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MOTORS

Project Title:

1. Introduction of Fixed Position Stop System in Engine Dispatch Slat Conveyor.

2. Study of Variable Frequency Drive (VT230SE).

Project Report Submitted by:

Siddharth Satyapriya

B.Tech

Electronics and Electrical

Engineering (EEE),

Kalinga Institute of Industrial

Technology (KIIT University),

Bhubaneswar

Duration of the project: June 3, 2013 to June 29, 2013

Under the guidance of:

Mr Kumar Satyam,

Manager, Electronics (Engine Factory)

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A C K N O W L E D G E M E N T

It is really a matter of great pleasure to acknowledge the invaluable guidance,

enormous assistance and excellent co-operation extended to me by TATA

MOTORS Jamshedpur in the completion of my project.

To start with I would like to convey my sincere regards to Mr. Nilesh Kumar

Panchal (Divisional Manager) for giving me the opportunity to do the Project

Training at Tata Motors. I would like to express my sincere gratitude to Mr. Kumar

Satyam, Manager of Electronics Dept. for his support & cooperation.

I would like to thank Mr. Nikendra Gautam, Mr. Sandip Ravan & Mr Abhirup for

their consistent support and guidance. I would also like to thank all the members

of electronics dept. for their help and assistance.

I would also like to express my thanks to my friends and my project partner.

This work would not have been possible but for the support and help from

them.

I also express my heartiest gratitude to all the people of Tata Motors for their constant help and support.

Thank you all.

Siddharth Satyapriya

Project Trainee

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D E C L A R A T I O N

I do hereby declare that Siddharth Satyapriya studying Electronics and Electrical

Engineering (6th semester) in the Kalinga Institute of Industrial Technology,

Bhubaneswar, has undergone the Summer Training Programme at TATA

MOTORS LTD, Jamshedpur from June 3, 2013 to June 29, 2013.

During the course of this training, He has successfully completed the projects titled:

1. Introduction of Fixed Position Stop System in Engine Dispatch

Slat Conveyor.

2. Study of Variable Frequency Drive.

He has followed all the policies, the safety guidelines and the code of conduct of

the company.

Mr. Kumar Satyam Mr. Nilesh Kumar Panchal

Manager, Divisional Manager

Electronics (Engine Factory) Electronics

Project Guide Date: Date:

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CONTENTS

S.N. Description Page No.

1. Introduction 5

2. TATA MOTORS LIMITED: An Overview 5

3. TATA MOTORS: The Jamshedpur Plant 10

I. The Cab and Cowl Factory 10

II. The Paint Shop 11

III. The PRIMA 12

IV. The Truck Factory 14

V. The Foundry 15

VI. The Engine Factory 17

VII. The Central Tool Room (CTR) 17

4. TATA MOTORS: A chronicle 18

5. Conveyer System 19

i. Automation 20

ii. Automation Tools 21

6. Programmable Logical Controller 22

7. PLC Programming 26

8. A Brief Introduction to CoDeSys 28

9. Ladder Diagram 29

10. Project Performed 32 I. Electrical drawing 37

11. .

II. Program

Study of Variable frequency Drive

38

12. Bibliography 49

13. Conclusion 50

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INTRODUCTION

TATA MOTORS LIMITED: An Overview

Tata Motors Limited is India's largest automobile company, with consolidated revenues

of INR 188,818 crores (USD 34.7 billion) in 2012-13. It is the leader in commercial vehicles

in each segment, and among the top in passenger vehicles with winning products in the

compact, midsize car and utility vehicle segments. It is also the world's fourth largest truck

and bus manufacturer.

The Tata Motors Group's over 55,000 employees are guided by the mission "to be

passionate in anticipating and providing the best vehicles and experiences that excite

our customers globally."

Established in 1945, Tata Motors' presence cuts across the length and breadth of India. Over 7.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company's manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow (Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and

Dharwad (Karnataka). Following a strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains.

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The company's dealership, sales, services and spare parts network comprises over

3,500 touch points. Tata Motors, also listed in the New York Stock Exchange (September

2004), has emerged as an international automobile company. Through subsidiaries

and associate companies, Tata Motors has operations in the UK, South Korea, Thailand,

Spain, South Africa and Indonesia. Among them is Jaguar Land Rover, acquired in 2008.

In 2004, it acquired the Daewoo Commercial Vehicles Company, South Korea's second

largest truck maker. The rechristened Tata Daewoo Commercial Vehicles Company has

launched several new products in the Korean market, while also exporting these

products to several international markets. Today two-thirds of heavy commercial vehicle

exports out of South Korea are from Tata Daewoo. In 2005, Tata Motors acquired a 21%

stake in Hispano Carrocera, a reputed Spanish bus and coach manufacturer, and

subsequently the remaining stake in 2009. Hispano's presence is being expanded in other

markets. In 2006, Tata Motors formed a 51:49 joint venture with the Brazil-based,

Marcopolo, a global leader in body-building for buses and coaches to manufacture fully-

built buses and coaches for India - the plant is located in Dharwad. In 2006, Tata Motors

entered into joint venture with Thonburi Automotive Assembly Plant Company of Thailand

to manufacture and market the company's pickup vehicles in Thailand, and entered the

market in 2008. Tata Motors (SA) (Proprietary) Ltd., Tata Motors' joint venture with Tata

Africa Holding (Pty) Ltd. set up in 2011, has an assembly plant in Rosslyn, north of

Pretoria. The plant can assemble, semi knocked down (SKD) kits, light, medium and

heavy commercial vehicles ranging from 4 tonnes to 50 tonnes.

Tata Motors is also expanding its international footprint, established

through exports since 1961. The company's commercial and passenger vehicles are

already being marketed in several countries in Europe, Africa, the Middle East, South

East Asia, South Asia, South America, CIS and Russia. It has franchisee/joint venture

assembly operations in Bangladesh, Ukraine, and Senegal.

