THIS REPORT IS USEFULL TO THE STUDENT WHO ARE TRAINING FROM BHEL HARIDWAR OR ANY OTHER PLACE ON CNC MACHINES. IT PROVIDES A DETAILED REPORT OF 60 PAGES.

1. Industrial Training Report
Bharat Heavy Electricals Limited
BHEL, Haridwar Uttarkhand
Submitted to the department of Electronics & Communication in partial fulfilment of the requirements for the
award of the degree of
Bachelor of Technology
In
Electronics & communication engineering
Submitted by
Nupur Goswami
1145031019
2014-15
Shri Ram Murti Smarak Women’s College of Engg. &Tech.
Bareilly-243202

2. CERTIFICATE
This is to certify that Mr./Ms. Nupur Goswami of B.Tech ( Electronics & Communication Engineering ) Roll
No. 1145031019 has completed her Industrial Training during the academic year 2013-14 as partial fulfilment
of B.Tech (Electronics & Communication Engineering) course.
The matter presented in this report has not been submitted by me in any otherUniversity/Institute for the award of any other degree.
Date:………………
Nupur Goswami
Signature of student
This is certifying that the above statement made by the student is correct to the best of my knowledge and
belief.
CO-ORDINATOR CO-ORDINATOR
(Ms. Neha Thakur) (Mr. Surendra Gangwar)
Assistant Professor ,EC Head of Department, EC
SRMSWCET,Bareilly SRMSWCET, Bareilly
Date-……………… Date-………………….
CO-ORDINATOR
(Mr. Mohit kumar)
Assistant Professor, EC
SRMSWCET, Bareilly
Date-………………
(ii)

3. Acknowledgement
It is my great pleasure to express my gratitude to MR. Raj Singh, Manager Training & Development Section,
BHEL, Haridwar Unit for his deep interest profile inspiration, valuable advice during the entire course of
vocational training.
I wish to express my gratitude to the Electronics & Communication department of BHEL for allowing me to
study various functions of their department.
It gives me an opportunity to understand the practical aspects of different functions of Electronics &
Communication department of BHEL. The present report bears the true justification of their investment.
My overriding dept continues to be the faculty members of our respected college for extending their unflinching
help & guidance.
For all this i would like to convey my wholehearted thanks to those entire people who helped me directly &
indirectly in completing my report.
Signature:
Nupur Goswami
(1145031019)
(iii)

4. ABSTRACT
Bharat Heavy Electricals Limited (BHEL) is an Indian integrated power plant equipment manufacturer and
operates as engineering and manufacturing company based in New Delhi, India. Established in 1964, BHEL
ushered in the indigenous Heavy Electrical Equipment industry in India. The company has been earning profits
continuously since 1971-72 and paying dividends since 1976-78.
It is engaged in the design, engineering, manufacture, construction, testing, commissioning and servicing of a
wide range of products and services for the core sectors of the economy, viz. Power, Transmission, Industry,
Transportation, Renewable Energy, Oil & Gas and Defence.
It is the 7th largest power equipment manufacturer in the world. In the year 2011, it was ranked ninth most
innovative company in the world by US business magazine Forbes. BHEL is the only Indian Engineering
company on the list, which contains online retail firm Amazon at the second position with Apple and Google at
fifth and seventh positions, respectively. It is also placed at 4th place in Forbes Asia's Fabulous 50 List of 2010.
BHEL was established more than 50 years ago, ushering in the indigenous Heavy Electrical Equipment industry
in India. The company has been earning profits continuously since 1971-72 and paying since 1976-77. 74% of
the total power generated in India is produced by equipment manufactured by BHEL.
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5. TABLE OF CONTENTS
Chapter No. Description of Chapter Page no.
COVER PAGE i
CERTIFICATE ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
CONTENT TABLE v-vi
LIST OF FIGURES vii
LIST OF TABLES viii
ABBREVIATIONS ix
1. INTRODUCTION OF COMPANY 1-9
1.1 INTRODUCTION 1-2
1.2 BHEL HARIDWAR 2-3
1.3 BHEL PRODUCTION TREE 4-6
1.4 DIVISION OF BHEL INTO BLOCKS 8
1.5 MANUFACTURING DIVISIONS 9
2. INTRODUCTION TO CNC 10-11
2.1 ADVANTAGE OF CNC 11
3. CNC SYSTEMS 12-13
3.1 INTRODUCTION 12
3.2 CONTROL SYSTEM 13

6. 3.2.1 OPEN LOOP SYSTEM 13
3.2.2 CLOSE LOOP SYSTEM 13
4. CONFIGURATION OF CNC SYSTEMS 14-16
4.1 INPUT DEVICES 15
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5 MACHINE CONTROL UNIT 17-23
5.1 MACHINE TOOL 17
5.2 DRIVING SYSTEM 18
6. SERVO DRIVE 24-33
7. INTERFACING 34-36
7.1 APPLICATIONS OF CNC MACHINES 36
8 . PLC PROGRAMMING 37-41
9 . PLC OPERATIONS 42-44
10. STRUCTURED PROGRAMMING 45-49
10.1. TIME CONTROL PROGRAM EXECUTIUON 46
10.2. EXAMPLE OF PLC PROGRAM 47-48
10.3. FLOW CHART 49
11. CONCLUSION 50
12. REFRENCES 51

7. (vi)
LIST OF FIGURES
Fig. no. Name of Fig. Page no.
1.1. BHEL MAIN GATE 3
3.1. OPEN LOOP SYSTEM 13
3.2. CLOSE LOOP SYSTEM 13
4.1. CNC MACHINE 14
4.2. SERIAL COMMUNICATION 16
5.1. BALL SCREW 18
5.2. BALL SCREW STRUCTURE 18

8. 5.3. DC SERVO MOTOR 18
5.4. AC SERVO MOTOR 19
5.5. STEPPING MOTOR 20
5.6. TRANSDUCER
5.7. ROTATORY ENCODER 21
5.8. TACHOMETER 23
6.1. CONFIGURATION OF 3100 CNC 25
6.2. OPERATOR CONTROL PANEL 28
6.3. MACHINE PANEL OF 3100 30
8.1. PLC BLOCK DIAGRAM 38
8.2. HARDWARE 40
9.1. PROGRAM CONTROLLER 43
10.1. STRUCTURED USER OROGRAM 46
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LIST OF TABLES
FIG NO. NAME OF TABLE PAGE NO.
1.1 BHEL PRODUCTION TREE 5-6
1.2 PRODUCTION OF BHEL AND THEIR ROUTING 7
10.1 SPINDLE ON 45

9. (viii)

10. ABBREVATIONS
• DPU DATA PROCESSING UNIT
• CLU CONTROL LOOP UNIT
• USB UNIVERSAL DATA BUS
• PLC PROGRAMALE LOGIC CONTROLLER
• ROM READ ONLY MEMORY
• HEEP HEAVY ELECTRICAL EQUIPMENT PLANT
• CEEP CENTRAL FOUNDRY FORGE PLANT
• OHT OVER HEAD TANK
• EMRP ELECTRICAL MACHINES REPAIR PLANT
• ASSCP AMORPHOUS SOLAR CELL PLANT
• CNC COMPUERIESED NUMERICAL CONTROL

11. (ix)

