INTRODUCTION

Industrial training is one of the requirement for all student of

engineering. The development of higher education and careers in the
21st century is discussed on knowledge, skill and ability of graduates
to meet industries expectation. The main objective is to give students
vast exposure to a real industrial environmental. Students will be able
to apply the skill that they have gained throughout their academic
year. They can enhance their knowledge and abilities at the
companies that they are attached too. The companies/industries
produce the professionals after completion of industrial training. The
industrial training should be complete within for the duration of
15/05/2019 to 30/05/2019.
 AKNOWLEDGEMENT
I am very thankful to Smart Pro System for giving me the opportunity to
undertake my industrial training during summer holidays. It was very good
learning experience for me.
I would like to convey my heartiest thanks to Mr. Santosh Patil
(Mangement Director), Mr. S. S. Lohar sir who guided and encouraged me all
through the industrial training. I would like to thank all team in Smart Pro System
for giving me their precious time and valuable guidance during my internship.
I am extremely thankful to Mr. C. D. Gurav sir (Head of Department), Mrs.
Matiwade mam for providing me the nice industry for my internship.
CONTENT PAGE
Chapter 1: Organizational structure of industry.
Chapter 2: Introduction industry/ organization (type of product and services,
history, no. of employees, etc.)
Chapter 3: Types of major equipment/ instrument/ machines used in industry with
their specifications, approximate cost and specific use.
Chapter 4: Panel designing.
Chapter 5: Testing of row materials, components and finished products along with
quality assurance procedure.
Chapter 6: Major materials handling products (conveyor belt) and material handling
procedures.
Chapter 7: Safety procedure followed in industry.
Chapter 8: Report on industrial visit.
Chapter 9: Short report/ description on the project.
Chapter 10: Special/ challenging experiences during training.
Automation training report:
Chapter 1: Organization structure of industry.
Organization definition: Organization structure is one of the main factor which affects
the projects in an organization. Depending on the market condition, competition,
industry and the history of the company, different organization structures can be
adopted by companies at different times.

Types of organization structure:

1. Administrative (used in large scale industries)
2. Functional (used in industries fie providing services)
3. Divisional (used in industries for manufacturing products)
4. Matrix (products and services both provided by industry)

1. Administrative structure: An administrative structure is a typically hierarchical arrangement

of lines of authority. It determines how the roles, power and responsibilities are assigned and
how the work process flows among different management levels.

2. Functional structure: The functional organizational structure is a structure used to organize

workers. They are grouped based on their specific skills and knowledge. It vertical structure
3. Each department with roles from president to finance and sales department, to employees
assigned to one product or service.

4. Divisional structure: The divisional organizational structure organize the activities of a

business around geographical, market, or product and service groups. Thus, a company
organized on divisional lines could have operating groups.

5. Matrix structure: A matrix organization structure is a company structure in which the

reporting relationship are set up as a grid, or matrix, rather than
6. In the traditional hierarchy. In their words, employees have dual reporting relationship-
generally to both a fictional manager.
Chapter 2: Introduction to industry.
Location of industry: Gat. No. 1289, plot no.19, Nr. Shrenik kapad shop
Nerli- Tamgoan road, Nerli, M.I.D.C. Gokul Shirgaon, Kolhapur-416234
Types of products and services:
 Manual lathe convert into CNC lathe
 Control panel manufacturing.
 CNC retrofitting and PLC based automation (with controller
SIEMENS,MITSUBISHI,FANUC,NERI,AD Tech)
 Old CNC machine sales and service
 Maintenance
 Switch gear, VFD, timer, counter sales
Chapter 3: Types of major equipment /instrument/machines used
in industry with their specifications, approximate cost and specific
use and their routine maintenance.
Major equipment used in industry:

