Internship Report on Programmable Logic Controllers (PLCs)

1. Introduction

This report summarizes my internship experience focused on Programmable Logic Controllers (PLCs),
their applications, programming, and integration in industrial automation systems. The internship was
conducted by Department of Electrical Engineering, Contai Polytechnic.

Title: “Two-week Internship on PLC Automation”

Duration: 29th July 2024 to 9th August 2024
Mode: Offline Mode at Electrical Engg. Departmental Lab, Contai
Polytechnic.
Faculty Coordinators: Mr. Kalyan Kr. Ghosh, Mr. Sushil Sahoo, Mr. Abhirup Giri, Mr.
Avijit Samanta, Mr. Souvik Maity

2. Objectives

The primary objectives of the internship were:

• To gain hands-on experience in PLC programming and configuration.

• To understand the role of PLCs in industrial automation.
• To learn the use of software tools like SoMachine, RSLogix, TIA Portal, etc.
• To participate in real-world projects involving PLCs.

3. Overview of Programmable Logic Controllers (PLCs)

PLCs are specialized computing devices used to automate industrial processes. They are robust, modular,
and designed for real-time control. The key features of PLCs include:

• Input/Output (I/O) Modules: Facilitate interaction with sensors and actuators.

• Programming Environment: Ladder Logic, Function Block Diagram (FBD), Structured Text, etc.
• Communication Protocols: Modbus, Profibus, Ethernet/IP, etc.

4. Internship Activities

4.1 Training and Familiarization

The internship began with an introductory training session covering:

• Basics of PLC hardware and architecture.

• Overview of industrial control systems and SCADA integration.
• Introduction to programming environments like SoMachine and TIA Portal.

4.2 Programming Tasks

During the internship, I worked on various programming tasks, including:

• Developing Basic Logic Gates:

o Implemented AND, OR, and NOT gates using Ladder Diagrams.
o Used timers and counters for complex logic sequences.
• Real-World Applications:
o Programmed a conveyor belt system for sorting items based on size.
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 o Automated a water-level control system using sensors and pumps.

4.3 Testing and Debugging

• Conducted extensive debugging to ensure error-free PLC code.

• Used simulation tools to test the functionality before deployment.
• Worked on hardware setups to test the PLC programs with real-world inputs.

4.4 Project Contribution

Contributed to a project involving:

• Integration of PLCs with Human-Machine Interfaces (HMIs) for real-time monitoring.

• Developing control logic for a packaging line.
• Configuring communication between PLCs and SCADA systems.

5. Challenges and Solutions

Challenges Faced:

• Understanding complex programming structures in Ladder Logic.

• Configuring communication protocols for multi-device systems.

Solutions Implemented:

• Attended additional training sessions on Ladder Logic and Function Block Diagrams.
• Consulted team members and technical documentation to resolve communication issues.

6. Key Learnings

The internship provided valuable insights into:

• Industrial Automation: Learned how PLCs play a pivotal role in modern manufacturing.
• Programming Skills: Gained proficiency in Ladder Logic and Structured Text.
• Teamwork and Collaboration: Worked effectively with engineers and technicians to meet project
goals.

7. Conclusion and Recommendations

The internship was a highly enriching experience that enhanced my technical and practical knowledge of
PLC systems. It strengthened my understanding of industrial automation and prepared me for future roles in
this field.

Recommendations for Future Interns:

• Gain a basic understanding of PLCs and Ladder Logic before starting the internship.
• Be proactive in seeking guidance and clarifying doubts.
• Focus on learning how PLCs integrate with broader automation systems like SCADA and HMIs.

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 8. Acknowledgments

I extend my gratitude to Dr. Prabir Maity, Principal-In-Charge Contai Polytechnic

& Department of Electrical Engineering Contai Polytechnic for providing this
opportunity and to my mentors Mr. Kalyan Kr. Ghosh, Mr. Sushil Sahoo,
Mr. Abhirup Giri, Mr. Avijit Samanta, Mr. Souvik Maity for their
invaluable guidance and support. Special thanks to the technical team for their
cooperation throughout the internship.

Student Name:

Student Signature:

Registration No:

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9. Appendices

Appendix A: PLC Program Code for Water Level Control.

