SUMMER TRAINING AT

BOSCH JAIPUR PLANT

Submitted By- Submitted to-

M.BHARADWAJ Mr. Naresh Purohit,
IIT Bhubaneswar And FCM ,
 Research Center, Jaipur Bosch Plant, Jaipur

I express my deep sense of gratitude to Ms. Manjusha Anthony(JaP/HRL) for

giving me a golden opportunity to pursue my summer training at Bosch Jaipur
Plant.

​I owe my heartiest thanks to my Mentor ​Mr. Naresh Purohit​ and project guide
​Mr. Divy Jagetia​ for showing confidence in me & for giving me
the opportunity to learn & understand the practical implementation of academic
studies. He was always there in the hours of need, without him my training
would not have been possible.

I pay my deep regards to ​All Staff ​who helped and supported me throughout my
training, for encouraging me at each and every step whenever I required. It is
indeed a great pleasure & privilege to express my special thanks to colleagues,
co-trainees, friends & other well wishers who in different ways have given
splendid help & valuable suggestions & encouragement.

M.BHARADWAJ
TABLE OF CONTENTS
Ch. No. Title
a. Certificate
b. Abstract
c. Acknowledgement
d. List of figures
e. List of tables
f. List of abbreviations
g. Table of contents

1. Company Profile
1.1 The Robert Bosch Group
1.2 Bosch in India
1.3 Bosch Plant in Jaipur
1.4 Bosch Values
1.5 Bosch locations in India
1.6 MICO jaipur
1.7 Jaipur plant
1.8 Bosch Products
1.9 Facts and Figures

2. Project 01 – EMS Implementation

2.1 Introduction
2.2 Objectives of EMS
2.3 Energy Management System
2.4 Layout Mapping
2.5 Single Line Diagram
2.6 Energy Analysis Of TMC Machines
 2.7 Observations

3. EARTH PIT BASICS

3.1 Introduction
3.2 Working Principle

4.VACUUM CIRCUIT BREAKERS

4.1 Construction of VCB
4.2 Advantages
4.3 Disadvantages
4.4 Working principle of VCB
4.5 Applications

5. RELAYS
5.1 Types of Relays
5.2 Electromagnetic Relays
5.3 Solid State Relays
5.4 Hybrid Relays
5.5 Thermal Relays
5.6 Reed Relays

6.Programmable Logic Controller

6.1 Introduction
6.2 Working of PLC
6.3 PLC in Industries
6.4 PLC Projects
Reference

​INTRODUCTION
 The Robert Bosch Group

Robert Bosch GmbH is closely associated with the automotive industry across the world. The
name Bosch is not just famous for automotive technology products like gasoline/ diesel/
chassis systems, & generators, electrical drives, steering systems and car electronics- it
is also a leader in the areas
automation technology, car multimedia systems, packaging technology, power tools, thermo
technology, household appliances and security systems.

Founded in 1886 in German, as a ‘Workshop for precision Mechanics and Electrical

Engineering’ by Robert Bosch, the Bosch Group today is the largest automotive technology
supplier in the world.
The Bosch Group is one of the world’s biggest private industrial corporations. Headquartered in
Stuttgart, Germany, the Bosch Group has approx. 271,000 employees worldwide, and generated
annual sales revenue of 49.2 billion Euros in 2009.
The Bosch Group is active in the following fields
1. Automotive technology
2. Automation technology
3. Metals technology
4. Packaging technology
5. Power tools
6. Thermo technology
7. Household appliances
8. Security system
The name of Robert Bosch is closely associated with the automobile. Since 2004, the Bosch
Group the world’s largest automotive supplier in terms of sales. The reason for this positive
effect is the high demand for modern diesel-systems. The Robert Bosch GmbH, Stuttgart,
Germany has been in the forefront of Fuel Injection technology for almost a century now. Today,
this sector, with its headquarters in Stuttgart, has factories all over the world at 108 locations.
The four largest business units are: fuel-injection technology for combustion engines (diesel and
gasoline), systems for active and passive driver and passenger safety (brakes, ABS, ESP, airbag
control units) and electrical machines (starters, alternators, small-power motors).

BOSCH at Jaipur, INDIA.

 ​BOSCH - VALUES

The Bosch values are the foundation upon which the successes of the past
were built, and upon which we will build our future. They guide our actions
and tell us what is important to us and what we are committed to.

