DEBRE BIRHAN UNIVERSITY

COLLEGE OF ENGINEERING
DEPARTEMENT OF ELECTRICAL AND COMPUTER ENGINEERING

INTERNSHIP REPORT AT ELSEWEDY CABLES ETHIOPIA

PLC
By:
Mengistu Biruke DBUR /0535/12
Dalasa Oljira DBUR/0552/12
Tadese Taye DBUR/0534/12
Period of internship: November 20, 2023 to February 18, 2024 G.C
university Advisor: Addisalem H.
company supervisor: Engineer Ayana
February 20, 2024 G.C
Debre Berhan, Ethiopia
 DECLARATION
th
We are 5 year electrical and computer Engineering student at Debre Birhan university, we declare
that this report is our original work based on the past consecutive for three month’s internship
programs from first week of November in 2023 to second week of January in 2024 at Elsewedy
Cables Ethiopia PLC.

In doing so, we assure that with all written above with our signature as follows.

Name of students Signature

1) Dalasa Oljira
2) Mengistu Biruke
3) Tadesse Taye

This is to certify that the above statement made by the candidates is correct to the best of my
knowledge and belief. This report has been submitted for the presentation with my approval.

Name of advisor Signature Date

i
 ACKNOWLEDGEMENTS
First of all, everything we would like to give our deepest thanks to GOD for giving us everything
that is good for us.
Secondly, we would like to thank our university industry linkage for employing this internship
program and its smooth linkage with industries.
Thirdly, we offer our heart gratitude to advisor Engineer. Ayana.T for his inspiration and guidance
in company.
Additionally, we would like to give special thanks to Mr. Engineer Bogale for his hospitality when
we get into company for the first time, and all the operators and engineers in company for their
encouragement for our effort to know about the company and technical support for us.
Lastly, we give thanks to our university advisor Mr. Addisalem.

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 Table of contents

Contents
DECLARATION .......................................................................................................................................... i
ACKNOWLEDGEMENTS ....................................................................................................................... ii
Table of contents .......................................................................................................................................... iii
List of figures ................................................................................................................................................. v
List of tables ................................................................................................................................................. vi
EXCUTIVE SUMMARY ................................................................................................................................. viii
CHAPTER ONE ......................................................................................................................................... 1
1. INTRODUCTION.................................................................................................................................. 1
1.1 Brief History of the Company ........................................................................................................ 1
1.2 Mission, Vision and Values of the company .................................................................................... 1
1.2.1 Mission ........................................................................................................................................ 1
1.2.2 Vision ........................................................................................................................................... 1
1.2.3 Core Values of the Company ..................................................................................................... 2
1.3 Main Product and Services .............................................................................................................. 2
1.4 Main Customers of the Company .................................................................................................... 4
1.5 Overall Organizational and Work Flow of the Company ............................................................. 5
CHAPTER TWO ........................................................................................................................................ 6
2. THE OVERALL INTERNSHIP EXPERIENCE ................................................................................. 6
2.1 How we got into the company ........................................................................................................... 6
2.2 Sections in the company and the work flow.................................................................................... 6
2.2.1 Metal section ............................................................................................................................... 6
2.2.2 Low Voltage Section ................................................................................................................. 15
2.2.3 Quality section .......................................................................................................................... 20
2.2.4 Maintenance section..................................................................................................................... 20
2.3 Procedures used for cable production .............................................................................................. 25
2.4 How good we have been performing our work tasks ..................................................................... 25
2.5 Challenges have been facing while performing work task ............................................................. 25
CHAPTER THREE .................................................................................................................................. 27
3. THE OVERALL BENEFITS YOU GAINED FROM THE INTERNSHIP ................................... 27
3.1 introduction to benefits of internship ............................................................................................ 27

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 3.1.1 Improving interpersonal communication skill.......................................................................... 27
3.1.2 upgrading theoretical knowledge............................................................................................ 28
3.1.3 Improving practical skill ......................................................................................................... 28
3.1.4 Improving team working skill ................................................................................................. 28
3.1.5 understanding about work ethics related issue ..................................................................... 29
3.1.6 Gaining entrepreneurship skill ............................................................................................... 30
CHAPTER FOUR..................................................................................................................................... 31
4. IDENTIFIED PROBLEM AND PROPOSED SOLUTION ............................................................. 31
4.1 Statement of problem...................................................................................................................... 31
4.2 Objective .......................................................................................................................................... 31
4.2.1 General Objective .................................................................................................................... 31
4.2.2 Specific Objective ..................................................................................................................... 31
4.3 Scope of Project ............................................................................................................................... 32
4.4 Significance of Project .................................................................................................................... 32
4.5 Limitation ........................................................................................................................................ 32
4.6 methodology..................................................................................................................................... 32
4.7 Components Used in the Proposed Project ................................................................................... 33
4.8 block diagram of the system ........................................................................................................... 39
4.9 Simulation and result ...................................................................................................................... 41
4.10 Visualization on WinCC HMI Screen ......................................................................................... 47
CHAPTER FIVE ...................................................................................................................................... 48
5. CONCLUSSION AND RECOMMENDATION................................................................................ 48
5.1 Conclusion ....................................................................................................................................... 48
5.2 Recommendation............................................................................................................................. 49
References .................................................................................................................................................. 50

iv
 List of figures
Figure 1. 1 Elsewedy cables Ethiopian plc ..................................................................................................... 2
Figure 1. 2 Over all organization and work flow of the company ................................................................. 5

Figure 2. 1 Drawing machine ...................................................................................................................... 10

Figure 2. 2 Machine types ........................................................................................................................... 12
Figure 2. 3 Rigid stranded machine ............................................................................................................. 13
Figure 2. 4 Sector conductors stranding ..................................................................................................... 14
Figure 2. 5 Extrusion process ...................................................................................................................... 16
Figure 2. 6 Block diagram of extrusion process .......................................................................................... 16
Figure 2. 7 Caterpillar .................................................................................................................................. 16
Figure 2. 8 Assembling process block diagram ........................................................................................... 17
Figure 2. 9 Assembly 1600 machine ........................................................................................................... 18
Figure 2. 10 Armoring process .................................................................................................................... 19
Figure 2. 11 Direct online motor starting mechanism ................................................................................ 21
Figure 2. 12 Forward-reverse motor starting mechanism .......................................................................... 22
Figure 2. 13 Star- delta motor starting mechanism .................................................................................... 22
Figure 2. 14 Forward-Reverse motor control using limit switch ................................................................ 23
Figure 2. 15 Starting motor in sequence ..................................................................................................... 24
Figure 2. 16 Procedures used for cable production .................................................................................... 25

Figure 4. 1 Block diagram of methodology of the system........................................................................... 33