12. CHAPTER 1
INTRODUCTION OF BHEL
1.1.Introduction:-
In 1956, India took a major step towards the establishment of its heavy engineering industry
when Bharat Heavy Electrical Ltd., the first heavy electrical manufacturing unit of the country was
setup at Bhopal. It progressed rapidly and three more factories went into production in 1965. The
main aim of establishing BHEL was to meet the growing power requirement of the country.
B.H.E.L appeared on the power map of India in 1969 when the first unit supplied by it was commissioned
at the Basin Bridge Thermal Power Station in Tamil Nadu. Within a decade, BHEL had
commissioned the 100 unit at Santaldih West Bengal.
BHEL had taken India from a near total dependence on imports to complete self-reliance in this vital area of
power plant equipment BHEL has supplied 97% of the power generating equipment. BHEL has
already supplied generating equipment to various utilities capable of generating over 18000 MW
power. Today BHEL can produce annually; equipment capable of generating 6000MW. This
will grow further to enable BHEL to meet all of India’s projected power equipment requirement. As well as
sizeable portion of export targets.
Probably the most significant aspect of BHEL’s growth has been it’s diversification. The constant
reorientation of the organization to meet the varied needs in time with time a philosophy that has led to the
development of a total capability from concepts to commissioning not only in the field of
energy but also in industry and transportation.
In the world power scene, BHEL ranks among the top ten manufactures of power plant equipment and in terms
of the spectrum of products and services offered, it is right on top. BHEL’s technological excellence and
turnkey capabilities have won it worldwide recognition. Over 40 countries in the world over have
placed orders with BHEL covering individual equipment to complete power stations on a turnkey basis.
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13. In1978-79 export earnings reached Rs. 122 crores, the highest for any one-year. BHEL has its headquarters
at New Delhi.Its operations are spread over 11 manufacturing plants and number of engineering and
service divisions located across the country/ the service divisions includes a network of regional
branch offices throughout India.
BHEL today is the largest Engineering Enterprise of its kind in India with excellent track record of
performance, making profits continuously since 1971-72. BHEL's vision is to become a world-class engineering
enterprise, committed to enhancing stakeholder value. The company is striving to give shape to its aspirations
and fulfill the expectations of the country to become a global player. BHEL business operations cater to core
sectors of Indian Economy.
 Power
 Industry
 Transportation
 Transmission
 Defences
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14. 1.2. BHEL-HARIDWAR
At the foothills of the majestic Himalayas, on the bank of the Holy Ganges in Ranipur, Uttarakhand is located
Heavy electrical equipment plant (HEEP) of B.H.E.L.
BHEL, completely owned by the Government of India is an integrated engineering complex consisting of
several plants of India, where about 70,000 workers are employed in the design and manufacturing of heavy
electrical equipment.
At present, 70 % of country’s electrical equipment is generated at BHEL Haridwar. BHEL is the largest
engineering and manufacturing enterprise in India in the energy-related / infrastructure sector, today.
BHEL is ushering in the indigenous Heavy Electrical Equipment industry in India-a dream that has
been more than realized with a well-recognized track record of Performance.
Fig1.1 BHEL HARIDWAR MAIN GATE
A widespread network comprising of 14 manufacturing companies, which have international
recognition for its commitment towards quality. With an export presence in more than 60 countries,
BHEL is truly India’s ambassador to the world. BHEL’s vision is to become world class engineering
enterprise, committed to enhancing stakeholder value.
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15. The greatest strength of BHEL is its highly skilled and committed 50,000 employees. Every employee is given
an equal opportunity to develop himself and grow in his career. Continuous training and retraining, career
planning, a positive work culture and participative style of management all these have engendered development
of a committed and motivated workforce setting new benchmarks in terms of productivity, quality and
responsiveness. At Haridwar, against the picturesque background of Shivalik Hills, 2 important manufacturing
units of BHEL are located viz. Heavy Electrical Equipment Plant (HEEP) & Central Foundry Forge Plant
(CFFP). The hum of the construction machinery working started under Shivalik Hills during early 60s and
sowed the seeds of one of the greatest symbol of Indo Soviet Collaboration – Heavy Electrical Equipment Plant.
Consequent upon the technical collaboration between India and USSR in 1959, BHEL’s prestigious unit, Heavy
Electrical Equipment plant (HEEP), was established in October, 1963, at Hardwar. It started manufacturing
thermal sets in 1967 and now thermal sets of 210, 250 and 500 MW, including steam turbines, turbo-generators,
condensers and all associated equipments, are being manufactured. This unit is capable of manufacturing
thermal sets up to 1000 MW. HEEP-manufactured gas turbines, hydro turbines and generators, etc., are not only
successfully generating electrical energy within and outside the country, but have also achieved a historic record
of the best operational availability.
POWER & WATER SUPPLY SYSTEM:
- 40 MVA sanctioned Electric Power connection from Grid (132 KV / 11KV / 6.6 KV) (Connected load –
around 185 MVA)
- 26 deep submersible Tube Wells with O.H. Tanks for water supply.
- A 12 MW captive thermal power station is located in the factory premises.
MAIN PRODUCTS:
- Steam Turbines
- Gas Turbines
- Turbo Generators
- Heat Exchangers
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16. 1.3.BHEL- Haridwar Organization/Production Tree
BHEL – Haridwar is divided into various sections/blocks for effective organization and management. Each
block manufactures a specific set of machinery and equipments which are described as below :
TABLE 1.1
Sr. No. Block Major Facilities Products
1. Block –I (Electrical
Machines)
Machine Shop,
Stator Winding
[THRI & LSTG],
Rotor Winding [THRI
& LSTG], Core
Assembly, Exciter
Section, over speed
balancing, Test Bed,
babbiting, Micalastic
impregnation [LSTG
& THRI]
Turbo Generator,
Brushless Exciters
2. Block – II
(Fabrication Block)
Stator Frame[THRI
& LSTG], Markings,
welding ,Cutting,
straightening, gas
cutting press, ,
grinding, assembly,
heat treatment,
cleaning & Shot
blasting, machining,
fabrication of pipe
coolers, painting
Large size fabricated
assemblies/
components for
power equipments
3. Block –III (Turbines
& Auxiliary Block)
Machining, facing
wax melting,
broaching, assembly
preservation &
packing, test stands/
station, painting
grinding, milling,
polishing etc.
Stem turbines, hydro
turbines, gas
turbines, turbine
bladders, special
tooling.
4. Block –IV (Feeder
Block)
1. ACM
Rotor Bar
Manufacturing [THRI
& LSTG]
Rotor Bars [Field
Bars]
2.CSM Stator bar
manufacturing
Stator bars and
exciter bars
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17. 5. Block – V Fabrication,
pneumatic hammer
for forgings, gas
fired furnaces,
hydraulic
manipulators
Fabricated parts of
steam turbine, water
box, storage tank
hydro turbine parts,
hydro turbines
assemblers &
Components
6. Block – VI
(Fabrication)
Welding, drilling,
shot blasting, CNC
flame cutting ,CNC
deep drilling, Shot
basting, sheet metal
work, assembly
Fabricated parts of
steam turbine water
box, stronger tanks,
hydro turbine parts,
Hydro turbines
assemblies &
components,
7. Block- VI (Stamping
& Die
Manufacturing)
Machining, turning,
grinding, jig boring
stamping presses,
de varnishing,
degreasing & de
rusting, varnishing
sport welding,
painting.
Wooden packing,
spacers etc.
8. Block- VII (wood
working)
Wood Cutting,
machines, grinding ,
packing
Wooden packing,
spacers etc.
9. Block – VIII Drilling ,turning,
saw, cutting,
welding, tig welding
LP Heater ejectors
glad, steam cooler
oil coolers, ACG
collers, oil tanks,
bearing covers.
BHEL has:-
Installed equipment for over 90,000MW of power generation for Utilities, captive and
Industrial users.
Supplied over 25000 Motors with Drive Control System to power projects, Petrochemicals Refineries,
Steel, Aluminum, Fertilizer, Cement plant, etc.
Supplied Traction electrics and AC/DC locos over 12000 kms Railway network.
Supplied over one million Values to Power Plants and other Industries
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18. RATINGS PRODUCTS OF BHEL HARIDWAR AND THEIR CAPACITY
TABLE 1.2
1
.
Thermal/nuclear set 210MW-1000MW
2
.
Hydro set 115MW
3
.
Generator according to requirement
4
.
gas turbine 60MW-200MW
5
.
heat exchangers, condensers Upto 800MW
6
.
AC/DC electrical machine 5kW-2000kW
(a)AC (250 kW-1600kW )
(b)DC (7kW-1000kW)
BHEL has turnkey capabalities for executing power projectors from concept to commissioning. it possesses the
technology and capability to produce thermal power plant equipment upto 1000MW rating and gas turbine generator
sets upto a unit rating of 240MW.Cogeration and combine cycle plants have been introduced to achieve higher plant
efficiencies. To make efficient use of the higher ash content crash coil manufacturers 235MW nuclear turbine
generator sets and has commenced the generation of 500 MW nuclear turbine generator head discharge
combinations are also engineered and manufactured is equally competitive.
1.4.BHEL is divided into many blocks:
1).Block-1:-In block one turbo generator, generator, exciter motors (A.C&D.C) are manufactured &
assembled
2). Block-2:-In block two large size fabricated assembliescomponent for power equipment are manufactured &
assembled.
3) Block-3:-In block -3 steam turbine, hydro turbines, and gas turbines, turbines blade are manufactured
& assembled.
4) Block-4:-In block -4winding for turbo generator, hydro generator, insulation of A.C&D.C motors
insulating component for turbo generator, hydro generator motors are manufactured & assembled.