1. Motors: motor

AC motor DC motor SPM

Induction synchronous shunt series compound stepper servo

Single phase
Three phase

2. Sensor: sensor

Temperature sensor Displacement sensor Proximity sensor Pressure sensor

RTDa.LVDTa.infrareda.strain-guage
Thermisterb.RVDTb.Ultrasonicb.bordon tube
Thermocoplec.pizoelectricc.Radar
LM35

3. SMPS:
Switched mode power supply is an electronic circuit which converts the power using
switching device that are turned on and off at high frequencies, and storage components such
as inductors or capacitor to supply power when the switching device is in its non-conduction
state. Its efficiency is high.
 Block diagram of SMPS:

4. PLC: Programmable Logic

In above figure, PLC consist of following basic parts. The control

processing unit is the heart of PLC system. The CPU is the microprocessor based control system
that replaces central relays, counters, timers and sequencers.
Communication devices: (RS485/RS232/ETHERNET)
5. Computer instruction sets:
a) RISC(Reduced Instruction Set): The main idea behind is more hardware simpler by
using an instruction set composed of a few basic step for loading, evaluating and storing
operations just like an addition command will be composed of loading data, evaluating
and storing.

b) CISC (Complex Instruction Set): The main idea is to make hardware complex as a
single instruction will do all loading, evaluating and storing operations just like a
multiplication command will do stuff like loading data, evaluating and storing it.
6. Relay: Relays are electromagnetic device that use electromagnet to operate a pair of
movable contact from an open position to a closed position.
7. Electricity power distribution:

8. Staircase wiring connection:

9. Microcontroller:
A microcontroller is a small computer on a single IC that integrates all the features
that are found in the microprocessor. In order to serve different application, it has a
high concentration of on chip facilities such as RAM, ROM, I/O ports, timer, serial port,
clock circuit and interrupt. Microcontroller are used in various automatically
controlled devices such as remote controls, automobile engine control system,
medical devices.
10. Types of rectifier:

A rectifier is a circuit that is used for converting AC supply into unidirectional DC

supply. This process of converting alternating current (AC) to direct current (DC) is also called
as rectification. These bridge rectifiers are available in different packages as modules ranging
from few amperes to several hundred amperes. Mostly in bridge rectifier circuits.
Semiconductor diode is used for converting AC since it allows the current flow in one direction
only (unidirectional device)

Bridge rectifier selection depend on load requirements and apart from this some more
consideration are component ratings, breakdown voltage, forward current rating, transient
current rating, temperature ranges, mounting requirements, etc. We can connect the diode
in different configurations for obtaining different types of rectifier.
11. DC motor:
A direct current or DC motor convert’s electrical energy into mechanical energy. It is one of
two basic types of motors: the other type is the alternating current or AC motor. Among DC motors
there are shunt-wound, series-wound, and compound-wound and permanent magnet motors.
A DC motor consist of stator an armature a rotor and a commentator with brushes. Opposite
polarity between the two magnetic fields inside the motor cause it to turn. DC motor are the simplest
type of motor and are used in household appliances such as electric razors and in electric windows
in cars.

1. Permanent Magnet DC Motors:

The permanent magnet motor uses a permanent magnet to create field flux. This type
of DC motor provides great starting torque and has good speed regulation, but torque
is limited so they are typically found on low horsepower applications.
2. Series DC motors:
In a series DC motor, the field is wound with a few turns of a large wire
carrying the full armature current. Typically, series DC motor create a
large amount of starting torque, but cannot regulate speed and can even
be damaged by running with no load. These limitations mean that they
are not a good option for variables speed drive applications.
3. Shunt DC motors:
In shunt DC motor the field is connected in parallel (shunt) with the
armature windings. These motors offer great speed regulation due to the
fact that the shunt field can be excited separately from the armature
windings, which also offers simplified reversing controls.
4. Compound DC motor:
Compound DC motors, like shunt DC motor, have a separately excited
shunt field. Compound DC motor have good starting torque but may
experience control problems in variable speed drive application.
12. Switchboard connection:

