College Name:Aryans College Of Engineering(Banur)

TWO MONTH SOFTWARE TRAINING IN CNT TECHNOLOGIES PVT LTD. (CHANDIGARH)A TRAINING REPORT

ON

ORCAD AND PLC

PUNJAB TECHNICAL UNIVERSITY

JALANDHAR, PUNJAB, INDIA

SUBMITTED BY SUBMITTED TO

NAME OF CANDIDATE: HARDEEP SINGH MRS. MANVI ROLL NUMBER: 1280088COURSE NAME: B-TECHMONTH YEAR: 5 / 2015

TWO MONTH SOFTWARE TRAINING IN CNT TECHNOLOGIES PVT LTD. (CHANDIGARH)ARYANS COLLEGE OF ENGINEERING

AND

TECHNOLOGY

PUNJAB TECHNICAL UNIVERSITYAryans College of Engineering and Technology

Village-Nepra, Chandigarh-Patiala Highway,

Chandigarh. Letter head of Aryans College of Engineering Date: 18/05/15

CANDIDATE'S DECLARATION

I hereby certify that the work which is being presented in the report entitled, ORCAD &PLC, by Hardeep Singh (1280088 ) , B.TECH in EEE submitted at Aryans College of Engineering, is an authentic record of my own work carried out during a period from JUNUARY 2015 to MAY 2015 under the supervision of Ms.Meenakshi, Software Trainer,CNT Chd.

Signature of the Student

ACKNOWLEDGEMENT

I express my sincere gratitude to Aryans Group of Colleges for giving me the opportunity to work on the Orcad and PLC during my B.Tech. Training is an important aspect in the field of engineering.

(Hardeep Singh)

1280088

TWO MONTHS SOFTWARE TRAINING

REPORT

Submitted for partial fulfillment of award of

BACHELOR OF ELECTRICAL & ELECTRONICS ENGINEERING

ARYANS COLLEGE OF ENGINEERING

BANUR (RAJPURA)CONTENTS1) Company profile2) PCB Designing Functions of PCB Classifications of PCBs Technique used for PCB design PCB design software

3) OrCad design environment PCB design steps in OrCad

Entry to schematic

Creating Netlist Placement of Layout Plus Setting board parameters Creating board outline Placement of components Conductor routing Design rule check Post processing

4) Power system design Unregulated power supplies Regulated power supplies Bench supply diagram5 .Instrumentation

Automation

Engineering tools

Relays concepts

Contactor concepts

6. Programmable logic controller

Programming of PLC

PLC wiring

Panel wiring

Software introduction

XIC-XIO concepts

Introduction to PLC memory

Introduction to Data files and Program Files.

Start Stop logic

Logic gates

Concept for Latch, Unlatch

Timer

Counter

Compare function

Compute math

Move logic

Higher instruction (jmp, lbl, jsr, sbr, tnd, ret, mcr)

7. Supervisory Control and Data Acquisition Digital control

Start stop control

Digital programming

Analog control

SCADA interface to PLC

Digital control with plc and scada

Analog control with plc and scada

ACKNOWLEDGEMENT

First of all I would like to thank almighty GOD who has given this wonderful gift of life to us. He is the one who is guiding us in right direction to follow noble path of humanity. In my six months industrial training it is a wonderful experience to be a part of CNT TECHNOLOGIES where I have opportunity to work under brilliant minds. I owe my deep regards for the supporting and kind staff authorities who are helping me in my lean patches during these six months. The knowledge I am gaining throughout my studies have the practical implementation during this period. I am grateful to all the staff of CNT and for their timely support and sharing of their experience with me. I would like to express my heartiest concern for Miss. Meenakshi for her able guidance and for his inspiring attitude, praiseworthy attitude and honest support. Not to forget the pain staking efforts of our college training and placement cell and specially my training and placement officer Mrs.Manvi Mam Last but not the least I would express my utmost regards for the electrical department of our Institute.

COMPUTER SOFTWARE AND NETWORKING TECHNOLOGIES

CNT is one of the most acknowledged names in Software development and Network Training. Apart from providing Software Solutions to the various companies, CNT is also involved in imparting High-end project based training to students of MCA and B.Tech etc. The training professionals are basically Software Developers having Industry experience and exposure to live projects on various technologies like Java (With Advanced Java), VB.NET, ASP.NET, C Sharp, MCSE, CCNA, CCNP, LINUX and Oracle etc. CNT has trained thousands of the Engineering/MCA students of various institutes by providing Industrial training. Special emphasis is laid on exposure to Real Time Projects.

The Trainees are equipped with thorough knowledge of various modules from basic to advance in the software involved in their projects. With a right blend of interactive coaching, laboratory tutoring and a case study based approach; the skills of the trainees are sharpened to their best.

CNT has an excellent infrastructure with Air conditioned labs, and classrooms and fully equipped library. The lab facility extended to the trainees is unparalleled with every trainee having an independent system access for the entire training period.

In short, Computer Software and Network Technologies is guided by a dynamic management team that believes in integrity, quality, continuous learning and personal dedication

OBJECTIVESa) To provide world-class technology and Indian expertise globally in all fields of networking and information technology.

b) To sustain, expand and excel in its operations in software technologies.

c) To acquire latest technology on a continuing basis.

FUTURECNT core competence in the Networking and Software Project has enabled it to earn respect of clients all over the world. CNT is now using state-of-the-art technology in the areas of Information Technology Access Networks. All in order to continue providing better solutions through better understanding.

