VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“Jnana Sangama”, Belagavi - 590 018, Karnataka

INTERNSHIP
Report on

“AUTOMATION AND INDUSTRY 4.0’ LOGIC”

Submitted in partial fulfillment for the Award of Degree of
Bachelor of Engineering
in
Electrical and Electronics Engineering

Submitted by
HARSHA MR 1RN21EE403

Internship Carried Out At

RVCE – REXROTH BOSCH

Internal Guide External Guide

Dr. ROOPA NAYAK Dr. S K Harisha
HoD & Assoc. professor Coordinator
RVCE- BOSCH REXROTH

Department of Electrical and Electronics Engineering

RN SHETTY TRUST®
RNS INSTITUTE OF TECHNOLOGY
Autonomous Institution Affiliated to VTU, Recognized by GOK, Approved by AICTE
NAAC ‘A+ Grade’ Accredited, NBA Accredited (UG – CSE, ECE, ISE, EIE and EEE)
Channasandra, Dr. Vishnuvardhan Road, Bengaluru - 560 098
Ph:(080)28611880,28611881 URL: www.rnsit.ac.in
2023 - 24
VISVESVARAYA TECHNOLOGICAL UNIVERSITY
“Jnana Sangama”, Belagavi - 590 018

INTERNSHIP
Report on
“AUTOMATION AND INDUSTRY 4.0’ LOGIC”
This is submitted in partial fulfillment for the Award of Degree of
Bachelor of Engineering
in
Electrical and Electronics Engineering

Submitted by
HARSHA MR 1RN21EE403

Internship Carried Out At

RVCE – REXROTH BOSCH

Internal Guide External Guide

Dr. ROOPA NAYAK Dr. S K Harisha
HoD & Assoc. professor Coordinator
RVCE- BOSCH REXROTH

Department of Electrical and Electronics Engineering

RN SHETTY TRUST®
RNS INSTITUTE OF TECHNOLOGY
Autonomous Institution Affiliated to VTU, Recognized by GOK, Approved by AICTE
NAAC ‘A+ Grade’ Accredited, NBA Accredited (UG – CSE, ECE, ISE, EIE and EEE)
Channasandra, Dr. Vishnuvardhan Road, Bengaluru - 560 098
Ph:(080)28611880,28611881 URL: www.rnsit.ac.in
2023 - 24
 RN SHETTY TRUST®
RNS INSTITUTE OF TECHNOLOGY
Autonomous Institution Affiliated to VTU, Recognized by GOK, Approved by AICTE
NAAC ‘A+ Grade’ Accredited, NBA Accredited (UG – CSE, ECE, ISE, EIE and EEE)
Channasandra, Dr. Vishnuvardhan Road, Bengaluru - 560 098
Ph:(080)28611880,28611881 URL: www.rnsit.ac.in
2023 - 24

Department of Electrical and Electronics Engineering

CERTIFICATE
Certified that the Internship entitled “AUTOMATION AND INDUSTRY 4.0’ LOGIC”
is carried out by HARSHA MR (1RN21EE403), RNS Institute of Technology in partial
fulfillment for the award of degree of Bachelor of Engineering in Electrical and
Electronics Engineering of Visvesvaraya Technological University, Belagavi, during
the year 2023-24. It is certified that all corrections/suggestions indicated during Internal
Assessment have been incorporated in the report. The Internship report has been approved
as it satisfies the academic requirements in aspect of the Internship work prescribed for the
award of degree of Bachelor of Engineering.

Dr. ROOPA NAYAK Dr. Roopa Nayak Dr. Ramesh Babu H S

HoD & Assoc. professor Assoc. Professor & HOD Principal

External Viva

Name of the Examiner Signature with date

1.

2.
 RN SHETTY TRUST®
RNS INSTITUTE OF TECHNOLOGY
Autonomous Institution Affiliated to VTU, Recognized by GOK, Approved by AICTE
NAAC ‘A+ Grade’ Accredited, NBA Accredited (UG – CSE, ECE, ISE, EIE and EEE)
Channasandra, Dr. Vishnuvardhan Road, Bengaluru - 560 098
Ph:(080)28611880,28611881 URL: www.rnsit.ac.in
2023 - 24

Department of Electrical and Electronics Engineering

DECLARATION
I hereby declare that the entire work embodied in this Internship report titled,
“AUTOMATION AND INDUSTRY 4.0’ LOGIC” submitted to Visvesvaraya
Technological University, Belagavi, is carried out at the department of Electrical
and Electronics Engineering, RNS Institute of Technology, Bengaluru under
the guidance of Dr. ROOPA NAYAK , HoD & Assoc. professor. This report has not
been submitted for the award of any Diploma or Degree of this or any other University.

Name USN SIGNATURE

HARSHA MR 1RN21EE403 ------------------------

(i)
(ii)
 ACKNOWLEDGEMENT
The fulfillment and rapture that go with the fruitful finishing of any assignment would be inadequate
without mentioning a token of gratitude to the people who made it conceivable and whose steady
direction and support delegated the endeavors with success.

I am thankful to Dr. M K Venkatesha, Director, RNS Institute of Technology as he has guided us

throughout and has provided various facilities which have helped us in acquiring valuable information
for the report.

I am thankful to Dr. Ramesh Babu H S, Principal, RNSIT, for encouraging in completion of this
report.

I am grateful to Dr. Roopa Nayak, Assoc. Professor and Head of Department, Electrical &
Electronics Engineering, RNSIT for her valuable suggestions and guidance throughout the period of
this report.

I wish to express my heartfelt gratitude to my external guide Mr. S K Harisha, Coordinator,

RVCE-Rexroth Bosch, Bengaluru. For his valuable guidance, suggestions, and cheerful
encouragement during the entire period of my internship.

I would like to sincerely thank all those people who have been supporting in the part of my
internship at RVCE- Rexroth Bosch.