19. (7)
5) Block-5:-In block -5 fabricated parts of steam turbine water box, hydro turbine turbines
parts are manufactured & assembled.
6) Block-6:-In block -6 fabricated oil tanks hollow guide blades, rings, stator frames rotor spiders are
manufactured & assembled.
7) Block-7:-In block -7 all types of dies including stamping dies, stamping for generators
&motors are manufactured & assembled.
8) Block-8:-In block-8 LP heaters, ejectors, steam coolers, oil coolers, ACG coolers, oil tanks are manufactured
& assembled.
1.5.MANUFACTURING DIVISIONS
Heavy Electrical Plant, Piplani, Bhopal
Electrical Machines Repair Plant (EMRP), Mumbai
Transformer Plant P.O. BHEL, Jhansi.
Bharat Heavy Electrical Limited : Central Foundry Forge Plant., Ranipur, Hardwar
Heavy Equipment Repair Plant, Varanasi.
Insulator Plant, Jagdishpur, Distt. Sultanpur.
Heavy Power Equipment Plant, Ramachandra Puram, Hyderabad
High PressureBoiler Plant & Seamless Steel Tube Plant, Tiruchirappalli.
Boiler Auxiliaries Plant, Indira Gandhi Industrial Complex, Ranipet.
Industrial Valves Plant, Goindwal.
Electronics Division :
 Electronics Systems Division.
Amorphous Silicon Solar Cell Plant (ASSCP).
Electro porcelains Division.
BANGALORE
Component Fabrication Plant, Rudrapur.
Piping Centre, Chennai.
Heavy Electrical Equipment Plant,
Regional Operations Division, New Delhi

20. (8)
1.5.1.TRANSMISSION-
BHEL also supplies a wide range of transmission products and systems upto 400kV class. These include high
voltage power, distribution transformers, instrument transformers, dry type transformer,SF6 switch gear,
capacitor and insulator,etc.Series and shunt compensation systems have been also developed and introduced to
minimize transmission losses.
1.5.2.TRANSPORTATION-
A high percentage of trains operated by the Indian Railways are equipped with BHEL’s traction and control
equipment including the metro at Calcutta and Delhi.the company supplies broad gauge.
Electrical locomotive to Indian Railway and diesel shunting locomotives to various industries 5000/6000 hp
AC/DC locomotive developed and manufactured by B.H.E.L. have been leased to Indian Railway, battery
powered road.
1.5.3.INTERNATIONAL OPERATIONS-
B.H.E.L.’s product series and projects have been exported to countries ranging from United states in the west
and New Zealand in the east and for India over 3000MW.a few notable ones are a 15o MW gas turbine to
Germany ,utility boiler and open cycle gas turbine plant to Malaysia, Tripoli west, power station in Libya and
Turkey .in Cyprus, hydro generator to New Zealand and hydro power plant to Thailand, Oman, Greece and
Egypt.

21. (9)

22. CHAPTER 2
INTRODUCTION TO CNC
Numerical control for machines .tools were introduced in 1950’s by Prof.John T Parsons. The first NC machine
was built at the Massachusetts institute of Technology in 1953 by joint efforts of US Air Force, the MIT and
parson’s cooperation. NC is control by numbers .NC is control recorded information called part program, which
is set of coded instructions given as numbers for automatic control of am machine in a pre-determined
sequence.
Numerical control can be defined as a technique of controlling a machine tool by the direct insertion of
numerical data at some point of the system .The functions that are controlled on the machine tool are
displacement of the slide members, spindle speeds ,tool selection etc.At first ,the numerical control was used to
produce geocentrically complex parts ,but later used for added efficiency in medium batch production of turned
and milled parts presently, Numerical control is employed in all sectors of production .
Rapid development in the field of electronics such as integrated circuit, large scale integrated circuits and
development of minicomputer lead to the development of minicomputers based CNC systems. Further
development and the electronic “chip” revolution have ushered in the current generation “compact and
powerful” Microprocessor based CNC systems.
Development of computer numerically controlled (CNC) machines is an outstanding contribution to the
manufacturing industries. It has made possible the automation of the machining process with flexibility to
handle small to medium batch of quantities in part production.
Initially, the CNC technology was applied on basic metal cutting machine like lathes, milling machines, etc.
Later, to increase the flexibility of the machines in handling a variety of components and to finish them in a
single setup on the same machine, CNC machines capable of performing multiple operations were developed.
To start with, this concept was applied to develop a CNC machining centre for machining prismatic components
combining operations like milling, drilling, boring and taping. Further, the concept of multi-operations was also
extended for machining cylindrical components, which led to the development of turning centers.
Computer Numerical Control (CNC) is a specialized and versatile form of Soft Automation and its
applications cover many kinds, although it was initially developed to control the motion and operation of
machine tools.
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23. Computer Numerical Control may be considered to be a means of operating a machine through the use of
discrete numerical values fed into the machine, where the required 'input' technical information is stored on a
kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc.
The machine follows a predetermined sequence of machining operations at the predetermined speeds
necessary to produce a workpiece of the right shape and size and thus according to completely predictable
results. A different product can be produced through reprogramming and a low-quantity production run of
different products is justified.
2.1.ADVANTAGE OF CNC MACHINES
 Higher flexibility
 Increased productivity
 Consistent quality
 Reduced scrap rate
 Reliable operation
 Reduced non productive time
 Reduced manpower
 Shorter cycle time
 High accuracy
 Reduced lead time
 Just in time (JIT) manufacture
 Automatic material handling
 Lesser floor space
 Increased operation safety
 Machining of advanced material
The definition of CNC given by Electronic Industry Association (EIA) is as follows:
“A system in which actions are controlled by the direct insertion of numerical data at some point.
The system must automatically interpret at least some portion of this data.”
In a simple word, a CNC system receives numerical data, interpret the data and then control the action
accordingly.

24. (11)
CHAPTER 3
CNC SYSTEMS
3.1.INTRODUCTION
Numerical control (NC) is a method employed for controlling the motions of a machine tool slide and its
auxiliary functions with input in the form of numerical data. A computer numerical control (CNC) is a
microprocessor-based system to store and process the data for the control of slide motions and auxiliary
functions of the machine tools. The CNC system is the heart and brain of a CNC machine which enables the
operation of various machine members such as slides, spindles, etc. as per the sequence programmed into it,
depending on the machining operations.
The main advantage of a CNC system lies in the fact that the skills of the operator hitherto required in the
operation of a conventional machine is removed and the part production is made automatic.
The CNC systems are constructed with a NC unit integrated with a programmable logic controller (PLC) and
some times with an additional external PLC (non-integrated). The NC controls the spindle movement and the
speeds and feeds in machining. It calculates the traversing path of the axes as defined by the inputs. The PLC
controls the peripheral actuating elements of the machine such as solenoids, relay coils, etc. Working together,
the NC and PLC enable the machine tool to operate automatically. Positioning and part accuracy depend on the
CNC system's computer control algorithms, the system resolution and the basic mechanical machine accuracy.
Control algorithm may cause errors while computing, which will reflect during contouring, but they are very
negligible. Though this does not cause point to point positioning error, but when mechanical machine
inaccuracy is present, it will result in poorer part accuracy.
Computer Numerical Control (CNC) is a specialized and versatile form of Soft Automation and its
applications cover many kinds, although it was initially developed to control the motion and operation of
machine tools.
Computer Numerical Control may be considered to be a means of operating a machine through the use of
discrete numerical values fed into the machine, where the required 'input' technical information is stored on a
kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The
machine follows a predetermined sequence of machining operations at the predetermined speeds
necessary to produce a work piece of the right shape and size and thus according to completely predictable
results. A different product can be produced through reprogramming and a low-quantity production run of
different products is justified.

