J.S. INSTITUTE OF J.S. INSTITUTE OF MANAGEMENT & MANAGEMENT &

TECHNOLOGYTECHNOLOGY

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Summer Training Seminar

Prepared by:Prepared by: Gaurav Khanna,Gaurav Khanna,

0725531017,0725531017,44thth ECE ECE 2

Ordnance Equipment Factory, Kanpur

Welcomes

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1859 Established as Government H & S Factory. 1862 Tannery was set up. 1960 Composite Boot Plant established. 1969 Rechristened as OEF, Kanpur. 1992 Ventured into International Market 1998 Established production of Electrical Safety

Shoe &Tail Unit of 1000 Lbs Bomb for IAF.2004 Shoe Oxford for Air Force.2004 Shorts P. C. Khaki. 2006-07 Bag Harness, Bag Kit Disruptive W/P with

Stroller [Duffle Bag].2007-08 Boot Paratrooper, Boot High Ankle,

Synthetic Camouflage Net, Tank WaterCollapsible 230 L [Improved Version].

Milestones

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FACTORY LAYOUT

• The Quila was built by Almasa Ali, Minister of Nawab Asaf-ud- Daula.

• Used by Nana Rao Peshwa during the First War of Independence 1857.

• Capt. John Stewarts of East India Co. established Commissary of Ordnance in 1859.

• First Tannery was established in 1862.

Heritage Building

•The Building was constructed by Raja of Oudh.• An underground tunnel connects the building with Bithoor. • The Anchor used by boats of Nana still exists.

Heritage Building

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Total Area of the Factory

30 Hectares

Total Area of Estate66 Hectares

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Assets Exhibition Ground

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Product Profile

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Product Profile Textile Division%V.O.P ( 80% )

Leather Division( 15% )

Engineering Division( 5% )

Bag Sleeping Mattress Kapok Net Mosquito Capes Waterproof Vehicle & Storage Cover Tents Infantry Combat Kit (ICK) N. B.C. Equipment Water Holding &

Carrying Equipt Bag Kit

Boot D.V.S. Industrial &

Electrical Safety Shoes

Saddlery items Gloves Leather Shoe Oxford

Components for Textile & Leather Division

Spares for weapon Tail Units• HSOB Ammunition Boxes & Carriers

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Textile Leather Engineering

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80

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Technology Share

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Production of Mattress Kapok

T. P. M. Ladies Shop

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Vacuum Dryer M/C Hot Air Conveyor

Lasting Operation Auto Spray

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CNC Machine Power Press 15

Quality Management

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LaboratoryWrap Reel Chemical Test Laboratory

Tensile Strength Testing Waterproofness testing for Sole Leather17

Flame Retardancy Test Colour Fastness to light. Bursting Strength Testing

Hardness Testing of Latex Foam

Test Sample Preparation Micro Processor based Tensile Strength Tester

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Quality Management

ISO 9001 – 2000 Certified.Well established Quality Assurance System.Started self-certification for Shorts Men PC

Khaki w.e.f. 01.04.2002. At present 9 items are self certified.Laboratory is accredited to ISO-17025 by

NABL, New Delhi vide their Certificate No. T-0663, dtd. 01.06.2004.

Responsibility for input material inspection taken over from DGQA w.e.f. 1st July 2005.

Final Rejection in production is NIL. 19

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What does PLC stand for?

PLC - programmable logic controller PLC implements logic control functions by means of a

program.

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Features

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PLC History

PLCs were first introduced in the 1960’s. The primary reason for designing such a device was eliminating the large cost involved in replacing the complicated relay based machine control systems. Bedford Associates (Bedford, MA) proposed something called a Modular Digital Controller (MODICON) to a major US car manufacturer. The MODICON 084 brought the world's first PLC into commercial production.