I would like to express our profound and cordial gratitude to our guide Dr. ROOPA NAYAK, HoD
& Assoc. professor, Department of Electrical and Electronics Engineering, RNSIT for his assistance
and guidance.

I would also like to thank all the teaching and non-teaching staff members of the Electrical and
Electronics Department, for their constant support and encouragement. I would also like to express
our immense gratitude to our parents who have been a source of inspiration in carrying out this project.
Lastly and most importantly, we would like to thank God for giving us the will power and strength to
take up this project.

HARSHA M R
1RN21EE403

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AUTOMATION AND INDUSTRY 4.0’ LOGIC 2023-24

ABSTRACT

As industries continue to evolve in the digital age, the role of automation has become
increasingly pivotal in achieving enhanced efficiency, accuracy, and productivity. This abstract
explores the transformative impact of automation across various sectors, including
manufacturing, healthcare, finance, and information technology. The fundamental principles of
automation, encompassing the use of advanced technologies such as artificial intelligence,
robotics, and machine learning. It delves into the integration of automated systems within
existing workflows, emphasizing the potential for streamlining repetitive tasks, reducing human
error, and optimizing resource utilization. Furthermore, the socio-economic implications of
widespread automation, addressing concerns related to job displacement and the need for
upskilling the workforce to adapt to a technologically advanced landscape. It highlights
successful case studies where automation has led to job creation, improved job satisfaction, and
the development of new, specialized roles.

Industry 4.0, the fourth industrial revolution, signifies a transformative era where digital
technologies converge with traditional manufacturing processes, leading to the creation of
intelligent, interconnected, and data-driven industrial ecosystems. This abstract provides an
overview of the key components and implications of Industry 4.0, shedding light on its potential
to revolutionize the global industrial landscape. The foundational technologies underpinning
Industry 4.0, including the Internet of Things (IoT), big data analytics, artificial intelligence
(AI), robotics, and cyber-physical systems. It explores how the seamless integration of these
technologies enables the creation of smart factories, where machines communicate, collaborate,
and make decisions autonomously. Furthermore, the transformative impact of Industry 4.0 on
manufacturing processes, highlighting the shift from mass production to personalized and
demand-driven production. The paper discusses the concept of "smart production," where real-
time data analytics optimize efficiency, reduce downtime, and enhance overall operational
performance.

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AUTOMATION AND INDUSTRY 4.0’ LOGIC 2023-24

TABLE OF CONTENTS

CHAPTER NO. DESCRIPTION PAGE NO.

DECLARATION i
CERTIFICATE ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
1 INTRODUCTION 1-4
1.1 About Company 1
1.2 Product And Technologies 3
2 ABOUT AUTOMATION 5-7
2.1 Elements of Automated System 5
3 PLC 8-14
3.1 Major components of PLC 8
3.2 Types of PLC Programming Language 9
3.3 PLC Ladder Programming 11
3.4 Types of Communication Protocols 13
4 SENSORS 15-17
4.1 Working 15
4.2 Types of Sensors 16
5 OTHER EQUIPMENTS 18-20
5.1 Relays 18
5.2 SMPS 19
6 SCADA 21-22
6.1 MOVICON Software 21
7 TASKS PERFORMED 23-32

7.1 PLC Program for bottle-filling process 23

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7.2 PLC Program for Material Sorting System 25

7.3 To setup a small organization using Cisco Packet Tracer 26
7.4 To simulate IoT based home automation using 31
CiscoPacket Tracer
7.5 To develop a SCADA screen by creating tags manually 35
inMOVICON
8 INTERNSHIP EXPERIENCE 37-39
8.1 Technical Outcomes 37
8.2 Non-Technical Outcomes 38
8.3 Overall Conclusion 38
REFERENCES 39

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LIST OF FIGURES

FIGURE NO. DESCRIPTION PAGE NO.

1.1 Company 1
1.2 Associates by region - 2022 2
2.1 Elements of an automated system 5
2.2 A feedback control system 6
2.3 An open loop control system 6
3.1 Block Diagram of PLC 7
3.2 Ladder logic diagram 9
3.3 Sequential function chart 9
3.4 Function block diagram 9
3.5 Structured text 10
3.6 Instruction list 10
3.7 Ladder logic components 11
5.1 Electromagnetic and Solid-state relay 19
5.2 SMPS 20
6.1 Movicon software 22
7.1 Bottle-filling schematic diagram 23
7.1.1 Bottle-filling ladder logic 24
7.2 Material sorting system 25
7.2.1 Material sorting ladder logic 26
7.3 Network established 27
7.3.1 Assigning IP address, subnet mask, default gateway 28
7.3.2 Fast Ethernet 28
7.3.3 Setting up DNS Server 29
7.3.4 Command prompt 30
7.3.5 Web browser 30
7.4 IoT Components 31
7.4.1 Naming of IoT device 31

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7.4.2 Copying of SSID 32

7.4.3 To connect to home gateway 32
7.4.4 Pasting the SSID 33
7.4.5 IoT server 33
7.4.6 Connected to the home gateway 33
7.4.7 Connecting smart device to home gateway 34
7.4.8 Login page 35
7.4.9 Dashboard 35
7.4.10 Overall outcome 35
7.5 SCADA screen 36
7.5.1 SCADA Outcome 36

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LIST OF TABLES

Table No. Title of the Table Page no.

Table 7.1 Requirements 26
Table 7.2 Assigning IP addresses, subnet masks, DNS server 27

Table 7.3 Fast Ethernet 28

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AUTOMATION AND INDUSTRY 4.0’ LOGIC 2023-24

CHAPTER 1
INTRODUCTION

1.1 ABOUT COMPANY

Fig 1.1 Company

The origin of Bosch Rexroth's long history is influenced by constant movement. It all started
with a water-powered hammer mill, followed by an iron foundry in Lohr am Main. Bosch
Rexroth’s unique industry expertise has become synonymous with tailored solutions.
It is the result of a merger on 1 May 2001, between Mannesmann Rexroth AG and the
Automation Technology Business Unit of Robert Bosch GmbH, and is a wholly owned
subsidiary of Robert Bosch GmbH.