25. (12)
3.2.Control Systems
3.2.1. Open Loop Systems :
Open loop systems have no access to the real time data about the performance of the system and therefore no
immediate corrective action can be taken in case of system disturbance. This system is normally applied only to
the case where the output is almost constant and predictable. Therefore, an open loop system is unlikely
to be used to control machine tools since the cutting force and loading of a machine tool is never a constant. The
only exception is the wirecut machine for which some machine tool builders still prefer to use an open loop
system because there is virtually no cutting force in wirecut machining.
FIG 3.1Block Diagram of an Open Loop System
3.2.2.Close Loop Systems:
In a close loop system, feedback devices closely monitor the output and any disturbance will be corrected in the
first instance. Therefore high system accuracy is achievable. This system is more powerful than the open loop
system and can be applied to the case where the output is subjected to frequent change. Nowadays, almost all
CNC machines use this control system.
FIG 3.2 Block Diagram of a Close Loop System

26. (13)
CHAPTER 4
CONFIGURATION OF THE CNC SYSTEM
Fig.1 shows a schematic diagram of the working principle of a NC axis of a CNC machine and the interface of a
CNC control.
CNC system
Fig.4.1. Schematic diagram of a CNC machine tool
A CNC system consists of the following 6 major elements:
a. Input Device
b. Machine Control Unit
c. Machine Tool
d. Driving System
e. Feedback Devices
f. Display Unit
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NC
PL
C
Servo Drive Servo Motor
Spindle Head
Work piece
Table
Encoder
Position Feedback
Tacho
GeneratorVelocity
Feedback
Tape Reader
Tape Punch
Other Devices
Machine
Elements
Inputs
Outputs
Lead
Screw
Command
value
• Proximity switches
• Limit switches
• Relay coils
• Pressure switches
• Float switches

27. 4.1.Input Devices
a. Floppy Disk Drive
Floppy disk is a small magnetic storage device for CNC data input. It has been the most
common storage media up to the 1970s, in terms of data transfer speed, reliability, storage
size, data handling and the ability to read and write. Furthermore, the data within a
floppy could be easily edited at any point as long as you have the proper program to read it.
However,this method has proven to be quite problematic in the long run as floppies have
a tendency to degrade alarmingly fast and are sensitive to large magnetic fields and as well
as the dust and scratches that usually existed on the shop floor.
b. USB Flash Drive
A USB flash drive is a removable and rewritable portable hard drive with compact
size and bigger storage size than a floppy disk. Data stored inside the flash drive are
impervious to dust and scratches that enable flash drives to transfer data from
place to place. In recent years, all computers support USB flash drives to read and
write data that make it become more and more popular in CNC machine control
unit.
c. Serial communication
The data transfer between a computer and a CNC machine tool is often accomplished
through a serial communication port. International standards for serial communications are
established so that information can be exchanged in an orderly way. The most common
interface between computers and CNC machine tools is referred to the EIA Standard RS-232.
Most of the personal computers and CNC machine tools have built in RS232 port and a
standard RS-232 cable is used to connect a CNC machine to a computer which enables the
data transfer in reliable way. Part programs can be downloaded into the memory of a
machine tool or uploaded to the computer for temporary storage by running a
communication program on the computer and setting up the machine control to interact with the
communication software.

28. (15)
Direct Numerical Control is referred to a system connecting a set of numerically
controlled machines to a common memory for part program or machine program
storage with provision for on-demand distribution of data to the machines. (ISO
2806:1980) The NC part program is downloaded a block or a section at a time into the
controller. Once the downloaded section is executed, the section will be discarded to
leave room for other sections. This method is commonly used for machine tools that do not
have enough memory or storage buffer for large NC part programs.
Distributed Numerical Control is a hierarchical system for distributing data between a
production management computer and NC systems. (ISO 2806:1994) The host computer is
linked with a number of CNC machines or computers connecting to the CNC
machines for downloading part programs. The communication program in the host
computer can utilize two-way data transfer features for production data communication
including: production schedule, parts produced and machine utilization etc.
FIG 4.2. Serial communication in a Distributed Numerical Control system

29. (16)
CHAPTER 5
MACHINE CONTROL UNIT
Machine Control Unit (MCU)
The machine control unit is the heart of the CNC system. There are two sub-units in the machine control unit:
the Data Processing Unit (DPU) and the Control Loop Unit (CLU).
a. Data Processing Unit
On receiving a part programme, the DPU firstly interprets and encodes the part programme into internal
machine codes. The interpolator of the DPU then calculate the intermediate positions of the motion in terms
of BLU (basic length unit) which is the smallest unit length that can be handled by the controller. The calculated
data are passed to CLU for further action.
b. Control Loop Unit
The data from the DPU are converted into electrical signals in the CLU to control the driving system to
perform the required motions. Other functions such as machine spindle ON/OFF, coolant ON/OFF, tool
clamp ON/OFF are also controlled by this unit according to the internal machine codes.
5.1.Machine Tool
This can be any type of machine tool or equipment. In order to obtain high accuracy and repeatability, the
design and make of the machine slide and the driving lead screw of a CNC machine is of vital importance. The
slides are usually machined to high accuracy and coated with anti-friction material such as PTFE and Turcite in
order to reduce the stick and slip phenomenon. Large diameter recirculating ball screws are employed to
eliminate the backlash and lost motion. Other design features such as rigid and heavy machine structure; short
machine table overhang, quick change tooling system, etc also contribute to the high accuracy and high
repeatability of CNC machines.

30. (17)
FIG 5.1. Ball Screw in a CNC machine FIG 5.2Ball screw structure
5.2.Driving System
The driving system is an important component of a CNC machine as the accuracy and repeatability depend very
much on the characteristics and performance of the driving system. The requirement is that the driving system
has to response accurately according to the programmed instructions. This system usually uses electric motors
although hydraulic motors are sometimes used for large machine tools. The motor is coupled either directly or
through a gear box to the machine lead screw to moves the machine slide or the spindle. Three types of
electrical motors are commonly used.
a. DC Servo Motor
This is the most common type of feed motors used in CNC machines. The principle of operation is based on the
rotation of an armature winding in a permanently energized magnetic field. The armature winding is
connected to a commutator, which is a cylinder of insulated copper segments mounted on the shaft. DC current
is passed to the commutator through carbon brushes, which are connected to the
machine terminals.

31. (18)
The change of the motor speed is by varying the armature voltage and the control of motor torque is
achieved by controlling the motor's armature current. In order to achieve the necessary dynamic behaviour it
is operated in a closed loop system equipped with sensors to obtain the velocity and position feedback signals.
FIG 5.3 DC Servo Motor
b. AC Servo Motor
In an AC servomotor, the rotor is a permanent magnet while the stator is equipped with 3-phase
windings. The speed of the rotor is equal to the rotational frequency of the magnetic field of the stator, which is
regulated by the frequency converter. AC motors are gradually replacing DC servomotors.