Figure 4. 2 Power Supply............................................................................................................................. 34
Figure 4. 3 CPU ............................................................................................................................................ 35
Figure 4. 4 Proximity sensor ........................................................................................................................ 36
Figure 4. 5 push button switch .................................................................................................................... 37
Figure 4. 6 contactor ................................................................................................................................... 37
Figure 4. 7 Danfoss drive terminal details ................................................................................................... 38
Figure 4. 8 Block diagram of the system ..................................................................................................... 39
Figure 4. 9 energizing start relay ................................................................................................................. 41
Figure 4. 10 motor forward running ........................................................................................................... 42
Figure 4. 11 automatic motor running ladder diagram .............................................................................. 42
Figure 4. 12 energizing running relay by proximity sensor 1 ...................................................................... 43
Figure 4. 13 motor running reverse ............................................................................................................ 43
Figure 4. 14 motor jogging forward while running mode ........................................................................... 44
Figure 4. 15 motor jogging forward while stop mode ................................................................................ 45
Figure 4. 16 motor jogging reverse while running mode ............................................................................ 45
Figure 4. 17 motor jogging reverse while stop mode ................................................................................. 46
Figure 4. 18 CPU device configuration with input and output module ...................................................... 46
Figure 4. 19 HMI visualization view............................................................................................................. 47

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 List of tables
Table 2. 1 Properties of raw material of cable factory .................................................................................. 9
Table 2. 2 Comparison between Copper and Aluminum Conductor cable ................................................... 9
Table2. 3 Formation of wire with the number of layer Conductor ............................................................. 13
Table 2. 4 Formation of wire with the number of layer .............................................................................. 13

Table 4. 1 PLC inputs ................................................................................................................................... 39

Table 4. 2 PLC outputs ................................................................................................................................. 40

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 ABBERIVATION
AC alternating current
AL aluminum
CPU central processing unit
CU copper
DC direct current
DOL direct online
EEPCO Ethiopian electric power corporation
HMI human machine interface
HV high voltage
LAN local area network
TIA totally integrated automation
PVC polyvinyl chloride
XLPE cross link polyethylene
IACS international
MV medium voltage
STA steel tape armoring
SWA steel wire armoring
NEMA national electrical manufacturers
association
PLC programable logic controller
PLC public limited company

vii
 EXCUTIVE SUMMARY
This report is mainly concerning the work that we have done during our internship program. We
have been written this report to express our duration in ELSEWEDY cables Ethiopia plc factory.
This report is going to be submitted to Debre Birhan University Department of Electrical and
Computer engineering. Firstly, from beginning up to end of this report we tried to put the overview
of the company background history, main product, raw materials and work flow of the company.
In addition, this report includes about some of machines used in the company. And also, during
our overall internship stay, we have acquired experiences and accomplished tasks that help us to
relate theoretical knowledge with real world technologies. Finally, the paper has benefits and skills
that we have gained conclusion and our recommendation to the company and University

viii
 CHAPTER ONE
1. INTRODUCTION
1.1 Brief History of the Company
As Ethiopia’s economy continues to grow, there is a strong demand in the overall energy sector
and specially for cables. To help meet this demand, Elsewedy PLC opened the first state of the art
cables manufacturing plant in Dukem, Ethiopia in 2009 G.C.

With roots going back over 70 years, Elsewedy successfully runs 30 production facilities in 14
countries in Africa, Europe and Asia. It exports wide range of high quality, safe products to more
than 110 countries worldwide. It is one of the oldest and most successful industrial and trading
business groups across the Middle East and regions.

This company is a major manufacturer of low voltage cables up to 1 KV, Control Cables and
overhead transmission lines according to International Electrical Code and other European
standards. Therefore, it aims to attain high quality products over the country.

1.2 Mission, Vision and Values of the company

1.2.1 Mission
➢ Exceeding customer expectations 100% of the time for enhancing long term value to its
stakeholders.
➢ Elsewedy Cables Ethiopia PLC is committed to strengthen its market leadership in low
voltage, control cables and overhead transmission lines manufacturing sector through
providing superior quality cables produced at internationally competitive costs.
➢ Working closely with diversified corporate sectors caring about serving integrated energy
solutions in an environmentally responsible manner as good citizens of the communities in
which they live and work.

1.2.2 Vision
➢ To be the first choice of customer over the world.
➢ To be center of excellence and leader in cable manufacturing in the world and competent
in EU market and pace-setter in research and education.

1
1.2.3 Core Values of the Company
➢ High Performance
➢ Customer focus
➢ Quality product
➢ Environmental responsibility
➢ Team work
➢ Integrity and trust

Figure 1. 1 Elsewedy cables Ethiopian plc

1.3 Main Product and Services

❖ Power Cable

Low Voltage Cables

➢ Building wires (CU/PVC)

Ranges:

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 • From 0.5 up to 300 sq.mm

Ratings:
• 300/500 V
• 450/750 V
• 600/1000 V
• 300/500 V and 450/750 V single core copper conductor with solid, flexible, or stranded
copper conductors and PVC insulated.
• 0.6/1 (1.2) KV multicore with stranded Aluminum conductors, PVC or XLPE insulated
and PVC sheathed.
• 0.6/1 (1.2) KV multicore with stranded copper conductors, PVC or XLPE insulated, steel
wire or steel tape armored and PVC sheathed.

Medium Voltage Cables

• 6/10 (12) KV single core copper or aluminum conductors, XLPE insulated.

• 12/20 (24) KV multicore copper or aluminum conductors, XLPE steel tape armored
and PVC sheathed.

High Voltage Cables

• High voltage cables 38/36 (72.5) KV or 127/120 (245) KV.

• Single core copper conductor, XLPE insulated, copper wire screen and HDPE sheathed.
❖ Overhead Conductor
• Bare had drawn copper.
• All aluminum conductor.
• All aluminum alloy conductor.
• Aluminum conductor steel reinforce
• ABC cables – service drop cables.
• Optical ground wire (OPGW).

3
 ❖ Special Cables
• Control cables: PVC insulated; steel wire armored; PVC sheathed.
• Instrumentation cables.
• Fire resistance cables.
• Fire alarm cables.
❖ Telecom cables and Accessories
Fiber optic cables
• Single mode, multi-mode up to 432 fibers.
• Outdoor, underground.
• Filled core semidry core, dry core, center loose tube.
• Corrugated steel armoring, non-metallic.
• All dielectric self-supporting.

Copper Telecom Cables

• LAN cables
• Coaxial cables
• Telephone cables

Winding cables
• Normal
• paper insulated
• Annealed wires
• welding wires

1.4 Main Customers of the Company

➢ Defense Engineering
➢ Power Engineering
➢ Sigma Electric PLC
➢ EEPCO
➢ Electrical World
➢ Dama Trading
➢ Sunshine Construction PLC

4
➢ ZF building and electrical mater PLC
➢ Ethio crown cork PLC

1.5 Overall Organizational and Work Flow of the Company

Figure 1. 2 Over all organization and work flow of the company

5
 CHAPTER TWO
2. THE OVERALL INTERNSHIP EXPERIENCE
2.1 How we got into the company
We get into Elsewedy Cables Ethiopia PLC after we have submitted internship placement request
letter which is prepared by the university to administration office on 2023 G.C
and got acceptance letter. On first week of November, we started our internship program by
attending the orientation given for us by Engineer Ayana Taka about the company and work process
in the company starting from the raw material pay off to the final product. In the first week we
tried to know the names and some main functions of machines used, by asking our company
supervisor and corresponding machine operators. The overall internship experience and what we
have done in each section are presented below.

2.2 Sections in the company and the work flow

There are five sections in the company and all sections have its own process. These sections are
➢ Metal Section
➢ Low voltage
➢ Quality control
➢ Maintenance Section
➢ Drum production
But we are performing our practice in only first four sections but special focus was given for
maintenance section since this section is highly related with our field of study ([1] website:
www.el-sewedy_cables.com, n.d., p. 351).