The foundation of the company's growth over the last 68 years is a deep understanding of economic stimuli and customer needs, and the ability to translate them into customer-desired offerings through leading edge R&D. With over 4,500 engineers, scientists and technicians the company's Engineering Research Centre, established in 1966, has enabled pioneering technologies and products. The company has R&D centres in Pune, Jamshedpur, Lucknow, Dharwad in India, and in South Korea, Spain, and the UK.

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It was Tata Motors, which launched the first indigenously developed Light

Commercial Vehicle in 1986. In 2005, Tata Motors created a new segment by launching

the Tata Ace, India's first indigenously developed mini-truck. In 2009, the company

launched its globally benchmarked Prima range of trucks and in 2012 the Ultra range of

international standard light commercial vehicles. In their power, speed, carrying

capacity, operating economy and trims, they will introduce new benchmarks in India

and match the best in the world in performance at a lower life- cycle cost.

Tata Motors also introduced India's first Sports Utility Vehicle in 1991 and, in 1998, the

Tata Indica, India's first fully indigenous passenger car.

In January 2008, Tata Motors unveiled its People's Car, the Tata Nano. The Tata Nano has

been subsequently launched, as planned, in India in March 2009, and subsequently

in 2011 in Nepal and Sri Lanka. A development, which signifies a first for the global

automobile industry, the Nano brings the joy of a car within the reach of thousands of

families.

Tata Motors is equally focussed on environment-friendly technologies in emissions and

alternative fuels. It has developed electric and hybrid vehicles both for personal and public

transportation. It has also been implementing several environment- friendly technologies

in manufacturing processes, significantly enhancing resource conservation.

Through its subsidiaries, the company is engaged in engineering and automotive

solutions, automotive vehicle components manufacturing and supply chain activities,

vehicle financing, and machine tools and factory automation solutions.

Tata Motors is committed to improving the quality of life of communities by working on

four thrust areas - employability, education, health and environment. The activities touch

the lives of more than a million citizens. The company's support on education and

employability is focused on youth and women. They range from schools to technical

education institutes to actual facilitation of income generation. In health, the company's

intervention is in both preventive and curative health care. The goal of environment

protection is achieved through tree plantation, conserving water and creating new water

bodies and, last but not the least, by introducing appropriate technologies in vehicles

and operations for constantly enhancing environment care.

With the foundation of its rich heritage, Tata Motors today is etching

a refulgent future.

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TATA GROUPS

The Tata group comprises over 100 operating companies in seven business sectors:

communications and information technology, engineering, materials, services, energy,

consumer products and chemicals. The group has operations in more than 80 countries

across six continents, and its companies export products and services to 85 countries.

The total revenue of Tata companies, taken together, was $100.09 billion (around Rs

475,721 crore) in 2011-12, with 58 percent of this coming from business outside India.

Tata companies employ over 450,000 people worldwide. The Tata name has been

respected in India for more than 140 years for its adherence to strong values and

business ethics.

Every Tata company or enterprise operates independently. Each of these companies has

its own board of directors and shareholders, to whom it is answerable. There are 32

publicly listed Tata enterprises and they have a combined market capitalisation of about

$85.42 billion (as on June 14, 2013), and a shareholder base of 3.8 million. The major Tata

companies are Tata Steel, Tata Motors, Tata Consultancy Services (TCS), Tata Power, Tata

Chemicals, Tata Global Beverages, Tata Teleservices, Titan, Tata Communications and

Indian Hotels.

Tata Steel is among the top ten steelmakers, and Tata Motors is among the top five

commercial vehicle manufacturers, in the world. TCS is a leading global software

company, with delivery centres in the US, UK, Hungary, Brazil, Uruguay and China, besides

India. Tata Global Beverages is the second-largest player in tea in the world. Tata

Chemicals is the world’s second-largest manufacturer of soda ash and Tata

Communications is one of the world’s largest wholesale voice carriers.

In tandem with the increasing international footprint of Tata companies,

the Tata brand is also gaining international recognition. Brand Finance, a UK-based

consultancy firm, valued the Tata brand at $18.16 billion and ranked it 39th among the

top 500 most valuable global brands in their Brand Finance® Global 500 2013 report. In

2010, BusinessWeek magazine ranked Tata 17th among the '50 Most Innovative

Companies' list. Founded by Jamshedji Tata in 1868, Tata’s early years were inspired by

the spirit of nationalism. It pioneered several industries of national importance in India:

steel, power, hospitality and airlines. In more recent times, its pioneering spirit has been

showcased by companies such as TCS, India’s first software company, and Tata

Motors, which made India’s first indigenously developed car, the Indica, in 1998 and

recently unveiled the world’s most affordable car, the Tata Nano.

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Tata companies have always believed in returning wealth to the society they serve. Two-

thirds of the equity of Tata Sons, the Tata promoter holding company, is held by

philanthropic trusts that have created national institutions for science and technology,

medical research, social studies and the performing arts.

The trusts also provide aid and assistance to non-government

organisations working in the areas of education, healthcare and livelihoods.

Tata companies also extend social welfare activities to communities

around their industrial units. The combined development- related expenditure of the trusts

and the companies amounts to around 3 percent of the group's net profits in 2011.

Going forward, Tata is focusing on new technologies and innovation to

drive its business in India and internationally.

The Nano car is one example, as is the Eka supercomputer (developed

by another Tata company), which in 2008 was ranked the world’s fourth fastest.

Anchored in India and wedded to traditional values and strong ethics, Tata

companies are building multinational businesses that will achieve growth through

excellence and innovation, while balancing the interests of shareholders, employees and

civil society.