History
1795 – 1964: Move from iron foundry to hydraulic solutions
1965 – 1995: Move from hydraulics to multi-technology provider
1996 – 2000: Move to provide integrated multi-technology solutions
2001 – 2016: Move to one brand for software driven and interconnectible Drive & Control
solutions
2017 – today: Move into the future of digital transformation

About Bosch in India

In India, Bosch is a leading supplier of technology and services in the areas of Mobility
Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology.
Additionally, Bosch has in India the largest development center outside Germany, for end-
to-end engineering and technology solutions. The Bosch Group operates in India through
twelve companies: Bosch Limited – the flagship company of the Bosch Group in India –

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Bosch Chassis Systems India Private Limited, Bosch Rexroth (India) Private Limited,
Bosch Global Software Technologies PVT LTD, Bosch Automotive Electronics India
Private Limited, Bosch Electrical Drives India Private Limited, BSH Home Appliances
Private Limited, ETAS Automotive India Private Limited, Robert Bosch Automotive
Steering Private Limited, Automobility Services and Solutions Private Limited, Newtech
Filter India Private Limited and Mivin Eng. Technologies Private Limited. In India, Bosch
set-up its manufacturing operation in 1951, which has grown over the years to include 17
manufacturing sites, and seven development and application centers.

1.1.1 Vision

“WE MOVE. YOU WIN.”

1.1.2 Figures

Bosch Rexroth employs over 32,000 people worldwide, and achieved total revenue of 7
billion euros in 2022 with locations in over 80 countries.
2022 associates by region:

Fig 1.2 Associates by region - 2022

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1.2 PRODUCT AND TECHNOLOGIES

Bosch Rexroth Assembly Technology is the expert in realizing future-proof production in

various industries. We offer intelligent and modular hardware and software solutions that
are seamlessly integrable into production IT.

Assembly Technology: Modular components meet current production needs and are
future-proof for the challenges ahead.

Electric Drives and Controls: The highest-performance CNC and Motion Control
on the market. From sensors and servo drives to revolutionary new platform, Rexroth
Bosch set the standard for automation with many products enabled for the Internet of
Things.

Industrial Hydraulics: Next generation hydraulic thinking. The latest connected

solutions that leverage hydraulic power, while saving space and energy.

Linear Motion Technology: Linear axes solutions that are fit for the future. A
diverse and versatile range of products and services, from simple components to smart
mechatronic solutions. By constantly developing new and innovative products, they have
been a leading provider of linear motion technology for 30 years.

Mobile Hydraulics, Electronics and IoT: Future-ready solutions for mobile

machines. Our electrified, electronic and digitally networked solutions are helping to
create the next generation of mobile machines.

Gear Technology: Planetary gearboxes are used as propel drives in tracked vehicles or
as wheel drives in wheeled vehicles as well as swing drives for rotary motion and as winch
drives for lifting and lowering loads. The planetary gearboxes have two, three or more
planetary stages.

Moulding and Casting Technology: Mould-breaking technology and innovation.

Offering exceptional casting capability for hydraulic casting, cast products for general
mechanical engineering, and cast components for glass mould production.

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Mobile Robotics: Bosch Rexroth's portfolio includes AMRs for automating the flow of
materials and goods as well as a modular robotics kit consisting of software and hardware
components that provide key technologies for a wide range of AGVs, AMRs and forklifts.

Haglund’s drive systems: Haglund’s Hydraulic direct drives gives a straight path to
high performance, through shaft-mounted hydraulic motors, freely placed drive units and
intelligent control.

Powerful cobots by Kassow Robots: Collaborative robots (or ‘cobots’) can help to
automate a wide selection of tasks in production and assembly environments. Kassow
Robots is a specialist brand in the field of cobots, that differentiates itself by unrivaled
flexibility and easy programming.

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CHAPTER 2

ABOUT AUTOMATION

Automation is the technology by which a process or procedure is performed with minimal

human interference through the use of technological or mechanical devices. It is the
technique of making a process or a system operate automatically. Automation crosses all
functions within almost every industry from installation, maintenance, manufacturing,
marketing, sales, medicine, design, procurement, management, etc. Automation has
revolutionized those areas in which it has been introduced, and there is scarcely an aspect
of modern life that has been unaffected by it.

Automation is a broad range of technologies that includes robotics and expert systems,
telemetry and communications, electro-optics, Cybersecurity, process measurement and
control, sensors, wireless applications, systems integration, test measurement, and more.
Industrial automation in manufacturing entails the use of machines to carry out
manufacturing processes with levels of speed, stamina, accuracy, and consistency with
capabilities of that which is beyond the human worker. The main benefits of automating
processes in manufacturing include reduced production cost, reduced waste, improved
quality and reliability, and drastically reduced workplace-related accidents

2.1 ELEMENTS OF AUTOMATED SYSTEM

An automated system consists of three basic elements:

 power to accomplish the process and operate the system.

 a program of instructions to direct the process, and

 a control system to actuate the instructions.

The relationship amongst these elements is illustrated in Figure 1.1. All systems that
qualify as being automated include these three basic elements in one form or another.

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Fig 2.1 Elements of an automated system

1) Power to accomplish the automated process.

An automated system is used to operate some processes, and power is required to drive the
process as well as the controls. The principal source of power in automated systems is
electricity. Electric power has many advantages in automated as well as non- automated
processes.

 Electrical power can be readily converted to alternative energy forms: mechanical,

thermal, light, acoustic, hydraulic, and pneumatic.

 Electrical power at low levels can be used to accomplish functions such as signal,
transmission, information processing, data storage and communication.

2) Program of Instructions

The actions performed in an automated process are defined by a program of instructions.

