SCHOOL OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

INTERNSHIP REPORT ON

AUTOMATION AND CONTROL DIAGRAM

Submitted By

Vedhesh murthy

Performed At

HARVESTERS DESK
(FROM : 31/05/2022 - 30/06/2022 )

Under the Guidance of: Submitted by:

Mr.Arun kumar Vedhesh murthy

Automation B. Tech- Department of EEE
Harvesters desk
Roll. No- 1960818
Bengaluru
Christ Deemed to be University
Bangalore
 ACKNOWLEDGEMENT

I wish to express my deepest gratitude towards Harvesters Desk. for giving me an

opportunity to be a part of their esteemed organization and enhance my knowledge by
granting permission to do my summer training project under their guidance.

I am grateful to Mr Arun Kumar, my guide, for his invaluable guidance and cooperation
during the course of the project. He provided me with his assistance and support whenever
needed that has been instrumental in completion of this project.

I would like to thank my Department of Electrical & Electronics Engineering, School of

Engineering & Technology, Christ (Deemed to be University) for making this experience of
summer training in an esteemed organization Harvesters Desk. The learning from this
experience has been immense and would be cherished throughout life.

At last, but not the least I would also like to express gratitude to my parents for their
continuous motivation and support.

Vedhesh murthy
B. Tech- Department of EEE
Roll. No- 1960818
School of Engineering & Technology
Christ (Deemed to be University), Bangalore

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INTERNSHIP CERTIFICATE

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 TABLE OF CONTENTS
S. NO. TOPIC PAGE NO.

INTRODUCTION
1.1 COMPANY PROFILE.

1.2 ABOUT INTERNSHIP.

1.2.1 COMPONENTS VIEW.

1.2.2 CIRCUIT DIAGRAMS.

1.2.3 PLC COMPONENT VIEW.

1. 1-14
1.2.4 PLC SOFTWARES
AND CIRCUIT DIAGRAMS.

1.2.5 HANDS-ON
CIRCUIT DIAGRAM
CONNECTION WITH PLC
AND WITHOUT PLC.

INDUSTRY VISIT
2. 2.1 PROFILE & PHOTOS OF THE 15
COMPANY.

3. SCADA OVERVIEW 16

4. CONCLUSION 17

5. REFERENCES 18

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 1. INTRODUCTION
1.1 COMPANY PROFILE
Harvesters Desk articulates a pipeline format of solutions that covers Control Panels, Control
Systems, PLC, DCS, and SCADA solutions for various clients over multiple segments of
process industries. They work together with OEMs from design to the commissioning stage
thus ensuring end-to-end services. They also undertake Upgradation/ Migration projects for
various industrial control systems.

Services they provide:

Our array of Automation services includes:
❖ Relay-based automation
❖ PLC automation HMI for operator control
❖ SCADA for process monitoring/ control and historical data
❖ VFD, Stepper drives commissioning for a smooth process
❖ Servo/ encoder for motion control processes
❖ Boiler/ PID/ Close loop control systems for process automation requirements.
❖ DCS for integrated system architecture
Products they provide:
Our range of control panels includes:
❖ Motor Control Center (MCC)
❖ Panels Power Control Center (PCC)
❖ Panels Automatic Power Factor Correction (APFC)
❖ Panels Programmable Logic Controller Panels (PLC)
❖ Lighting Distribution Boxes (LDBs)
❖ Power Distribution Boxes (PDBs) Relay Control Panels
Company has ample of experience in the following domains:
❖ RCC Batching plants
❖ Fly ash brick plants
❖ Aerated Autoclaved Concrete (AAC) block plants
❖ Crusher plants
❖ Chemical plating plants
❖ Steam/Gas turbines
❖ Industrial boilers
❖ Industrial Cranes/Lifts
❖ Material Handling equipment like conveyor/ Assembly Line automation
❖ Special Purpose Machinery (SPM)

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1.2 ABOUT INTERNSHIP
1.2.1 Components view:

❖ Relays
❖ Circuit breakers(MCB, MPCB, MCCB).
❖ SMPS
❖ Contactors
❖ Push Buttons(ON/OFF)
❖ VFD(Variable Frequency Drive)
❖ PLC
❖ Limit Switch
❖ Proximity Sensor
1.2.2 Diagrams:

❖ Power line diagrams

❖ Control diagrams
1.2.3 PLC component view:

❖ Input and output lines.

❖ Processors line.
1.2.4 PLC Softwares and the circuit diagrams:

❖ Comfort software.
❖ Ladder diagrams.
1.2.5 Hands-on circuit diagram connection with PLC and without PLC

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1.2.1 COMPONENTS VIEW
OLR:

Overload relays protect a motor by sensing the current going to

the motor. Many of these use small heaters, often bi-metallic
elements that bend when warmed by current to the motor. When
current is too high for too long, heaters open the relay contacts
carrying current to the coil of the contactor. Overload relays are
designed to meet the special protective needs of motor control
circuits,These relays allow harmless temporary overloads (such
as
motor starting) without disrupting the circuit.