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MANUFACTURING- AT TATA MOTORS

Tata Motors owes its leading position in the Indian automobile industry to its strong

focus on indigenisation. This focus has driven the Company to set up world- class

manufacturing units with state-of-the-art technology. Every stage of product evolution-

design, development, manufacturing, assembly and quality control, is carried out

meticulously. Our manufacturing plants are situated at Jamshedpur in the East, Pune and

Sanand in the West and Lucknow and Pantnagar in the North.

Jamshedpur

Pune Lucknow

Pantnagar

Sanand Dharwad

JAMSHEDPUR PLANT

Established in 1945, the Jamshedpur unit was the company’s first unit and is spread over an area of 822 acres. It consists of 6 major divisions- Truck Factory (vehicle factory I & II), Engine Factory, Cab and Cowl Factories, Foundry, Prima (vehicle factory III) and Central Tool Room (CTR) and Forge Division. The divestment in March 2000 hived off the Axle and Engine plants into independent subsidiaries viz. HVAL and HVTL respectively.

The Cab and Cowl Factory

The fabrication and the fitment of the cab/cowl are done in the Cab and Cowl Factory of the plant. Different procedures of manufacturing are used for different models of trucks. Fabrication refers to the process in which the steel structure is made with all the welding which are then tested and painted and then sent for the fitment, which refers to the process in which the other parts and auxiliary items are fitted in like the seats the dashboard, the headlights and blinkers, the mirrors etc. World Truck cabs are manufactured in fully robotic assembly lines inside the vehicle factory III. The various segments used for making the cab are supplied from CTR.

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The robots are pre-taught on procedures to be followed for assembling the parts (roof, doors, and body). Spot-welding during the assembling of the parts is done by ABB robots and that of the doors of the cab is done by a Fanuc robot. Since the World Truck cabs are completely assembled by robots, the finishing is of superior quality. Other models are manufactured by partially using robots and partially assembled manually. The finishing is not as superior as that of World Truck- since manual welding differs from the perfection of robotic welding.

The Paint Shop

After the cab/cowl’s steel structure is completely assembled, it is shifted to the painting area in the shop. The process of Painting involves the following steps: The cab/cowl is washed with high speed jet of water to remove all the dust particles. Then it is passed through jets of chemicals to eliminate the dirt. In an electro-dipping tank, the cab/cowl is dipped while a current of 700V DC passes through the tank. The paint gets charged and attached to the body of the cab/cowl, hence the primer is done.

Next it is sent through a heating oven to strengthen the primer coat. The cab/cowl is given sandpaper finishing, thus smoothening the surface before the painting. In the next stage, a line of robots are taught to paint the cab/cowl according to the colour input given by the operator. At the end, the painted cab/cowl is again passed through the oven to dry thepaint.

Fitment of the cab:

This final process involves the attachment of seats, handles, lights, steering wheel and other necessary parts to the cabins. The cabs or cowls move on a conveyor that runs through a stretch that is divided into marked regions. The conveyor moves with such as speed, that the cab/cowl remains in a certain marked region for three minutes. Within these three minutes, the assigned operator has to finish attaching the parts of the cabin that he is responsible for. At the end of the process a quality check is done.

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The PRIMA (Vehicle Factory III)

The Prima section of the plant handles the making of World Trucks solely. The welded and assembled structure of the cabin is brought in from Truck III and long members are supplied from Truck I. The remaining procedures involved to make a World Truck are carried out here. Asia’s longest conveyor belt system is installed in Prima along with a unique Glass Glazing Robot, which due to its complex programming is not used in any other industry. There are three lines – assembly line, trim line and frame line.

The long members are brought in position under the gantry system by a motor driven conveyor system. The motor is driven by a Mitsubishi VFD. A variable-frequency drive (VFD) is a type of adjustable-speed drive used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage. The gantry system hoists the long member and shifts it to the Vinark conveyor system. There are 3 kinds of conveyors – slat conveyor, single chain and double chain conveyor. An Electrified Monorail System, that is, an overhead conveyor system is installed inside the shop. The conveyor is brought down at lower levels for loading and unloading purposes. An overhead conveyor basically consists of a track, chain, drive unit, and take up unit, oiler and carriers. The track is supported from roof, floor or wall as per site conditions. The chain is guided in the track and moved by a drive unit. The take up unit is provided to adjust the chain tension. The carriers are fixed to the chain at a predefined pitch. The component to be conveyed is loaded on the custom designed carrier. The oiler lubricates the chain. The Electrified Monorail System is controlled by CNC. The long members are first fitted with the appropriate parts on the upturned long members. Then an Inversion System turns these long members to their original position. The inversion system is monitored by PLC and consists of overhead conveyors carrying suspension trolleys. A barcode is fitted along the entire overhead system. A laser reader installed on the suspension trolleys sends the position signal to the PLC. Acting on this, the PLC sends the required instructions for the trolleys to move towards the load, invert the load at a particular position and stop to load or unload. The suspension trolleys pick up the load and invert them using motor run pulleys. In total six motors are used in the trolleys. An Axle Alignment System is used to check the position of the axles. If the axles are not aligned perfectly, the truck shall move in a tilted angle even when the steering is kept straight. To avoid this, laser signals are projected on the lines of the front and rear axle and analog measurements are taken. These measurements are sent through Bluetooth to the computer analysing the procedure. If the axles form opposite ends of a rectangle, the axles are aligned correctly.