32. (19)
The main reason is that there is no commutator or brushes in AC servomotor so that maintenance is virtually not
required. Furthermore, AC servos have a smaller power-to-weight ratio and faster response.
FIG 5.4 AC Servo Motor
c. Stepping Motor
A stepping motor is a device that converts the electrical pulses into discrete mechanical rotational
motions of the motor shaft. This is the simplest device that can be applied to CNC machines since it can
convert digital data into actual mechanical displacement. It is not necessary to have any analog-to-
digital converter nor feedback device for the control system. They are ideally suited to open loop systems.
However, stepping motors are not commonly used in machine tools due to the following drawbacks: slow
speed, low torque, low resolution and easy to slip in case of overload. Examples of stepping motor application
are the magnetic head of floppy-disc drive and hard disc drive of computer, daisy-wheel type printer, X-Y tape
control, and CNC EDM Wire-cut machine.

33. (20)
FIG 5.5 Stepping Motor
Feedback Device
In order to have a CNC machine operating accurately, the positional values and speed of the axes need to be
constantly updated. Two types of feedback devices are normally used positional feedback device and velocity
feedback device.
a. Positional Feed Back Devices
There are two types of positional feedback devices: linear transducer for direct positional measurement and
rotary encoder for angular or indirect linear measurement.
Linear Transducers –
A linear transducer is a device mounted on the machine table to measure the actual displacement of the
slide in such a way that backlash of screws; motors, etc would not cause any error in the feedback data. This
device is considered to be of the highest accuracy and also more expensive in comparison with other measuring
devices mounted on screws or motors.
FIF 5.6 Linear Transducer

34. (21)
Rotary Encoders –
A rotary encoder is a device mounted at the end of the motor shaft or screw to measure the angular
displacement.
This device cannot measure linear displacement directly so that error may occur due to the backlash of screw
and motor etc. Generally, this error can be compensated for by the machine builder in the machine
calibration process.
FIG 5.7 Incremental and Absolute Rotary Encoder
b. Velocity Feedback Device
The actual speed of the motor can be measured in terms of voltage generated from a tachometer mounted at the
end of the motor shaft.DC tachometer is essentially a small generator that produces an output voltage
proportional to the speed. The voltage generated is compared with the command voltage corresponding to the
desired speed.
(22)

35. The difference of the voltages can is then used to actuate the motor to eliminate the error.
FIG 5.8 Tachogenerator
Display Unit
The Display Unit serves as an interactive device between the machine and the operator. When the machine is
running, the Display Unit displays the present status such as the position of the machine slide, the spindle
RPM, the feed rate, the part programmes, etc. In an advanced CNC machine, the Display Unit can show the
graphics simulation of the tool path so that part programmes can be verified before the actually
machining. Much other important information about the CNC system can also displayed for maintenance and
installation work such as machine parameters, logic diagram of the programmer controller, error massages and
diagnostic data.

36. (23)
CHAPTER 6
SERVO DRIVE
A servo drive consists of a servo amplifier and a servo motor. The main task of a servo amplifier (also called
amplifier, servo controller, or just controller) is the control of the motor current. In addition, ESR servo
amplifiers offer a broad spectrum of functionality
While most of the electrical drives are operated at constant speed, a servo drive has a rather "hectic" life. Often
it has to accelerate to the rated speed within a few milliseconds only to decelerate a short time later just as
quick. And of course the target position is to be reached exactly with an error of a few hundredths of a milli
-meter.
Compared to other controlled drives servo drives have the advantage of high dynamics and accuracy, full stall
torque, and compact motors with high power density.
Servo drives are used where high dynamics (i. e. fast acceleration and deceleration) and good accuracy at
reaching target positions are important. The good control behaviour allows the optimal adaptation to the
application (e. g. positioning without overshoot). But also the smooth run (due to sinusoidal commutation) and
the possibility of exact synchronisation of two or more drives open a wide field. Because of their wide speed
range servo drives can be used in a huge number of applications.
Servo drives run in large, highly automated installations with several dozens of axes as well as in machines with
only a few axes which perhaps operate independently.
Servo motor
Servo motors are electric motors that are designed specially for high dynamics. Servo motors by ESR
distinguish themselves by a compact design with high power density and a high degree of protection (up to IP
65). They come as AC servo motors (brush less) or DC servo motors (with brushes for the commutation). The
high power density is achieved by permanent magnets made of neodymium-iron-boron (NdFeB), samarium-
cobalt (SmCo), or ferrite material. The servo motor is equipped with a position sensor which provides the
controller with position and speed information.
As a standard, the AC servo motors are equipped with resolvers. In combination with the digital servo
amplifiers sincos encoders (absolute encoder, single-turn or multi-turn) and high-resolution incremental
encoders may be used as well, in case higher accuracy or dynamics is required.

37. (24)
The DC servo motors can be equipped with tacho generators and/or incremental encoders. For dimensioning
the motor the following data are important: the mass of the parts to be moved, the cycle time of the application,
and the friction torque. With these data the rated and peak torque (maximum acceleration or deceleration) and
the rated speed can be calculated. If required, gears are used to match the moment of inertia of the motor to the
moment of inertia of the application.
Servo amplifier
The servo amplifier (also called amplifier, servo controller, or just controller) controls the current of the motor
phases in order to supply the servo motor with exactly the current required for the desired torque and the desired
speed. The essential parts of a servo amplifier are the power section and the control loops.
The power section consists of a mains rectifier, a DC-bus, and a power circuit which supplies the individual
motor phases with current.
The control loops (analogue or digital) drive the power circuit and by constantly comparing setpoint with actual
values ensure that the motor keeps exactly to the desired motions even under varying load.

38. (25)
SYSTEM 3
SINUMERIK SIEMENS
Z -
X -
Z+
X+
POWER
ON
Emergency Stop
Cycle
Fig.6.1 Typical numerical control configuration of Hinumerik 3100 CNC system
Tape Puncher Tape Reader
Power
Supply NC PLC1
Logic Unit
Machine
Control
Panel
Expansion
Machine
Control
Panel
LSM2
LSM1
PLC 2, external
LSM-
Logic Sub
module

39.  Operator Control Panel
Fig.4 shows a typical Hinumerik 3100 CNC system's operator control panel. The operator control panel
provides the user interface to facilitate a two-way communication between the user, CNC system and the
machine tool. This consists of two parts:
• Video Display Unit (VDU)
• Keyboard
Video Display Unit (VDU)
The VDU displays the status of the various parameters of the CNC system and the machine tool. It displays all
current information such as:
• Complete information of the block currently being executed
• Actual position value, set or actual difference, current feed rate, spindle speed
• Active G functions
• Main program number, subroutine number
• Display of all entered data, user programs, user data, machine data, etc.
• Alarm messages in plain text
• Soft key designations
In addition to a CRT, a few LEDs are generally provided to indicate important operating modes and status.
Video display units may be of two types:
1. Monochrome or black and white displays
2. Color displays

40. (27)
Operator's and machine panel
SYSTEM 3
SINUMERIK SIEMENS
Z -
X -
Z+
X+
POWER
ON
Emergency Stop
Cycle
Control elements and indicators of the operator's panel
Program in progress
Feed hold
Position not yet reached
(Machine in motion)
Alarm
Basic display
Tool compensation
Zero offset
Test
Part program
CRT
LED-indicator
For assignment
Of keys
Change to actual
value display
Change of display
Leaf forwards
Leaf backwards
Right-Left Cursor
Reset changeover
Assignment of keys
Cancel word
Alter word
Enter word
Change over to
customer display
Operator guidance
Yes,No
Delete input
Start
Fig.6.2 Operator control panel of Hinumerik 3100 system
Address
Keys/Numerical
keyboard

41. Keyboard
A keyboard is provided for the following purposes:
• Editing of part programs, tool data, and machine parameters.
• Selection of different pages for viewing.
• Selection of operating modes, e.g. manual data input.
• Selection of feed rate override and spindles speed override.
• Execution of part programs.
• Execution of other toll functions.
 Machine Control Panel (MCP)
It is the direct interface between operator and the NC system, enabling the operation of the machine through the
CNC system. Fig.5 shows the MCP of Hinumerik 3100 system.
During program execution, the CNC controls the axis motion, spindle function or tool function on a machine
tool, depending upon the part program stored in the memory. Prior to the starting of the machine process,
machine should first be prepared with some specific tasks like,
• Establishing a correct reference point
• Loading the system memory with the required part program
• Loading and checking of tool offsets, zero offsets, etc.
For these tasks, the system must be operated in specific operating mode so that these preparatory functions can
be established.