Contactor:

A contactor is an electrically controlled switch used for switching an

electrical power circuit, similar to a relay except with higher current
ratings. A contactor is controlled by a circuit which has a much lower
power level than the switched circuit. Unlike a circuit breaker, a
contactor is not intended to interrupt a short circuit current. Contactors
range from those having a breaking current of several amperes to
thousands of amperes and 24 V DC to many kilovolts. Contactors are
used to control electric motors, lighting, heating, capacitor banks,
thermal evaporators, and other electrical loads.

SMPS(SWITCH MODE POWER SUPPLY):

A switched-mode power supply is an electronic power supply

that incorporates a switching regulator to convert electrical
power efficiently. Like other power supplies, an SMPS transfers
power from a source, like mains power, to a load, such as a
personal computer, while converting voltage and current
characteristics. The higher power conversion efficiency is an
important advantage of a switched-mode power supply.
Switched-mode power supplies may also be substantially smaller and lighter than a linear
supply due to the smaller transformer size and weight.

Relay:

A relay is an electrically operated switch. Many relays use an

electromagnet to mechanically operate a switch, but other
operating principles are also used, such as solid-state relays.
Relays are used where it is necessary to control a circuit by a
separate low-power signal, or where several circuits must be
controlled by one signal.

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Limit switch:

In electrical engineering a limit switch is a switch operated by the

motion of a machine part or presence of an object. They are used
for controlling machinery as part of a control system, as safety
interlocks, or to count objects passing a point. A limit switch is an
electromechanical device that consists of an actuator mechanically
linked to a set of contacts. When an object comes into contact with
the actuator, the device operates the contacts to make or break an
electrical connection. Limit switches are used in a variety of
applications and environments because of their ruggedness, ease
of
installation, and reliability of operation. They can determine the presence or absence, passing,
positioning, and end of travel of an object.

MCB(MINIATURE CIRCUIT BREAKER):

An MCB or miniature circuit breaker is an electromagnetic device that

embodies a complete enclosure in a molded insulating material. The main
function of an MCB is to switch the circuit, i.e., to open the circuit
automatically when the current passing through it exceeds the value for
which it is set. It can be manually switched ON and OFF as similar to a
normal switch if necessary.

MCCB(MODULE CASE CIRCUIT BREAKER):

The traditional moulded-case circuit breaker uses electromechanical

(thermal magnetic) trip units that may be fixed or interchangeable. An
MCCB provides protection by combining a temperature sensitive device
with a current sensitive electromagnetic device. Both these devices act
mechanically on the trip mechanism.

MPCB(MOTOR PROTECTION CIRCUIT BREAKER):

A motor protection circuit breaker, or MPCB, is a specialized

electromechanical device that has several functions that allow it to
provide a safe electrical supply for motors: Protection against electrical
faults such as short circuits, line-to-ground faults and line-to-line faults.
The MPCB can interrupt any electrical fault that is below its breaking
capacity. Motor overload protection, when a motor draws electric
current above its name plate value for an extended period of time.
Overload protection is normally adjustable in MPCB.

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PLC(PROGRAMMABLE LOGIC CONTROLLER):

A programmable logic controller, PLC, or programmable

controller is a digital computer used for automation of typically
industrial electromechanical processes, such as control of
machinery on factory assembly lines, amusement rides, or light
fixtures. PLCs are used in many machines, in many industries.
PLCs are designed for multiple arrangements of digital and
analog inputs and outputs, extended temperature ranges,
immunity to
electrical noise, and resistance to vibration and impact. Programs to control machine
operation are typically stored in battery-backed-up or non-volatile memory. PLC can be
available in brick and modular type.

Proximity sensor:

A proximity sensor is a sensor able to detect the presence of

nearby objects without any physical contact. A proximity sensor
often emits an electromagnetic field or a beam of electromagnetic
radiation, and looks for changes in the field or return signal. The
object being sensed is often referred to as the proximity sensor's
target. Different proximity sensor targets demand different
sensors. For example, a capacitive or photoelectric sensor might
be suitable for a plastic target; an inductive proximity sensor
always requires a metal target. The maximum distance that this sensor can detect is defined as
nominal range. Some sensors have adjustments of the nominal range or means to report a
graduated detection distance.

Push Button:

Pushbutton switches are mechanical switches defined by the method

used to activate the switch. The activation method is typically in the
form of a plunger that is pushed down to open or close the switch. There
are several pole and throw configurations for pushbutton switches. The
number of switch contact sets used is known as the number of poles and
the number of conducting positions is referred to as the throw.

VFD(VARIABLE FREQUENCY DRIVE):

A variable frequency drive is a type of motor controller that drives an

electric motor by varying the frequency and voltage of its power
supply. The VFD also has the capacity to control ramp-up and ramp-
down of the motor during start or stop, respectively. Even though the
drive controls the frequency and voltage of power supplied to the
motor, we often refer to this as speed control, since the result is an
adjustment of motor speed.

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1.2.2 CIRCUIT DIAGRAMS
POWER LINE DIAGRAMS AND CONTROL DIAGRAMS:

The power diagrams are used to analyze the power flow in any circuit, starting from the line
power to the load, only the components are given with connection, not accurate.