Each part or product style made in the operation requires one or more processing steps that
are unique to that style, these processing steps are performed during a work cycle.

3) Control System

The control element of the automated system executes the program of instructions. The
control system causes the process to accomplish its defined function which is to carry out
some manufacturing operation. The controls in an automated system can be either closed

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loop or open loop. A closed loop control system, also known as a feedback control system
is one in which the output variable is compared with an input parameter, and any
difference between the two is used to drive the output into agreement with the input.

Fig 2.2 A feedback control system

The input parameter often referred to as the set point, represents the desired value of the
output. The process is the operation or function being controlled. In particular, it is the
output variable that is being controlled in the loop. A sensor is used to measure the output
variable and close the loop between input and output. Sensors perform the feedback
function in a closed loop control system. The controller compares the output with the input
and makes the required adjustment in the process to reduce the difference between them.
The adjustment is accomplished using one or more actuators, which are the hardware
devices that physically carry out the control actions, such as an electric motor or a flow
valve. The model in Figure 2 shows only one loop, however, most industrial processes
require multiple loops, one for each process variable that must be controlled.

Fig 2.3 An open loop control system

In contrast to the closed loop control system, an open loop control system operates without
the feedback loop. In this case, the controls operate without measuring the output variable
so no comparison is made between the actual value of the output and the desired input
parameter.

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CHAPTER 3
PLC

Programmable Logic Controllers (PLC) are often defined as miniature industrial

computers that contain hardware and software used to perform control functions. More
specifically, a PLC would be used for the automation of industrial electromechanical
processes, such as control of machinery on factory assembly lines, amusement rides, or
food processing. They are designed for multiple arrangements of digital and analog
inputs and outputs with extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. A PLC will consist of two basic sections: the central
processing unit (CPU) and the Input/Output (I/O) interface system. Interfacing to
Devices

Fig 3.1 Block diagram of PLC

3.1 Major components of PLC

 POWER SUPPLY Provides the voltage needed to run the primary PLC
components.

 PROCESSOR Provides intelligence to command and govern the activities of the

entire PLC systems. The CPU controls all system activity primarily through its
processor and memory system. The CPU consists of a microprocessor, memory chip
and other integrated circuits to control logic, monitoring, and communications. The
CPU has different operating modes. In programming mode, the CPU will accept
changes to the downloaded logic from a PC. When the CPU is placed in run mode it

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will execute the program and operate the process. Input data from connected field
devices (e.g., switches, sensors, etc.) is processed, and then the CPU “executes” or
performs the control program that has been stored in its memory system. to run or
upon saving. In the latter case, the executable and the source code are merged
into a single file.

 PROGRAMMING DEVICE Used to enter the desired program that will

determine the sequence of operation and control of process equipment or driven
machine.

 I/O MODULES Provides signal conversion and isolation between the internal
logic level signals inside the PLC and the field’s high-level signal. The I/O
interface section of a PLC connects it to external field devices. The main purpose
of the I/O interface is to condition the various signals received from or sent to the
external input and output devices. Input modules converts signals from discrete or
analog input devices to logic levels acceptable to PLC’s processor. Output modules
convert signal from the processor to levels capable of driving the connected discrete
or analog output devices.

3.2 Types of PLC Programming Language

IEC 1131-3 is the international standard for programmable controller programming

languages. The following is a list of programming languages specified by this standard:

 Ladder logic

 Sequential function chart

 Function block diagram

 Structured text

 Instruction list
LADDER LOGIC:
 It is a graphical PLC programming languages (based on relay logic circuit diagrams).

 It consists of two parallel bars connected by a series of rungs, resembling in a ladder

appearance.

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Fig 3.2 Ladder logic diagram

SEQUENTIAL FUNCTION CHART:

 It consists of steps and transitions steps are the action to be performed, transitions are
the logic conditions that need to be met before moving on to the next step.

 Easier to text than any other language.

 Multi-state process, linked state process to run in parallel.

Fig 3.3 Sequential Function Chart

FUNCTION BLOCK DIAGRAM :

 It is a graphical PLC program, it is a kind of block which consits of inputs & outputs.

 Devices are connected to inputs, variables are connected to output. Output of one
block can be added to inputs.

 It is a great choice for safety PLCs and PID loops.

Fig 3.4 Function Block diagram

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STRUCTURED TEXT:

 It is a high-level programmable language, it is a textual language with syntax is

compared to C, C++

 It is used for barcode, looping, manipulation data, bridging the gap to machine code,
complication math or searching data.

Fig 3.5 Structured text

INSTRUCTION LIST:

 It is doubtful that new PLC’s will be programmed. Since some current PLCs are
using it. It consists of simple instructions “jump”, ”store”.

 Due to depreciation of IL, if you are considering using it for new programs. ST can
be used.

Fig 3.6 Instruction list

3.3 PLC LADDER PROGRAMMNING

PLC ladder programming is a graphical programming language used to create logic

control programs for Programmable Logic Controllers (PLCs). It is called "ladder
programming" due to its resemblance to electrical relay logic diagrams, where rungs of
a ladder represent individual control circuits. The language is widely used in industrial

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automation to design and implement control logic for various processes and machines.

3.3.1 Ladder Logic Components

Rail and Rung:
 Vertical lines are called rails.
 Horizontal lines are called rungs.
Normally Open:
 A normally open switch or contact is open when not actuated.
 It closes the circuit when pressed or activated, allowing current flow.
 In ladder logic diagrams, a normally open contact is shown as an open gap and
becomes a solid line when activated.
Normally Closed:
 Normally closed switch/contact is closed when not actuated.
 Activation of the switch opens the circuit, stopping current flow.
 In ladder logic diagrams, it’s represented as a solid line, becoming an open gap
when activated.
Output/Coil:
 Output devices are such as motor, valve, indicator, lights etc. but in LLD it is
represented by vertical line with a label representing the output device.