2.2.1 Metal section

This section is a place where the first step for cable manufacturing is carried out. This section is
basically divided into two main areas.
➢ Drawing section: - The area at which drawing process take place
➢ Stranding section: - The area at which stranding process carried out
There are three types of raw material used in Elsewedy Cables manufacturing
➢ Aluminum (Al) with diameter 9mm and weight 1.5 ton
➢ Aluminum Alloys with diameter 9.5mm and weight 2.5 ton
➢ Copper (Cu) with diameter 8mm and weight (3-4) ton

6
The raw material that is copper aluminum and aluminum alloy are prepared with the diameter of
8mm, 9mm and 9.5mm respectively from the company place at Egypt. The drawing process starts
based on the diameter given above and can get all possible dimensions after drawing process to
accomplish this process there are heavy and intermediate drawing machines ([1] website: www.el-
sewedy_cables.com, n.d., pp. 352-357).
The different properties of row material used in cable factory.
Copper Rod ([1] website: www.el-sewedy_cables.com, n.d., pp. 360-380)
Application: -Copper rod is mainly used for electric cables were conductors drawn as soft or hard.
This rod is drawn to minimum size of 0.2mm diameter.
Standards: The latest edition of the following standard is applicable.
➢ BS EN 13601
➢ ASTM B49
➢ BS EN 1977
Requirements:
✓ Size:
➢ Copper rod shall be of round cross-sectional area of 8mm diameter with ±0.38mm as
tolerance.
✓ Electrical properties:
➢ Minimum conductivity of 101% IACS
➢ Maximum electric resistivity shall not exceed 17.07 ohm.mm2/km at 200c
➢ Mass resistivity shall not exceed 0. 15176ohm.g/m2 at 200c i.e. density shall not exceed
8.89G/mm2/M at 200c.
✓ Mechanical properties:
➢ Minimum tensile strength is 200N/mm2
➢ Minimum elongation 35% (in 250mm)
✓ Chemical properties:
➢ Surface oxide to be less than 400Å
✓ Appearance: Copper rod should be supplied in form of rose coiler coils in one continuous
length without any kind of joints. Rod should be clean, smooth and free from pipes, twists
seem, damage ends, excessive oil and other injuries.

7
 ✓ Packing and marking: The copper rod coil should be of maximum diameter of 2.0m and
of maximum height 1.0m. Each coil weight should not exceed 4.5MT and not less than
3MT.
Acceptance test: The following tests and checks are conducted as acceptance test.
➢ Appearance checks
➢ Diameter measurements
➢ Electrical properties
➢ Mechanical properties
➢ Density
➢ Surface oxide
➢ Chemical composition analysis (first time supply)
Aluminum Rod
Application: Aluminum rod is mainly used for the underground and overhead cable conductors.
This rod is drawn to minimum size of 1.05mm diameter.
Standards: The latest edition of the ASTM B233 standard is applicable.
Requirements:
✓ Size: Aluminum rod shall be of round CSA of 9.0mm diameter with ±0.3mm as tolerance
or 9.5mm diameter of with ±0.5mm as tolerance.
✓ properties:
➢ Minimum conductivity of 61.5% IACS
➢ Maximum electrical resistivity shall not exceed 28.035ohm.mm2/km at 20oc.
✓ Mechanical properties: Tensile strength should range from 8.5 up to 11.9 kg/mm2
✓ Finishing and appearance: Aluminum rod should be supplied in form of coils in one
continuous length without any kinds of joints. Rod should be clean, smooth and free
from excessive oil, damaged ends and other defects.
✓ Packing and marking: The Aluminum rod coil should be of maximum diameter of
1.5m and of maximum height 1.0m. Each coil weight should not exceed 2.3 ton and
not less than 1.8ton.
✓ Acceptance Test: The following tests and checks are conducted as acceptance test;
➢ Appearance checks
➢ Diameter measurements

8
 ➢ Electrical properties
➢ Mechanical properties
➢ Density

Raw material Diameter Electrical Tensile Elongation Weight(g/mm2/m)

(mm) Resistive Strength
(ohmm2/km) (Kg/mm2)
AL.H12 9 28.264 8.10 20% 2.7
AL.H14 9 28.264 10.5:14 15% 2.7
AL. Alloy 9.5 32.53 17:22 3.5% 2.7
Copper 8 17.241 Max.250 40% 8.89

Table 2. 1 Properties of raw material of cable factory

Notes:
✓ The max. Tensile strength of the copper means the maximum force that can apply over
cross section area.
✓ Low efficiency of conductor when Elongation and Cross-sectional area increasing because
the resistance will increase too.

Copper (Cu) Aluminium (Al)

Low specific resistance About 40% higher specific resistance
Good conductor of electricity with small CSA Good conductor of electricity with large CSA
Heavy in weight Light in weight
More expensive Cheaper than copper
Best for cables required for high stresses Best for cables required for flexibility
Mainly used for underground cables Mainly used for underground cables

Table 2. 2 Comparison between Copper and Aluminum Conductor cable

9
 Drawing process: -Drawing is a mechanical deformation process carried out as the metal is below
its re-crystallization temperature, to reduce the wire diameter by tension force. This has two main
functions ([1] website: www.el-sewedy_cables.com, n.d., pp. 381-400).
➢ It gives the required shape to the metals.
➢ It improves the mechanical properties of metals by refining the structure.

PAY OFF
Figure2.1 Drawing machine
Figure 2. 1 Drawing machine
Here in the drawing section between 17 to 33% of the initial diameter can be reduced by passing
the wire through a series of 12 dies with certain sequence till we get the required diameter. The
number depends on the sizes of cable required.
Calculation of reduction ratio or Elongation
From conservation of mass, the mass of cable before and after drawing is constant therefore;

10
Main components of drawing machines
➢ Payoff
➢ Drawing Block
➢ Final Capstan Block
➢ Annealing Machine
➢ Dancer
➢ Take Up
➢ Payoff: -It is the first stage in the drawing process for both copper and aluminum; its
function is to guide (take) the raw material straight to the “basin”.
➢ Drawing block: -this is the place where reduction in diameter of the rod entering the
“basin” takes place. The function of this machine is to reduce the diameter of conductor by
stretching it which means by increasing the number of die series.
➢ Final Capstan Block: -The function of the last capstan is to be sure that the diameter of
wire not changed, to reduce the possibilities of the conductor from cut off. To have good
tension in the system the conductor turns three times on the capstan.
➢ Annealing Machine: - Since the drawing process done is cold working drawing operation,
the conductor losses its mechanical and electrical properties such as tensile strength and
resistance. The deformation takes place when the applied stress exceeds the elastic limit
during cold pressure when severe stresses known as residual stresses are developed in the
metal. These stresses can be removed by suitable heat treatment known as annealing.
Annealed exists only in copper wire drawing process. The principle operation is using
high current through a transformer to get high temperature for copper metal after drawing
operation done but it can lead to undesirable oxidation so to reduce this risk lubricant is

11
 put inside the annealed Annealing decrease the hardness and retain material properties of
copper again since its properties are changed in the drawing process.
Aluminum alloy is annealed in a special furnace. But no annealing for aluminum.

