Internship report phase 2 (1)
Internship report phase 2 (1)
submitted by
YOGESHWAR N
(4NI22EE433)
Ms. ASHWINI G
Assistant Professor
Dept. of Electrical and Electronics Engineering
The National Institute of Engineering, Mysuru
2025
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
CERTIFICATE
This is to certify that the internship report entitled “FAR – FENWICK AND RAVI” is a bona
fide work carried out by Mr. Yogeshwar N (4NI22EE433) under the guidance of Ms. Ashwini
G. This report is submitted in partial fulfillment of the requirements for the award of the degree
of Bachelor of Engineering in Electrical and Electronics Engineering at The National Institute
of Engineering (An Autonomous Institute under VTU) during the academic year 2024-2025.
Principal
The National Institute of
Engineering Mysuru
1.
2.
ACKNOWLEDGEMENT
I express my sincere gratitude to everyone who has contributed to the successful completion of
my internship. I extend my heartfelt thanks to all those who have encouraged and guided me
throughout this learning experience. I would like to convey my profound appreciation to my
guide, Ms. Ashwini G for her continuous support, insightful guidance, and valuable suggestions.
Her expertise and encouragement have been instrumental in enhancing my knowledge and skills
during this internship. I also extend my gratitude to Dr. Pradeepa H, Head of the Department,
for his support and leadership, which have provided me with a strong foundation in my field of
study. I consider myself privileged to have been a part of The National Institute of Engineering,
Mysuru, where I have gained invaluable learning experiences.
Lastly, I extend my gratitude to all the faculty and staff members of the Department of Electrical
and Electronics Engineering for their support and assistance throughout my internship journey.
YOGESHWAR N
(4NI22EE433)
ABSTRACT
This internship report highlights the practical experience and technical skills gained during my internship
at Fenwick and Ravi (FAR), a leading manufacturer specializing in automation solutions. My primary
focus areas were the Quick Feeder (QF) bar feeder system, the intermediate magazine for the auto loader,
and the implementation of motor control using a Delta Variable Frequency Drive (VFD)—all integral to
modern CNC machine automation.
During the internship, I was actively involved in the panel board wiring and feedback switch analysis of
the Quick Feeder system. This included hands-on work with proximity sensors used for bar detection,
positioning, and error handling, as well as HMI interfacing to monitor and control feeder operations. I
participated in the full-cycle testing process to verify proper sensor feedback and reliable signal
communication with the PLC.
Additionally, I contributed to the design and implementation of the intermediate magazine for the auto
loader, where I assisted in developing automation logic for seamless part transfer and loading. This
enhanced my understanding of sensor placement, timing coordination, and control logic design in an
industrial setup.
Furthermore, I worked on the VFD-based motor control project using a Delta VFD055E43A, where I
performed the wiring for a Siemens 3-phase induction motor and studied key parameters like V/f control,
frequency settings, and protection features. This project deepened my knowledge of variable speed drive
systems and energy-efficient motor operation.
Overall, this internship significantly strengthened my skills in PLC programming, control panel wiring,
sensor integration, and motor drive control, giving me a solid foundation for a career in industrial
automation and control systems.
CONTENTS
Acknowledgement i
Abstract ii
Contents iii
3.1 Introduction 16
3.2 Project Methodology 16
3.3 Main Components & Specifications 16-17
3.4 Circuit Diagram & Wiring Connections 18
4. Chapter 4: Conclusion 19
5. Chapter 5: References 20
FAR – FENWICK AND RAVI
Chapter 1
Quick Feeder Barfeeder Machine
1.1 Introduction to Quick Feeder Barfeeder
The Quick Feeder (QF) is an automated bar feeding system designed to enhance the efficiency of CNC
machines by enabling smooth and continuous loading of bar stock. It automates the feeding process,
reducing manual intervention and increasing productivity in machining operations. The system consists
of a loader mechanism, pusher mechanism, proximity sensors, control panel, and PLC integration for
automated control.
• Feeding by Hydraulic/Pneumatic
• Easy to setup
• High productivity
• Economically priced
• Improved Efficiency – Ensures uninterrupted bar feeding, reducing machine idle time.
• Increased Precision – Provides accurate positioning and feeding of bars for high-quality
machining.
• Reduced Manual Effort – Minimizes operator intervention, improving safety and consistency.
• Enhanced Productivity – Allows CNC machines to operate with minimal downtime, leading to
higher output.