42. (29)
Control elements of the machine control panel
Modes of operation
Generally, the CNC system can be operated in the following modes:
• Manual mode
• Manual data input (MDI) mode
• Automatic mode
• Reference mode
• Input mode
• Output mode, etc.
Z -
X -
Z+
X+
POWER
ON
Emergency Stop
Cycle
Mode selector
Switch
Spindle speed
override
Feedrate/rapid traverse
override
Rapid traverse activate
Direction keys
Spindle
OFF ON
Feed
Hold/Start
Cycle start
NC ON Key operated
switch for input
inhibit
Block search
Single
block
Dry RunBlock
Delete
Rapid Traverse
Override active
Manual encoder active
in
X-and Z-axis resp.
Fig.6.3 Machine control panel of Hinumerik 3100
system

43. (30)
Manual mode:
In this mode, movement of a machine slide can carried out manually by pressing the particular jog button (+
or -). The slide (axis) is selected through an axis selector switch or through individual switches (e.g., X+, X-,
Y+, Y-, Z+, Z-, etc.). The feed rate of the slide movement is prefixed. CNC system allows the axis to be jogged
at high feed rate also. The axis movement can also be achieved manually using a hand wheel interface instead
of jog buttons. In this mode slides can be moved in two ways:
• Continuous
• Incremental
Continuous mode: In This mode, the slide will move as long as the jog button is pressed.
Incremental mode: Hence the slide will move through a fixed distance, which is selectable. Normally, system
allows jogging of axes in 1, 10, 100, 1000, 10000, increments. Axis movement is at a prefixed feed rate. It is
initiated by pressing the proper jog+ or jog- key and will be limited to the no of increments selected even if the
jog button is continuously pressed. For subsequent movement the jog button has to be released and once again
pressed.
Manual Data Input (MDI) Mode
In this mode the following operation can be performed:
• Building a new part program
• Editing or deleting of part program stored in the system memory
• Entering or editing or deleting of:
------ Tool offsets (TO)
------ Zero offsets (ZO)
------ Test data, etc.

44. (31)
Teach-in
Some system allows direct manual input of a program block and execution of the same. The blocks thus
executed can be checked for correctness of dimensions and consequently transferred into the program memory
as part program.
Playback
In setting up modes like jog or incremental, the axis can be traversed either through the direction keys or via the
hand wheel, and the end position can be transferred into the system memory as command values. But the
required feed rates, switching functions and other auxiliary functions have to be added to the part program in
program editing mode.
Thus, teach-in and playback operating method allows a program to created during the first component prove
out.
Automatic Mode (Auto and Single Block)
In this mode the system allows the execution of a part program continuously. The part program is executed
block by block. While one block is being executed, the next block is read by the system, analyzed and kept
ready for execution. Execution of the program can be one block after another automatically or the system will
execute a block, stop the execution of the next block till it is initiated to do so (by pressing the start button).
Selection of part program execution continuously (Auto) or one block at a time (Single Block) is done through
the machine control panel.
Many systems allow blocks (single or multiple) to be retraced in the opposite direction. Block retrace is allowed
only when a cycle stop state is established. Part program execution can resume and its execution begins with the
retraced block. This is useful for tool inspection or in case of tool breakage. Program start can be effected at any
block in the program, through the BLOCK SEARCH facility.

45. (32)
Reference Mode
Under this mode the machine can be referenced to its home position so that all the compensations (e.g., pitch
error compensation) can be properly applied. Part programs are generally prepared in absolute mode with
respect to machine zero. Many CNC systems make it compulsory to reference the slides of the machine to their
home positions before a program is executed while others make it optional.
Input Mode and Output Mode (I/O Mode)
In this mode, the part programs, machine setup data, tool offsets, etc. can be loaded/unloaded into/from the
memory of the system from external devices like programming units, magnetic cassettes or floppy discs, etc.
During data input, some systems check for simple errors (like parity, tape format, block length, unknown
characters, program already present in the memory, etc.). Transfer of data is done through a RS232C or
RS422C port.
 Other Peripherals
These include sensor interface, provision for communication equipment, programming units, printer, tape
reader/puncher interface, etc.

46. (33)
CHAPTER 7
INTERFACING
Interconnecting the individual elements of both the machine and the CNC system using cables and connectors is
called interfacing.
Extreme care should be taken during interfacing. Proper grounding in electrical installation is most essential.
This reduces the effects of interference and guards against electronic shock to personnel. It is also essential to
properly protect the electronic equipment.
Cable wires of sufficiently large cross-sectional area must be used. Even though proper grounding reduces the
effect of electrical interference, signal cable requires additional protection. This is generally achieved by using
shielded cables. All the cable shields must be grounded at control only, leaving other end free. Other noise
reduction techniques include using suppression devices, proper cable separation, ferrous metal wire ways, etc.
Electrical enclosures should be designed to provide proper ambient conditions for the controller.
MONITORING
In addition to the care taken by the machine tool builder during design and interfacing, basic control also
includes constantly active monitoring functions. This is in order to identify faults in the NC, the interface
control and the machine at an large stage to prevent damages occurring to the work piece, tool or machine. If a
fault occurs, first the machining sequence is interrupted, the drives are stopped, the cause of the fault is stored
and then displayed as an alarm. At the same time, the PLC is informed that an NC alarm exits. In Hinumerik
CNC system, for example, the following can be monitored:
• Read-in
• Format
• Measuring circuit cables
• Position encoders and drives
• Contour
• Spindle speed
• Enable signals
• Voltage
• Temperature
• Microprocessors

47. • Data transfer between operator control panel and logic unit
• Transfer between NC and PLC
• Change of status of buffer battery
• System program memory
• User program memory
• Serial interfaces
DIAGNOSTICS
The control will generally be provided with test assistance for service purposes in order to display some status
on the CRT such as:
• Interface signals between NC and PLC as well as between PLC and machine
• Flags of the PLC
• Timers of the PLC
• Counters of the PLC
• Input/output of the PLC
For the output signals, it is also possible to set and generate signal combinations for test purposes in order to
observe how the machine react to a changed signal. This simplifies trouble shooting considerably.
MACHINE DATA
Generally, a CNC system is designed as a general-purpose control unit, which has to be matched with the
particular machine to which the system is interfaced. The CNC is interfaced to the machine by means of data,
which is machine specific. The NC and PLC machine data can be entered and changed by means of external
equipment or manually by the keyboard. These data are fixed and entered during commissioning of the machine
and generally left unaltered during machine operations.
Machine data entered is usually relevant to the axis travel limits, feed rates, rapid traverse speeds and spindle
speeds, position control multiplication factor, Kv factor, acceleration, drift compensation, adjustment of
reference point, backlash compensation, pitch error compensation, etc. Also the optional features of the control
system are made available to the machine tool builder by enabling some of the bits of machine data.