Product cost:
Sr.no. Product name Cost
1 PLC (Siemens, st20) 16,000
2 External analog card 9,856
3 Relay board 1,620
4 Contactor 160
5 SMPS 1,000
6 HMI 6,785
7 Connector 100
8 Panel box 4,850
9 Switches 180
10 RTD sensor with controller 1,200
11 Proximity sensor 850
12 ABB 512
13 Delta 4,250
Chapter 4: Manufacturing process along with production planning
and control methods.
 Panel designing: Control panel design for industrial equipment and machinery is an
important undertaking resulting in an interface designed to control a machine or process. It’s
not a simpematter of selecting an appropriate enclosure and a back panel that houses the
electrical hardware. So the proper hardware must be mounted on a back panel and properly
wire integrated into the machine-any improper configuration result in malfunctioning
machinery, but it’s also likely to pose an unnecessary risk to operator.

 I/O list: I/O list is a document containing list of instrumentation which serve as an input or
output of control system. Therefore only the tag number that physically has a cable which
connects it the control system appears on I/O list.
When there are more than one control system in a plant, the I/O list shall clearly
indicates which instruments is assigned to which control system or may separate them to
different section in the document.
In I/O list, the following information should be stated but not limited to:
 Tag number
 Loop number
 Service description
 Type of instrument
 P&ID number
 Location
 I/O type
 Control system
 Range or set point

Selection of PLC: For selection of PLC following parameter are important.

1. Supply power: This is one of the easiest ways to narrow down the selection of PLCs.
2. Operator interface: The PLC will need some sort of input feeding it information so it can
decide what to do based on your programming.
3. Communication protocols.
4. Programming: another item to consider is how the PLC is going to be program. Most
PLCs require specific software to connect it to a computer and program it. Taking a look
at the software will give you an idea of what language you can use in case you are more
familiar or want a particular one. It will also give you an idea of the capabilities of it
which can make certain task much easier. Price is another think to look at, it is free, a
onetime purchase, or subscription based.
  Communication devices in PLC:
1. Ethernet 2. Ether CAT 3.RS-232C 4.RS-422 5.RS-485
 HMI selection: HMI designer can simplify their for the appropriate switch or
HMI components by carefully analyzing their application requirements then
determining the following:
a. Electrical ratings
b. Actuation preferences (momentary, maintained, rotary, etc.)
c. Physical configuration and mounting needs.
d. Special requirements such as illumination, marking, environmental sealing etc.
 Selection of sensors: A systematic method is developed to select the most
appropriate sensors for a particular application. A wide range of candidate sensors
exists, and many are based in coupled electrical and mechanical phenomena, such as
electric, magentostrictive and pyro-electric effect. Performance chart for sensor are
constructed from supplier’s data for commercially available devices.
 Contactor listing:
a. The contactor are the current carrying part of the contactor. This include
power contact,
b. Auxiliary and contact spring.
c. The electromagnet provides the driving force to close the contacts.

 Ratings: contractors are rated by designed load current per contact, maximum
fault withstand current, duty cycle, voltage and coil voltage. A general purpose
motor control contractor may be suitable for heavy starting duty on large motors; so
called “definite purpose” contractors are carefully adopted so much application as
air conditioning compressor motor starting.
 SMPS placing: Switch mode power supplies are widely used because of the
advantages they offer in terms of size, weight, cost, efficiency and overall
performance. SMPS have become an accepted part of the electronics scene and are
often referred to as switch mode power convert, or switchers. It is generally used to
indicate an item that can be connected to the mains, or other external supply and
used to generate the source power.
  Panel box defining and designing:

FP 0471

Mi. 9311

 Built in dimensions W 306 x H 486 x D

140 mm.
 Door locking with hand operation.
 With closing plates for box walls.
 Max. Installation depth with built-in
mounting plate 136mm, with built-in
DIN rate 125mm.
 With opaque door.
 Box size 4.
 Door locking sealable.
 Please DIN rates, mounting plates or
covers additionally.
 Connector: 6 items.
 Order flanges separately.
 Material: PC(Poly carbonate)
 Protection class: II.
 Color: gray, RAL 7035.
 Built-in dimensions W 275 x H 425 x D
195mm.
 Max. Installation depth with built-in
mounting plate 191mm.
 Box size 3.
 Please order DIN rate, mounting
plates or covers additionally.
 Trilaterally combinable.
 3 walls with metric knock outs for
cable entry and assembly.
 Lid hinges attached.
 With opaque, hinged lid.
 Lid fasteners for tool operation.
 Material: PC (poly carbonate).
 Protection class: II.
 Color: gray, RAL 7035.
 Wiring/cabling:
Cable selection
 Armored cables (for outdoor,
underground )
 Unarmored cables (for indoor but
open in cable trays)
 Submersible cables
 Size of cable(as per load)
 Insulation on cable (PVC,XPLE)
 Core 3(where neutral not
required)or 3 ½ cable (where neutral
required)
 3 core cable in HT, motor, capacitor
 3 ½ core in light load

Dinrailplacing:

DIN, an acronym for “Deutsche

institute Von Norman”
Or “German institute of standards”,
is a word wide standards ensuring
dimensional uniformity for products
regardless of the manufacturer. DIN
rail is the metal rail used to mount
the various electrical components(
for example, terminal blocks , motor
starters, relays, circuit breakers,
contactors, remote I/O, power
supplies, etc…)in a control cabinet.

DIN rails is available in various base

metals of which, the most common
are steel, aluminum, and stainless-
steel and copper. In addition, DIN rail
is available in various finishes with
respect to base metal. The most
common base metal and finish
combination in the industry is zinc
plated, yellow chromatid steel.
 Chapter 5: Testing of raw material/ components and finished product with
Raw Material Testing
Raw material testing and quality control.

Intertie tests raw materials, feedstock and other commodities, ingredients and component
used in a wide range of product. Testing raw material can include evaluation and screening
of feedstock, unprocessed material, semi- processed and finished product for quality
specifications, impurities and more, including higher-end analytic testing and
characterization if required.

 Finished products by company:**products:

 All types temperature sensors(RTD, Thermocouple)
 All type single and 3 phase motor
 DC motor
 All type temperature controller
 SMPS
 Relay board
 Graphic recorder
 Encoder
 Encoder coupling
 Cables
 Contactors
 Pressure, temperature, flow, level switches
 Rota meter
 Pressure, temperature, flow, level transmitter
 Control panel equipment
 Proximity sensors
 Foot switches
 LED projects
 CCTV projects
 Biometric machine
 Sugar industry process
 All type of conveyor system
Log book for raw materials:

Sr no date Name of Material Mfg. B. no Mfg. date Exp. date

raw code no
material

GRN no Manufactur Qty. Sampled by Sampled A.R.NO./d Remarks

e/supplier received/no qty. ate
of contains

Log book for raw material work sheet issuance:

Sr. no. Name of A.R. no. Date of Work Given by Sign Remarks
raw issue sheet no.
material
Chapter 6: major material handling product (conveyor belt)
In the process or manufacturing industry, raw materials and products need to be
transported from one manufacturing stage to another. Material handling equipment are
designed such that they facilitate easy, cheap, fast and safe loading and unloading with least
human interference. For instant, belt conveyor system can employed for easy handling of
materials beyond human capacity in terms of weight and height. This paper discusses the
design calculation and consideration of belt conveyor system for limestone using 3 rolls
idlers, in terms of size, length, capacity, speed, roller, diameter, power and tension, idler
spacing, type of driver unit, diameter, location and arrangement of pulley, angle and axis for
rotation, control mode, intended application, product to be handled as well as its maximum
loading capacity in order ensure fast, continuous and efficient moment of crushed limestone
while avoiding halt or fatalities during loading and unloading. The successful completion of
this research work has generated design data for industrial uses in the development of an
automated belt conveyor system which is fast, safe and efficient.