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A Glass glazing robot is installed, which is one of its kinds. The robot applies a sealant along the perimeter of the glass which is installed as the windshield in the trucks. The programming of this robot is of complex nature due to its delicate job of accurate measurements while applying the sealant on the glass. When the robot is working, even a slight deviation from these measurements may result in the cracking of the glass. At the end of the process, a Dynamometer Test is done to measure the amount of horsepower and torque the engine produces and the proper functioning of the brakes. When running a chassis dynamometer test, the vehicle to be tested is driven onto the dynamometer platform that simulates resistance through the use of automated wheels. A computer instructs the driver of the chassis on the speed of the vehicle and the time of applying the brakes. A variable-frequency drive (VFD) is used in the analysing system. Thus the trucks are manufactured under extreme care so that the customers get what they pay for. Quality checks at appropriate junctions are provided for this purpose.

Assembly Line of PRIMA

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Truck Factory (Vehicle Factory I & II)

The truck factory is also basically an assembly line and is more or less like the assembly line in the Prima which was discussed above, the differences being that the truck factory manufactures many models of vehicles and also the long members are also made and assembled inside this factory. There are three assembly lines in this plant; first the Frame Shop where the long members are assembled, second, the assembly line 1 and third, assembly line 2. The finished product of the frame shop is the starting point of the two assembly lines.

Assembly Line of Vehicle Factory I and II

The making of the long members starts from the large metal sheet rolls which are the raw materials. They are supplied mainly by TISCO. They are first decoiled by a decoiler machine which also cuts them into the specified lengths as required. The cut sheets are then checked for camber and then sent to a 5000 Ton Press to make it into a long member. The 5000T press is a hydraulic press which automatically takes in the sheets and presses then to give the required shape. It also cuts the metal and makes holes wherever required as per the model of the vehicle.The long member is then washed to remove the dirt.

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Next comes the process known as Shot Blasting. This process is necessary to remove the layer of iron oxides from the surface. Very small metal balls are fired upon the long member at a very high speed. This method is called shot blasting. The long members are then taken to the LMCED area by automatic robots. In the LMCED area the long members are coated by a layer of primer by the process of cathode electro-deposition (CED).

They are then sent to the oven for the coat to become permanent.This completes the manufacturing of long members and after this their assembly starts.

The Foundry:

The fully equipped Foundry, that the unit is supported by, supplies high-grade SG Iron castings for automobile components and excavators, and is rated as one of the cleaner, better and highly automated foundries in the world. It has an annual capacity of 42,000 MT of Good castings and makes, both, Gey and SG cast Iron Casting.

It manufactures all critical automobile castings. For example Cylinder Block, Cylinder

Head etc. It has a sophisticated Kunkel Wagner High Pressure Moulding line of a rated production capacity of 90moulds/hour.

This is supported by a sand cooler and sand mixer from Kunkel Wagner. Its melting

shop has Medium Frequency Induction Furnaces for melting and Channel Furnaces for holding.

The pouring is done by a Channel Press Pour coupled with a Steam Inoculation

Dispenser. The core shop has a state-of-the-art Cold Box Machine, making four cores per minute.

It has elaborated sand and metallurgical laboratories. In 1993 the foundry was ISO

9002 certified by the Bureau VERITAS Quality International, which was later followed by the more stringent QS 9000 certification from the BVQI in the year 2000. Currently it is certified as TS: 16949 by BVC.

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Furnace in the Foundry division

Robots assembling the cask

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The Engine Factory:

The Engine Factory is responsible for the in-house manufacture of Tata 697/497. Naturally Aspirated and Turbo Charged engines, and the 6B series engines manufactured at Tata Cummins.

Engine Dispatch Line

The Central Tool Room: The CTR section is responsible for the designing of the cabs and making the dies.

As one of the most modern forging set-ups in the country, the Forge Division is equipped

with a semi-automated forging line with 40,000 MKg Beche Hammer and state-of-the-art

presses from Kurimoto of Japan. It produces critical forgings like crankshafts, front axle

beams and steering parts for the automobile plant. The new forging line, installed in April

1984, has the capacity to forge front axle beams at 90 seconds per piece and crankshafts

at 120 seconds per piece. Mechanical presses help produce a variety of heavy forgings. The

sophisticated FIDIA digit 165 CC Graphite Milling Machine links shop floor machines to the

design workstation. The Forge has been certified as ISO 9002 and QS 9000 by the BVQI.

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TATA MOTORS: A Chronicle

1954 Vehicle manufacture commenced 1961 First vehicle shipped to Sri Lanka 1964 Manufacture of 1210 model vehicle started 1965 100,000th vehicles completed at Telco, Jamshedpur 1969 “Tata” mark succeeds “Tata-Mercedes Benz” 1974 300,000th vehicles completed at Jamshedpur. Also first

‘S’ model 1977 Assembly of vehicles started 1978 400,000th vehicle produced at Jamshedpur 1979 Silver jubilee of auto division, Jamshedpur 1981 500,000th vehicle produced (Pune and Jamshedpur

combined) 1982 Inauguration of 807 vehicle 1986 407 LCV launched 1987 608 LCV launched 1988 207 Tata Mobile introduced 1991 Tata SIERRA launched 1992 Tata ESTATE rolled out 1999 Tata INDICA launched 2000 Gearbox division separated from Telco 2001 100000th Indica rolls out 2002 Launch of Tata Sedan and Tata Indigo 2005 Tata ACE- India’s first mini truck launched 2006 Tata NOVUS launched 2008 Acquired the British car maker Jaguar Land Rover 2009 The revolutionary TATA NANO launched

Unveiled the Tata World Truck range jointly developed with Tata Daewoo

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CONVEYOR SYSTEM

A conveyor system is a common piece of mechanical handling equipment that moves

materials from one location to another. Conveyors are especially useful in applications

involving the transportation of heavy or bulky materials. Conveyor systems allow quick and

efficient transportation for a wide variety of materials, which make them very popular in

the material handling and packaging industries. Many kinds of conveying systems are

available, and are used according to the various needs of different industries. There are

chain conveyors (floor and overhead) as well. Chain conveyors consist of enclosed tracks,

I-Beam, towline, power & free, and hand pushed trolleys.