48. (35)
7.1. Applications of CNC Machines
CNC machines are widely used in the metal cutting industry and are best used to produce
the following types of product:
• Parts with complicated contours
• Parts requiring close tolerance and/or good repeatability
• Parts requiring expensive jigs and fixtures if produced on conventional
machines
• Parts that may have several engineering changes, such as during
the development stage of a prototype
• In cases where human errors could be extremely costly
• Parts that are needed in a hurry
• Small batch lots or short production runs
Some common types of CNC machines and instruments used in industry are as
following:
• Drilling Machine
• Lathe / Turning Centre
• Milling / Machining Centre
• Turret Press and Punching Machine
• Wirecut Electro Discharge Machine (EDM)
• Grinding Machine
• Laser Cutting Machine
• Water Jet Cutting Machine
• Electro Discharge Machine

49. • Coordinate Measuring Machine
• Industrial Robot
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CHAPTER 8
PLC PROGRAMMING
Programmable Logic Controller (PLC)
A PLC matches the NC to the machine. PLCs were basically introduced as replacement for hard wired relay
control panels. They were developed to be reprogrammed without hardware changes when requirements were
altered and thus are reusable. PLCs are now available with increased functions, more memory and large
input/output capabilities. Fig.7 gives the generalized PLC block diagram.
In the CPU, all the decisions are made relative to controlling a machine or a process. The CPU receives input
data, performs logical decisions based upon stored programs and drives the outputs. Connections to a computer
for hierarchical control are done via the CPU.
The I/O structure of the PLCs is one of their major strengths. The inputs can be push buttons, limit switches,
relay contacts, analog sensor, selector switches, proximity switches, float switches, etc. The outputs can be
motor starters, solenoid valves, position valves, relay coils, indicator lights, LED displays, etc.
The field devices are typically selected, supplied and installed by the machine tool builder or the end user. The
voltage level of the field devices thus normally determines the type of I/O. So, power to actuate these devices
must also be supplied external to the PLC. The PLC power supply is designated and rated only to operate the
internal portions of the I/O structures, and not the field devices. A wide variety of voltages, current capacities
and types of I/O modules are available.
The principle of operation of a PLC is determined essentially by the PLC program memory, processor, inputs
and outputs.
The program that determines PLC operation is stored in the internal PLC program memory. The PLC operates
cyclically, i.e. when a complete program has been scanned, it starts again at the beginning of the program. At
the beginning of each cycle, the processor examines the signal status at all inputs as well as the external timers
and counters and are stored in a process image input (PII). During subsequent program scanning, the processor
the accesses this process image.

50. (37)
To execute the program, the processor fetches one statement after another from the programming memory and
executes it. The results are constantly stored in the process image output (PIO) during the cycle. At the end of a
scanning cycle, i.e. program completion, the processor transfers the contents of the process image output to the
output modules and to the external timers and counters. The processor then begins a new program scan.
Fig.6 System with peripheral devices
Fig.8.1. Generalized PLC block diagram
Programming
Units
Tape
Reader
PrintersTape
Puncher
Processor Logic
memory
Storage
memory
Power
Supply
Inputs
Outputs
Power
Supply
Programmer Field
Devices

51. (38)
What does ‘PLC’ mean?
A PLC (Programmable Logic Controllers) is an industrial computer used to monitor inputs, and depending
upon their state make decisions based on its program or logic, to control (turn on/off) its outputs to automate a
machine or a process.
PROGRAMMABLE LOGIC CONTROLLER
“A digitally operating electronic apparatus which uses a programmable memory for the internal
storage of instructions by implementing specific functions such as logic sequencing, timing,
counting, and arithmetic to control, through digital or analog input/output modules, various
types of machines or processes”.
Traditional PLC Applications
*In automated system, PLC controller is usually the central part of a process control system.
*To run more complex processes it is possible to connect more PLC controllers to a central computer.
Disadvantages of PLC control
- Too much work required in connecting wires.
- Difficulty with changes or replacements.
- Difficulty in finding errors; requiring skillful work force.
- When a problem occurs, hold-up time is indefinite, usually long.
Advantages of PLC control
* Rugged and designed to withstand vibrations, temperature, humidity, and noise.
* Have interfacing for inputs and outputs already inside the controller.
* Easily programmed and have an easily understood programming language.
Major Types of Industrial Control Systems
Industrial control system or ICS comprise of different types of control systems that are currently in operation in
various industries. These control systems include PLC, SCADA and DCS and various others:

52. (39)
PLC
They are based on the Boolean logic operations whereas some models use timers and some have continuous
control. These devices are computer based and are used to control various process and equipments within a
facility. PLCs control the components in the DCS and SCADA systems but they are primary components in
smaller control configurations.
DCS
Distributed Control Systems consists of decentralized elements and all the processes are controlled by these
elements. Human interaction is minimized so the labor costs and injuries can be reduced.
Embedded Control
In this control system, small components are attached to the industrial computer system with the help of a
network and control is exercised.
SCADA
Supervisory Control And Data Acquisition refers to a centralized system and this system is composed of various
subsystems like Remote Telemetry Units, Human Machine Interface, Programmable Logic Controller or PLC
and Communications.
Hardware Components of a PLC System
Processor unit (CPU), Memory, Input/Output, Power supply unit, Programming device, and other devices.
FIG 8.2 HARDWARE

53. (40)
Central Processing Unit (CPU)
CPU – Microprocessor based, may allow arithmetic operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.
CPU makes a great number of check-ups of the PLC controller itself so eventual errors would be discovered
early.
System Busses
The internal paths along which the digital signals flow within the PLC are called
busses.
The system has four busses:
- The CPU uses the data bus for sending data between the different elements,
- The address bus to send the addresses of locations for accessing stored data,
- The control bus for signals relating to internal control actions,
- The system bus is used for communications between the I/O ports and the I/O unit.
Memory
System (ROM) to give permanent storage for the operating system and the fixed data used by the CPU.
RAM for data. This is where information is stored on the status of input and output devices and the values of
timers and counters and other internal devices. EPROM for ROM’s that can be programmed and then the
program made permanent.
I/O Sections
Inputs monitor field devices, such as switches and sensors.
Outputs control other devices, such as motors, pumps, solenoid valves, and lights.
Power Supply
Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC controllers have electrical supply as a
separate module, while small and medium series already contain the supply module.
Programming Device
The programming device is used to enter the required program into the memory of the processor.
The program is developed in the programming device and then transferred to the memory unit of the PLC.

54. (41)
CHAPTER 9
PLC OPERATIONS:
Input Relays
These are connected to the outside world. They physically exist and receive signals from switches, sensors, etc.
Typically they are not relays but rather they are transistors.
Internal Utility Relays
These do not receive signals from the outside world nor do they physically exist. They are simulated relays and
are what enables a PLC to eliminate external relays.
There are also some special relays that are dedicated to performing only
one task.
Counters
These do not physically exist. They are simulated counters and they can be programmed to count pulses.
Typically these counters can count up, down or both up and down. Since they are simulated they are limited in
their counting speed.
Some manufacturers also include highspeed counters that are hardware based.
Timers
These also do not physically exist. They come in many varieties and increments.
The most common type is an on-delay type.
Others include off-delay and both retentive and non-retentive types. Increments vary from 1ms through 1s.
Output Relays
These are connected to the outside world. They physically exist and send on/off signals to solenoids, lights, etc.
They can be transistors, relays, or triacs depending upon the model chosen.
Data Storage
Typically there are registers assigned to simply store data. Usually used as temporary storage for math or data
manipulation.
They can also typically be used to store data when power is removed from the
PLC.

55. (42)
The Simatic S5 PLC is an automation system based on PLC. It was manufactured and sold by Siemens. Such
automation systems control process equipment and machinery used in manufacturing.
STEP 5 programming language is used for writing user programs for SIMATIC S5 programmable controllers.
The program can be written and entered into the programmable controller as in:
 Statement list (STL), Fig.12 (a)
 Control system flowchart (CSF), Fig.12 (b)
 Ladder diagram (LAD), Fig.12 (c)
(a)
Fig.9.1 Programmable controller
The statement list describes the automation task by means of mnemonic function designations.
The control system flowchart is a graphic representation of the automation task.
The ladder diagram uses relay ladder logic symbols to represent the automation task.
The statement is the smallest STEP 5 program component. It consists of the following:
Operation, i.e. what is to be done?
Statement list
STL
A I 2.3
A I 4.1
O I 3.2
= Q 1.6
A I 2.3
A I 2.3
I 2.3
A
N
D
O
R
I 2.3
I 4.1
I 3.2 Q 1.6
Statement
OperandOperation
Operand identifier
Parameter
(b) Control system flow
chart CSF
(c) Ladder diagram LAD
I 2.3 I 4.1
I 3.2

56. (43)
E.g. A = AND operation (series connection)
O= OR operation (parallel connection)
S= SET operation (actuation)
Operand, i.e. what is to be done with?
E.g. I 4.5, i.e. with the signal of input 4.5
The operand consists of:
 Operand identifier (I = input, Q = output, F = flag, etc.)
 Parameter, i.e. the number of operand identifiers addressed by the statement. For inputs, outputs and
flags (internal relay equivalents), the parameter consists of the byte and bit addresses, and for timers and
counter, byte address only.
The statement may include absolute operands, e.g. I 5.1, or symbolic operand, e.g. I LS1. Programming is
considerably simplified in the later case as the actual plant designation is directly used to describe the device
connected to the input or output.
Typically, a statement takes up one word (two bytes) in the program memory.