• Automation & Control – Integrates with PLC and HMI for automated monitoring and control,
reducing errors.
Specifications:
Relay Output:
2.Control System
PLC (Programmable Logic Controller) – Delta Model
2.1 Delta DVP14SS2 (Main PLC Unit)
• Digital Inputs: 8
• Digital Outputs: 6 (Relay/Transistor type)
• Power Supply: 24V DC
• Communication: RS485 (Modbus)
• Function: Controls bar feeder operations by receiving sensor inputs and triggering outputs.
• Application: Manages automation logic, controls relays, solenoids, and motors.
1.5 Conclusion
I worked on the control panel wiring and understood the complete bar feeder mechanism in
coordination with a CNC machine. This included hands-on integration of relays, MCBs, contactors,
and proximity sensors. I observed how PLC logic and HMI manage the automated bar loading and
ejection process. The project enhanced my understanding of sensor feedback, automation workflow,
and industrial safety practices. Overall, it strengthened my practical skills in electrical wiring, system
logic, and real-time control integration.
Key Learning:
✓ Gained hands-on experience in industrial control panel wiring, sensor integration, and
understanding the PLC-HMI-based bar feeding mechanism.
✓ Developed practical knowledge of automation workflow, safety practices, and system
synchronization with CNC machines.
This project focuses on creating a programmable solution using ladder logic to control various pneumatic
cylinder movements such as forward, down, up, and reverse, based on feedback from sensors. The system
ensures proper synchronization between magazine job presence detection and cylinder actuation.
In addition, the project emphasizes eliminating human error, increasing loading efficiency, and reducing
operator fatigue. The operation is initiated via a start button, and it executes the cycle based on input
from job sensors, cylinder position sensors, and timers that help delay or pace each movement for smooth
operation.
By using the Delta DVP-14SS2 PLC, the system achieves reliable performance in real-time control.
Inputs from photoelectric sensors ensure that jobs are detected before any motion occurs, and solenoids
control the pneumatic cylinders precisely. The use of timers introduces necessary delays to simulate
realistic mechanical movements, such as waiting for full extension or retraction before proceeding to the
next stage.
The integration of this system into an automated production line brings advantages such as increased
productivity, consistent job handling, and reduced need for manual supervision. With proper calibration
and programming, the intermediate magazine auto loader proves to be a valuable addition to smart
manufacturing practices.
Block Diagram:
• Model: Saizer
• Type: Manual rotary switch
• Function: Used to turn ON or OFF the main supply to the panel safely
• Brand: ABB
• Type: 2 Pole
• Function: Protection against overcurrent or short circuits on both Live and Neutral lines
• Rated Voltage: 230V AC
• Rated Current: Typically 6A to 10A (as per design)
• Brand: Delta
• Input Range: 85–264V AC or 120–370V DC
• Output: 24V DC / 2A or 5A depending on load
• Function: Converts 230V AC to 24V DC to power sensors, relays, and the PLC
8. Power ON Indicators
• Voltage: 24V DC
• Color: Green
• Function: Shows the status of control power availability in the panel
9. Sensors
• Type: Inductive
• Sensing Voltage: 24V DC
• Function: Detect metal objects (e.g., job presence or cylinder positions)
• Terminal Blocks
• Cable Ducts
• Ferrules and Tags
Down Start Delay Timer T2 Adds a delay before the cylinder moves down
2.6 Conclusion
The implementation of the Intermediate Magazine for Auto Loader system has significantly improved
the automation and efficiency of job handling in a semi-automated production environment. By
integrating a Delta DVP-14SS2 PLC, reliable sensors, and well-structured ladder logic programming,
the system ensures smooth, accurate, and safe transfer of jobs from the magazine to the workstation.
I worked on the wiring of control components, sensor placement, and PLC ladder logic development for
cylinder actuation and sequencing. I also assisted in testing the system’s response to sensor feedback and
fine-tuning the logic for reliable operation.
The use of proximity and reed sensors enables real-time detection of job presence and cylinder positions,
while timers and relays ensure precise coordination of movements. The system operates with minimal
human intervention, reducing cycle time and increasing overall productivity.
Overall, the project demonstrates a practical and scalable automation solution, with room for further
expansion and optimization. It serves as a strong foundation for future developments in automated
material handling, aligned with modern industrial automation standards.
Parameter Specification
Input Current 14 A
Output Current 13 A
Parameter Specification
Brand Siemens
Frequency 50 Hz
Efficiency 77.1%
Weight 16 kg
Brand ABB