Industries that use conveyor systems

A line-shaft roller conveyor conveys boxed produce at a distribution centre

A Conveyor belt conveys papers at a newspaper print plant

Roller conveyor for carton transport in the apparel industry

Conveyor systems are used widespread across a range of industries due to

the numerous benefits they provide.

Conveyors are able to safely transport materials from one level to another, which

when done by human labour would be strenuous and expensive.

They can be installed almost anywhere, and are much safer than using a forklift or

other machine to move materials.

They can move loads of all shapes, sizes and weights. Also, many have advanced

safety features that help prevent accidents.

There are a variety of options available for running conveying systems, including

the hydraulic, mechanical and fully automated systems, which are equipped to fit individual

needs.

Conveyor systems are commonly used in many industries, including the automotive,

agricultural, computer, electronic, food processing, aerospace, pharmaceutical, chemical,

bottling and canning, print finishing and packaging. Although a wide variety of materials

can be conveyed, some of the most common include food items such as beans and

nuts, bottles and cans, automotive components, scrap metal, pills and powders, wood

and furniture and grain and animal feed. Many factors are important in the accurate

selection of a conveyor system. It is important to know how the conveyor system will be

used beforehand. Some individual areas that are helpful to consider are the required

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conveyor operations, such as transportation, accumulation and sorting, the material

sizes, weights and shapes and where the loading and pickup points need to be.

AUTOMATION

Automation is the use of machines, control systems and information

technologies to optimize productivity in the production of goods and delivery of services.

The correct incentive for applying automation is to increase productivity, and/or quality

beyond that possible with current human labour levels so as to realize economies of scale,

and/or realize predictable quality levels. In the scope of industrialisation, automation is a

step beyond mechanization. Whereas mechanization provides human operators with

machinery to assist them with the muscular requirements of work, automation greatly

decreases the need for human sensory and mental requirements while increasing load

capacity, speed, and repeatability. Automation plays an increasingly important role in the

world economy and in daily experience.

Automation has had a notable impact in a wide range of industries beyond

manufacturing (where it began). Once-ubiquitous telephone operators have been

replaced largely by automated telephone switchboards and answering machines. Medical

processes such as primary screening in electrocardiography or radiography and laboratory

analysis of human genes, sera, cells, and tissues are carried out at much greater speed

and accuracy by automated systems. Automated teller machines have reduced the need

for bank visits to obtain cash and carry out transactions. In general, automation has been

responsible for the shift in the world economy from industrial jobs to service jobs in the

20th and 21st centuries.

The term automation, inspired by the earlier word automatic (coming from

automaton), was not widely used before 1947, when General Motors established the

automation department. At that time automation technologies were electrical, mechanical,

hydraulic and pneumatic. Between 1957 and 1964 factory output nearly doubled while the

number of blue collar workers started to decline.

AUTOMATION TOOLS

Engineers can now have numerical control over automated devices. The

result has been a rapidly expanding range of applications and human activities. Computer-

aided technologies (or CAx) now serve the basis for mathematical and organizational tools

used to create complex systems. Notable examples of CAx include Computer- aided design

(CAD software) and Computer-aided manufacturing (CAM software). The improved

design, analysis, and manufacture of products enabled by CAx has been beneficial for

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industry.

Information technology, together with industrial machinery and processes, can assist in the

design, implementation, and monitoring of control systems. One example of an industrial

control system is a programmable logic controller (PLC). PLCs are specialized hardened

computers which are frequently used to synchronize the flow of inputs from (physical)

sensors and events with the flow of outputs to actuators and events.

Human-machine interfaces (HMI) or computer human interfaces (CHI), formerly known as

man-machine interfaces, are usually employed to communicate with PLCs and other

computers. Service personnel who monitor and control through HMIs can be called by

different names. In industrial process and manufacturing environments, they are called

operators or something similar. In boiler houses and central utilities departments they are

called stationary engineers.

Different types of automation tools exist:

ANN - Artificial neural network

BPM - Bonita Open Solution

DCS - Distributed Control System

HMI - Human Machine Interface

SCADA - Supervisory Control and Data Acquisition

PLC - Programmable Logic Controller

PAC - Programmable automation controller

Instrumentation

Motion control

Robotics

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PROGRAMMABLE LOGIC CONTROLLER

Automation control systems

These control systems are used in manufacturing plants of all types, and some other

applications that you may not have considered.

The control systems are built around special devices, designed to operate industrial

machines, and processes. We call these devices Programmable Logic Controllers (PLC) and

Programmable Automation Controllers (PAC).

PLC and PAC Systems

PLCs were introduced in the early 1970s. The term “PAC”, was developed to

differentiate those older systems from today’s much more powerful, and flexible devices.

An analogy can be made between the VHS video tape, and a DVD. Both systems allow

viewers to record TV programs for viewing at a later time, but the DVD also can also be

used to record music, data, and more.

PLCs were designed to control machinery. PACs can be used for machine control, process,

motion control, and other applications.

Basic Components of a PLC System

There are five basic components in a PLC system:

The PLC processor or controller

I/O (Input /Output) modules

Chassis or backplane

Power supply

Programming software that runs in a PC

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Processor, Controller, or CPU

Stores the control program and data in its memory

Reads the status of connected input devices

Executes the control program

Commands connected outputs to change state based on program execution –For example: Turn a light on, start a fan, adjust a speed, or temperature

Comes in various physical forms

Processor that fits in a chassis

Standalone PLC

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I/O Modules

Physically connect to field devices

Input modules convert electrical signals coming in from input field devices such as

pushbuttons, to electrical signals that the PLC can understand.