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Structure of a PLC

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Comparing traditional and programmable control systems

In traditional control, the switches S1, S2 and S3 must close for K1 to be turned on - the wiring makes the rule

In PLC systems, the program is written to perform the logic “when S1 is closed AND S2 is closed AND S3 is closed, THEN turn on K1” - the program makes the rule

It is much simpler to

change program then wiring! 25

A computer is optimized for calculation and display tasks A computer is programmed by specialists A PLC is designed for (logic) control and regulation tasks A PLC is programmed by non-specialists A PLC is well adapted to industrial environment

How does a PLC differ from a computer?

Why are PLCs so common? They are cost-effective They are flexible, reliable and compact They have significant advantages over traditional control systems based on relay

or pneumatics

Where are PLCs used?

In every industry where automation is involved, from individual machines to whole processes

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The logic control tasks such as interlocking, sequencing, timing and counting (previously undertaken with relays or pneumatics)

In addition, PLCs can perform a variety of calculation, communication and monitoring tasks

What tasks do PLCs perform?

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Inputs

Outputs & Power Supply

Com

mun

icat

ion

Ports

(RS-

485)

PLC Input/Output Devices

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Pushbuttons

Selector Switches

Limit Switches

Level Switches

Photoelectric Sensors

Proximity Sensors

Motor Starter Contacts

Relay Contacts

120/230 VAC

24 VDC

-Sourcing

-Sinking

Thumbwheel Switches

Input Devices / Output DevicesValves Motor Starters Solenoids Control Relays Alarms Lights Fans HornsRelays

-120 VAC/VDC-240 VAC-24 VAC/VDC

Triac-120/230 VAC

Transistor MOSFET-24 VDC

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Input Scan

Program ScanOutput Scan

Housekeeping

START

Each ladder rung is scanned using the data in the Input file. The resulting status (Logic being solved) is written to the Output file (“Output Image”).

The status of external inputs (terminal block voltage) is written to the Input image (“Input file”).

The Output Image data is transferred to the external output circuits, turning the output devices ON or OFF.

Internal checks on memory, speed and operation. Service any communication requests, etc.

PLC Operating Cycle

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Typical PLC Operating Cycle Input scan – inputs are read by

processor and stored in memory. Program scan – control program is

executed Input values stored in memory are used in the control logic calculations to determine values of outputs.

Output scan – output values are updated to agree with calculated values.

Time to perform the three steps (scan time) varies between 1 and 25 msec.

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PLC ProgrammingGraphical languages:

1. Ladder logic diagrams – most widely used2. Function block diagrams – instructions composed of

operation blocks that transform input signals3. Sequential function charts – series of steps and

transitions from one state to the next (Europe)

Text-based languages:

1. Instruction list - low-level computer language2. Structured text – high-level computer language

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Most PLC manufacturers offer software packages that allow a standard computer to be used as a programming terminal

Programming through standard computer

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BOOLEAN ALGEBRA

The techniques can model a logical system with a single equation.

The equation can then be simplified and/or manipulated into new forms.

The three basic operators are AND, OR and NOT; more complex operators include exclusive or (EOR), not and (NAND), not or (NOR).

Truth tables are a simple method for showing all of the possible combinations that will turn an output on or off.

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Logic Symbols, Truth Tables, and Equivalent Ladder/PLC Logic Diagrams

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Rules To Implement Ladder Logic From Boolean Equation

When simplifying Boolean equations that are to be implemented in ladder logic there are a few basic rules.

1. Eliminate NOTs that are for more than one variable. This normally includes replacing NAND and NOR functions with simpler ones using DeMorgan’s theorem.

