, humidity, and noise.

* Have interfacing for inputs and outputs already inside the controller.

* Easily programmed and have an easily understood programming language.

Major Types of Industrial Control Systems

Industrial control system or ICS comprise of different types of control systems that are currently in operation in

various industries. These control systems include PLC, SCADA and DCS and various others:

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PLC

They are based on the Boolean logic operations whereas some models use timers and some have continuous

control. These devices are computer based and are used to control various process and equipments within a

facility. PLCs control the components in the DCS and SCADA systems but they are primary components in

smaller control configurations.

DCS

Distributed Control Systems consists of decentralized elements and all the processes are controlled by these

elements. Human interaction is minimized so the labor costs and injuries can be reduced.

Embedded Control

In this control system, small components are attached to the industrial computer system with the help of a

network and control is exercised.

SCADA

Supervisory Control And Data Acquisition refers to a centralized system and this system is composed of various

subsystems like Remote Telemetry Units, Human Machine Interface, Programmable Logic Controller or PLC

and Communications.

Hardware Components of a PLC System

Processor unit (CPU), Memory, Input/Output, Power supply unit, Programming device, and other devices.

FIG 8.2 HARDWARE

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Central Processing Unit (CPU)

CPU – Microprocessor based, may allow arithmetic operations, logic operators, block memory moves,

computer interface, local area network, functions, etc.

CPU makes a great number of check-ups of the PLC controller itself so eventual errors would be discovered

early.

System Busses

The internal paths along which the digital signals flow within the PLC are called

busses.

The system has four busses:

- The CPU uses the data bus for sending data between the different elements,

- The address bus to send the addresses of locations for accessing stored data,

- The control bus for signals relating to internal control actions,

- The system bus is used for communications between the I/O ports and the I/O unit.

Memory

System (ROM) to give permanent storage for the operating system and the fixed data used by the CPU.

RAM for data. This is where information is stored on the status of input and output devices and the values of

timers and counters and other internal devices. EPROM for ROM’s that can be programmed and then the

program made permanent.

I/O Sections

Inputs monitor field devices, such as switches and sensors.

Outputs control other devices, such as motors, pumps, solenoid valves, and lights.

Power Supply

Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC controllers have electrical supply as a

separate module, while small and medium series already contain the supply module.

Programming Device

The programming device is used to enter the required program into the memory of the processor.

The program is developed in the programming device and then transferred to the memory unit of the PLC.

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CHAPTER 9

PLC OPERATIONS:

Input Relays

These are connected to the outside world. They physically exist and receive signals from switches, sensors, etc.

Typically they are not relays but rather they are transistors.

Internal Utility Relays

These do not receive signals from the outside world nor do they physically exist. They are simulated relays and

are what enables a PLC to eliminate external relays.

There are also some special relays that are dedicated to performing only

one task.

Counters

These do not physically exist. They are simulated counters and they can be programmed to count pulses.

Typically these counters can count up, down or both up and down. Since they are simulated they are limited in

their counting speed.

Some manufacturers also include highspeed counters that are hardware based.

Timers

These also do not physically exist. They come in many varieties and increments.

The most common type is an on-delay type.

Others include off-delay and both retentive and non-retentive types. Increments vary from 1ms through 1s.

Output Relays

These are connected to the outside world. They physically exist and send on/off signals to solenoids, lights, etc.

They can be transistors, relays, or triacs depending upon the model chosen.

Data Storage

Typically there are registers assigned to simply store data. Usually used as temporary storage for math or data

manipulation.

They can also typically be used to store data when power is removed from the

PLC.

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The Simatic S5 PLC is an automation system based on PLC. It was manufactured and sold by Siemens. Such

automation systems control process equipment and machinery used in manufacturing.

STEP 5 programming language is used for writing user programs for SIMATIC S5 programmable controllers.

The program can be written and entered into the programmable controller as in:

Statement list (STL), Fig.12 (a)

Control system flowchart (CSF), Fig.12 (b)

Ladder diagram (LAD), Fig.12 (c)

(a)

Fig.9.1 Programmable controller

The statement list describes the automation task by means of mnemonic function designations.

The control system flowchart is a graphic representation of the automation task.