TRAININGThe business of CNT is characterized by Hi-tech mainly in the field of Network and IT, and technology in this area is advancing very fast and with the view to keep update with the latest technology. CNT undertakes training activities either through its own resources or through external agencies.

CNT has also organized a number of training programmes catering to specific requirements.IT SERVICES

Turnkey Solution to meet end-to-end customer requirements

Networking Solutions with total System Integration and Implementations

Project Consultancy services from concept to commissioning

IT Training

MISSION

To provide world class professional training and solutions in advance networking, Embedded systems design and career services for IT professionals as well as electronic system designers.

PCB DESIGNINGPCB stands for PRINTED CIRCUIT BOARD. Printed circuit board (PCB) provides both the physical structure for mounting and holding the components as well as the electrical interconnection between the components. That means a PCB = PWB (printed wiring board) is the platform upon which electronic components such as integrated circuit chips and other components are mounted. A PCB consists of a non-conducting substrate (typically fiber glass with epoxy as resin) upon which the conductive pattern or circuitry is formed. Copper is the most prevalent conductor although nickel, silver and tin are also used in some cases.

Types of PCB

PCB may be of different types:-

1) Single-sided

2) Double-sided

3) Multilayer

Single sided PCBs: - As the name suggest in these designs the conductive pattern is only at in one side. And also the size is large in these case but these are cheap.

Double sided PCBs: - These are the PCBs on which the conductive pattern is in on both sides. The size of board is small in this case but it is costlier than that of above.

Multilayer PCBs: - In this case the board consists of alternating layers of conducting pattern and insulating material. The conductive material is connected across the layers through plated through holes. The size of this PCB is smaller than that of double sided PCB but it is very costly.PCBs may also be either rigid, flexible, or the combination of two (rigid-flex). When the electronic components have been mounted on the PCB, the combination of PCB and components is an electronic assembly, also called PRINTED CIRCUIT ASSEMBLY. This assembly is the basic building block for all the electronic appliances such as television, computer and other goods.

FUNCTIONS OF PCBPrinted circuited boards are dielectric substrates with metallic circuitry formed on that. They are some times referred to as the base line in electronic packaging. Electronic packaging is fundamentally an inter connection technology and the PCB is the baseline building block of this technology.

TECHNIQUES USED FOR PCB DESIGNINGThere mainly two techniques which are use for the PCB designs.

1. Hand Taping

2. Computer Aided Design

1) PCBs using Hand Taping:

PCB design using hand taping is the process of technical drawing.

In hand taping method layout should be prepared on grid paper.

In hand taping, components pads can be prepared by using black pads.

Routing of the board can be done by tapes with different widths.

Each layer (top, bottom) has to prepare separately.

DISADVANTAGS OF HAND-TAPING FOR PCB DESINING:

Each layer has to be designed separately.

We cannot generate NCD files for CNC drilling.

Difficult to modify the design in the designing process or after designing.

Difficult to get good design overview. 2) PCB DESIGNING USING CAD

All the above difficulties can be removed by using CAB system.

CAD system for PCB designing requires following:

A computer system.

PCB design software like OrCad, CADSTAR, Protel, TANGO, Mentor etc.

A photo plotter for art work generation.

There are many enhanced features in electronics design automation tools which not possible in the hand taping. The main advantages are given below:

Auto placement

Auto routing

After routing, optimization of tracks can be done.

Provides physical design reuse modules

Electrical rule check (ERC)

All the layers are generated from the same design by giving different options.

Bill of material can be generated which contains number of different components used.

We can draw conductors as an arc, semi-circular at different angles.

Design Rule Check

Advanced CAD systems have high speed analysis.

BASIC DESIGN STEPS IN CAD- SYSTEM

The following design steps are very common while designing a PCD in CAD:

Entry the schematic diagram.

Net list file creation.

Placement of components manually or automatically.

Routing of the board using manual routing tools or auto router

Design rule check physical and electrical.

Artwork generation.

A TRADITIONAL DESIGN FLOW IN CAD- SYSTEM

Overview of a PCB Design SoftwareThere many soft wares which are used for PCB designs. Some of them are given below:-

OrCad

CADSTAR

Protel

TANGO

Mentor

The most commonly software which are used for PCB design in India are Protel and OrCad

OrCad Design EnvironmentOrCad has a long history of providing individuals and teams with a complete set of technologies that offer unprecedented productivity, seamless tool integration, and exceptional value. New 10.5 release continues that tradition.

Today's lower cost and yet highly sophisticated electronic design automation systems have created a unique challenge to nearly every engineering department. Therefore the use of EDA tools has become increasingly important as product lifecycles have become shorter and shorter. Modern electronic design automation (EDA) tools are beginning to support a more efficient and integrated approach to electronic.OrCad Capture design entry is the most widely used schematic entry system in electronic design today for one simple reason: fast and universal design entry. Whether you're designing a new analog circuit, revising schematic diagram for an existing PCB, or designing a digital block diagram with an HDL module, OrCad Capture provides simple schematic commands you need to enter, modify and verify the design for PCB. OrCad Layout offers PCB designers and PCB design teams the power and flexibility to create and share PCB data and constraints across the design flow. OrCad Layout delivers all the capabilities to designers need from netlist to place and route, to final output. The ease-of use and intuitive capabilities of OrCad Layout provides for quick startup and rapid learning right out of the box.PCB DESIGN STEPS IN OrCad 10.5Entry of Schematic Diagram

Schematic diagram provides the functional flow and the graphical representation of an electronic circuit. The entry of schematic diagram is the first step in PCB design using OrCad.