Here as well, the main objective is to enhance the company's competitiveness by clearly setting
out the basic values which each associate has committed to and put into practice.
Values act as a compass in times of change, and provide appropriate orientation. They also point
the direction which cultural change within the company is meant to take. The values are designed
to help shape cooperation among associates and to lay the foundation stone for the necessary
strong economic development of the company. This means increasing performance ability by
providing orientation and trust, increasing speed by reducing bureaucracy and controls,
strengthening the identification of associates with an international and culturally diverse
company.

1) Future and Result focus​:

In order to ensure dynamic development of our company and to guarantee long term corporate
success, we participate in shaping the changes in markets and technologies. By doing so, we
provide our customers with innovative solutions and our associates with attractive jobs. We act
result focused in order to secure growth and financial independence. With the dividends
generated, the Robert Bosch Foundation supports charitable activities.

2) ​Responsibility
We accept that our actions must accord with the interests of society. Above all else, we place our
products and services in the interests of the safety of people, the economic use of resources, and
environmental sustainability.

3) ​Initiative and Determination

We act on our own initiative, with an entrepreneurial but accountable spirit, and demonstrate
determination in pursuing our goals.

4) ​Openness and Trust

We inform our associates, business partners, and investors in a timely and open fashion of
important
developments within our company. This is the best basis for a trustful relationship.

5) ​Fairness
We view mutual fairness as a condition of our corporate success when dealing with each other
and
with our business partners.

6) ​Reliability, Credibility, and Legality

We promise only what we can deliver, accept agreements as binding, and respect and observe
the law
in all our business transactions.

7) ​Cultural Diversity
We are aware of our company's regional and cultural origins and at the same time regard
diversity as
an asset, as well as a precondition of our global success.

BOSCH LOCATIONS IN INDIA

​MICO JAIPUR
 Jaipur plant (JaP) is the fourth location of Motor Industries Company Ltd. Commissioned on
24​th
march 1999 with a state-of-the-art manufacturing facility to produce distributor type fuel
injection
pump as per Euro II and Euro III norms. A TS 16949 certified company, is a technological oasis
in the
developing state of Karnataka
 ​ ​The Jaipur Plant (JaP)

Jaipur plant is the fourth manufacturing location of Mico started in 1997, manufacturing VE
pump for
inland and other countries. Jaipur is located in Karnataka. Mico’s additional space requirements
up to
2000 were projected to be 102,450 sqm whereas the generate able space in existing plants
(BanW, NaW, NhW) was only 72, 150sq.m. Therefore the need for a fourth location to cater to
 the needs of the automobile sector was felt.

When Mico started the selection process for a new manufacturing location in India, Jaipur was
able
to prove itself better in comparison with the competing locations including the Jaipur plant is the
fourth manufacturing location of Mico started in 1997, manufacturing VE pump for inland and
other
countries. Jaipur is located in Karnataka. Mico’s additional space requirements up to 2000 were
projected to be 102,450 sqm whereas the generate able space in existing plants (BanW, NaW,
NhW)
was only 72, 150sq.m. Therefore the need for a fourth location to cater to the needs of the
automobile
sector was felt.
When Mico started the selection process for a new manufacturing location in India, Jaipur was
able to
prove itself better in comparison with the competing locations including the already existing
Mico
locations. As a result, Jaipur was selected as the fourth location for Mico. The selected location
was
Sitapura Industrial Area as it was a developed Industrial estate with adequate power and water
supply
and well connected by road, rail and air. Moreover the government provided better fiscal
incentives.
March 24, 1999 will go down as an important date in the annals of Mico history as the fourth
manufacturing plant was inaugurated at Sitapura. It was set to manufacture Distributor – type
diesel
fuel injection pumps, a product with promising growth potential in line with the emerging trends
in
automobile technology.
The plant started commercial production in December 2000 and was recommended for QS 9000
in
December 2000, it has been issued in March 2001.

Since the foundation of the plant in 1999 the demand of the customers has increased
continuously. Only a small amount of pumps is produced for export, most of them are sold on
the growing Indian

Currently a lot of pre-parts are shipped from suppliers in Europe. Higher labor costs and
transportation as well as long lead-times should be avoided by localization projects that are
running in the Jaipur Plant. In the last years a high quantity of material has been sent by air
freight to provide fluctuating demand of the customers.

The current target per month is 50000 pumps. Actually this number is not produced in Jaipur
Plant. That’s why some of them have to be imported from a plant in Brazil (Curitiba / CtP).
This causes additional costs especially for transportation.