The ladder diagram uses relay ladder logic symbols to represent the automation task.

The statement is the smallest STEP 5 program component. It consists of the following:

Operation, i.e. what is to be done?

Statement list STL

A I 2.3A I 4.1O I 3.2= Q 1.6

A I 2.3

A I 2.3

I 2.3

AND

OR

I 2.3

I 4.1

I 3.2 Q 1.6

Statement

OperandOperation

Operand identifier

Parameter

(b) Control system flow chart CSF

(c) Ladder diagram LAD

I 2.3 I 4.1

I 3.2

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E.g. A = AND operation (series connection)

O= OR operation (parallel connection)

S= SET operation (actuation)

Operand, i.e. what is to be done with?

E.g. I 4.5, i.e. with the signal of input 4.5

The operand consists of:

Operand identifier (I = input, Q = output, F = flag, etc.)

Parameter, i.e. the number of operand identifiers addressed by the statement. For inputs, outputs and

flags (internal relay equivalents), the parameter consists of the byte and bit addresses, and for timers and

counter, byte address only.

The statement may include absolute operands, e.g. I 5.1, or symbolic operand, e.g. I LS1. Programming is

considerably simplified in the later case as the actual plant designation is directly used to describe the device

connected to the input or output.

Typically, a statement takes up one word (two bytes) in the program memory.

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CHAPTER 10

STRUCTURED PROGRAMMING

The user program can be made more manageable and straightforward if it is broken down into relative sections.

Various software block types are available for constructing the user program.

Program blocks (PB ) contain the user program broken down into technologically or functionally related

sections (e.g. program block for transportation, monitoring, etc.). Further blocks, such as program blocks or

function blocks can be called from a PB.

Organization blocks (OB ) contain block calls determining the sequence in which the PBs are to be processed. It

is therefore possible to call PBs conditionally (depending on certain conditions).

In addition, special OBs can be programmed by the user to react to interruptions during cyclic programming

processing. Such an interrupt can be triggered by a monitoring function if one or several monitored events

occur.

Function block (FB ) is block with programs for recurrent and usually complex function. In addition to the basic

operations, the user has a extended operation at his disposal for developing function blocks. The program in a

function block is usually not written with absolute operands (e.g. I 1.5) but with symbolic operands. This

enables a function block to be used several times over with different absolute operands.

For even more complex functions, standard function blocks are available from a program library. Such FBs are

available, e.g. for individual controls, sequence controls, messages, arithmetic operations, two step control

loops, operator communications, listing, etc. These standard FBs for complex functions can be linked it the user

program just like user written FBs simply by means of a call along with the relevant parameters.

The Sequence block (SB ) contain the step enabling conditions, monitoring times and conditions for the current

step in sequence cascade. Sequence blocks are employed, for example, to organise the sequence cascade in

communication with a standard FB.

The data blocks (DB ) contain all fixed or variable data of the user program.

CYCLIC PROGRAM PROCESSING

The blocks of the user program are executed in the sequence in which they specified in the organisation block.

INTERRUPT DRIVEN PROGRAM PROCESSING

When certain input signal changes occur, cyclic processing is interrupted at the next block boundary and an OB

assigned to this event is started. The user can formulate his response program to this interrupt in the OB. The

cyclic program execution is the resumed from the point at which it was interrupted.

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10.1.TIME CONTROLLED PROGRAM EXECUTION

Certain Obs are executed at the predetermined time intervals (e.g. every 100ms, 200ms, 500ms, 1s, 2s, and 5s).

For this purpose, cyclic program execution is interrupted at the block boundary and resumed again at this point,

once the relevant OB has been executed. Fig.13 gives the organisation and execution of a structured user

program.

PB1

PB2 FB3

FB2OB1

Structured programming

PB FB

PB FB

Organisation block (OB)Program block (PB) Function block (PB)

Cycle execution

OB

PB FBOB

Interrupt-driven execution

Points at which interrupt-driven program can be inserted

Start and finish of interrupt-driven program execution

Fig.10.1 Organisation and execution of a structured user program

(46)10.2.EXAMPLES OF PLC PROGRAM

Before attempting to write a PLC program, first go through the instruction set of the particular language used

for the equipment, and understand the meaning of each instruction. Then study how to use these instructions in

the program (through illustration examples given in the manual). Once the familiarization task is over, then start

writing the program.