A schematic diagram consists of:-

Electrical connections(nets)

Junctions

Integrated circuits symbols

Discrete components symbols like resistors, capacitors etc.

Input / output connectors

Power and ground symbols

Buses

No connection symbols

Components reference names

TextThe Schematic Page Editor:

The schematic page editor is used to display and edit schematic pages. So that one can parts; wires; buses and draw graphics. The schematic page editor has a tool palette that you can use to draw and place everything you need to create a schematic page. One can print from within the schematic page editor, or from the project window.

The Part editor:

The part editor is used to create and edit parts.

From the view menu of the part editor you can choose either part or package. In part view one can:-

Create and edit parts and symbols, then store in new or existing libraries.

Create and edit power and ground symbols, off-page connector symbols, and title block

Use the tool palettes electrical tools to place pins on parts, and its drawing tools to draw parts and symbols.

The Session Log:

The session log lists the events that have occurred during the current Capture session, includes message resulting from using captures tools. To display context-sensitive help for an error message, put the cursor in the error message line in the session log press F1.

The ruler along the top appears in either inches or mill meters, depending on which measurement system is selected in the window panel. Your tab setting are saved and used each time you start capture.

One can search for information in the session log using the find command on the Edit menu. You can also save the contents of the of the session log to a file, which is useful when working with Orcads technical support to solve technical problems. The default filename is SESSION.TXT.

The Toolbar:

Captures toolbar is dock able (that means you can select and drag the toolbar to new location) as well as resizable, and displays tool tips for each tool; by choosing a tool button you can quickly perform a task. If tool button is dimmed, you cant perform that task in the current situation.

Some of the tools operate only on what you have selected, while others give you a choice of either operating on what is selected or expanding the scope to entire project.

You can hide the toolbar, then display it again when u need it. For hiding select from the schematic page editors view menu, choose TOOLBAR.The Tool Palette:Capture has two tool palettes: one for the schematic page editor and one for the part editor. Both tool palettes are dock able and resizable. They can also display tool tips that identify each tool. The drawing tools on the two tool palettes are identical, however, each tool palette has different electrical tools after you choose a tool, and you press the right mouse button to display a context- sensitive pop-up menu.

The schematic page editor tool palette:

The first group of tools on the tool palette is electrical tools, used to place electrical connectivity objects. The second group of tools is

Drawing tools, used to create graphical objects without electrical connectivity.

The part editor tool palette:

The first group of tools on the part palette is electrical tools, used to place pins and symbols. They have been already explained above within the schematic page editor tools. The second group of tools is drawing tools, used to create graphical objects without objects any electrical connectivity and is described:

Pin Tools: Place pins on part

Pin Array: Place multiple pins on part

Selecting and deselecting of objects

Once one selects an object, one can perform operations on it, include moving, copying, cutting, mirroring, rotating, resizing, or editing. One can also select multiple, objects and edit them, or group them in to a single object. Grouping objects maintain relation ship among them while one moves them to another location.

Creating Net list FileNet-list file is a document file which contains information about the logical interconnections between signals and pins. Before one create a net list file, be sure ones project is completed, annotated and it is free from electrical rule violations.

A net list file consists of nets, components, connectors, junctions, no connection symbol, power and ground symbols.

Creation of net list in capture:

Select your design in the project manager.

From the tools, choose create net list. The net list dialog box displays.

Choose a net list format tab.

If necessary, set the part value and PCB foot print combined property strings to reflect the information you want in the net list.

Click ok to create the net list.

In the net list file text box, enter a name for the output file. If the selected format creates an additional file, enter its file name in the second text box.

PLACEMENT OF LAYOUT PLUS

What is Layout Plus?

Layout plus is one part for the PCB design in which we place as well as route the components an set unit of measurement, grids, and spacing in OrCad. Within other soft wares you also have to place and route the components in similar way. For the placement and routing of the components we normally use auto-placement and auto-routing. Unfortunately, in a lot of soft wares some critical signals have to be routed manually before auto-routing. In layout plus we also define the layer stacks, pad stacks and via's.

Steps for board design:

At first, we have created a net list from our schematic diagram by using capture.

Layout plus includes design rules in order to guide logical placement and routing. That means, load the net list into layout to create the board. At the same time you have to specify the board parameters.

Specify board parameters: Specifying global setting for the board, including nits of measurements, grid, and spacing

Place components: Use the components tool in order to place manually the components which are fixed by the system designer on the board or otherwise use auto-placement.

Route the board: Use different routing technologies to route the board and take advantage of push and shove (a routing technology), which moves track you are currently routing as well as you can also auto route the board.

Provide finishing of the board: Layout supplies an ordered progression of commands on the auto menu for finishing your design. These commands include design rule check, cleanup design, rename components, back annotate, run post processor, and create reports.

The design window:The design window provides a graphical display of printed circuit board, it is primary window you use when designing your board. It also provides tools to facilitate the design process such as to update components and design rule violation.

Main window

Method to create a board with Layout Plus:

Ensure that net list with all footprints and necessary information has been created.

Create a directory in which the schematic design, net list, and boar will co-exit and put the schematic design and net list. OrCad provides a directory for this purpose.

From the layout session frames file menu, choose New. The load template file in the dialog box displayed.