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CHAPTER 10
STRUCTURED PROGRAMMING
The user program can be made more manageable and straightforward if it is broken down into relative sections.
Various software block types are available for constructing the user program.
Program blocks (PB) contain the user program broken down into technologically or functionally related
sections (e.g. program block for transportation, monitoring, etc.). Further blocks, such as program blocks or
function blocks can be called from a PB.
Organization blocks (OB) contain block calls determining the sequence in which the PBs are to be processed. It
is therefore possible to call PBs conditionally (depending on certain conditions).
In addition, special OBs can be programmed by the user to react to interruptions during cyclic programming
processing. Such an interrupt can be triggered by a monitoring function if one or several monitored events
occur.
Function block (FB) is block with programs for recurrent and usually complex function. In addition to the basic
operations, the user has a extended operation at his disposal for developing function blocks. The program in a
function block is usually not written with absolute operands (e.g. I 1.5) but with symbolic operands. This
enables a function block to be used several times over with different absolute operands.
For even more complex functions, standard function blocks are available from a program library. Such FBs are
available, e.g. for individual controls, sequence controls, messages, arithmetic operations, two step control
loops, operator communications, listing, etc. These standard FBs for complex functions can be linked it the user
program just like user written FBs simply by means of a call along with the relevant parameters.
The Sequence block (SB) contain the step enabling conditions, monitoring times and conditions for the current
step in sequence cascade. Sequence blocks are employed, for example, to organise the sequence cascade in
communication with a standard FB.
The data blocks (DB) contain all fixed or variable data of the user program.
CYCLIC PROGRAM PROCESSING
The blocks of the user program are executed in the sequence in which they specified in the organisation block.
INTERRUPT DRIVEN PROGRAM PROCESSING
When certain input signal changes occur, cyclic processing is interrupted at the next block boundary and an OB
assigned to this event is started. The user can formulate his response program to this interrupt in the OB. The
cyclic program execution is the resumed from the point at which it was interrupted.

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10.1.TIME CONTROLLED PROGRAM EXECUTION
Certain Obs are executed at the predetermined time intervals (e.g. every 100ms, 200ms, 500ms, 1s, 2s, and 5s).
For this purpose, cyclic program execution is interrupted at the block boundary and resumed again at this point,
once the relevant OB has been executed. Fig.13 gives the organisation and execution of a structured user
program.
PB1
PB2 FB3
FB2
OB1
Structured programming
PB FB
PB FB
Organisation block (OB)
Program block (PB) Function block (PB)
Cycle execution
OB
PB FB
OB
Interrupt-driven execution
Points at which interrupt-driven program can be inserted
Start and finish of interrupt-driven program execution

59. Fig.10.1 Organisation and execution of a structured user program
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10.2.EXAMPLES OF PLC PROGRAM
Before attempting to write a PLC program, first go through the instruction set of the particular language used
for the equipment, and understand the meaning of each instruction. Then study how to use these instructions in
the program (through illustration examples given in the manual). Once the familiarization task is over, then start
writing the program.
Follow the following steps to write a PLC program.
 List down each individual element (field device) on the machine as Input/Output.
 Indicate against each element the respective address as identifier during electrical interfacing of these
elements with the PLC.
 Break down the complete machine auxiliary functions that are controlled by the PLC into individual, self
contained functions.
 Identify each individual function as separate block (PBxx/FBxx)
 Once the PBs and FBs for each function are identified, take them one by one for writing the program.
 List down the preconditions required for the particular function separately.
 Note down the address of the listed elements.
 Write down the flow chart for the function.
 Translate the flow chart into PLC program using the instructions already familiarized.
 Complete the program translation of all individual functions in similar lines.
 Check the individual blocks independently and correct the program to get the required results.
 Organize all the program blocks in the organization block depending upon the sequence in which they are
supposed to be executed as per the main machine function flow chart.
 Check the complete program with all the blocks incorporated in the final program.

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Example TABLE 10.1: Spindle ON
Preconditions Feedback elements Address Fault indication Address Remark
Tool clamp Pressure switch I 2.4 Lamp Q 2.1
Job clamp Proximity switch I 3.2 Lamp Q 1.7
Door close Limit switch I 5.7 Lamp Q 4.0
Lubrication ON PLC output bit Q 1.0 Lamp Q 7.7
Drive ready Input signal from I 4.6 Lamp Q 0.4
Drive unit
TABLE
PB 12 written is the individual function module for spindle ON for all the preconditions checked and found
satisfactory. This function is required to be executed only when the spindle rotation is requested by the NC in
the form of a block in the part program.
Whenever NC decodes the part program block, it in turn informs the PLC through a fixed buffer location that
spindle rotation is requested. Say Flag bit F 100.0 is identified for this information communication. With this
data, spindle ON function module can be recalled in the organisation block OB1 as follows.
OB 1
……
A F 100.0
JC PB12
……
BE
Now, spindle ON function module PB12 will be executed only when F 100.0 is set. Otherwise the function
execution will be bypassed.

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10.3. FLOW CHART
START
TOOL CLAMP
JOB CLAMP
DOOR CLOSED
LUBRICATION
ON
DRIVE READY
ANY FAULT
DO SPINDLE
ON
INDICATE
FAULT
INDICATE
FAULT
INDICATE
FAULT
INDICATE
FAULT
INDICATE
FAULT
STOP
SPINDLE
PB12
AN I 2.4 Tool not clamped
= Q 2.1 Display fault lamp
AN I 3.2 Job not clamped
= Q 1.7 Display fault lamp
AN I 5.7 Door not closed
= Q 4.0 Display fault lamp
AN Q 1.0 Lubrication not on
= Q 7.7 Display fault lamp
AN I 4.6 Drive not ready
= Q 0.4 Display fault lamp
Comments
ON I 2.4 Tool not clamped
ON I 3.2 Job not clamped
ON I 5.7 Door not closed
ON Q 1.0 Lubrication not on
ON I 4.6 Drive not ready
R Q 67.3 Reset spindle enable bit
BEC Block end conditionally
A I 2.4 Tool clamped
A I 3.2 Job clamped
A I 5.7 Door closed
A Q 1.0 Lubrication ON
A I 4.6 Drive ready
S Q 67.3 Set spindle enable bit
BE Block end
Exit
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
YES

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END

63. CHAPTER 11
CONCLUSION
The second phase of training has proved to be quite faithful. It proved an opportunity for encounter with such
huge machines like turbo-generator, hydro generator etc.
The architecture of B.H.E.L., the way various units are linked and the way working of whole plant is controlled
make the students realize that Engineering is not just structural description but greater part is planning and
management. It provides an opportunity to learn tech. Used at proper place and time can save a lot of
labour.
But there are few factors that require special mention. Training is not carried in true spirit. It is recommended
that there should be projectors especially for trainees where presence of authorities is ensured.
However, training has proved to be an enriching experience. It has allowed us an opportunity to get an exposure
of the practical implementation of theoretical fundamentals.
It has provided an opportunity to learn that optimization of technology used at proper place and time can save a
lot of labour.
The training has proved to be immensely helpful as it has helped me to have an exposure of the practical
implementation of the theoretical knowledge that I have gained till date.
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64. CHAPTER 12
REFRENCES
1. https://www.himaanshuderwal.blogspot.in
2. http://about.me/himanshuderwal
3. http://www.wikipedia.org
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