Follow the following steps to write a PLC program.

List down each individual element (field device) on the machine as Input/Output.

Indicate against each element the respective address as identifier during electrical interfacing of these

elements with the PLC.

Break down the complete machine auxiliary functions that are controlled by the PLC into individual, self

contained functions.

Identify each individual function as separate block (PBxx/FBxx)

Once the PBs and FBs for each function are identified, take them one by one for writing the program.

List down the preconditions required for the particular function separately.

Note down the address of the listed elements.

Write down the flow chart for the function.

Translate the flow chart into PLC program using the instructions already familiarized.

Complete the program translation of all individual functions in similar lines.

Check the individual blocks independently and correct the program to get the required results.

Organize all the program blocks in the organization block depending upon the sequence in which they are

supposed to be executed as per the main machine function flow chart.

Check the complete program with all the blocks incorporated in the final program.

(47)Example TABLE 10.1: Spindle ON

Preconditions Feedback elements Address Fault indication Address Remark

Tool clamp Pressure switch I 2.4 Lamp Q 2.1Job clamp Proximity switch I 3.2 Lamp Q 1.7Door close Limit switch I 5.7 Lamp Q 4.0Lubrication ON PLC output bit Q 1.0 Lamp Q 7.7Drive ready Input signal from I 4.6 Lamp Q 0.4

Drive unit

TABLE

PB 12 written is the individual function module for spindle ON for all the preconditions checked and found

satisfactory. This function is required to be executed only when the spindle rotation is requested by the NC in

the form of a block in the part program.

Whenever NC decodes the part program block, it in turn informs the PLC through a fixed buffer location that

spindle rotation is requested. Say Flag bit F 100.0 is identified for this information communication. With this

data, spindle ON function module can be recalled in the organisation block OB1 as follows.

OB 1

……

A F 100.0

JC PB12

……

BE

Now, spindle ON function module PB12 will be executed only when F 100.0 is set. Otherwise the function

execution will be bypassed.

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10.3. FLOW CHART

START

TOOL CLAMP

JOB CLAMP

DOOR CLOSED

LUBRICATION ON

DRIVE READY

ANY FAULT

DO SPINDLE ON

INDICATE FAULT

INDICATE FAULT

INDICATE FAULT

INDICATE FAULT

INDICATE FAULT

STOP SPINDLE

PB12

AN I 2.4 Tool not clamped= Q 2.1 Display fault lamp

AN I 3.2 Job not clamped= Q 1.7 Display fault lamp

AN I 5.7 Door not closed= Q 4.0 Display fault lamp

AN Q 1.0 Lubrication not on= Q 7.7 Display fault lamp

AN I 4.6 Drive not ready= Q 0.4 Display fault lamp

Comments

ON I 2.4 Tool not clampedON I 3.2 Job not clampedON I 5.7 Door not closedON Q 1.0 Lubrication not onON I 4.6 Drive not readyR Q 67.3 Reset spindle enable bitBEC Block end conditionallyA I 2.4 Tool clampedA I 3.2 Job clampedA I 5.7 Door closedA Q 1.0 Lubrication ONA I 4.6 Drive readyS Q 67.3 Set spindle enable bitBE Block end

Exit

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

YES

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END

CHAPTER 11

CONCLUSION

The second phase of training has proved to be quite faithful. It proved an opportunity for encounter with such

huge machines like turbo-generator, hydro generator etc.

The architecture of B.H.E.L., the way various units are linked and the way working of whole plant is controlled

make the students realize that Engineering is not just structural description but greater part is planning and

management. It provides an opportunity to learn tech. Used at proper place and time can save a lot of

labour.

But there are few factors that require special mention. Training is not carried in true spirit. It is recommended

that there should be projectors especially for trainees where presence of authorities is ensured.

However, training has proved to be an enriching experience. It has allowed us an opportunity to get an exposure

of the practical implementation of theoretical fundamentals.

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.

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CHAPTER 12

REFRENCES

1. https://www.himaanshuderwal.blogspot.in

2. http://about.me/himanshuderwal

3. http://www.wikipedia.org

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