Fig 3.7 Ladder logic Components

3.3.2 Ladder logics

1. Boolean Logic: The ON/OFF, TRUE/FALSE algebra of binary systems. The basics
of which are AND, OR, and NOT operators.
2. Timing: Timer instructions are available to allow for on-delayed or off-delayed
events. Once triggered, the timer will turn its associated output ON (on-delay) or OFF
(off-delay) after the set time has elapsed.
3. Counting: Count-up and count-down functions increase or decrease the counter value
on every transition of the input.

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4. Comparisons: Compare instructions are available to determine if values are less than,
equal to, or greater than each other.
5. Math: These instructions not only allow for the simple addition and subtraction but
also for more complex operations like tangents, square roots, etc.
6. Special functions: PID loops, communication instructions, shift registers, drum
sequencers, ramp generators, etc.

3.4 Types of Communication Protocols

There are several types of communication protocols used in the field:

 Profibus
 Ethernet
 OPC (open platform communication)
 Device net
 Modbus
 DNP3 ( Distributed network protocol)

Open Communication Platform:

OPC protocol consists of two types:

OPC DA: OPC data consists of branches of OPC DA server.
 Scada clients needs a data from a PLC, item is requested to OPC server.
 Server grabs the data and sends the data to Scada.
 If not goes well it will send as VQT.
 V- actual item value, Q- quality of the data, T- time stamp.
OPC UA: It is platform independence, and it transports the data.
 It is a cross platform protocol, does not depend on operation system.
 The security provided by the OPC-UA is robust.
Modbus:
 Modbus is one of the oldest and most widely used protocols in industrial
automation.
 Modbus is based on a master-slave architecture, where one device (the master)
initiates a request and one or more devices (the slaves) respond to it.
 Modbus can operate over serial or Ethernet networks, using different variants such
as Modbus RTU, Modbus ASCII, or Modbus TCP.

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Ethernet/IP:
 Ethernet/IP is a relatively newer protocol in industrial automation, developed in
2001 by Rockwell Automation and the Open Device Net Vendor Association
(ODVA).
 Ethernet/IP stands for Ethernet Industrial Protocol, and it is based on the Common
Industrial Protocol (CIP), a set of rules and services for data exchange between
industrial devices. Ethernet/IP uses the standard Ethernet network and the TCP/IP
stack to transmit data and commands, making it compatible with other Ethernet-
based protocols and devices.
DNP3:
 The DNP3 or distributed network protocol is a communication protocol that is used
to do the communication between the industrial devices.
 It is utilized to monitor several industrial data, DNP3 protocol is widely used in the
SCADA network.
 This protocol is widely utilized by several electric and water utilities.

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CHAPTER 4

SENSORS
Sensors play a fundamental role in capturing and converting real-world information into
a form that can be easily understood and utilized by electronic systems. In various fields
such as industrial automation, healthcare, automotive, and consumer electronics,
sensors serve as crucial components that enable devices to perceive and respond to their
environment.

At its core, a sensor is a device or transducer that detects and measures a physical
property or stimulus and converts it into an electrical signal. This transformation allows
for the acquisition of data that can be processed, analyzed, and used for decision-
making. Sensors come in a diverse range, each designed to detect specific types of
physical phenomena.

4.1 WORKING

The working of a sensor depends on its type and the physical property it is designed to
detect. General working principle common to many sensors:

1. Detection of Physical Property:

Input: Sensors are designed to detect specific physical properties such as light, temperature,
pressure, motion, or chemical composition.
Interaction: When the sensor is exposed to the target physical property, it undergoes a
change.

2. Transduction:

Transformation: The change in the physical property is transduced into a measurable and
often electrical signal. Different sensors employ various transduction mechanisms like
Electromagnetic Transduction, Piezoelectric Transduction, Thermal Transduction.

3. Output:

Representation: The processed signal is then represented in a form suitable for

interpretation or use.
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Output Interface: Sensors typically have an output interface, which could be analog
voltage, current, digital signals, or other specific output types depending on the sensor type.

4.2 TYPES OF SENSORS

In automation, various types of sensors are used to detect and measure physical
properties, providing crucial input for control systems to make decisions and automate
processes. These sensors are integral components in automated systems. The
combination of different sensor types in an automation setup allows for sophisticated
control and monitoring capabilities across various industries. Here are some main types
of sensors commonly used in automation:

1. Proximity Sensors:

 Working Principle: Detect the presence or absence of an object without physical

contact.

 Types: Inductive, capacitive, ultrasonic, photoelectric.

 Applications: Conveyor systems, robotics, automated doors.

2. Photoelectric Sensors:

 Working Principle: Emit a beam of light and detect changes in the light pattern
when an object interrupts the beam.

 Types: Through-beam, retro-reflective, diffuse reflective.

 Applications: Object detection, counting, sorting.

3. Pressure Sensors:

 Working Principle: Measure pressure changes and convert them into electrical
signals.

 Types: Piezoelectric, piezoresistive, capacitive.

 Applications: Industrial automation, pneumatic systems, hydraulic systems.

4. Temperature Sensors:

 Working Principle: Measure temperature changes and convert them into

electrical signals.

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 Types: Thermocouples, thermistors, infrared sensors.

 Applications: Climate control, industrial processes, equipment monitoring.

5. Motion Sensors:

 Working Principle: Detect movement or acceleration.

 Types: Accelerometers, gyroscopes, infrared motion detectors.

 Applications: Robotics, security systems, gaming consoles.

6. Level Sensors:

 Working Principle: Measure the level of liquids or solids.

 Types: Ultrasonic, capacitive, float.

 Applications: Tank level monitoring, chemical processing.

7. Flow Sensors:

 Working Principle: Measure the flow rate of liquids or gases.

 Types: Turbine, electromagnetic, ultrasonic.

 Applications: Water management, chemical processing, HVAC systems.

8. Humidity Sensors:

 Working Principle: Measure the moisture content in the air.

 Types: Capacitive, resistive, optical.