Output modules take information coming from the PLC and convert it to

electrical signals the output field devices can understand, such as a motor starter,

or a hydraulic solenoid valve.

I/O comes in various forms

Input Modules Input modules interface directly to devices such as switches and temperature sensors.

Input modules convert many different types of electrical signals such as

120VAC, 24VDC, or 4-20mA, to signals which the controller can understand.

Input modules convert real world voltage and currents to signals the PLC can

understand. Since there are different types of input devices, there is a wide variety of

input modules available, including both digital and analog modules.

Output Modules Output modules take a signal from a PLC and convert it to a signal that a field device

needs to operate. Since there are different types of output devices, there is a wide

variety of output cards available, including both digital and analog cards.

Power Supply

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Power Supply A power supply is needed to provide power to the PLC and any other modules. Power

supplies come in various forms:

Power supply modules that fit into one of the slots in a chassis

External power supplies that mount to the outside of a chassis

Standalone power supplies that connect to the PLC or I/O through a power

cable

Embedded power supplies that come as part of the PLC block.

Programming Software Software that runs on a PC is required to configure and program PLCs.

Different products may require different programming software

Software allows programs to be written in several different languages

Network Interface

Most PLCs have the ability to communicate with other devices. These devices include

computers running programing software or collecting data about the manufacturing

process, a terminal that lets an operator enter commands into the PLC or I/O that is

located in a remote location from the PLC.The PLC will communicate with the other

devices through a network interface.

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PLC Control Panel Typically, PLCs are installed in enclosures, on a “panel”

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PLC PROGRAMMING

Every PLC has associated programming software that allows the user to enter a program

into the PLC.

Software used today is Windows based, and can be run on any PC.

Different products may require different software: PLC5, SLC, and Control-Logix each

require their own programming software.

Before a PLC can perform any control task, it must be programmed to do so. The most

popular language used to program a PLC is ladder logic.

In a conveyor system, we have several “requirements” to accomplish; for example,

timing and counting parts on the conveyor. Each of these requirements must be

programmed into the PLC so that it knows how to respond to different events.

The programmer develops the program, and connects their personal computer to the

PLC through a network or cable and then downloads the program to the PLC.

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A Brief Introduction to CoDeSys

What is CoDeSys CoDeSys is a complete development environment for your PLC. (CoDeSys stands for Controlled Development System).

CoDeSys puts a simple approach to the powerful IEC language at the disposal of the PLC programmer. Use of the editors and debugging functions is based upon the proven development program environments of advanced programming languages (such as Visual C++).

Overview of CoDeSys Functions How is a project structured?

A project is put into a file named after the project. The first POU (Program Organization Unit) created in a new project will automatically be named PLC_PRG. The process begins here (in compliance with the main function in a C program), and other POUs can be accessed from the same point (programs, function blocks and functions). Once you have defined a Task Configuration, it is no longer necessary to create a program named PLC_PRG. You will find more about this in chapter 6.7, Task Configuration. There are different kinds of objects in a project: POUs, data types, display elements (visualizations) and resources. The Object Organizer contains a list of all the objects in your project.

How do I set up my project? First you should configure your PLC in order to check the accuracy of the addresses

used in the project. Then you can create the POUs needed to solve your problem. Now you can program the POUs you need in the desired languages. Once the programming is complete, you can compile the project and remove errors should there be any.

How can I test my project? Once all errors have been removed, activate the simulation, log in to the simulated

PLC and "load" your project in the PLC. Now you are in online mode. Now open the window with your PLC Configuration and test your project for correct sequence. To do this, enter input variables manually and observe whether outputs are as expected. You can also observe the value sequence of the local variables in the POUs. In the Watch and Receipt Manager you can configure data records whose values you wish to examine.

Debugging In case of a programming error you can set breakpoints. If the process stops at such

a breakpoint, you can examine the values of all project variables at this point in time. By

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working through sequentially (single step) you can check the logical correctness of your program.

Project Components

Project A project contains all of the objects in a PLC program. A project is saved in a file named

after the project. The following objects are included in a project: POUs (Program Organization Units), data types, visualizations, resources, and libraries.

POU (Program Organization Unit) Functions, function blocks, and programs are POUs which can be

supplemented by actions. Each POU consists of a declaration part and a body. The body is written in one of the IEC programming languages which include IL, ST, SFC, FBD, LD or CFC.

CoDeSys supports all IEC standard POUs. If you want to use these POUs in your project, you must include the library standard.lib in your project. POUs can call up other POUs. However, recursions are not allowed. Visualization

CoDeSys provides visualizations so that you can display your project variables. You can plot geometric elements off-line with the help of the visualization. In Online mode, these can then change their form/colour/text output in response to specified variable values. A visualization can be used as a pure operating interface for a PLC with CoDeSys HMI or as a Web-Visualization or Target-Visualization running via Internet resp. directly on the PLC.

Ladder Diagram (LD)

The Ladder Diagram is also a graphics oriented programming language which approaches the structure of an electric circuit. On the one hand, the Ladder Diagram is suitable for constructing logical switches, on the other hand one can also create networks as in FBD. Therefore the LD is very useful for controlling the call of other POUs. The Ladder Diagram consists of a series of networks. A network is limited on the left and right sides by a left and right vertical current line. In the middle is a circuit diagram made up of contacts, coils, and connecting lines. Each network consists on the left side of a series of contacts which pass on from left to right the condition "ON" or "OFF" which correspond to the Boolean values TRUE and FALSE. To each contact belongs a Boolean variable. If this variable is TRUE, then the condition is passed from left to right along the connecting line. Otherwise the right connection receives the value OFF.

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Example of a network in a Ladder Diagram made up of contacts and coils .