PLC program for Water Level Control using Ladder Logic. The system maintains the water level in a tank
using a pump, with sensors to monitor high and low water levels.

Objective:

1. Pump ON: When the water level is below the low-level sensor.
2. Pump OFF: When the water level reaches the high-level sensor.
3. Ensure the pump operates only between the low and high water levels.

Components:

1. Inputs:
• Low-Level Sensor (I0.0) – Normally Open (NO): Activates when the water level is low.
• High-Level Sensor (I0.1) – Normally Closed (NC): Activates when the water level is high.
2. Outputs:
• Pump (Q0.0)
3. Auxiliary Relay:
• Pump Latch Relay (M0.0)

Ladder Diagram Code:

|----[ I0.0 ]----+----[ M0.0 ]---------------( M0.0 )----|

| | |
| +----[ I0.1 ]---------------------------------- |
| |
|----[ M0.0 ]-------------------------------------------( Q0.0 )----|

Explanation:

• Rung 1:
o I0.0 (Low-Level Sensor): Activates when the water level drops below the low sensor. It
latches the pump relay M0.0 to keep the pump running.
o I0.1 (High-Level Sensor): Deactivates the pump relay when the water level reaches the high
sensor, turning the pump OFF.
• Rung 2:
o M0.0: Controls the output Q0.0, which operates the pump. The pump runs while M0.0 is
active.

Operating Logic:

1. When the water level is below the low-level sensor (I0.0 is ON), the pump turns ON (Q0.0 is
energized).
2. As the water level rises and reaches the high-level sensor (I0.1 is ON), the pump turns OFF.
3. The pump will remain OFF until the water level drops below the low-level sensor again.

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 Appendix B: PLC program for traffic light control using Ladder Logic.

The system manages a three-light sequence: Green, Yellow, and Red.

Objective:

1. Control a traffic light sequence with three lights: Green, Yellow, and Red.
2. Each light stays ON for a specific duration:
o Green: 10 seconds
o Yellow: 3 seconds
o Red: 10 seconds
3. The sequence repeats indefinitely.

Components:

1. Inputs:
o Start Button (I0.0) – Starts the traffic light sequence.
o Stop Button (I0.1) – Stops the traffic light sequence.
2. Outputs:
o Green Light (Q0.0)
o Yellow Light (Q0.1)
o Red Light (Q0.2)
3. Timers:
o Timer T1 (Green Duration): 10 seconds
o Timer T2 (Yellow Duration): 3 seconds
o Timer T3 (Red Duration): 10 seconds

Ladder Diagram Code:

Rung 1: Start/Stop Logic

|----[ I0.0 ]----+----[ M0.0 ]----------------( M0.0 )----|
| | |
| +----[ I0.1 ]--------------------------- |

Rung 2: Green Light Control

|----[ M0.0 ]-------------------[ T3 ]-------------------( Q0.0 )----|

Rung 3: Yellow Light Control

|----[ T1 ]---------------------------------------------( Q0.1 )----|

Rung 4: Red Light Control

|----[ T2 ]---------------------------------------------( Q0.2 )----|

Rung 5: Timer Control

|----[ M0.0 ]----+---[ Q0.0 ]---( T1 10s )---|
| +---[ Q0.1 ]---( T2 3s )----|
| +---[ Q0.2 ]---( T3 10s )---|

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Explanation:

1. Rung 1:
o The Start Button (I0.0) latches M0.0, enabling the traffic light sequence. The Stop
Button (I0.1) stops the process by breaking the latch.
2. Rung 2:
o The Green Light (Q0.0) is ON during the first timer (T3), indicating the green phase.
3. Rung 3:
o The Yellow Light (Q0.1) is ON during the second timer (T1), indicating the caution phase.
4. Rung 4:
o The Red Light (Q0.2) is ON during the third timer (T2), indicating the stop phase.
5. Rung 5:
o The timers (T1, T2, T3) control the duration of each light. The sequence loops back to T1 after
T3 completes, creating a continuous cycle.

Timings:

• T1 = 10 seconds (Green)
• T2 = 3 seconds (Yellow)
• T3 = 10 seconds (Red)

Customization:

We can adjust the timers or add additional lights and phases, like a pedestrian crossing signal, to fit specific
traffic control requirements.