 Applications: Climate control, agricultural automation, food processing.

9. Force Sensors:

 Working Principle: Measure force or load.

 Types: Strain gauges, piezoelectric, capacitive.

 Applications: Robotics, industrial automation, material testing.

10. Gas Sensors:

 Working Principle: Detect the presence and concentration of gases.

 Types: Electrochemical, semiconductor, infrared.

 Applications: Air quality monitoring, industrial safety, environmental

monitoring

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CHAPTER 5
OTHER EQUIPMENTS
5.1 Relays

Electrical Relays are essential and crucial because they help to control the high current loads
by using a small amount of current. Relay applies voltage to the coil that causes low current
flow through it. It allows a larger current to pass through the contacts and control
the electrical load. Relays are essential for Applications where a low-power control signal
needs to command high-power circuits.

A relay is an electrically operated switch that uses an electromagnet to open or close any
electrical circuit. In other words, A Relay is an electromechanical switch that has the ability
to turn ON or OFF any electrical circuit. It consists of a flexible moving mechanical part
that can be controlled electrically through an electromagnet.
Types of relays

1. Electrothermal relay: When two different materials are joined together it forms into
a bimetallic strip. When this strip is energized it tends to bend, this property is used
in such a way that the bending nature makes a connection with the contacts.
2. Electromechanical relay: With the help of few mechanical parts and based on the
property of an electromagnet a connection is made with the contacts.
3. Solid State relay: Instead of using mechanical parts as in electrothermal and
electromechanical relays, it uses semiconductor devices. So, the switching speed of
the device can be made easier and faster. The main advantages of this relay are its
more life span and faster switching operation compared to other relays.
4. Hybrid relay: It is the combination of both electromechanical and solid-state relays.
5. Protective Relays: These are designed to detect abnormal conditions such as
overcurrent, overvoltage, or under-frequency, and trigger protective actions to
prevent equipment damage.
6. Latching relays: Latching relays hold the position of contacts indefinitely even if the
supply to the coil is removed. It consists of two separate coils, one to latch and others
to release.

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Applications

 They are used in electronic circuits and home appliances for isolating low voltage or
DC circuits from high voltage AC circuits.
 They are the backbone of industrial process automation systems. They are used in
combination with PLCs for process control. They are one of the key components in
an automation cabinet.
 Used for signalling and control in railway networks.
 In motor control circuits for motor switching, protection as well as control.
 In substations and power distribution centers for sensing various faults and operating
the circuit breaker.

Fig 5.1 Electromagnetic and solid-state relay

5.2 Switch Mode Power Supply (SMPS)

A switching regulator is included in an electronic power supply called a switched-mode

power supply (SMPS) to facilitate effective electrical power conversion. An SMPS converts
voltage and current while transferring power to DC loads via a DC or AC source, just like
other suppliers.
Switching regulators are employed in SMPS devices to maintain & regulate the output
voltage by turning on or off the load current. The mean value between on and off is the
appropriate power output for a system. The SMPS reduces depletion strength because, in
contrast to the linear power supply, it carries transistor switches between low dissipation,
full-on as well as full-off phases and spends significantly fewer seconds in high dissipation
cycles.
SMPS can utilize different topologies, such as buck, boost, buck-boost, and flyback, to achieve
the desired output voltage. The specific topology employed depends on factors such as the input
voltage range, load characteristics, and efficiency requirements.

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Advantages of SMPS

 The SMPS weighs relatively little.

 The production spectrum of SMPS is broad.
 The switch-mode power supply is compact size.
 Strongly anti-interference.
 It is recommended to use SMPS power consumption, which is normally between 60 – 70
percent.
Disadvantages of SMPS

 The SMPS has a very high level of complexity.

 There is only one voltage output in an SMPS.
 SMPS control is poorer and its output ripple is higher.
 In the case of SMPS, the production reflect is substantial and its control is inadequate.
 SMPS usage is limited to step-down regulation.

Fig 5.2 SMPS

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CHAPTER 6
SCADA

SCADA stands for Supervisory Control and Data Acquisition. It's a system of software and
hardware elements that allows industrial organizations to control industrial processes locally
or at remote locations. SCADA systems are used in industries such as telecommunications,
water and waste control, energy, oil and gas refining, transportation, and more.

The primary function of SCADA is to collect data from sensors and devices in real-time and
to process, analyze, and present this data to operators or supervisors. It enables them to
monitor processes and make decisions based on the data received. Additionally, SCADA
systems often include control capabilities, allowing operators to remotely control industrial
processes, adjust setpoints, and issue commands to field devices.

Main Components of SCADA:

Remote Terminal Units (RTUs) or Programmable Logic Controllers (PLCs): These are
field devices that monitor and control processes such as valves, pumps, sensors, etc.
Human-Machine Interface (HMI): This is the graphical interface used by operators to
monitor the processes in real-time and interact with the system.
Communication infrastructure: SCADA systems rely on communication networks to
transmit data between field devices and the central control system. These networks can be
wired or wireless, depending on the application and requirements.
Supervisory system: This is the central software component that collects data from
RTUs/PLCs, processes it, and presents it to operators through the HMI. It also includes
functions for alarm management, historical data logging, and reporting

6.1 MOVICON Software

Movicon is a popular SCADA/HMI (Supervisory Control and Data Acquisition/Human-

Machine Interface) software developed by Progea. It is widely used in industrial automation
and control applications across various industries.

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Key Features:
User-Friendly Interface: Movicon provides an intuitive and user-friendly interface for
designing and operating SCADA systems. Its drag-and-drop interface makes it easy to
create graphical displays, configure alarms, and set up data logging.

Openness and Flexibility: Movicon is designed to be an open and flexible platform that
supports a wide range of hardware devices, communication protocols, and data sources. It
allows integration with PLCs, RTUs, DCS (Distributed Control Systems), databases, and
other industrial equipment.