Since July ’07 the plant in Jaipur has become leadplant for VE-pumps. The consequences are
more responsibilities for customer and supplier prices, but also additional technical tasks. In
the previous years FeP had been in charge for this.

​Bosch Products
 ​FACTS AND FIGURES

Bosch Group in India employs over 31,000 associates and generated consolidated revenue of
about ₨. 19,204 crores* (2.61 billion euros) in 2017 of which ₨. 13,790 crores* (1.88 billion
euros) from third party. The Group in India has close to 18,000 research and development
associates. In India, Bosch Limited is the flagship company of the Bosch Group. It earned
revenue of over ₨.10,842crores (1.47 billion euros) in 2017.
 PROJECT 01:
ENERGY MANAGEMENT SYSTEM IMPLEMENTATION

Introduction:

Energy Management System: (Source – Internet)* An energy management system (EMS) is a

system of computer-aided tools used by operators of electric utility grids to monitor, control, and
optimize the performance of the Energy generation and/or transmission system in the real time.
These monitor and control functions are known as SCADA; the optimization packages are often
referred to as "advanced applications".

Manufacturers of EMS also commonly supply a corresponding dispatcher training simulator

(DTS). This related technology makes use of components of SCADA and EMS as a training tool
for control Centre operators.

Energy management systems are also often commonly used by individual commercial entities to
monitor, measure, and control their electrical building loads. Energy management systems can
be used to centrally control devices like HVAC units and lighting systems across multiple
locations, such as retail, grocery and restaurant sites. Energy management systems can also
provide metering, sub metering, and monitoring functions that allow facility and building
managers to gather data and insight that allows them to make more informed decisions about
energy activities across their sites.

OBJECTIVES OF EMS:
1. Reduce Energy cost
2. Improve business performance
3. Engage top management
4. Integrate your management system
5. Secure energy supply

ENERGY MANAGEMENT SYSTEM

Capability to monitor, control, and optimize the operation of Energy Consumption and
generation assets in real -time
LAYOUT MAPPING

SINGLE LINE DIAGRAM

ENERGY ANALYSIS OF TMC REGION
The below picture is depicting the energy consumption and energy per piece graphs
which are varying through the months
OBSERVATIONS
● If we look at the above graph only in the month of march suddenly energy
consumption and energy per quantity shoot up.
The above three graphs are the comparison of identical machines
● March recorded for highest E/Q ratio and less Production.
● In the first graph energy consumed by the one machine is exactly half the energy
consumed by the other identical machine.
● In all the graphs again production is decreased but the energy consumed by the
machine increased which is not the ideal case

REASONS FOR UNEVEN ENERGY CONSUMPTION

● Number of motors(Auxiliary) are different
● Ratings of the motors are Different
● Working time(Due to Breaks) of machines may not be same

EARTH PIT-Basics,Testing,Maintenance
❏ EARTH PIT
In electrical system, an Earth pit refers to a pit, dug in earth with some standard
filling. Primarily Earth pits are used for SAFETY towards SHORT CIRCUITS.
It also acts as the reference point for different electric power sources. As Earth Pits
are easy to make and maintain so since starting of commercialized Electricity, Earth
pits are used as reference points.
 ❏ WORKING PRINCIPLE
If a machine or equipment is properly grounded into the earth, it has less chances to
get damaged. In case of short circuit or any other accident, the current will rush to
the lowest resistance path i.e. into the earth. And a OCR(over current relay) will
sense the high current and will cut off the supply

Vacuum Circuit Breaker Working and Applications 

A circuit breaker is a device that interrupts an electric circuit to prevent unwarranted current,
caused by a short circuit, typically resulting from an overload. Its basic functionality is to interrupt
current flow after a fault is detected.
A vacuum circuit breaker is a kind of circuit breaker where the arc quenching takes place
in vacuum medium. The operation of switching on and closing of current carrying contacts and
interrelated arc interruption takes place in a vacuum chamber in the breaker which is called
vacuum interrupter​.
Construction of Vacuum Circuit Breaker

The vacuum circuit breaker comprises a steel arc chamber in the center-symmetrically arranged
ceramic insulators. The pressure inside the vacuum interrupter is maintained below 10^-4 torr.