Select the technology template (.TCH), then choose the open button and load the net list in other box.

Then apply the auto ECO.

If necessary, respond to link footprints to component dialog.

Draw the board outline by using the obstacle tool in the tool bar.

Setting board parameters:

There is some parameter which should be set before placing the components on board. They are as follows:-

Set Datum

Create a board outline

Set units of measurements

Set system grid

Add mount holes

Creating of board outline:

Board outline is the graphical representation of the size of the actual PCB board. So it is the main step in layout, to draw the board outline of the actual size of PCB board.

Placement of components:

Placement of components means that to place the components in designed box. A designer should follow the following steps before going for it:-

Optimize the board for component placement.

Load the placement strategy file.

Place components on the board.

Optimize placement using various placements

Components can be placed by using two techniques:-

1) Manual placement of components

2) Auto placement of components

Choose the components tool bar button. From the pop up men, choose the queue for placement. The components selection criteria dialog box appears. Enter the reference designator of the components that you want to place in the appropriate text box, and click ok. Drag the components to desired location, place it there.

Conductor Routing in Layout:-

After placing all the components the other main step is to route the board from the electrical connections between the components. One may route board manually or automatically by auto router.

100% auto routing can be achieved only when components are placed in the order of functional flow of electronic circuit. The main routing tool available in OrCad is as flow:-

Add/edit route mode

Edit segment mode

Shove track mode

Auto path route mode

Design Rule Check:-

In manual designs every thing was checked as a possible source of error. Components sizes, hole sizes, conductor widths and clearance, land-to-hole-ratio, board areas to be free of components, clearance to the edges, positional accuracy and of course electrical interconnections had tad to be personally reviewed with a great deal of care. After completing the design of printed circuit board with the help of an EDA-Tool, a designer has again to verify the PCB in order to find out errors. Such type of verifications/design rule check contains beside the general verifications commonly two types:-

Physical verification

Electrical verification

Post processing:-

Post processing can be done once the design is completed in all aspects. The common way is still a process to generate GERBER data and NCD files which can be used for photo plotting and for steps of CNC manufacturing and PCB- drilling.

POWER SYSTEM DESIGNFirst part of electronics ckts. is power. The main power supply is in AC but mostly electronic ckts. work with DC. So a system is required to convert ac to dc and these sources should able to produce stable supplies.

Power supplies may be used in. may be of different types such as regulated, unregulated, smps etc.

Unregulated power suppliesThese are the power supplies in which the out put is not constant. That it is varies with input voltage, load, and also effected by the environment conditions such as temperature, etc. so these are the variable supplies. Commonly these supplies are not employed as there efficiency is very less. The unregulated power can be obtained using rectifying circuit after AC supply.

Regulated power supplies These are the power supplies in which the output voltage is constant, i.e. the out put voltage is independent of the input voltage, load and other external conditions. So to obtain the regulated voltage using different regulators. The regulator voltage is mainly the DC voltage, it may AC to or DC to DC voltage. A better approach to power supply design is to use enough capacitance to reduce ripple to low level, then use an active feedback circuit to eliminate the remaining ripple and dependence of output voltage on input, load and environment conditions. These active devices are known as Regulators. These regulators can be used to produce negative and positive voltage of required value.

The voltage regulators are of three types:-

1) Constant positive voltage regulators

2) Constant negative voltage regulators

3) Variable voltage regulators

Constant positive voltage regulators:- These are the regulators which are able to produce positive and constant voltage. Some of them are given below:-

S. no.Name of regulatorOutput voltage

1LM 78055v

2LM 781010v

3 LM 781212v

4LM 781515v

These regulators are used according to the required voltage need.Constant negative voltage regulators:- These are also the constant output voltage regulator but there output is negative in polarity. These regulators are also employed according to voltage requirements. Some of them are given below with there outputs:-

S. noName of regulatorOutput voltage

1LM7905-5v

2LM7910-10v

3LM7912-12v

4LM7915-15v

Variable voltage regulators:- These are the regulator whose output voltage can be varied according to the desired need. These regulators again of two types i.e.:-

Positive

Negative

The output of these regulators can be varied by varying the resistance of the variable resistance which is connected to the adjustable pin the regulators. So these are the most commonly used regulators in the electronic industry as wide range of stable voltage can be obtained from single chip by varying the resistance connected to the adjustable pin of the regulators. The most commonly variable regulators are:-

LM317 (it is positive regulator)

LM 337(it is negative regulator)

There description is given below:-

LM317 3-Terminal Adjustable Regulator:-

General Description:

The LM317 series of adjustable 3-terminal positive voltage regulators is capable of supplying in excess of 1.5A over a 1.2V to 37V output range. They are exceptionally easy to use and require only two external resistors to set the output voltage. Further, both line and load regulation is better than standard fixed regulators. Also, the LM117 is packaged in standard transistor packages which are easily mounted and handled. In addition to higher performance than fixed regulators, theLM317 series offers full overload protection available only in ICs. Included on the chip are current limit, thermal overload protection and safe area protection. All overload protection circuitry remains fully functional even if the adjustment terminal is disconnected. Normally, no capacitors are needed unless the device is situated more than 6 inches from the input filter capacitors in which case an input bypass is needed. An optional output capacitor can be added to improve transient response.

The adjustment terminal can be bypassed to achieve very high ripple rejection ratios which are difficult to achieve with standard voltage, supplies of several hundred volts can be regulated as long as the maximum input to output differential is not exceeded, i.e., avoid short-circuiting the output.