Scalability: Movicon is scalable, meaning it can be used for small, standalone applications
as well as large, distributed systems. It can handle complex control and monitoring
requirements across multiple sites or locations.

Advanced Functionality: Movicon offers advanced functionality such as trending, recipe

management, batch processing, scheduling, and scripting. It also supports advanced data
visualization techniques and analysis tools for optimizing industrial processes.

Security: Movicon includes security features to protect SCADA systems from unauthorized
access, data breaches, and cyber threats. It supports user authentication, role-based access
control, and encryption to ensure the integrity and confidentiality of data.

Fig 6.1 MOVICON software

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CHAPTER 7
HANDS ON EXPERIMENTS

7. 1 PLC Program for bottle-filling process

AIM: To simulate the process using Plc logic should be solved using ladder program technique
for bottle packaging process.

Sequence of Tasks:

 Start button is on

 Motor is on

 Conveyor starts

 Bottle gets detected by sensor

 Motor gets off and conveyor stops

 Solenoid valve gets on

 Upper sensor senses the water level

 Solenoid valve gets off

 Motor gets on and conveyor starts

Fig 7.1 Schematic diagram

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Fig 7.1.1 Ladder logic

In Logic:
cycleon – start button
cycleled – motor
sensor1 - bottom proximity sensor
sensorfull – upper proximity sensor
solenoid(set) – valve gets on
solenoid(reset) – valve gets off

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7.2 PLC Program for Material Sorting System

Sequence of events:

 When the start button is pressed, the conveyor turns on the conveyor belt rotation

 Sensor 1 waits for the object to be placed on the conveyor belt

 As it proceeds, both sensor 2 and sensor 3 determines the height of the object and classify the

material

 The solenoid is also triggered to change the path.

 Once the sensor 4 senses the object, solenoid changes the position and thus the path.

 The conveyor runs again and the material is dropped into appropriate collection box.

Fig 7.2 Material Sorting System

Procedure:

 Switch on the computer and start the “CODE SYS‟.

 Choose the respective PLC board and start configuring the ON board connections for the same.

 Construct the ladder diagram as shown in the diagram.

 Make the necessary connections from the PLC kit to the processor set up. Using the patch chords
provided.
 Also provide the process setup power supply necessary for it to work.

 Build the file created and download the same on to the PLC using RS 232 interface.

 Run the program on software, and switch on the process setup to observe 3 different categories
of material sorted

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Ladder Diagram

Fig 7.2.1 Material sorting ladder logic

The simulation is done successfully using PLC logic using ladder program for material sorting system.

7.3 To setup a small organization using Cisko Packet Tracer

Step 1: Open the Cisco Packet Tracer.
Step 2: After opening the Cisco Packet tracer, add a router, 4 switches, 6 PCs, and a server
to build a network for a small organization.
Router 1
Switch 4
Server 1
Pc 6

Table 7.1 Requirements

Assume there’re four sections in this small organization:
1. Administration section
2. Accounts and Finance
3. Information Technology (IT).
4. Database section.

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There are four different networks in this organization:
192.168.1.0/24
192.168.2.0/24
192.168.3.0/24
192.168.4.0/24.

Fig 7.3 Network established

Step 3: Connect the router with 4 switches, 3 switches are connected with 2PCs each, and 1
switch is connected with the server using a cable.
Step 4: Give IP, subnet mask, default gateway, and DNS server to each PC and server in
this network. To assign IP to each PC and server, click on each PC, go to Desktop, and then
click on IP configuration.

Table 7.2 assigning IP addresses , Subnet mask , Default Gateway ,DNS server

Components IP Address Subnet Mask Default DNS Server

Gateway
PC0 192.168.2.3 255.255.255.0 192.168.2.1 192.168.1.100
PC1 192.168.2.2 255.255.255.0 192.168.2.1 192.168.1.100
PC2 192.168.3.3 255.255.255.0 192.168.3.1 192.168.1.100
PC3 192.168.3.2 255.255.255.0 192.168.3.1 192.168.1.100
PC4 192.168.4.3 255.255.255.0 192.168.4.1 192.168.1.100
PC5 192.168.4.2 255.255.255.0 192.168.4.1 192.168.1.100
Server 192.168.1.100 255.255.255.0 192.168.1.1 192.168.1.100

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Fig7.3.1 Assigning IP address, subnet mask, default gateway

Step 5: Now, configure the router according to the details given below and then turn on the
port status.
Table 7.3 Fast Ethernet

FastEthernet0/0 192.168.2.1 255.255.255.0

FastEthernet0/1 192.168.3.1 255.255.255.0
FastEthernet1/0 192.168.1.1 255.255.255.0
FastEthernet1/1 192.168.4.1 255.255.255.0

For example, for FastEthernet0/1:

Fig 7.3.2 Fast Ethernet

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Step 6: Now, we’ve to maintain the DNS server. For this click on the server, go to the
services section, and then click on DNS. Turn on the DNS server, Enter any domain in the
‘Name’ section For eg: “www.google.com” enter the IP address of the server in the
‘Address section’, and then click on save.

Fig 7.3.3 Setting up DNS server

Step 7: Again, click on the server, go to services, and then click on HTTP. Turn on the
HTTP and HTTPS services. You can also edit the index.html file which will show when you
search the domain you entered in DNS in the web browser.

Step 8: To check the connection between PCs present in different networks in this
organization, you can use the ping command. Click on any PC, go to Desktop, and then
click on the command prompt, enter the ping command, and check if they’re able to
communicate with each other.
For example , ping 192.168.3.1

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fig 7.3.4 Command prompt

Step 9: Click on any PC, go to the Desktop section, and then open the web browser. Enter
the domain or address you’ve given in the DNS server and it will show the index.html file
from HTTP services.