The material used for current carrying contacts plays an important role in the performance of the
vacuum circuit breaker. The alloys like, Copper-bismuth or copper-chrome are the ideal material
to make VCB contacts.
Construction Of Vacuum Circuit Breaker

From the figure shown above, the Vacuum circuit breaker consists of a fixed contact, a moving
contact and a vacuum interrupter. The moving contact is connected to the control mechanism
by stainless steel bellow. The arc shields are supported the insulating housing such that they
cover on these shields and is prevented from condensing on the insulating enclosure. The
possibility of a leak is eliminated due to permanent sealing of vacuum chamber for that a glass
vessel or ceramic vessel is used as the outer insulating body.

Advantages of VCB

Vacuum offers the utmost insulating strength. So it has extreme superior arc quenching
properties than any other medium.

● The vacuum circuit breaker has a long life.

● Unlike Oil Circuit Breaker (OCB) or air blast Circuit Breaker (ABCB), the
explosion of VCB is avoided. This enhances the safety of the operating
personnel.
● No fire hazard
 ● The vacuum CB is fast in operation so ideal for fault clearing. VCB is suitable
for repeated operation.
● Vacuum circuit breakers are almost maintenance free.
● No exhaust of gas to the atmosphere and Noiseless operation.

Disadvantages of VCB

● The main disadvantage of VCB is that it is uneconomical at voltages

exceeding 38 kVolts.
● The cost of the breaker becomes excessive at higher voltages. This is due to
the fact that at high voltages (above 38 kV) more than two numbers of the
circuit breaker are required to be connected in series.
● Moreover, the VCBs production is uneconomical if produced in small
quantities.

Working of Vacuum Circuit Breaker

The sectional view of vacuum circuit breaker is shown in the figure below when the contacts are
separated due to some abnormal conditions, an arc is struck between the contacts, the arc is
produced due to ionization of metal ions and depends very much on the material of contacts.
● The separation of contacts causes the release of vapor which is filled in the
contact space. It consists of positive ions liberated from contact material. The
vapor density depends on the current in the arc. When the current decreases, the
rate of vapor release decreases and after current zero, the medium regain its
dielectric strength if the vapor density is reduced.
● When current to be interrupted is very small in a vacuum, the arc has several
parallel paths. The total current is divided into many parallel arcs which repel
each other and spread over the contact surface. This is called diffused arc which
can be interrupted easily.
● At high values of current, the arc gets concentrated in a small region. It causes
rapid vaporization of the contact surface. The interruption of the arc is possible if
arc remains in diffused state. If it is quickly removed from the contact surface, the
arc will be re-strike.
 ● Arc extinction in vacuum breakers is greatly influenced by material and shape of
the contacts and the technique of considering metal vapor. The path of the arc is
kept moving so that temperature at any one point will not be high.
● After the final arc interruption, there is rapidly building up of dielectric strength
which is peculiar of the vacuum breaker. They are suitable for capacitor switching
as it will give a re-strick free performance. The small current is interrupted before
natural current zero, which may cause chopping whose level depends on the
material of contact.

Applications of Vacuum Circuit Breaker

❖ The vacuum circuit breaker is today recognized as most reliable current

interruption technology for medium voltage switchgear. It requires minimum
maintenance compared to other circuit breaker technologies.
❖ The technology is mainly suitable for mainly medium voltage application. For
higher voltage vacuum technology has been developed, but it is not commercially
feasible. Vacuum circuit breakers are used in metal clad Switchgear and also in
porcelain housed circuit breakers.

Air Circuit Breaker (ACB) – Construction, Operation,

Types and Uses
Air Circuit Breaker
The type of circuit breaker, which operates in air (where air-blast as an arc quenching
medium) at atmospheric pressure, is known to be an ​Air Circuit Breaker​. Air circuit
breaker has completely replaced by oil circuit breaker. In different countries, still it is a
preferable choice to use an Air circuit breaker up to 15KV because, there is no chance
of oil fire like in oil circuit breaker.