➢ Dancer: -it is constructed from two capstans, pneumatic system, and its function is
synchronizing the speed between take up and the feed speed of drawing block.
➢ Take up: -It is a basket or bobbin that is used to hold coils.
Types of Drawing Machines:
There are basically two types of drawing machine used in the factory
1) Heavy drawing machine
➢ Copper drawing machine
➢ Aluminum drawing machine

2) Intermediate drawing machine for flexible copper

Intermediate Drawing Heavy Drawing Heavy Drawing

Machine Copper Machine Aluminum Machine
Max.no of Dies 14 13 13

Min Diameter(mm) 0.18 1.2 Inlet Dia

9.5 9
2.1 1.7
Max. Diameter 1.35 4 Inlet Dia
9.5 9
4.5 4
Max. Speed (m/s) 30 25 37.5

Figure 2. 2 Machine types

Stranding process: - The need of making the stranding operation is that current flows typically
along the surface of the conductor (skin effect), so to allow the conductor to carry more current
more wires of smaller cross-sectional areas are used instead of using just one of larger area. In this
way conductors are made of layers of wires. The conductor of cables consists of a number of

12
strands of wire of circular cross section so that it may become flexible and carry more current.
Operation of stranding can be summarized as follows. One wire is placed at the center of the
conductor and a second layer containing 6 wires is stranded around it. Then the “1+6” conductor
becomes the center of the third layer, which contains 12 wires. If the conductor needs to have
another layer “1+6+12” conductor becomes the center of the forth layer ([1] website: www.el-
sewedy_cables.com, n.d., pp. 401-415).
The number of strands cables is 7,19,37,61,127 and169.

Table2. 3 Formation Number of layers Layers

of wire with the number of layer
Conductor
7 Wires 2 1+6
19 Wires 3 1+6+12
37 Wires 4 1+6+12+18
61 Wire 5 1+6+12+18+24

Table 2. 4 Formation of wire with the number of layer

Figure 2. 3 Rigid stranded machine

Three types of stranded conductors:
1. Round (circular): only stranding process is carried out.
2. Compacted round: some pressure is applied to the conductor using” roller” in order to
make it compact.

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 3. Sector conductor: the stranding process is the same with compact round only the shape of
the roller used is different.
Classification of stranding machines
➢ Rigid stranding machine: This machine has a capacity of stranding up to 61 wires but
in this factory, it strands a maximum of 37 wires.

Figure 2. 4 Sector conductors stranding

➢ Double twist machine: - This machine strands the wires by using a rotating arm which
rotates fast twisting the wires, and then the wires are reversed to be turned on the
receiving pulley which rotates around itself and that is the other twist.
➢ Tubular stranding machine: - It is seven wires, both copper and aluminum, stranding
machine used to strand wires of small size.
➢ Bunchier stranding machine: -This machine is used to strand flexible wires drawn by
intermediate drawing machine. It can stand up to 14 wires bobbins as pay off.

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2.2.2 Low Voltage Section
Five processes are carried out in this section:
➢ Insulation
➢ Assembly
➢ Bedding
➢ Armoring
➢ Sheathing
Insulation: -Two types of plastic materials are used for insulation process.
Thermoplastic material: - can be recycled such as Polyvinyl chloride (PVC).
Thermosetting material: -type of material that can’t be recycled such as XLPE
The XLPE material consists of PE (polyethylene) and Catalyst to increase the speed of reaction
and cross link PE.

PE+ Catalyst LPE

Both PVC and XLPE are used as insulation for low voltage cable, while XLPE is also used just
for MV and HV cable. However, the material property of XLPE used in MV and HV is purer than
in low voltage so it is stronger and more expensive.
PVC and XLPE are colorless by nature. The ratio of color is 2% for PVC and 0.5% to 1% for
XLPE the material used for coloring is called “master batch”. The basic colors are red, yellow,
blue, and black Insulation section is the most important part of the overall production section.
Before starting the extrusion process great care must be taken on the following part.
➢ The quality of the product should be checked at every stage
➢ The dimension should be standardized
➢ Cooling system must be checked

15
 Figure 2. 5 Extrusion process

Caterpillar Extruder Cooling Sparking

Pay off Take up
Trough Tester

Figure 2. 6 Block diagram of extrusion process

Payoff: feed the machine with conductor.
Caterpillar: to pull the conductor. There are two caterpillars one at the beginning of the machine
and other at the end. The speed of two caterpillars must be synchronize.

Figure 2. 7 Caterpillar

16
Extruder: consists of large tube with specially designed screw, barrel and crosshead. The screw
consists of five heater zones which used to heat the insulation material PVC or XLPE before going
to the crosshead of the machine which has four heaters. Two different types of tools are used to
attach the insulation material to the conductor.
Tube tool: for round conductor where there is no need of making pressure to the
conductor. And it has 4 screws to adjust the centering of the insulation.
Pressure tool: for sector conductor the insulation is attached to the conductor by pressuring. No
need of those screws used in case of tube tool because the insulation is totally attached to the
conductor.
Cooling Trough: necessary to cool it before going into the reel.
Spark Tester: it is a device designed to detect pinholes in an insulated wire by applying 10KV
DC voltage for short period of time, if any error happens i.e. insulation failure it produces an alarm
to inform the operator.
Take up: is the reel that is ready to go to the assembly process.
➢ Assembly process ([1] website: www.el-sewedy_cables.com, n.d., pp. 420-440)
The purpose of this process is to assemble insulated cores together with suitable lay length.
Polypropylene filler (if necessary) is used to fill the space between cores to make the assembled
shape round. Then wrapped with suitable tape to form a compact round cable.

Assembly Correct Armoring Dies

Pay Off Take Up
Block Angle Stage Stage

Figure 2. 8 Assembling process block diagram

Payoff: wood or metal drams are used. At this stage it is important to give a great care for the
tension between the pay off and the take up so motor is used since low tension is needed. But if
high tension is needed pneumatic system is used.
Assembly block: it assembles the phases and filler together.
Correct angle: when performing the lay with sector cables we must be sure that all lays have
correct angle with each other this block do this job by trying to correct the angle based on the
adjustment but if the angle is larger or smaller than the rang the machine will stop.
Die stage: three dies are used the first die make the assembling function, the second one compact

17
the cable and the last die used with the second die when we need segmental cable.
Tape or armoring block: tape block tapes the cable with polypropylene and depending on the
customer requirement armoring of cable with steel is carried out on armoring block.
Take up: reel whose tension must be synchronized with pay off. Assembly machines.
Assembly machines:

➢ Assembly 1600
➢ Assembly 260
➢ Assembly 1600
It is used just for assembling and armoring (steel wire). In the assembly operation, this machine is
used just with round conductors with small sizes basically control cables, and made up to 24.

Figure 2. 9 Assembly 1600 machine

Assembly 2600
This machine is used with all kind of process: Assembly armoring (steel wire armoring SWA or
steel tape armoring STA) and screening.
➢ Armoring process ([1] website: www.el-sewedy_cables.com, n.d., pp. 450-460)
The armoring stage is carried out to protect the cable against any mechanical stresses. For instance,
when a big truck passes over it generates a pressure force through the soil that may reach the
underground cable. When the cable is working under normal conditions, the current flowing
through the conductors generates a magnetic field which produces current circulating along the
layer of armoring; therefore, it needs to be grounded in some point.