Also, it makes an especially simple adjustable switching regulator, a programmable output regulator, or by connecting a fixed resistor between the adjustment pin and output, theLM317 can be used as a precision current regulator. Supplies with electronic shutdown can be achieved by clamping the adjustment terminal to ground which programs the output to 1.2V where most loads draw little current.

Typical application:

Features:1. Guaranteed 1% output voltage tolerance (LM317A)

2. Guaranteed max. 0.01%/V line regulation (LM317A)

3. Guaranteed max. 0.3% load regulation (LM317)

4. Guaranteed 1.5A output current

5. Adjustable output down to 1.2V

6. Current limit constant with temperature

7. P+ Product Enhancement tested

8. 80 dB ripple rejection

9. Output is short-circuit protected

Packages of LM317

I

Application Hints:

In operation, the LM317 develops a nominal 1.25V reference voltage, VREF, between the output and adjustment terminal. The reference voltage is impressed across program resistor R1 and, since the voltage is constant, constant current I1 then flows through the output set

resistor R2, giving an output voltage of

Since the 100A current from the adjustment terminal represents an error term, the LM317 was designed to minimize IADJ and make it very constant with line and load changes. To do this, all quiescent operating current is returned to the output establishing a minimum load current requirement. If there is insufficient load on the output, the output will rise.PROTECTION DIODES:When external capacitors are used with any IC regulator it is sometimes necessary to add protection diodes to prevent the capacitors from discharging through low current points into the regulator. Most 10F capacitors have low enough internal series resistance to deliver 20A spikes when shorted. Although the surge is short, there is enough energy to damage parts of the IC. When an output capacitor is connected to a regulator and the input is shorted, the output capacitor will discharge into the output of the regulator. The discharge current depends on the value of the capacitor, the output voltage of the regulator, and the rate of decrease of VIN. In the LM317, this discharge path is through a large junction that is able to sustain 15A surge with no problem. This is not true of other types of positive regulators. For output capacitors of 25F or less, there is no need to use diodes.

The bypass capacitor on the adjustment terminal can discharge through a low current junction. Discharge occurs when either the input or output is shorted. Internal to the LM317 is a 50resistor which limits the peak discharge current. No protection is needed for output voltages of 25V or less and 10F capacitance. Figure 3 shows an LM317 with protection diodes included for use with outputs greater than 25V and high values of output capacitance.

LM337 3-Terminal Adjustable Regulator:General Description:

The LM337 is adjustable 3-terminal negative voltage regulators capable of supplying in excess of 1.5A over an output voltage range of 1.2V to 37V. These regulators are exceptionally easy to apply, requiring only 2 external resistors to set the output voltage and 1 output capacitor for frequency compensation. The circuit design has been optimized for excellent regulation and low thermal transients. Further, the LM337 series features internal current limiting, thermal shutdown and safe-area compensation, making them virtually blowout-proof against overloads. The LM337 serves a wide variety of applications including local on-card regulation, programmable-output voltage regulation or precision current regulation. The LM337 are ideal complements to the LM317 adjustable positive regulators.

Pin diagram

Features:

1) Output voltage adjustable from 1.2V to 37V

2) 1.5A output current guaranteed, 55C to +150C

3) Line regulation typically 0.01%/V

4) Load regulation typically 0.3%

5) Excellent thermal regulation, 0.002%/W

6) 77 dB ripple rejection

7) Excellent rejection of thermal transients

8) Temperature-independent current limit

9) Internal thermal overload protection

10) Standard 3-lead transistor package

11) Output is short circuit protected.These two Ic's i.e. LM337and LM317are mainly used in the regulated power supplies because using these regulator a wide range of output can be obtain which can be varied from 0v to 30v, which is much sufficient to drive any electronic circuit.

Bench supply diagram

Instrumentation

Automation

Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience.

Consider the examples of automation:

1. Automated video surveillance

2. Automated highway systems

3. Automated manufacturing

4. Home automation

5. Industrial automation

6. Agent-assisted Automation

1.1 Advantages of Automation:

7. Replacing human operators in tasks that involve hard physical or monotonous work.

8. Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.)

9. Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc.

10. Economy improvement: Automation may improve in economy of enterprises, society or most of humanity. For example, when an enterprise invests in automation, technology recovers its investment; or when a state or country increases its income due to automation like Germany or Japan in the 20th Century.

`1.2 Disadvantages of Automation:

11. Unemployment rate increases due to machines replacing humans and putting those humans out of their jobs.

12. Technical Limitation: Current technology is unable to automate all the desired tasks.

13. Security Threats/Vulnerability: An automated system may have limited level of intelligence; hence it is most likely susceptible to commit error.

14. Unpredictable development costs: The research and development cost of automating a process may exceed the cost saved by the automation itself.

15. High initial cost: The automation of a new product or plant requires a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches of things.