Growing Importance of Material Handling Systems

Businesses create a place and time utility through the help of material handling. It is most
helpful for retail stores, warehouses, and manufacturing plants. In the job of all production
workers, material moving equipment place a vital role.

 Orientation- this principal promotes the assessment of any available system

relationship prior to the preliminary planning. It may include and evaluation of the
problems and existing method.
 Planning- when it comes to the planning, it should involve the basic requirements,
contingency planning, and other desirable alternates.
 Systems- this principal should integrate storage and handling that are cost-
efficiently integrated into the system.
 Unit load- this is the handling of products through unit loads as big as possible.
 Space utilization- encouraging efficient utilization of available space is another
excellent principal in material handling.
 Standardization- this principal encourages handling methods standardization for
better equipment performance.
 Ergonomic- this recognize limitation and human capabilities through the design.
 Energy- with this principal, it considers the energy consumption during the handling
process.
 Ecology- it should have a minimum impact on the ecology.
 Mechanization- this is to encourage efficiency in handling materials.
 Flexibility- equipment and, methods should be practical in any condition.
 Simplification- simplified process is better than complex method as it removes
unnecessary movements.
 Chapter 7: safety procedures followed and safety gear used.
Safety procedure:
Before working on any electronics, consider following these basic safety precautions to
help to reduce hazards.

 Remove any electronic equipment you’re testing or working on from the power source.
 Never assume the power circuit is off. Test and test again with a voltmeter to confirm.
 Remove uses and replace them only after the power to the circuit is disconnected.
 Don’t connect power to a circuit until you’re done working on it sa rechecked the work.
 Always ensure that all electronics equipment is properly grounded.
 If it’s damaged, replace it. For instance, replace cables instead of repairing with insulating
tape.
 Always use the right electronics repair and maintenance tools.
 Always return covers after removing then to reduce the risk of electric shock.
 Always have safety equipment like a fire extinguisher, a basic first aid kit and a mobile
phone nearby.
Personal safety
It’s important to ensure that you’re safe when working on electronic circuit. Here are some
personal safety precautions to keep in mind.

 Always keep your work area dry.

 Always work in a well-ventilated area.
 Don’t wear flapping or loose clothing when working.
 Don’t work with metallic jewelry on your hands like watches, rings and bracelets
 Always wear nonconductive shoes
 Always wear safety goggles

High voltage safety

 One mistake that electronics expert make when doing repairs or maintenance work is
assuming routine safety procedure after getting all too familiar with their work.it is
important to know that most electronic equipment use high voltage that is dangerous and
can be fatal. Always follow voltage that it dangerous and can be fatal. Always follow these
safety precautions when working on or near high voltage circuits.
 Don’t work on electronic equipment or make repairs with high voltage on.
 Don’t take chance doing what you’re not sure about.
 Keep electronic equipment away from water and other liquids.
 Always check for signs of wear, defects and fraying on electronic equipment cables, cords
and connectors.
 Use special safety rubber gloves and shoes.
 Chapter 8: particulars of practical experience in industry.
1. Introduction:
Simplification of engineering and precise control of manufacturing process can result
in significant cost savings. The most cost-effective way, which can pay big dividends in the
long run is flexible automation; a planned approach towards integrated control systems. It
requires a conscious effort on the part of plant managers to identify areas where automation
can result in better deployment/utilization of human resources and savings in man-hours,
down time. Automation need not be high ended and too sophisticated; it is the phased, step-
by-step effort to automate, employing control systems tailored to one’s specific requirements
that achieves the most attractive results. That is where Industrial electronics has been a
breakthrough in the field of automation and control techniques. It is required System design
and specification, Electrical and mechanical design using industry standard CAD tools and E
plan, PL software development Panel manufacture to highest quality Panels and systems can
be tested to customer specification and test procedures On-site commissioning using
equipment’s. Diagnostics and troubleshooting Control Panel as the name implies, are used to
provide proper control of operations of any electrical equipment’s. These are also used to
protect the electrical equipment’s from being damaged due to various faults like short circuit,
overload and earth leakage etc.