18
 Figure 2. 10 Armoring process

Types of Armoring
➢ Steel tape armoring: This type of armoring is carried out basically to protect the cable against
any horizontal mechanical stresses as explained before. Apart from that, it can also carry the
earthling fault current. This type of armoring is done with two steel tapes by using an over gap
process: The second layer of tape is placed over the first one by 50 % over gap of the tape
width, the size of the tape is specified by its width and thickness.
Tape width x Tape thickness
➢ Steel wire armoring (galvanized): This type of armoring is carried out to protect the cable
against strains: the horizontal tensions appeared along the cable. The wires can also carry the
earthling fault current. The operation is carried out by covering all the surface area of the cable
with wire called "Armoring Lay" .one period of wire moving around the cable can be
determined as;
Armoring lay = factor X diameter of the cable
Bedding: This process is done right after the assembly process (before armoring or sheathing).
The main function of Bedding is to give mechanical protection for insulation in case of armored
cables only. Extruded poly vinyl chloride (PVC) or when there is higher mechanical hazard
polyethylene (PE) is used.

Sheathing: The sheath is the cover of a cable just used for mechanical protection. This process
uses the same extrusion method as that one used for insulation and bedding. PVC is used as
sheathing material. It is outer jacket of the cable; its main function is mechanical protection. Most
of the time it has Black color.

19
Coiling process: Single core cables, insulated by Ex80 extrusion machine and of size 1.5-2.5, are
coiled by two coiling machines. Cables have pay off and take up. The spool, which is produced in
that company from waste of PVC insulating material, is used as take up. Cables are coiled in length
of 100m and packed by closed loop operated packing machine. Spark tester “Sekora” is available
to test insulation fault on the cable being coiled.

2.2.3 Quality section

There are four classes of quality section
➢ Quality assurance
➢ Quality Control
➢ Electrical Lab

2.2.4 Maintenance section

When machine is in operation it may fail electrically and mechanically due to friction and electrical
fault. This section plays a vital role in maintaining break down machines and installing new
machines. Both mechanical and electrical Engineers are available in section to maintain
mechanical system and electrical circuits, design dies and install program on PLC.As mentioned
before since, we have spent more time in this section we were practicing machine starting
mechanisms based on the assignments given by our company Supervisor. Some of Workshop
practices we have been performing;
➢ Direct-Online motor starting method (DOL)
➢ Star-Delta motor starting method
➢ Forward - Reverse motor control using limit switch
➢ Reverse-Forward motor control
➢ Starting motor in sequence

Direct-Online motor starting method

In this method the polyphaser stator on to the main supply is directly switched. Depending
on size and design the motor takes low power factor starting current of 5 to 8 times its full
load current. Such large currents of short duration don’t harm the rugged squirrel cage
motor, but the high currents may cause objectionable voltage drop in the power supply
lines feeding the induction motor. These large voltage drops cause, undesirable dip in the

20
 supply line voltage consequently the operation of other equipment’s connected to the same
supply line is affected considerably.
For this task one contactor, one stop push button and one start push button are enough
which means it is simply to implement.

Figure 2. 11 Direct online motor starting mechanism

Forward-reverse motor starting

To change the direction a three-phase induction machine rotation, two of its phases needs to be
exchanged, thus changing the phase sequence form, say RYB to BYR. This can be accomplished
by using two contactors, one for the forward rotation and one for the reverse rotation. The forward
and reverse contactors are mechanically interlocked i.e., if one of them is closed the other cannot
close. This is done to avoid dead short circuit in case both the contactors closing simultaneously.

21
 Figure 2. 12 Forward-reverse motor starting mechanism

Star-delta motor starting method

In this starting motor method, it employed to provide reduced voltage of start. In this method the
normal connection is delta while running. If these windings are connected in star at start, the phase
voltage is reduced, resulting in less current of starting. As the motor approaches its full speed and
the windings will be connected in delta. Star delta connection also reduces starting torque to one
third of that produced by direct switching in delta.

Figure 2. 13 Star- delta motor starting mechanism

22
Forward-Reverse motor control using limit switch

Forward Reverse Motor Control Wiring with Limit Switch,3 phase Motor Reverse Forward
Controller. Power circuit and control circuit required to rotate a 3-phase motor in both directions.
This circuit has the ability to change the direction of rotation of the forward motor simultaneously.

Figure 2. 14 Forward-Reverse motor control using limit switch

Starting motor in sequence

The purpose of the sequential control is to maintain the predetermined order at which the motors
are forced to stop or start. Nowadays, most applications use two motors for operation. But the
major thing is they need not to be activated at a time, Motors need to start after some interval.

In our task we successfully start three motors in sequence and for all of them they are light indicator
which are used to indicate the starting of corresponding motors. For example, when first motor
start running simultaneously light indicator which indicate starting of first motor become turned

23
on. For starting motor in sequence, we use on delay timer which set to specified or required time
to start one motor after another.

Figure 2. 15 Starting motor in sequence

24
2.3 Procedures used for cable production

Stranding Insulation Insulation Single/Mul

Drawing Assembly
Process required Process ti Core
Process

Bare conductor

Single core

Final Bedding
Inspection Sheathing Armoring Bedding Lead
Process
and Testing

Without load

Finished
Packing Goods
Store

Figure 2. 16 Procedures used for cable production

2.4 How good we have been performing our work tasks

Internship program has a great importance to approve theoretical knowledge by practical one. So
we have been doing we work best without being exhausted and respecting work ethics.
When we execute our tasks the following steps as follow;
➢ Identifying the problems
➢ Identifying what cause the problems
➢ Then finally solve the problem

2.5 Challenges have been facing while performing work task

➢ The company were not given safety material
➢ There is no access of an internet
➢ Lack of transportation
➢ The environmental condition influence during internship practices were major challenge
and

25
 ➢ Besides, these during our practice there were some challenges in the factory due to the
failure of different machines.
The measure taken to overcome the challenge
➢ We use our pocket money to solve transportation problem
➢ We use internet package in order to solve internet access
➢ We use our access so as to overcome safety material problem

26
 CHAPTER THREE
3. THE OVERALL BENEFITS YOU GAINED FROM THE
INTERNSHIP
3.1 introduction to benefits of internship
An internship is on-the-job training for many professional jobs often taken up by college and
university students during his undergraduate one semester of five years’ time to supplement their
formal education and expose them to the world of work. So, the Knowledge gained from the
internship very important in everyone future work. Some of the knowledge we gained from the
internship. For example: -
➢ Improving interpersonal communication skill
➢ Upgrading theoretical knowledge
➢ Improving practical skill
➢ Improving team working skills
➢ Improving leadership skills
➢ Understanding about work ethics related issues
➢ Gaining entrepreneurship skill
➢ Understanding of professional and ethical responsibility
➢ Gain work experience and transferable skills

3.1.1 Improving interpersonal communication skill

The purpose of communication is to share ideas with each other clearly and unambiguously. In a
recent survey of recruiters from companies about 700 employers, is the communication skills were
cited as the single more important decisive factor in choosing managers. Points out those
communication skills including written and oral presentations, as well as an ability to work with
others are the main factor contributing to job success. In spite of the increasing importance placed
on communication skills. Many individuals continue to struggle with this unable to communicate
their thoughts and ideas effectively whether in verbal or written format. This inability makes it
nearly impossible for them to compete effectively in the workplace and stands in the way of career
progression. From this point of view without improving our communication skill there is no
success on our job.