Contact Each network in LD consists on the left side of a network of contacts (contacts are

represented by two parallel lines: | |) which from left to right show the condition "On" or "Off". These conditions correspond to the Boolean values TRUE and FALSE. A Boolean variable belongs to each contact. If this variable is TRUE, then the condition is passed on by the connecting line from left to right, otherwise the right connection receives the value "Out". Contacts can be connected in parallel, then one of the parallel branches must transmit the value "On" so that the parallel branch transmits the value "On"; or the contacts are connected in series, then contacts must transmit the condition "On" so that the last contact transmits the "On" condition. This therefore corresponds to an electric parallel or series circuit. A contact can also be negated, recognizable by the slash in the contact symbol: |/|. Then the value of the line is transmitted if the variable is FALSE.

Coil

On the right side of a network in LD there can be any number of so-called coils which are represented by parentheses: ( ). They can only be in parallel. A coil transmits the value of the connections from left to right and copies it in an appropriate Boolean variable. At the entry line the value ON (corresponds to the Boolean variable TRUE) or the value OFF (corresponding to FALSE) can be present. Contacts and coils can also be negated (in the example the contact SWITCH1 and the coil %QX3.0 is negated). If a coil is negated (recognizable by the slash in the coil symbol: (/)), then it copies the negated value in the

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appropriate Boolean variable. If a contact is negated, then it connects through only if the appropriate Boolean value is FALSE.

Function blocks in the Ladder Diagram Along with contacts and coils you can also enter function blocks and programs In the

network they must have an input and an output with Boolean values and can be used at the same places as contacts, that is on the left side of the LD network

Set/Reset coils Coils can also be defined as set or reset coils. One can recognize a set coil by the

"S" in the coil symbol: (S)) It never writes over the value TRUE in the appropriate Boolean variable. That is, if the variable was once set at TRUE, then it remains so. One can recognize a reset coil by the "R" in the coil symbol: (R)) It never writes over the value FALSE in the appropriate Boolean variable: If the variable has been once set on FALSE, then it remains so.

LD as FBD When working with LD it is very possible that you will want to use the result of the contact switch for controlling other POUs. On the one hand you can use the coils to put the result in a global variable which can then be used in another place. You can, however, also insert the possible call directly into your LD network. For this you introduce a POU with EN input. Such POUs are completely normal operands, functions, programs, or function blocks which have an additional input which is labelled with EN. The EN input is always of the BOOL type and its meaning is: The POU with EN input is evaluated when EN has the value TRUE. An EN POU is wired parallel to the coils, whereby the EN input is connected to the connecting line between the contacts and the coils. If the ON information is transmitted through this line, this POU will be evaluated completely normally. Starting from such an EN POU, you can create networks similar to FBD.

Example of a LD network with an EN POU

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Project Title:-

Introduction of Fixed Position Stop System in Engine Dispatch Slat

Conveyor.

Introduction

The Engine Despatch Line Slat Conveyer, we had been working on has nine stations for

assembly of engine components. Controls for Emergency stop, FPS & Reset and

Indicators for them has been provided at three control station each for three assembly

station. Emergency Stop Push button can be pressed to STOP the conveyer instantly and

Red indicator glows. FPS push button can be pressed to STOP the conveyer at a fixed

position specified by the Limit Switch when there is a need to fix a problem. Yellow

indicator glows. If the problem is fixed before the STOP, Reset button is pressed the

conveyer keep on moving otherwise the conveyer will STOP at the fixed position and the

Red Indicator will glow. Again to make the conveyer RUN, Reset button can be pressed

and Green Indicator glows.

Fixed Position Stop System (FPS)

In the fixed-position stop system, an operator discovering a problem with parts, tools, materials supply, safety conditions, etc., pulls a rope or pushes a button to signal the supervisor. The supervisor assesses the situation and determines if the problem can be fixed before the end of the current work cycle. If the problem can be fixed, the supervisor resets the signal system so the line doesn’t stop. If the problem can’t be corrected within the remainder of the cycle time, the line stops at the end of the work cycle/a fixed position

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CoDeSys LD PROGRAM

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Advantages of FPS

The main advantage of the fixed position stop system is that it allows workers to find

problems and pull the andon cord without stopping the line and causing production delays.

This reduces reluctance by workers to pull the cord and so smaller problems are identified

more frequently, thus promoting earlier corrective action and a stronger spirit of kaizen. Of

course when there is a safety problem the line should stop immediately regardless of where

the work piece is relative to the fixed position.

The fixed position stop system is also insures that operations are not left half-finished.

Workers do not go to break in the middle of a work sequence, returning later to remember

exactly where they were. The fixed position stop requires the work to continue until it

reaches the position.

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Study of Variable Frequency Drive

What is VFD?

A variable-frequency drive (VFD) (also termed adjustable-frequency drive, variable-speed drive, AC drive, micro drive or inverter drive) is a type of adjustable-speed drive used in electro-mechanical drive systems to control AC motor speed and torque by varying motor input frequency and voltage.

VFDs are used in applications ranging from small appliances to the largest of mine mill drives and compressors. However, about a third of the world's electrical energy is consumed by electric motors in fixed-speed centrifugal pump, fan and compressor applications and VFDs' global market penetration for all applications is still relatively small. This highlights especially significant energy efficiency improvement opportunities for retrofitted and new VFD installations.

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A variable frequency drive is a device used in a drive system consisting of the following three main sub-systems: AC motor, main drive controller assembly, and drive operator interface.