2. Product and application:

A Programmable controller is a solid state user programmable control system with
functions to control logic, sequencing, timing, arithmetic data manipulation and counting
capabilities. It can be viewed as an industrial computer that has a central processor unit,
memory, input/output interface and a programming device. The central processing unit
provides the intelligence of the controller. It accepts data, status information from various
sensing devices like limit switches, proximity switches, executes the user control program
store in the memory and gives appropriate output commands to devices like solenoid valves,
switches etc. Input output interface is the communication link between field devices and the
controllers; field devices are wired to the I/O interfaces. Through these interfaces the
processor can sense and measure physical quantities regarding a machine or process, such
as, proximity, position, motion, level, temperature, pressure, etc. Based on status sensed,
the CPU issues command to output devices such as valves, motors, alarms, etc. Programmer
unit provides the man machine interface. It is used to enter the application program, which
often uses a simple user-friendly logic.

3. DESIRED QUALIFICATIONS FOR PROMOTER:

Graduate in any discipline, preferably science.
4. MARKET POTENTIAL AND MARKETING ISSUES, IF ANY:
With the rapid electrification and industrialization and by virtue of being a functionally
integral part of all electrical equipment’s like Motor, Generator, Transformer, Motor Control
Centre, Incinerator etc. the control panel has get immense scope. The phased increase in
power generation and transmission has by itself necessitated increased production of
electrical equipment’s thereby creating a good scope for the control panel. In the present
industrial world, a flexible system that can be controlled by user at site is preferred.
Systems, whose logic can be modified but still, used without disturbing its connection to
external world, is achieved by PLC. Utilizing the industrial sensors such as limit switches,
ON-OFF switches, timer contact, counter contact etc., PLC controls the total system. The
drive to the solenoid valves, motors, indicators, enunciators, etc. are controlled by the PLCs.
The above said controlling elements (normally called as inputs of PLCs) and controlled
elements (called as outputs of PLCs) exist abundantly in any industry. These inputs,
outputs, timers, counters, auxiliary contacts are integral parts of all industries. As such, it is
difficult to define where a PLC cannot be used. Proper application of a PLC begins with
conversion of information into convenient parameters to save money, time and effort and
hence easy operation in plants and laboratories.

5. RAW MATERIAL REQUIREMENTS:

The major raw materials required are 5 way connectors (30 A Bakelite), am meter
A Panel
Mount, Capacitor, Capacitor, 36 Faradays/440 V), CRC steel sheet, (18 gauge). Fuse unit (15
A), Hinges, (1/2" x 1" size). Indication Lamp Set, Metal coating powder, Overload Relay unit,
Packing Material, Push Button Station (on-off), Screws, Nut and Bolt, Bottom Bush and
sticker, Voltmeter, (0 to 300 V Panel Mount), Wires (2.5 sq. mm copper of 5 different colors)

6. MANUFACTURING PROCESS:
The Control Panel is sheet metal fabricated in closure open, semi-enclosed or totally
enclosed type, which provide and control electric power to equipment and appliances.
Provision for indicating electrical parameters like voltage, current, frequency, power factor
etc. will be available on the face of the panel. Regulation of the power supply is also possible
with the help of auto transformer switches and circuit breaker. The sheet metal enclosure for
the Control Panel is designed and fabricated in the unit. The components are bought out
from the reputed sources and fitted at appropriate places on the panel as per manufacturers
design. The circuit as per the design is laid out and the control panel is tested for the proper
functioning as per relevant specifications.
2. Quality Control: The LT Control Panel shall be tested as per IS: 8623-1977 regarding
technical aspects.
3. Production Capacity (per annum): LT Control Panel of a short range - 300 Nos. per year.
4. Approximate Motive Power Requirement: 20 KVA
5. Pollution Control Requirement: No Objection Certificate to obtain from DIC level.