27
3.1.2 upgrading theoretical knowledge
When people decide that they truly want to learn and master a new skill they need a book that is
dedicated to that subject with details of materials, illustrations of techniques and explicit patterns
to follow or design source books with examples. This internship has a benefit for interns to upgrade
their theoretical knowledge. In this internship program we found much theoretical and practical
knowledge on the following ones: starting mechanisms of motor, types of motor and their working
principles, PLC, Sensors, different types of machines with their working principles and controlling
mechanisms and etc.

3.1.3 Improving practical skill

Practice is said to be the best of instructors. Educators admit this universal truth, but are unable to
provide students with opportunities for developing their practical skills. Most of skill refers to the
ability of using that information and applying it in a context.
During this internship time we have gained a lot of benefits according to improving our skills
specially in terms of improving practical skills. Since we have been working on different machine
parts and equipment, we improved our practical skills for solving engineering problems. we have
seen and tried to understand the application of materials such as contactor, relay, limit switch,
proximity sensor, spark detector, motor drives, plc., potentiometer, etc. in machines, and systems
i.e., closed loop and forward reverse system and so on. we have also deep-rooted our theoretical
knowledge in concurrence with the practical one.

3.1.4 Improving team working skill

Teams need strong team players to perform well. Teams need people who speak up and express
their thoughts and ideas clearly, directly, honestly, and with respect for others and for the work of
the team. That's what it means to communicate constructively. Such a team member does not shy
away from making a point but makes it in the best way possible in a positive, confident, and
respectful manner. Teamwork has a dramatic effect on organizational performance. An effective
team can help an organization achieve incredible results. A team that is not working can cause
unnecessary disruption, failed delivery and strategic failure. Nowadays it is almost impossible to
avoid being a member of team. So, it's important for our personal and career development to know
our team working strengths and weaknesses. This implies that team work skill is the backbone of
team playing skill. So, we have learned the following points from them;
➢ Listening the idea of others whatever it is

28
 ➢ Be patient, wise and respectful of the voice of others
➢ Open minded to others point of view
➢ Able to share information freely
➢ Able to be an optimistic and attractive person
➢ Able to celebrate the successes and learn the set backs
➢ Focus on the positive and take the negative in stride not let them down
➢ Understand complains of others and make sure that the communication channel flow is
free Be flexible rather than rigid for new concepts and chance
Obviously, be with group is better than being alone. we share idea on different things regarding
our work in our hosting company. We also by a team in a maintenance section of our hosting
company to work on the technical issues in the factory with them.

3.1.5 understanding about work ethics related issue

The work ethic is a cultural norm that advocates being personally accountable and responsible for
the work that one does and is based on a belief that work has intrinsic value. The term is often
applied to characteristics of people both at work and at play. Work ethics include not only how one
feels about their job, career or vocation but also how one does his/her job or responsibilities. These
involve attitude, behavior, respect, communication, and interaction how one gets along with others.
Work ethics demonstrate many things about whom and how a person is. Thus, employer expects
employees to develop certain desirable traits that will help them to perform their jobs well so that
the company can succeed. Those rule and guidelines are usually designed to facilitate efficient
working. Labor disciplines are listed below.

• Punctuality
• Proper use of instrument of work place
• Working harmoniously in cooperation with co-workers
• Being obeyed for what we have pleased.

The work discipline that we have been listed before are one of the vital thing that we have been
learned from the factory and also we have been experiencing this labor discipline in our duration

29
3.1.6 Gaining entrepreneurship skill
In the factory there are problems that comes in different period of time. So, solution is must for
these problems. In the progress of finding solution for the problem new thing is invented or the
machines are modified. When we observe this, we are initiated for creativity and in addition to this
there are many entrepreneurship skills that we have developed in the company: -

• Multi skilled in the work place

• Being creative and innovative
• The risk taker for our work

A wide range of skills are seen as entrepreneurial and useful to entrepreneurs, these include
➢ Management skills - the ability to manage time and people (both yourself and others)
successfully.
➢ Communication skills and the ability to sell ideas and persuade other.
➢ The ability to work both as part of a team and independently.
➢ Able to plan, coordinate and organize effectively.
➢ Able to research effectively for example available markets, suppliers, customers and the
competition.
➢ Self-motivated and disciplined.
➢ Innovative thinking and creative.
➢ The ability to multi-task.
➢ Able to take responsibility and make decisions.
➢ The ability to work under pressure.

30
 CHAPTER FOUR
4. IDENTIFIED PROBLEM AND PROPOSED SOLUTION
4.1 Statement of problem
During our stay away in Elsewedy Cables Ethiopia we saw different problems happens on the
different machines which leads to interruption in the whole production processes. Among those
problem we have been focused on one which was happened on 37 stranding machines. The
problem was at the take up section of the machine which was due to the breakdown of PLC which
affects the output of drive that controls the transverse motor operation of the take up. After that
PLC for transverse operation is represented by relay which is the old fashion control namely
classical control. This classical control is difficult to use as well as space consuming when installed.
So, this operation must be re-automated. Not only 37 stranding machine needs traverse motor
operation for take up but also other machine needs automatic motor traverse operation which
are now operating manually. Operating this system manually makes an operator tiered and is
uncomfortable in working process.

4.2 Objective
4.2.1 General Objective
➢ The main objective of this project is to come up with the solution for fail happen on 37
stranding machine which is happened at take up of machine particularly at transverse
control by designing and simulating transverse motor control.

4.2.2 Specific Objective

The specific objectives of this project are: -

➢ Selecting the PLC type for transverse motor control on TIA PORTAL.
➢ Constructing ladder logic for transverse motor control using TIA PORTAL.
➢ Downloading selected hardware configuration on TIA PORTAL.
➢ Simulating constructed program logic on TIA PORTAL that automatically open PLCSIM.
➢ Selecting HMI configuration and selecting all required component on its root screen.
➢ Simulating constructed HMI configuration on TIA PORTAL which automatically open
WINCC V7.

31
4.3 Scope of Project
37 stranding machines has a number of interrelated systems work together to give the final
products through the stranding process. Among those processes our project is only limited to the
transverse control at take up of the machines. At the end of these machines its take up must move
toward right and left automatically as well as manually to scroll stranded wires over the bobbin
or drum equally. The target of our project is limited to controlling right and left movement of the
take up by controlling forward and reverse movement of motor.

4.4 Significance of Project

The whole system exist in 37 stranding machines are interrelated. If fail is happened in one of
those system the overall process become interrupted. These interruptions not affect only the
stranding process but also the next processes like insulation, assembly, etc. because of the
stranded wires (output of stranding process) may use as payoff(input) to those processes.
Therefore, this project is important since it solves problem related to one component of these
machine which is transverse control of the take up in turn saves the working process of machines
and leads to the required end products safely and on time.

4.5 Limitation
There were number of obstacles when we are working our projects. Among them: -

✓ Knowing working of PLC takes a time.