PROGRAMMING OF PLC

PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming languages. A graphical programming notation called Sequential Function Charts is available on certain programmable controllers. Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3 currently defines five programming languages for programmable control systems: FBD (Function block diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming language), IL (Instruction list, similar to assembly language) and SFC (Sequential function chart). These techniques emphasize logical organization of operations. While the fundamental concepts of PLC programming are common to all manufacturers, differences in I/O addressing, memory organization and instruction sets mean that PLC programs are never perfectly interchangeable between different makers. Even within the same product line of a single manufacturer, different models may not be directly compatible.In Allen Bradley PLCs the logic used for the programming is ladder logic. Ladder logic is a programming language that represents a program by a graphical diagram based on the circuit diagrams of relay-based logic hardware. It is primarily used to develop software for Programmable Logic Controllers (PLCs) used in industrial control applications. The name is based on the observation that programs in this language resemble ladders, with two vertical rails and a series of horizontal rungs between them. An argument that aided the initial adoption of ladder logic was that a wide variety of engineers and technicians would be able to understand and use it without much additional training, because of the resemblance to familiar hardware systems. This argument has become less relevant given that most ladder logic programmers have a software background in more conventional programming languages, and in practice implementations of ladder logic have characteristicssuch as sequential execution and support for control flow featuresthat make the analogy to hardware somewhat imprecise.Ladder logic is widely used to program PLCs, where sequential control of a process or manufacturing operation is required. Ladder logic is useful for simple but critical control systems, or for reworking old hardwired relay circuits. As programmable logic controllers became more sophisticated it has also been used in very complex automation systems.

Fig 7. Simple ladder logicThe language itself can be seen as a set of connections between logical checkers (contacts) and actuators (coils). If a path can be traced between the left side of the rung and the output, through asserted (true or "closed") contacts, the rung is true and the output coil storage bit is asserted (1) or true. If no path can be traced, then the output is false (0) and the "coil" by analogy to electromechanical relays is considered "de-energized". The analogy between logical propositions and relay contact status is due to Claude Shannon.

Ladder logic has contacts that make or break circuits to control coils. Each coil or contact corresponds to the status of a single bit in the programmable controller's memory. Unlike electromechanical relays, a ladder program can refer any number of times to the status of a single bit, equivalent to a relay with an indefinitely large number of contacts.

So-called "contacts" may refer to physical ("hard") inputs to the programmable controller from physical devices such as pushbuttons and limit switches via an integrated or external input module, or may represent the status of internal storage bits which may be generated elsewhere in the program.

Each rung of ladder language typically has one coil at the far right. Some manufacturers may allow more than one output coil on a rung.

--( )-- a regular coil, energized whenever its rung is closed

--(\)-- a "not" coil, energized whenever its rung is open

--[ ]-- A regular contact, closed whenever its corresponding coil is energized

--[\]-- A "not" contact, open whenever its corresponding coil is energized

The "coil" (output of a rung) may represent a physical output which operates some device connected to the programmable controller, or may represent an internal storage bit for use elsewhere in the program.

Fig 2.8.PLC Trainer Kit

The above figure shows the view of PLC trainer kit. On this kit various operations are performed. It has following components mounted:

1 .PLC MicroLogix1000 2 .SMPS (220V AC-24V DC)

3. A Contactor Relay 4. An Electromechanical Relay

5. Normally open Switch (4) 6. Normally closed Switch (4)

7. Output LEDs (4) 8. RS 232 Comport for communication with PC

The above fig shows the trainer board of Micrologix 1100 PLC. It has following components:

1. PLCmicrologix 1100 2. SMPS (220V ac to 24V dc)

3. Analog I/O card 4. A Contactor Relay

5. An Electromechanical Relay 6. Normally open Switch (4)

7. Normally closed Switch (4) 8. Output LEDs (4)

9.RS 232 Comport for communication with PC

2.6.1 COMMUNICATION OF PLC WITH PC

To make communication of PLC with PC following steps are noted down:

Connect PC and PLC via RS232 comport or Ethernet.

Then click on RS Linx icon, a window will appear as shown in fig below

Fig2. 10.RS Linx classic window

In this window add drivers i.e. whether it is RS232 comport or Ethernet and configure the drivers and closes the windowThen click on icon RS who on the RS Linx classic window, another window will appear as shown in fig.

After opening the RS who window click on AB DF1-1 DH-485, the PLC is running is shown on the window. Then close this window and double click on RS Logix 500 starter.When we double click on RS Logix 500 starter a window will appear as shown in fig.

Fig 2.11. RS Logix 500 window

2.6.2 PLC INSTRUCTIONS

There are various instructions which are useful for making ladder logic for PLC programming. These are as follows:9.2.1 XIC (Examine if closed):

Use the XIC instruction in your ladder program to determine if a bit is ON. When the instruction is executed, if the bit addressed is on (1), then the instruction is evaluated as true. When the instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as false.

I/PO/P

00

11

XIC (Examine if closed):

Examples of devices that turn on or off include:

A push button wired to an input (addressed as I:0/4).

An output wired to a pilot light (addressed as O:0/2).

A timer controlling a light (addressed as T4:3/DN).

2.6.2.2 XIO (Examine if open):Use the XIO instruction in your ladder program to determine if a bit is OFF. When the instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as true. When the instruction is executed, if the bit addressed is on (1), then the instruction is evaluated as false.

I/PO/P

01

10

Examples of devices that turn on or off include:

Motor overload normally closed (N.C.) wired to an input (I:0/10).

An output wired to a pilot light (addressed as O:0/4).

A timer controlling a light (addressed as T4:3/DN).2.6.2.3 Output Energize (OTE):

Use the OTE instruction in your ladder program to turn on a bit when rung conditions are evaluated as true. An example of a device that turns on or off is an output wired to a pilot light (addressed as O:0/4).

