Industrial visit Report of sugar factory

TITLE: Industrial Visit Report of Programmable logic controller .

DATE: 24/10/2024

PLACE: Someshwar Sahakari Sakhar Karkhana,Someshwarnagar,Tal.Baramati,Dist.Pune

As per curriculum of Pune University our department arranged a visit at Someshwar
Sahakari Sakhar Karkhana, Someshwarnagar, Tal.Baramati Dist.Pune on 24.10.2024, for second
year students of Mechanical Engineering Department. This visit was helpful to develop and
enhance the practical knowledge of students and they get to know about Demonstration and
actual working of PLC. Objective for this visit is to gain detail knowledge about the PLC.

Name of Company Someshwar Sahakari Sakhar Karkhana

Address of Industry Someshwarnagar,Tal.Baramati,Dist.Pune

Established Year 1962

Nature of Business Sugar Selling.

Capacity 5500-8000Tons of Canes Per Day

Date of Visit 24/10/2024

Concerned Subject Mechatronics

Faculty Coordinators Prof. Sorate S.B.

Sugar factory that we visited consist of following section,

 Automation section.

 How they work

 How they communicate

 How they compare to hard-wired systems

 How they are designed

 Programmable logic controller (PLC)

A programmable logic controller (PLC) is a digital computer that controls and monitors industrial
equipment and machinery. PLCs are used in industrial automation systems (ICSs) and are often
called the "brains of a production line".

Here are some things to know about PLCs:

How they work

PLCs use custom instructions to perform tasks, and they operate in a repeating loop of input scan,
program scan, output scan, and housekeeping.

How they communicate

PLCs use a variety of communication protocols to communicate with external devices, field
components, and over networks.

How they compare to hard-wired systems

PLCs are smaller, easier to change, and have integrated diagnostics. They also replace many of the
Inter connecting wires required by hard-wired systems.

How they are designed

PLCs come in many sizes and form factors, and some can be customized with additional modules.
When designing a PLC enclosure, designers consider things like:

NEMA or IP ratings to protect against hazards

Rugged construction materials like polycarbonate, ABS, steel, or aluminum

Protection against EMI and RFI

Mounting flanges for surface mount electrical boxes

PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a housing
integral with the processor, to large rack-mounted modular devices with thousands of I/O, and
which are often networked to other PLC and SCADA systems.[1] They can be designed for many
arrangements of digital and analog I/O, extended temperature ranges, immunity to electrical noise,
and resistance to vibration and impact.

PLCs
were first developed in the automobile manufacturing industry to provide flexible, rugged and easily
programmable controllers to replace hard-wired relay logic systems. Dick Morley, who invented
the first PLC, the Modicon 084, for General Motors in 1968, is considered the father of PLC.

A PLC is an example of a hard real-time system since output results must be produced in response to
input conditions within a limited time, otherwise unintended operation may result. Programs to
control machine operation are typically stored in battery-backed-up or non-volatile memory.

Communications protocol used with its PLCs. Mudbugs has since become a standard open protocol
commonly used to connect many industrial electrical devices

One of the first 084 models built is now on display at Schneider Electric's facility in North Andover,
Massachusetts. It was presented to Modicon by GM, when the unit was retired after nearly twenty
years of uninterrupted service. Modicon used the 84 moniker at the end of its product range until
after the 984 made its appearance
Allen-Bradley
edit
In a parallel development, Odo Josef Struger is sometimes known as the "father of the programmable
logic controller" as well. He was involved in the invention of the Allen-Bradley programmable
logic controller and is credited with coining the PLC acronym. Allen-Bradley (now a brand owned
by Rockwell Automation) became a major PLC manufacturer in the United States during his
tenure. Struger played a leadership role in developing IEC 61131-3 PLC programming language
standards.

Early methods of programming edit

Many early PLC programming applications were not capable of graphical representation of the logic,
and so it was instead represented as a series of logic expressions in some kind of Boolean format,
similar to Boolean algebra. As programming terminals evolved, because ladder logic was a
familiar format used for electro-mechanical control panels, it became more commonly used.
Newer formats, such as state logic, function block diagrams, and structured text exist. Ladder
logic remains popular because PLCs solve the logic in a predictable and repeating sequence, and
ladder logic allows the person writing the logic to see any issues with the timing of the logic
sequence more easily than would be possible in other formats.

Up to the mid-1990s, PLCs were programmed using proprietary programming panels or special-
purpose programming terminals, which often had dedicated function keys representing the various
logical elements of PLC programs. Some proprietary programming terminals displayed the
elements of PLC programs as graphic symbols, but plain ASCII character representations of
contacts, coils, and wires were common. Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were minimal due to a lack of memory capacity. The
oldest PLCs used magnetic-core memory.
Programming edit

Example of a ladder diagram logic

Programmable logic controllers are intended to be used by engineers without a programming
background. For this reason, a graphical programming language called Ladder Diagram (LD,
LAD) was first developed. It resembles the schematic diagram of a system built with
electromechanical relays and was adopted by many manufacturers and later standardized in the
IEC 61131-3 control systems programming standard. As of 2015, it is still widely used, thanks to
its simplicity.

As of 2015, the majority of PLC systems adhere to the IEC 61131-3 standard that defines 2 textual
programming languages: Structured Text (ST; similar to Pascal) and Instruction List (IL); as well
as 3 graphical languages: ladder logic, function block diagram and sequential function chart.
Instruction List (IL) was deprecated in the third edition of the standard.

Modern PLCs can be programmed in a variety of ways, from the relay-derived ladder logic to
programming languages such as specially adapted dialects of BASIC and C.

While the fundamental concepts of PLC programming are common to all manufacturers, differences
in I/O addressing, memory organization, and instruction sets mean that PLC programs are never
perfectly interchangeable between different makers. Even within the same product line of a single
manufacturer, different models may not be directly compatible.

Programming device edit

PLC programs are typically written in a programming device, which can take the form of a desktop
console, special software on a personal computer, or a handheld programming device.Then, the
program is downloaded to the PLC directly or over a network. It is stored either in non-volatile
flash memory or battery-backed-up RAM. In some programmable controllers, the program is
transferred from a personal computer to the PLC through a programming board that writes the
program into a removable chip, such as EPROM.

Manufacturers develop programming software for their controllers. In addition to being able to
program PLCs in multiple languages, they provide common features like hardware diagnostics
and maintenance, software debugging, and offline simulation.
Simulation edit
PLC simulation is a feature often found in PLC programming software. It allows for testing and
debugging early in a project's development.

Incorrectly programmed PLC can result in lost productivity and dangerous conditions. Testing the
project in simulation improves its quality, increases the level of safety associated with equipment
and can save costly downtime during the installation and commissioning of automated control
applications .