Fig 7.3.5 web browser

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7.4 To simulate IoT based home automation using Cisco Packet Tracer

Step 1: Drag and place the components from the home components section in home icon as
shown in the below figure

Fig 7.4 IoT components

Step 2: Additionally, you can change the name of Appliances by clicking on respective
Appliances and select the config option. You have to repeat the same steps to rename the
other devices too. For example we have shown below

Fig 7.4.1 Naming of IoT device

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Step 3: Establishing a wireless connection. Go to wireless devices and choose home gateway
Step 4: Now copy the SSID of home gateway by clicking on home gateway

Fig 7.4.2 Copying of SSID

Step 5: Its necessary to configure all devices to connect wirelessly to Home Gateway. This can
be achieved by following the below figure

Fig 7.4.3 To connect to home gateway

Step 6: Then paste the SSID in each appliance by clicking on the configuration. Similarly repeat
the steps for other devices as well.

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Fig 7.4.4 pasting the SSID

Step 7: Now selecting IOT server as home gateway to all appliances. This can be done by
following the below figure

Fig 7.4.5 IOT Server

Step 8: Thus, we can notice that all devices are connected to the home gateway.

Fig 7.4.6 Connected to the home gateway

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Step 9: Now selecting smart device to control and monitor appliances. Select end devices at
bottom left corner.
Step 10: Now connect your smart device also to your home gateway

Fig 7.4.7 connecting smart device to home gateway

Step 11: Thus, your smart device is connected to your home gateway. Click on smart device and
choose desktop. You can now log in.

Fig 7.4.8 Login page

Step 12: Finally, we can control and monitor in the dashboard.

Fig 7.4.9 Dashboard

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Result:

Fig 7.4.10 Overall outcome

7.5 To develop a SCADA screen by creating tags manually in Movicon

Step 1: Open the Movicon software.
Step 2: After opening the software, create new project and add a new screen.
Step 3: From toolbox, take 4 switches and name it as Lamp1,2,3 and 4 ON/OFF switch. Then go
to properties and select command types as on/off command and save.
Step 4: Take 4 LEDs for lamps from toolbox. Assign colors for on and off condition in the
properties of LEDs and command type as executive command.
Step 5: In Project explorer section, under Real Time DB - variable tags, create a new folder
called animation and add 4 tags by selecting add new tags for Lamp1,2,3 and 4 respectively.

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Fig 7.5 SCADA Screen

Step 5: In Project explorer section, under Real Time DB - variable tags, create a new folder
called animation and add 4 tags by selecting add new tags for Lamp1,2,3 and 4 respectively.
Step 6: Assign the tags to the respective switch and lamp in the properties under execution –
command variable and save.
Step 7: Run the Software, and when the switches are pressed, its respective lamp will glow.

Fig 7.5.1 Outcome

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CHAPTER 8

INTERNSHIP EXPERIENCE

The time I spent as an intern from 14th August 2023 to 9th September 2023 was
memorable one. I had so many experiences and opportunities which helped me to discover
my potential. Internship in RVCE-Bosch Rexroth helped me to increase my skills and
knowledge, understanding of particular job in an industry, gaining an insight into the way
organization operates and challenges they face and networking. Internship also provided an
opportunity for me to get to grips with working- meeting deadlines and working in team. It
clarifies whether this type of work really for me.

I am feeling too much glad to work as an intern at RVCE-Bosch Rexroth. For interns
working hours are from morning 9:30 to evening 4:00. During this period of my
internship, initially I was trained on PLC with several tasks and application-based
programs. I have learnt how projects will be done in real scenario.

8.1 TECHNICAL OUTCOMES

My goals in internship are:

1. Planning and creating a rewarding event and utilizing imaginative ideas to create
dynamic experiences.
2. Helping organization to build their brand and connect with their customers to strengthen
relationships.
3. Ensuring that the clients expectations are exceeded in the flawless staging of the
event, taking care of all the details so that the clients can have peace of mind.

I have learnt new software tool that is ABB- Codesys and Movicon. ABB- Codesys is a
platform to develop a PLC programming logics and Movicon is to develop SCADA screens

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I learnt about sensor-based application like temperature sensor, object sensor, motor and I
Got hands on experience. Finally, I gained real-world experience, often learning about the
latest technology and equipment used in the workplace.

8.2 NON-TECHNICAL OUTCOMES

8.2.1 Verbal and Written Communication

Along with the technical aspects I have grown my verbal and written communication skills.
In any of the field, it may be technical and non-technical like management; good verbal
and written communication skill is must. I came to know the significance of verbal and
written communication skill.

8.2.2 Personality Development

In course of this internship the best part was how I developed myself. This internship
boosted me with lots of confidence. I talked to many employees, senior officials. It was an
amazing experience in getting into conversation with them. I learnt to behave with senior
officials. Personality developments very important factor to survive in any of the
organization.

8.2.3 Time Management

Time Management is a very important skill which takes anyone towards their success. In
an internship what I saw is everyone is very particulars about timing.

8.3 OVERALL CONCLUSION

As we all know that Codesys and Movicon is a open software and used widely in automation
industry. Programming language of PLC involves block diagrams, logics which makes easy
to implement as well as understand.

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REFERENCES

[1] https://www.boschrexroth.com/en/in/
[2] https://en.wikipedia.org/wiki/Bosch_Rexroth
[3] https://cdn.automationdirect.com/static/eBooks/PLC%20Handbook.pdf
[4] https://davidrojasticsplc.wordpress.com/wp-content/uploads/2009/01/libro-en-espanol.pdf
[5] DESIGNING OF AUTOMATIC BOTTLE FILLING SYSTEM USING PLC by Prateek
Siroya, Aashiq Mahammad Shah, Rahul Jat , e-ISSN: 2582-5208
[6] PLC and SCADA based Industrial Automated System by Basant Tomar, Narendra Kumar
DOI: 10.1109/INOCON50539.2020.9298190
[7] https://www.cedengineering.com/userfiles/SCADA%20System%20Fundamentals-R1.pdf
[8] https://www.netacad.com/courses/packet-tracer

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