2.6.2.4Output Latch (OTL) and Output Unlatch (OTU):

OTL and OTU are retentive output instructions. OTL can only turn on a bit, while OTU can only turn off a bit. These instructions are usually used in pairs, with both instructions addressing the same bit. Your program can examine a bit controlled by OTL and OTU instructions as often as necessary.

Latch output and Unlatch output

2.7. TIMERS AND COUNTERS

2.7.1 TIMER

Timers are used to perform the timing operations. Time base is the minimum value of time in second that can be taken by the timer. Preset value is the total number of the seconds for which the timing operation has to be done Accumulator starts increasing the time in secondsupto the preset value. Upto the preset value of the accumulator the enable bit of timer is high & the timer runs. When accumulator reaches the preset value then the timer stops and the done bit of the timer becomes high. The timer has following bits and these bits are useful in the operation of timer:

EN- Enable- This bit will high when the input is given to the timer

TT - Timer timing bit - This bit will be high during the timing process. It remains high till accumulator value becomes equal to preset value

DN Done This bit will be high when the timing process is ended. It set to high when the accumulator value becomes equal to preset value.

In Micrologix 1000 and 1100 PLC there are three types of timers i.e.

TON Timer

T-OFF Timer

Retentive timer ON (RTO)

2.7.1.1 TONTimer:Use the TON instruction to turn an output on or off after the timer has been on for a preset time interval. The TON instruction begins to count time-base intervals when rung conditions become true. As long as rung conditions remain true, the timer adjusts its accumulated value (ACC) each evaluation until it reaches the preset value (PRE). The accumulated value is reset when rung conditions go false, regardless of whether the timer has timed out

Fig 2.12a.TON timer

2.7.1.2 T-OFF Timer: Use the TOF instruction to turn an output on or off after its rung has been off for a preset time interval. The TOF instruction begins to count time base intervals when the rung makes a true-to-false transition. As long as rung conditions remain false, the timer increments its accumulated value (ACC) based on the time base for each scan until it reaches the preset value (PRE). The accumulated value is reset when rung conditions go true regardless of whether the timer has timed out.

Fig 2.12b.T-OFF timer

2.7.1.3 Retentive Timer (RTO):Use the RTO instruction to turn an output on or off after its timer has been on for a preset time interval. The RTO instruction is a retentive instruction that begins to count time base intervals when rung conditions become true.The RTO instruction retains its accumulated value when any of the following occurs:

Fig 2.12c.Retentive Timer (RTO)

2.7.2 Counters:

Counters are used to count the number of operations. Its function is same as the timer accepts that the timer counts the number of seconds and the counter counts the number of operations or pulses. At each operation the value of the accumulator increases and when the value of the accumulator comes to the preset value of the counter then the counter stops.Counter bits: TT - Timer timing bit - This bit will be high during the counting process. It remains high till accumulator value becomes equal to preset value

DN Done This bit will be high when the counting process is ended. It set to high when the accumulator value becomes equal to preset value.

2.7.2.1 Counter UP (CTU):The CTU is an instruction that counts false-to-true rung transitions. Rung transitions can be caused by events occurring in the program (from internal logic or by external field devices) such as parts traveling past a detector or actuating a limit switch. When rung conditions for a CTU instruction have made a false-to-true transition, the accumulated value is incremented by one count, provided that the rung containing the CTU instruction is evaluated between these transitions. The ability of the counter to detect false-to-true transitions depends on the speed (frequency) of the incoming signal. The accumulated value is retained when the rung conditions again become false. The accumulated count is retained until cleared by a reset (RES) instruction that has the same address as the counter reset.

Fig 2.12d.Counter UP (CTU)

2.7.2.1 Counter Down (CTD):The CTD is an instruction that counts false-to-true rung transitions. Rung transitions can be caused by events occurring in the program such as parts traveling past a detector or actuating a limit switch. When rung conditions for a CTD instruction have made a false-to-true transition, the accumulated value is decremented by one count, provided that the rung containing the CTD instruction is evaluated between these transitions. The accumulated counts are retained when the rung conditions again become false. The accumulated count is retained until cleared by a reset (RES) instruction that has the same address as the counter reset.

Fig 2.12e.Counter Down (CTU)

2.7.2.3 EQU (equal to)

Fig 2.12f.Equal to

This input instruction is true when source A becomes equal to source B. The EQU instruction compares two user specified values if values are equal, it allows rung continuity. The rung goes true and output energies.

2.7.2.4 GEQ (greater than equal to)

This instruction compares two values and will be high when the counted value becomes equal to or greater than the fixed value and will energize everything that is connected next to it.

Fig 2.12g.Greater than Equal to

2.7.2.5 LEQ(less than equal to

Fig 2.12h.Less than Equal to

This instruction compares two values and will be high when the counted value becomes equal to or less than the fixed value and will energize everything that is connected next to it.

2.7.2.6 GRT (greater than)

Fig 2. 12i.Greater Than

Use of the GRT instruction to test whether one value (source A) is greater than another (source B). If the value at source A is greater than the value at source B, the instruction is logically true. If the value at source A is less than or equal to the value at source B, the instruction is logically false. Source A must be an address. Source B can either be a program constant or an address. Negative integers are stored in twos complement form.

2.7.2.7 LES (less than)

Use of the LES instruction is to test whether one value (source A) is less than another (source B). If source A is less than the value at source B, the instruction is logically true. If the value at source A is greater than or equal to the value at source B, the instruction is logically false. Source A must be an address. Source B can either be a program constant or an address. Negative integers are stored in twos complement form.