✓ Learning how to program PLC also takes time because it was new for us.
✓ Learning how to use TIA PORTAL application was also another task which needs times.

At the end we are successfully done our project by solving those all obstacles!!

4.6 methodology
This project requires procedures for getting information on how each part functions, design and
construction held hardware and software requirements. Hardware such as proximity sensor,
contactor, relay, switch, ac motor and ac drive. For successful completion of this project some
steps will be followed to carry out different tasks. Different literature will be revised relating to
this project and data will be collected about condition and control principles of traverse control,
TIA Portal (PLC) etc. Based on this parameter system model was designed. Some software's were
selected to develop the software programming. So here a system is designed with alternative

32
 methods using TIA Portal. Generally, the methodology is concluded by the block diagram given
bellow. This project is aimed at solving this cable factory problem by taking into consideration
Technology appropriateness, cost can be used to research problem is described in this section.

Problem Concept System Analysis Simulation Evaluation

Identification Generation Design

Figure 4. 1 Block diagram of methodology of the system

4.7 Components Used in the Proposed Project

For this proposed project we use different types of electrical device that are connected to each other to
perform the operation of our project. Those components of electrical materials are siemens plc, ac drive,
relay and other device that are programmed in plc, proximity sensor, contactor, push buttons and others.

Siemens PLC is used to design and simulate the hardware components listed above. The details
of these components are emphasized below as follows.

PLC

The National Electrical Manufacturers Association (NEMA) defines a PLC(S7-200) as 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 analogue I/O modules various types of machines or
processes. Basically, it's a solid-state, programmable electrical/electronic interface that can
manipulate, execute, and/or monitor, at a very fast rate, the state of a process or communication
system. It operates on the basis of programmable data contained in an integral microprocessor-
based system. A PLC is able to receive (input) and transmit (output) various types of electrical and
electronic signals and can control and monitor practically any kind of mechanical and/or electrical
system ([2] Waleed, (2009)., pp. 210-215).
Therefore, it has enormous flexibility in interfacing with computers, machines, and many other
peripheral systems or devices. It's usually programmed in relay ladder logic and is designed to
operate in an industrial environment ([2] Waleed, (2009)., p. 216).
A Programmable Logic Controller, or PLC for short, is simply a special compute device used for
industrial control systems. They are used in many industries such as oil refineries, manufacturing
33
lines, conveyor systems, tank level control and so on. Where ever there is a need to control devices
the PLC provides a flexible way to "soft wire" the components together ([4]Ahmed, (2008)., p.
450).
The basic units have a CPU (a computer processor) that is dedicated to run one program that
monitors a series of different inputs and logically manipulates the outputs for the desired control.
They are meant to be very flexible in how they can be programmed while also providing the
advantages of high reliability (no program crashes or mechanical failures), compact and
economical over traditional control systems ([2] Waleed, (2009)., p. 239).
a) The basic components of the PLC are the following
➢ Power supply
➢ Input module
➢ Output module
➢ Processor
➢ Programming device
Power supply
It is a part of PLC which supplies power to the components of a PLC. These units step down the
given power to give suitable amount of power to each PLC components ([3] A.Thue., p. 101).

Figure 4. 2 Power Supply

a) Input module
The input module has two functions: reception of an external signal and status display of that input
point. In other words, it receives the peripheral sensing unit's signal and provides signal
conditioning, termination, isolation and/or indication for that signal's state. The input to an input
module is in either a discrete or analogue form. If the input is an ON/OFF type, such as with a
push button or limit switch, the signal is considered to be of a discrete nature. If, on the other hand,

34
the input varies, such as with temperature pressure, or level, the signal is analogue in nature.
Peripheral devices sending signals to input modules that describe external conditions can be
switches (limit, proximity, pressure, or temperature) push buttons, or logic, binary coded decimal
(BCD) or analog to digital (A/D) circuits. These input signal points are scanned, and their status is
communicated through the interface module or circuitry within each individual PLC and I/O base
([2] Waleed, (2009)., p. 109).
a) Output module

The output module transmits discrete or analogue signals to activate various devices such as
hydraulic actuators, solenoids, motor starters, and displays the status (through the use of LEDs) of
the connected output points. Signal conditioning, termination, and isolation are also part of the
output module's functions. The output module is treated in the same manner as the input module
by the processor ([2] Waleed, (2009)., p. 112).

b) Central processing unit (CPU)

The function of the CPU is to control the operation of memory and I/O devices and to process data
according to the program or in other words, makes decisions and executes control instructions
based on program instructions in memory. It is responsible for reading inputs, executing the control
program, and updating outputs. It is always referred to as the processor consists of the arithmetic
logic unit, timing, program counter, address stack and instruction register ([2] Waleed, (2009)., p.
120).

Figure 4. 3 CPU

35
Memory

It is the area that holds the operating system and user memory. The operating system is actually
system software that the PLC, ladder diagram, timer and counter values are stored in the user
memory. Depending on users need varies types of memory are available for choice. Such as RAM
ROM, EPROM, and EEPROM. EEPROM (electrically erasable programmable read only memory)
combines the access flexibility of RAM and non-volatility of EPROM in one ([2] Waleed, (2009).,
p. 120).

Proximity sensor

Proximity Sensor" includes all sensors that perform non-contact detection in comparison to sensors, such
as limit switches, that detect objects by physically contacting them. Proximity Sensors convert information
on the movement or presence of an object into an electrical signal. There are three types of detection
systems that do this conversion: systems that use the eddy currents that are generated in metallic sensing
objects by electromagnetic induction, systems that detect changes in electrical capacity when approaching
the sensing object, and systems that use magnets and reed switches.

Figure 4. 4 Proximity sensor

Switch
There are two fundamental uses for switches. First, switches are used for operator input to send
instructions to the control circuit. The second switch is an emergency switch which is used to stop
the system when there is an emergency case. The most common switch is the pushbutton. It is also

36
the one that needs the least Description because it is widely used in automotive and electronic
equipment applications ([3] A.Thue., p. 110).
There are two types of pushbuttons, the momentary and maintained. The momentary pushbutton
switch is activated when the button is pressed, and deactivated when the button is released. The
deactivation I done using an internal spring. The maintained pushbutton activates when pressed,
but remains activated when it is released. Then to deactivate it, it must be pressed a second time
([3] A.Thue., p. 111).
The contacts on switches can be of two types. These are normally open (NO) and normally closed
(NC). Whenever a switch is in its deactivated position, the NO contacts will be open (non-
conducting) and the NC contacts will be closed (conducting). Figure below shows the schematic
symbols for a normally open pushbutton (left) and a normally closed pushbutton (center) ([3]
A.Thue., p. 112).

Figure 4. 5 push button switch

Contactor
Contactors are relays that switch high current loads. Used as an electrical switching device. Is
used to control an electric load in control systems and Make or break a set of contacts that control
the voltage applied to some load in cooling systems.
Contactor Contacts: The contacts of a contactor make a complete circuit when the contactor is
energized, allowing voltage to flow to the controlled load.
Contactor Coil: Coil Characteristics depends on the type of wire and the manner in which it is
wound.

Figure 4. 6 contactor

37
Danfoss drive
This illustration shows all control terminals of the frequency converter. Applying Start (term. 18)
and an analog reference (term. 53 or 60) make the frequency converter run.