Construction of Air-Circuit Breaker

The following fig shows the main and external parts of an ACB. (ABB EMax Low

Voltage, Current Limiting Air Circuit Breaker and Selective (Non-Current Limiting) Air

Circuit Breaker).
Delixi Air Circuit Breaker External labels (Rated Current and Voltage = 1kA, 415V)
1. OFF button (O)
2. ON button (I)
3. Main contact position indicator
4. Energy storage mechanism status indicator
5. Reset Button
6. LED Indicators
7. Controller
8. “Connection”, “Test” and “isolated” position stopper (the three-position
latching/locking mechanism)
9. User-supplied padlock
 10. Connection “,” Test “and” separation “of the position indication
11. Connection (CE) Separation, (CD) Test (CT) Position indication contacts
12. Rated Name Plate
13. Digital Displays
14. Mechanical energy storage handle
15. Shake (IN/OUT)
16. Rocker repository
17. Fault trip reset button

The following fig shows the Internal Construction of Air Circuit Breaker

(ABB EMax Low Voltage Current Limiting Air Circuit Breaker and Selective (Non-Current Limiting) Air
Circuit Breaker)
● 1. Sheet Steel Supporting Structure
● 2. Current Transformer for Protection Trip Unit
● 3. Pole Group insulating box
● 4. Horizontal rare terminals
● 5a. Plates for fixed main contacts
● 5b. Plates for fixed arcing Contacts
 ● 6a. Plates for Main moving contacts
● 6b. Plates for Moving Arcing contacts
● 7. Arcing Chamber
● 8. Terminal box for fixed version – Sliding Contacts for withdrawable
version
● 9. Protection Trip Unit
● 10. Circuit breaker Closing and Opening Control
● 11. Closing Springs

Principle of Operation of Air Circuit Breaker

The working principle of Air Circuit breaker is rather different from other types of circuit
breaker. The main aim of circuit breaker is to prevent reestablishment of arcing after
current zero where the contact gap will withstand the system recovery voltage. It does
the same work, but in a different manner. During interruption of arc, it creates an arc
voltage instead of supply voltage. Arc voltage is defined as the minimum voltage
required for maintaining arc .The circuit breaker increases the voltage in three different
ways:

● Arc voltage can be increased by cooling arc plasma. As soon as the

temperature of the arc plasma motion of particle in arc plasma is reduced,
more voltage gradient will be required to maintain the arc.
● By splitting the arc into a number of series will increases the arc voltage.
● Arc voltage can be increased by lengthening the arc path. As soon length of
arc path is increased the resistance path will increase more arc voltage is
applied across the arc path hence arc voltage is increased.
● It is operated within voltage level up to 1 KV. It contains two pairs of contact.
The main pair carries the current and the contact made of copper. An additional
pair of contact is made of carbon. When the breaker is opened, the main contact
opens first. During opening of the main contact, the arc contact remains in touch
with each other. The arcing gets initiated when arc contacts are separated. The
circuit breaker is obsolete for medium voltage.
Types of Air Circuit Breaker
There are four types of ACBs used in the control and protection to maintain and stable operation
of switch gears and indoor medium voltage.

● Plain Break Type Air Break Circuit Breaker or Cross-Blast Air Circuit Breaker
● Magnetic Blowout Type Air Break Circuit Breaker
● Air Chute Air Break Circuit Breaker
● Air Blast Circuit Breaker

Different Types of Relays and their Working Principles 

● Relays are the primary protection as well as switching devices in most of the control
processes or equipment. All the relays respond to one or more electrical quantities like
voltage or current such that they open or close the contacts or circuits. A relay is a
switching device as it works to isolate or change the state of an electric circuit from one
state to another.
● Classification or the types of relays depends on the function for which they are used.
Some of the categories include protective, reclosing, regulating, auxiliary and monitoring
relays.
● Protective relays continuously monitor these parameters: voltage, current, and power;
and if these parameters violate from set limits they generate alarm or isolate that
particular circuit. These types of relays are used to protect equipment like motors,
generators, and transformers, and so on.
● Reclosing relays are used to connect various components and devices within the system
network, such as synchronizing process, and to restore the various devices soon after
any electrical fault vanishes, and then to monitor the system conditions such as direction
of power and accordingly generates the alarm. These are also called directional relays.

​Different Types of Relays

Depending on the operating principle and structural features relays are of different types such
as electromagnetic relays, thermal relays, power varied relays, multi-dimensional relays, and so
on, with varied ratings, sizes and applications.
1. Electromagnetic Relays

These relays are constructed with electrical, mechanical and magnetic components, and have
operating coil and mechanical contacts. Therefore, when the coil gets activated by a supply
system, these mechanical contacts gets opened or closed. The type of supply can be AC or DC.