Fig 2.12j. Less than

2.7.2.8 LIM (Limit):

Fig 2.12k.Limit

Use the LIM instruction to test for values within or outside a specified range, depending on how you set the limits.2.7.2.9 RES (Reset):

Fig2. 12l.Reset

Use a RES instruction to reset a timer or counter. When the RES instruction is enabled, it resets the Timer ON Delay (TON), Retentive Timer (RTO), Count UP (CTU), or Count Down (CTD) instruction having the same address as the RES instruction. When resetting a counter, if the RES instruction is enabled and the counter rung is enabled, the CU or CD bit is reset. If the counter preset value is negative, the RES instruction sets the accumulated value to zero. This in turn causes the done bit to be set by a countdown or count up instruction.2.8. PLC PROGRAMS

2.8.1 Program no. 1:

A bottle takes 7 sec to be completely filled, if the filling is interrupted then it should resume from the same level. When the filling of one bottle is completed the motor should run for 2 sec for changing the bottle.

Sol:

In this program we have used two inputs and two outputs of PLC i.e. I:0/0 & I:0/1 as inputs and O:0/0 & O:0/1 as outputs. We have used a RTO as timer and compare instructions LEQ and LIM. When input I:0/0 is ON the RTO will start and conveyor motor is started for 7 sec by using LEQ instruction and after 7 sec conveyor motor is stopped and then the valve is operated for 2 sec using LIM instruction. Then after 2 sec the conveyor motor again starts automatically.

When RTO and conveyor motor runs by pressing start push button

when the valve operates and conveyor motor stops

after filling bottle the valve stops and conveyor starts again

2.8.2 Program no. 2:

When a momentary start push button is pressed, a lamp goes ON. If again same start push button is pressed first lamp goes off and it remains off for the next 20 seconds. If start push button is pressed again in between these 20 seconds, lamp should not go ON. It should go ON again on pressing start push button only after completing 20 seconds.Sol: In this program one input and one output of PLC is used. A Counter, Timer and a Greater than instructions are used.

Program of controlling lamp by timer and counter

When lamp glows by pressing push button

.When lamp goes off by pressing push button second time

Lamp will not glow even if we press push button. The lamp will glow after 20 sec by pressing push button.

SCADA

The term SCADA stands for Supervisory Control and Data Acquisition. A SCADA system is a common process automation system which is used to gather data from sensors and instruments located at remote sites and to transmit and display this data at a central site for either control or monitoring purposes. The collected data is usually viewed on one or more SCADA Host computers located at the central or master site. A real world SCADA system can monitor and control hundreds to hundreds of thousands of I/O points. A typical Water SCADA application would be to monitor water levels at various water sources like reservoirs and tanks and when the water level exceeds a preset threshold, activate the system of pumps to move water to tanks with low tank levels. Common analog signals that SCADA systems monitor and control are levels, temperatures, pressures, flow rate and motor speed. Typical digital signals to monitor and control are level switches, pressure switches, generator status, relays & motors.

3.1 Features of SACDA:

Dynamic process Graphic

Alarm summery

Alarm history

Real time trend

Historical time trend

Security (Application Security)

Data base connectivity

Device connectivity

Scripts

Recipe management

3.2 Manufactures of SCADA:

Modicon (Telemecanique) Visual look

Allen Bradley : RS View

Siemens: win cc

Gefanc:

KPIT : ASTRA

Intelution : Aspic

Wonder ware : In touch

3.3 Working with project:

A project consists of a folder on your hard disk that contains, at minimum, the following items:

1. project file (.rsv)

2. tag folder

3. comprf (communications profile) folder

4. cache folder

3.3.1 Steps for creating a project:

3.3.2 Creating tag:

Tags and the tag database: In the tag database, you define the data you want RSView32 to monitor. Each entry in the database is called a tag. A tag is a logical name for a variable in a device or in local memory (RAM). For example, a tag can represent a process variable in a programmable controller

3.3.3 Naming tag:

Tag names can be up to 255 characters long. If you create a folder, the folder name becomes part of the tag name. The tag name can contain the following characters: A to Z

0 to 9

underscore (_) and dash (-)

3.3.4 Tag database

3.3.5 Creating graphic display:

A graphic display represents the operators view of plant activity. The display can show system or process data and provide operators with a way to write values to an external device such as a programmable controller. Operators can also print the display at runtime to create a visual record of tag values.The graphic display editor:

To open the Graphic Display editor:

In the Project Manager, open the Graphics folder.

Open the Graphic Display editor by doing one of the following:

doubleclick the Display icon

rightclick the Display icon and then click NewThe editor main components:

3.3.6 Setting up the display:

3.3.7 Animation:

About the Animation dialog box

The Animation dialog box is a floating dialog box, which means you can have it open all the time and can move it around the screen, select other objects, and open other dialog boxes.

Dialog box:

Animation on slider:

Horizontal position animation:

Visibility animation:

REFERENCE

1. Manual of allenbradley Rslogix500 .

2. Instruction manual of RS view 32

3.

4. 5.

BIBLIOGRAPHY

Books Recommended Websites

William Bottom for PLC www.plcs.net Keller, William L Jr.Graft www.rockwellautomation.comMikroElektronika

Software

RSLogix 500

RS view 32

THANKS YOUCapture

Libraries

Footprint libraries

Layout

Gerber tools

Gerber and drill files

Gerber and plotter drawing

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