Figure 4. 7 Danfoss drive terminal details

38
 4.8 block diagram of the system

Power Power Danfoss

source
Supply ac
Drive

Siemens
Proximity PLC
sensor Contactor
forward

Switch Contactor
reverse

Figure 4. 8 Block diagram of the system

Input for PLC

No Input devices name Input Address

1 Emergency stop I0.0

2 Stop push button I0.1
3 Start push button I0.2
4 Right proximity I0.3
5 Left proximity I0.4
6 Right traverse I0.5
7 Left traverse I0.6
8 Right jog I0.7
9 Left jog I1.0
Table 4. 1 PLC inputs

39
Output from plc
No Output devices name Output address

1 Relay (R) Q0.0

2 Running relay Q0.1
3 Motor Run forward Q0.2
4 Motor Run reverse Q0.3
5 Jog forward Q0.4
6 Jog reverse Q0.5
7 Contactor forward Q0.6
8 Contactor reverse Q0.7

Table 4. 2 PLC outputs

Basic Procedure for PLC programming

First of all, we can configure the device with the input and the output modules. Connect the
Controller via the Serial Port and Configure the Serial Driver. Secondly creating a program for our
40
project, the program is done by ladder logic programming. In this section we will cover some of
the basic and most used instructions in PLC programming. Following the explanations on how to
program the controller, we will then have a look at how we can implement and use those
instructions in real life applications.

4.9 Simulation and result

In this project we are going to control the AC Gear Motor using power supply, PLC, ac drive,
proximity sensor, switch, Magnetic Contactor, and relay logic. Now a day’s most of industrial
application require forward reverse motor movement. The project is mainly focused on 37
stranding machines take up. We are using 24 V DC power supply control circuit to provide supply
for AC Gear Motor.

In this operation two loading points are there one is for forward loading point and another one is
reverse loading point. Two proximity sensors are required one is for forward direction and another
is for reverse direction. When a metal object placed near sensor then sensor will sense the metal
and send output to plc. The output of plc sends an information to drive.

The project is mainly done with STEP 7-1200 TIA PORTAL software was used for designing this
project. The figure below shows when we press the Start push button, Power will pass through the
start Relay coil (R) and it becomes energized, at this time the normally open start relay contact (R)
will closed and it can latch the circuit after the start push button release.

Figure 4. 9 energizing start relay

41
The normally open start relay (Q0.0) becomes normally closed in network 2, and the power flow
through it energizes the forward running motor (Q0.2). These output of the PLC FWD (Q0.2) goes
to the forward running mode of the AC drives or in our project to Danfoss AC drive.

Figure 4. 10 motor forward running

The running direction of the motor can be changed automatically from forward to reverse or vice
versa via proximity sensor or manually by using right traverse push button or left traverse push
button. To understand how the motor changes its direction considers the following ladder logic:

Figure 4. 11 automatic motor running ladder diagram

42
The above ladder logic diagram is used to play the motor in forward and reverse direction. When
the proximity reverse (I0.3) reach the stationary metal rod the proximity sense that metal and send
feedback to PLC. At that time running relay energized, simultaneously the normally open and
closed change its states at this time the forward running motor changes its direction of motion to
reverse. The motor running direction return again from reverse direction to forward direction via
proximity sensor 2 automatically or by pressing L traverse PB manually.

Figure 4. 12 energizing running relay by proximity sensor 1

Figure 4. 13 motor running reverse

43
37 stranding machines take up also requires another task, when we want the transverse motor goes
faster, we need to jog the take up to wrap the wire properly. So, in our project we include jog
forward and jog reverse by using higher frequency of ac drive, when the system is in running mode
and by using full speed of ac motor, when the motor is in stop mode.

When the machine is in running mode and we press jog forward push button, jog forward relay
becomes energized which leads to close the normally open contact of jog forward relay. This forces
PLC to give output JOG FWD to AC drive which commands motors jogging in forward direction.

Figure 4. 14 motor jogging forward while running mode

When the machine is in stop mode PLC and ac drive is out of function. At this state we use
contactor to jog forward the motor at full load speed.

44
 Figure 4. 15 motor jogging forward while stop mode
When the machine is in running mode and we press jog reverse push button, jog reverse relay
becomes energized which leads to close the normally open contact of jog reverse relay. This forces
PLC to give output JOG RVS to AC drive which commands motors jogging in reverse direction.

Figure 4. 16 motor jogging reverse while running mode

When the machine is in stop mode PLC and ac drive is out of function. At this state we use
contactor to jog reverse the motor at full load speed.

45
 Figure 4. 17 motor jogging reverse while stop mode

Figure 4. 18 CPU device configuration with input and output module

46
 4.10 Visualization on WinCC HMI Screen
The HMI screen shown below has seven buttons, two proximity sensors, motor and box to visualize the
forward reverse movement. Those HMI components are connected with PLC via tags.

Figure 4. 19 HMI visualization view

47
 CHAPTER FIVE
5. CONCLUSSION AND RECOMMENDATION
5.1 Conclusion
The ELSEWEDY CABLES ETHIOPIA PLC manufacturing factory have the main plants such as
drawing plant, stranding plant, twisting plant, extrusion plant, assembling plant, packing plant,
bunching plant, water and oil pumping plant, rewinding plant, air compressor plant, water chiller
plant as common with electrical power gained either from ELPA or generator to accomplish the
cable manufacturing process. Almost all instruments and equipment that we are used to control the
factory process parameters (pressure, flow, liquid levels and speed) and the control system strategy
are almost the same for each plant. There are both analog and digital systems in ELSWEDY cables
Ethiopia plc factory. Theoretical knowledge is the basic prerequisite for gaining the practical skill
such that we develop our practical skill in contactor, relay, induction motor, limit switch, timer,
plc, drive and electrically operated switch to limit the movement of the moving part of machines
to protect them from colliding, proximity sensors, annealing principles to make the copper wire so
flexible, temperature sensors, about invertors, dies to elongate the copper wire into the desired
size, tension regulator and so on during our internship period.

During our stay in the factory, we have grasped a lot of knowledge also we relate the theory that
we have learned in the University with practice and the most satisfactory advantage of internship
program was understanding the theory that we did not understand in the University, when we
observe it practically. We have got a lot of skill during the internship program but dominantly the
skills that we got during the internship program are: -

• Communication skill
• Leadership skill
• Practical skill
• Team working skill
• Entrepreneurship skill

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5.2 Recommendation

We successfully done our project which is motor traverse control for 37 stranding machines take
up and for other related machine in that company. In our project we design the control circuit
diagram and configure PLC hardware, HMI screen and other required components on TIA portal.

Lastly, we simulate the constructed design via TIA portal successfully. But because of shortage
of time and lack of selected plc type we cannot implement our project practically. So, we
recommend that the one who is interested or the company itself can implement this problem
solver project.

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References
[1] website: www.el-sewedy_cables.com,n.d.
[2] Waleed, T. ((2009).). Elsewedy Cable Manuals.
[3] A.Thue., W. (n.d.). Electrical Power Cable Engineering, Third Edition.
[4]Ahmed. ((2008).). Elsewedy ,Power Cable Catalogues.

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