DC vs AC Relays

● Both AC and DC relays work on the same principle as electromagnetic induction, but the
construction is somewhat differentiated and also depends on the application for which
these relays are selected. DC relays are employed with a freewheeling diode to
de-energize the coil, and the AC relays uses laminated cores to prevent eddy current
losses.
● The very interesting aspect of an AC is that for every half cycle, the direction of the
current supply changes; therefore, for every cycle the coil loses its magnetism since the
zero current in every half cycle makes the relay continuously make and break the circuit.
So, to prevent this – additionally one shaded coil or another electronic circuit is placed in
the AC relay to provide magnetism in the zero current position.

Attraction Type Electromagnetic Relays

Attraction Type Relays

These relays can work with both AC and DC supply and attract a metal bar or a piece of metal
when power is supplied to the coil. This can be a plunger being drawn towards the solenoid or
an armature being attracted towards the poles of an electromagnet as shown in the figure.
These relays don’t have any time delays so these are used for instantaneous operation.

Induction Type Relays

These are used as protective relays in AC systems alone and are usable with DC systems. The
actuating force for contacts movement is developed by a moving conductor that may be a disc
or a cup, through the interaction of electromagnetic fluxes due to fault currents.

These are of several types like shaded pole, watt-hour and induction cup structures and are
mostly used as directional relays in power-system protection and also for high-speed switching
operation applications.

Magnetic Latching Relays

These relays use permanent magnet or parts with a high remittance to remain the armature at
the same point as the coil is electrified when the coil power source is taken away.

2. Solid State Relays

Solid State uses solid state components to perform the switching operation without moving any
parts. Since the control energy required is much lower compared with the output power to be
controlled by this relay that results the power gain higher when compared to the electromagnetic
relays. These are of different types: reed relay coupled SSR, transformer coupled SSR,
photo-coupled SSR, and so on.
Solid State Relays

The above figure shows a photo coupled SSR where the control signal is applied by LED and it
is detected by a photo-sensitive semiconductor device. The output form this photo detector is
used to trigger the gate of TRIAC or SCR that switches the load.

3. Hybrid Relay

These relays are composed of electromagnetic relays and electronic components. Usually, the
input part contains the electronic circuitry that performs rectification and the other control
functions, and the output part include electromagnetic relay.

4. Thermal Relay

These relays are based on the effects of heat, which means – the rise in the ambient
temperature from the limit, directs the contacts to switch from one position to other. These are
mainly used in motor protection and consist of bimetallic elements like temperature sensors as
well as control elements. Thermal overload relays are the best examples of these relays.

5. Reed Relay
 Reed Relay

Reed Relays consist of a pair of magnetic strips (also called as reed) that is sealed within a
glass tube. This reed acts as both an armature and a contact blade. The magnetic field applied
to the coil is wrapped around this tube that makes these reeds move so that switching operation
is performed.

Based on dimensions, relays are differentiated as micro miniature, subminiature and miniature
relays. Also, based on the construction, these relays are classified as hermetic, sealed and
open type relays. Furthermore, depending on the load operating range, relays are of micro, low,
intermediate and high power types.

Relays are also available with different pin configurations like 3 pin, 4 pin and 5 pin relays. The
ways in which these relays are operated is shown in the below figure. Switching contacts can be
SPST, SPDT, DPST and DPDT types. Some of the relays are normally open (NO) type and the
other are normally closed (NC) types.
 Relay pin configurations

​ ​Programmable Logic Controller

PLC definition:

A programmable logic control is an industrial computer that accepts input from switches and
sensors and evaluate these in accordance with a stord program and generates output to control
machines and devices.

Programmable Logic Controllers are basically used to control automated systems in

industries. They are one of the most advanced and simplest forms of control systems which
are now replacing hard wired logic relays at a large scale. These controllers are specially
designed to survive in harsh situations and shielded from heat, cold, dust, and moisture etc.
PLC ​consists of a microprocessor which is programmed using the computer language.
The program is written on a computer and is downloaded to the PLC via cable. These loaded
programs are stored in non – volatile memory of the PLC. During the transition of relay control
panels to PLC, the hardware relay logic was exchanged for the program fed by the user. A
visual programming language known as the Ladder Logic was created to program the PLC.
What constitute a PLC:
Working of PLC (Programmable Logic Controller)
The Programmable logic controller functions in four steps.