2. Eliminate complex functions such as EORs with their equivalent.

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A Boolean Equation and Derived Circuit and Ladder Logic

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Advantages of PLCs Compared to Relay Control Panels

Programming a PLC is easier than wiring a relay control panel

PLC can be reprogrammed PLCs take less floor space Greater reliability, easier maintenance PLC can be connected to computer systems

(CIM) PLCs can perform a greater variety of control

functions

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Areas of Application· Manufacturing / Machining· Food / Beverage· Metals· Mining· Power· Petrochemical / Chemical· Conveyor control· Printed circuit board handling equipment· SCADA(Supervisory Control And Data Acquisition)· Remote pump/lift station (water/wastewater)· Flow monitoring for leak detection (Oil & Gas)· Strapping machinery / trash compactors· Palletizers· Compressor control· Amusement park rides and attractions· Hard-wired relay panels or Single Board Computers

Many,many more39

PLC can sense a vehicle at the entrance or exit, and open and close the gate automatically

The current vehicle count is easily determined by programming a simple counter

An application example 1: Gate Control

An application example 2: Conveyor System

PLC can be used to start/stop latching logic for motor control Counters can be used for monitoring product amounts

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CNC stands for Computer Numerical Control.

It is a versatile system that allows you to control the motion of tools and parts through computer programs that use numeric data.

CNC can be used with nearly any traditional machine.

CNC may be defined as the numerical control system where in a dedicated programs in a computer are used to replace some or all of its control functions.

In CNC the program is read once by he tape reader as the input device & is stored in the controller’s random access memory.

Controlling a machine tool by means of prepared program, which consists of blocks, or series of commands/numbers, is known as numerical control. Numerical Control [NC] for machine tools was introduced in 1950 by Prof. John T Parsons. The first CNC machine was built at the Massachusetts institute of technology [MIT] in 1953 by joint efforts of US Air force, MIT and the Parsons Corporation.

   

Introduction to CNC?

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Servo Motor Slide

Axis servocontroller

ComputerNumerical

Control

Encoder

ProgrammableMachinecontroller

UserInterface

(key board,monitor)

Machine Tool

Basic Functional Blocks Of A CNC Machine

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Functions Of A Control SystemSome important functions, controlled by control system.Displacement of machine slidesAngular rotation of circular tableStart / Stop of the main spindleChanging of spindle speedReverse spindle directionChanging the feed rate of machine slidesRotate tool turretChange tool Coolant ON / OFFLock table in position 47

Machine ToolsTurning center

A sophisticated CNC machine that specializes in turning, boring, drilling, and threading operations, all at the same location.

SpindleThe part of the machine tool that spins. On the turning center, the spindle

holds the work piece, On the machining center, the spindle holds a cutting tool.

Turret  This holds the tools required for machining.

Usually on a turret in the rear, most lathes have 8 to 12 tools on a single, indexing turret. 

Axis This is the moving slide, and a turning center has a minimum of two axes.(named X and Z),controlled by the CNC. The turret is mounted on the axes in such a way that,The tool can be moved in both directions.

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z

x

Z axis

X axis

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Turning center Operations FacingTurningDrillingBoringGrooving on OD or IDFace groovingChamferingThread Cutting Etc.,,

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Structure of a CNC program

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Evolution

• Punched tape and input through tape reader.

• Programming directly on the machine.• Programming through hand held device.• Programming from centralized PC.

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Part drawing - indicates which are the characteristics to be machinedMachining plan – how many set ups, fixtures, tooling, sequence of operation etc.Part programming – Writing program considering the machining plan.

Process of Programming

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Part drawing Part programming CNC Machine

tool

Programming Operation

Basic Flow For CNC Preparation

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How to set the machineMachine ON

Origin

Fixture Mounting

Fixture dialing

Locator/clamp fixing

Tool mtg on the holders

Measure the tool length

Tool pocketing

Tool offset inputing

Programming

Find work co ordinate

Dry run with out component/single block

Cutting in single block

Rapid /feed lesser rate

Component inspection

Correction of work co ordiante

Correction of tool offset

Component cutting @100% feed/ speed/Rapid 55

Advantages of CNC

FlexibilityAccuracySpeedSimplified fixture and generic cutting toolsStorage of machining skill in NC programsLess skilled operators will doLess fatigue to the operatorsReduced lead timeGreater flexibilityUser written programsProgram editing at the machine site

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