AC Motor

The AC electric motor used in a VFD system is usually a three-phase induction motor. Some types of single-phase motors can be used, but three-phase motors are usually preferred. Various types of synchronous motors offer advantages in some situations, but three phase induction motors are suitable for most purposes and are generally the most economical motor choice. Motors that are designed for fixed-speed operation are often used. Elevated voltage stresses imposed on induction motors that are supplied by VFDs require that such motors be designed for definite-purpose inverter-fed duty in accordance to such requirements as Part 31 of NEMA Standard MG-1.[6]

Controller

The variable frequency drive controller is a solid state power electronics conversion system consisting of three distinct sub-systems: a rectifier bridge converter, a direct current (DC) link, and an inverter. Voltage-source inverter (VSI) drives (see 'Generic topologies' sub-section below) are by far the most common type of drives. Most drives are AC-AC drives in that they convert AC line input to AC inverter output. However, in some applications such as common DC bus or solar applications, drives are configured as DC-AC drives. The most basic rectifier converter for the VSI drive is configured as a three-phase, six- pulse, full-wave diode bridge . In a VSI drive, the DC link consists of a capacitor which smooth out the converter's DC output ripple and provides a stiff input to the inverter. This filtered DC voltage is converted to quasi-sinusoidal AC voltage output using the inverter's active switching elements. VSI drives provide higher power factor and lower harmonic distortion than phase-controlled current-source inverter (CSI) and load-commutated inverter (LCI) drives (see 'Generic topologies' sub-section below). The drive controller can also be configured as a phase converter having single-phase converter input and three-phase inverter output.[7]

Controller advances have exploited dramatic increases in the voltage and current ratings and switching frequency of solid state power devices over the past six decades. Introduced in 1983, the insulated-gate bipolar transistor (IGBT) has in the past two decades come to dominate VFDs as an inverter switching device.[9][10][11]

The two other drive control platforms, vector control and direct torque control (DTC), adjust the motor voltage magnitude, angle from reference and frequency[14] such as to precisely control the motor's magnetic flux and mechanical torque.

Operator interface

The operator interface provides a means for an operator to start and stop the motor and adjust the operating speed. Additional operator control functions might include reversing, and switching between manual speed adjustment and automatic control from an external process control signal. The operator interface often includes an alphanumeric display and/or indication lights and meters to provide information about the operation of the drive. An operator interface keypad and display unit is often provided on the front of the VFD controller as shown in the photograph above. The keypad display can

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often be cable-connected and mounted a short distance from the VFD controller. Most are also provided with input and output (I/O) terminals for connecting pushbuttons, switches and other operator interface devices or control signals. A serial communications port is also often available to allow the VFD to be configured, adjusted, monitored and controlled using a computer.

Name of each part

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Project Title:

Study of Variable Frequency Drive (VT230SE):

Run Motor at three different frequencies by remote I/O.

Main circuit block

Description:

L+1 & L+2 are shorted. L1, L2, L3 are given 3-phase 440v power supply via Red, yellow and blue wires respectively.

U, V, W are connected to motor.

Green wires of 3 phase input and motor are grounded as per above figure.

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Control Circuit Block

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Modes and parameters The parameters used differ according to the control mode (C30-0). The parameters include the V/f control (constant torque, variable torque) parameters, the IM vector control (sensor-less, with sensor) and the PM motor control parameters. These parameters are grouped into Modes and Blocks according to their

functions and frequency of usage.

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Control Input / Output Input/output terminal function

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Procedure:

3 Push buttons (NO type) are used.

VT230SE (VFD) is used.

Motor is used.

One terminal of PB1, PB2 and PB3 is connected to RUN, PSI1 and PSI2 of control circuit respectively.

Other terminal of PB1, PB2 and PB3 are shorted and connected to RY0.

3 phase supply is given

Operation panel gets activated

Motor output parameters are fed in b00- (0~7)

B00-0

Rated input voltage setting

3.0

B00-1

Max./base frequency simple setting

1

B00-2

Motor rated output (kW)

30.0

B00-3

Rated output voltage (V)

415

B00-4

Max. frequency (Hz)

50.0

B00-5

Base frequency (Hz)

50.0

B00-6

Motor rated current (A)

8.0

B00-7

Carrier frequency (Hz) Small/large

17.0/10.0

We know for input in PSI is controlled by C03 (0~9)

C03-0 was set to 2

B11.0 is used for program frequency setting. It sets X %.

X % of 50Hz= desired frequency.

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Parameter

Set value

Desired Frequency

B11.0

50%

25 Hz

B11.1

20%

10 Hz

B11.2

60%

30 Hz

C11 – Operation panel mode setting is done.

The initial operation mode for when the power is turned ON

Set=1: Local 2: Remote.

Setting 2 switches from Local to remote control.

Pressing Push button 1 motor runs at 25 Hz frequency.

Pressing Push button 2 with Push button 1 motor runs at 10 Hz frequency.

Pressing Push button 3 with Push button 1 motor runs at 30 Hz frequency. Hence, it is observed that motor runs at three different frequencies.

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BIBLIOGRAPHY

Previous projects of TATA motors. Siemens PLC instruction manual.

CoDeSys manual.

Through various sources on Internet.

Ladder programming logic pdf.

VT230SE manual.

VFD pdf.

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CONCLUSION

With the active help and support of all the employees in the Electronics

department of the Engine Factory, I was able to complete my project and I am

extremely grateful to them while doing this project I got an insight of

the application of my branch in this factory. Unless one undergoes practical

training it is difficult to relate to all that is being taught in theory. Moreover

one gets the feel of working in a factory.

The next important thing that one learns in the training is how to relate himself

to his colleagues, his seniors and the employees of his division. Until and unless

a person interacts actively with his co-workers, he will not be able to dispel

his duties well because in an organization an individual alone, isolated from

his workforce cannot complete a job.

Finally I would like to thank Mr. Nilesh Kumar Panchal, Mr. Kumar Satyam for

their constant guidance and help without their support it would not have been

possible. I would also like to thank the administration of TATA MOTORS for

providing me with this wonderful opportunity of completing my training here.