Input scan​: ​The state of the input is scanned which is connected externally. The inputs
include switches, pushbuttons, and proximity sensors, limit switches, pressure switches.
Ideally, they are transformers and not relays.​
Program scan​: T ​ he loaded program is executed to carry out the function appropriately.
Output scan​: The input sources have a control over the output ports to energize or de-energize
them. The outputs include solenoids, valves, motors, actuator, and pumps. Depending on the
model of PLC, these relays can be transistors, triacs or relays.

​ ​PLC​ ​Applications:
 The simple suitable application is a conveyor system. The requirements of the conveyor systems are
as follows:

● A programmable logic controller is used to start and stop the motors of the conveyor belt.
● The conveyor system has three segmented conveyor belts. Each segment is run by a motor.
● To detect the position of a plate, a proximity switch is positioned at the segment’s end.
● The first conveyor segment is turned ON always.
● The proximity switch in the first segment detects the plate to turn ON the second conveyor
segment.
● The third conveyor segment is turned ON when the proximity switch detects the plate at the
second conveyor.
● As the plate comes out of the detection range, the second conveyor is stopped after 20 secs.
● When the proximity switch fails to detect the plate, the third conveyor is stopped after 20 secs.

Ladder Logic:

● Ladder logic is a PLC programming language.​ ​Ladder logic is a graphical programming language
which means that instead of text, the programming is done by combining different graphic
elements. These graphic elements are called symbols.​ ​Ladder diagram programming allows PLCs
to perform several different types of tasks, including Boolean logic, timing, counting, arithmetic,
and special functions.​ ​ Boolean logic is actually what PLCs and relay systems perform. The legal
operations in Boolean logic are AND, OR, and NOT.
● The AND operation simply means all of the inputs must be ON for the output to be ON; it's
analogous to relay contacts connected in series.
● The OR operation means that the output is ON if at least one of the inputs is ON; it's analogous to
relay contacts connected in parallel.
● The NOT operation means that the output is OFF if the input isON and vice-versa; it's analogous
to a normally closed relay contact.
● Timing instructions- The basic timing instructions are on-delay and off-delay.
With on-delay timers, the output associated with the timing instruction is turned ON some
specified time after the input is ON, but it turns OFF immediately when the input is turned OFF.
With off-delay timers, the output is turned ON immediately when the input is turned ON.
However, it remains ON for a specified period of time after the input has been turned OFF, but
before going OFF Timing instructions
PLC IN INDUSTRIES

● A​ programmable logic controller (​PLC​) is a computer with a microprocessor but has no

keyboard, mouse or monitor. It is essentially built to withstand very harsh industrial
environments.
● It is a distinctive form of computer device designed for use in industrial control systems.
It has a robust construction and unique functional features such as sequential control, ease
of programming, timers and counters, easy-to-use hardware and reliable controlling
capabilities.
● It is designed to be enormously robust, so it could withstand harsh industrial
environments such as extreme temperatures, vigorous vibrations, humidity and electrical
noise.
● The logic controllers are often tasked to control and monitor a very large number of
sensors and actuators. They are therefore different from other regular computer systems
in their extensive I/O (input/output) arrangements.
● In addition to being used as a special-purpose digital computer, the PLC can be used in
other control-system areas and industries. This explains why PLCs are often referred to as
industrial PCs.
The PLC is also commonly used in civil applications such as in washing machines and for
controlling traffic signals and elevators. They are used in many industries to monitor and control
production processes and building systems.

​ nce programmed, the PLC will perform a sequence of events triggered by stimuli referred
O
to as inputs. It receives these stimuli through delayed actions such as counted occurrences or
time delays.

1. A PLC performs only a single set or sequence of tasks, with greater reliability and
performance, except when it is under real-time constraints. This is in contrast to
regular PCs and smartphones that are designed to execute any number of roles
simultaneously within the Windows framework.
2. The PLC has a number of features that you don’t find in normal computers, such
as protection from the open area conditions like heat, dust and cold.
3. It is low cost compared with other microcontroller systems. When you’re using a
PLC in various applications, you only need to change the software component for
each application. With other microcontroller systems however, you would have to
change the hardware components too with different applications.

PLC PROJECTS:-

1. DOL FOR INDUCTION MOTOR

2.FORWARD-REVERSE ROTATION OF INDUCTION MOTOR
​ ​ 3. STAR-DELTA IMPLEMENTATION
4. TWO FLOOR ELEVATOR LOGIC
REFERENCES
1. Bosch Global Network (BGN)/ Bosch Intranet
2. Internet
3. Supplier manuals
4. SAATHI (Locally developed online monitoring system)