The control diagrams are used to connect the circuit accurately with proper components etc.,

Ex 1: DOL Starters(DIRECT ON-LINE STARTERS)

Ex 2: RDOL Starters(DIRECT ON-LINE STARTERS)

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1.2.3 PLC COMPONENT VIEW
● For PLC we always need to do the I/O list(INPUTS/OUTPUTS), so that circuit
connection will be easy, and we will be aware of the components connected.
● Inputs are like push buttons, sensors, etc., Outputs are like motor, limit switch,
actuators, etc.,and it has a microprocessor unit to store the memory, and do the
function as the logic is designed.

❖ At starting we build the logic using ladder programming using specified software like
Comfort logo software, Codesys etc.,
❖ Then, we download the logic into PLC using ethernet/data cable, and we run the
program.
❖ In order to interact with the PLC in real time, users need an HMI, or Human Machine
Interface. These operator interfaces can be simple displays, with a text-readout and
keypad, or large touchscreen panels more similar to consumer electronics, but either
way, they enable users to review and input information to the PLC in real time.

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1.2.4 PLC SOFTWARES AND THE CIRCUIT DIAGRAMS
Comfort software:

Full Screen:

Tools Palette:

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Circuit Diagrams:

Circuit diagram we used was ladder Diagram

Here I have written some logic using:

❖ Input contact(Externally Switch)

❖ Output Relay coil
❖ On delay Timers
❖ OFF delay Timers
❖ NO contact
❖ NC contact
❖ Retentive delay timers
❖ Counters(UP/DOWN)

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1.2.5 HANDS-ON CIRCUIT DIAGRAM CONNECTION
WITH PLC AND WITHOUT PLC
Problem 1: Direct-On line starters (DOL STARTERS)

Control Diagram:

Ladder Diagram:

Problem 2: Reverse Direct-On line starters (R-DOL STARTERS)

Control Diagram:

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Ladder Diagram:

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Problem 3: Reversing the polarity of motor and controlling the speed using VFD(Variable
Frequency Drive)

● VFDs can be used to control AC motor speeds by changing the motor's frequency
without sacrificing the output power of the motor. This is done by turning the speed
pot of an AC motor drive.
● The VFD can be controlled remotely by using PLC/DCS systems. The PLC has to
give a set point for VFD drive to control the motor speed, this can be achieved either
automatically from the PLC or by the operator action from the HMI.

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Problem 4: Timers (On delay, Off delay)

These circuits we used to control problem 1 and problem 2 by giving delays.

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Problem 5: PLC with Limit switch

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 2. INDUSTRY VISIT
2.1 PROFILE & PHOTOS OF THE COMPANY
Company Name: “Suchana Engineering & Logistics Solutions Private Limited”

Motive: “Suchana Engineering & Logistics Solutions Private Limited” is manufacturing Tow
Truck,Material Handling Equipment etc.,

Address: Koppa Rd, Suraksha nagar, Akshaya Vana, Akshayanagar, Bengaluru, Karnataka -
560076.

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 3. SCADA OVERVIEW

Supervisory Control and Data Acquisition (SCADA) is a system that aims to monitor and
control field devices at your remote sites. SCADA systems are critical as it helps maintain
efficiency by collecting and processing real-time data. SCADA is a centralized system that
monitors and controls the entire area.

Arun sir took other industry where they set up this plant and it was a brick manufacturing
plant, and sir was explaining about the working of this module and software.\

Components of a SCADA system

Sensors and actuators - A sensor is a feature of a device or system that detects inputs from
industrial processes. An actuator is a feature of the device or system that controls the
mechanism of the process. In simple terms, a sensor functions like a gauge or meter, which
displays the status of a machine; an actuator acts like a switch, dial or control valve that can
be used to control a device. Both sensors and actuators are controlled and monitored by
SCADA field controllers.

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SCADA field controllers -These interface directly with sensors and actuators. There are two
categories of field controllers:

1) Remote telemetry units, also called remote terminal units (RTUs), interface with
sensors to collect telemetry data and forward it to a primary system for further action.
2) Programmable logic controllers (PLCs) interface with actuators to control industrial
processes, usually based on current telemetry collected by RTUs and the standards set
for the processes.

SCADA supervisory computers - These control all SCADA processes and are used to
gather data from field devices and to send commands to those devices to control industrial
processes.

HMI software - This provides a system that consolidates and presents data from SCADA
field devices and enables operators to understand and, if needed, modify the status of
SCADA-controlled processes.

4. CONCLUSION
It was a great experience as an intern in Harvesters Desk, and I learnt a lot about types of
PLC, and had hands-on experience on ladder programming logic, comfort logo softwares,
timers, counters.

And also there was a Industrial visit, where we saw an actual setup of PLCs Panel board,
HMI, Push Buttons, Input and output components connected, and we saw the real time
working.

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5. References:
❖ https://drive.google.com/file/d/1MYDNI5fUyLHQNy-
v2kuk01D6QKgJEna8/view?usp=sharing
❖ https://www.harvestersdesk.com/
❖ https://www.indiamart.com/suchanaengineeringlogisticssolutions/

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