BUFFER STORE SIMULATION USING PLC

CHAPTER 1

COMPANY PROFILE

1.1 BOSCH GROUP

FIG 1.1 BOSCH LOGO

Robert Bosch GmbH (commonly known as Bosch) is a German multinational

engineering and electronics company headquartered in Gerlingen, near Stuttgart. It is the
world's largest supplier of automotive components. The company was founded by Robert
Bosch in Stuttgart in 1886. Bosch's core products are automotive components, industrial
products and consumer goods and building products. Bosch has more than 350 subsidiaries
across over 60 countries and its products are sold in around 150 countries. Bosch employs
around 303,000 people and had revenues of approximately €51.4 billion in 2011. In 2010 it
invested around €3.8 billion in research and development and applied for over 3,800 patents
worldwide. Bosch is the leader in terms of numbers of patents at the German Patent and Trade
Mark Office (GPTO) with 3,213 patents [1].

Bosch is 92 percent owned by the Robert Bosch charitable Foundation, which uses its
60% of funds to support a variety of social, welfare and arts and science causes. Bosch group
is a global company in the presence of Automotive, Industrial and consumer goods and building
services with a turnover of € 51 billion.

Bosch Rexroth is a 100% owned company of Robert Bosch. Bosch Rexroth India is a 100%
owned company of Bosch Rexroth, AG, Germany. Bosch Rexroth is a supplier of industrial

RASHMI S 1
 BUFFER STORE SIMULATION USING PLC

technology, producing hydraulic, electric, and pneumatic machinery for driving, controlling,
and moving machines in applications ranging from automotive to mining.

1.2 BOSCH REXROTH:

FIG 1.2 REXROTH BOSCH LOGO

As a global partner, Bosch Rexroth supports mechanical and plant engineering

challenges around the world with its cutting-edge technology and unique industry knowledge.
More than 30,500 employees worldwide work on safe, efficient, intelligent and powerful
solutions [1].

Bosch Rexroth is one of the leading specialists in the field of drive and control
technologies. They develop innovative concepts for machine and plant manufacturers all over
the world. With its long history and unique industry expertise, the company has become
synonymous with tailored solutions. Below is a brief history of Bosch Rexroth, spanning more
than 200 years.

• In 1795, Georg Ludwig Rexroth puts a water-powered hammer mill into operation in
Elsavatal (Spessart), thus signaling the start of the company's illustrious history.
• 1850 - Following the acquisition of the Stein'schen Eisengießerei iron foundry in Lohr,
the company establishes its headquarters in this city in Germany's Maintal region.

RASHMI S 2
 BUFFER STORE SIMULATION USING PLC

• 1952 - The company starts producing standardized hydraulic components and

hydraulics.
• 1966 - Following its acquisition of Indramat GmbH in the previous year, Rexroth sets
up a specialist department for electronic controls and control units.
• 1968 - Development of swash plate axial piston units for mobile machines.
Mannesmann AG acquires share in Rexroth.
• 1975 - Rexroth becomes a wholly owned subsidiary of Mannesmann AG.
• 1979 - Mannesmann Rexroth develops the world's first maintenance-free AC
servomotor, thus revolutionizing the mechanical engineering industry.
• 2001 - Merger of Mannesmann Rexroth AG and Bosch Automation Technology to
form Bosch Rexroth AG.
• 2005 - Launch of IndraDrive Mi, the first motor-integrated servo controller, in which
the motor and controller are combined in a single unit [1].

Facts and Figures:

• Total staff – 30500.

• 22900 in Europe
• 4700 in Asia / Pacific / Africa
• 2900 in America

Major market for Rexroth Bosch is in Europe which covers more than 50% of their sales
(3.16bn €). Asia / Pacific / Africa has a market of € 1.37bn and America has € 0.97bn.

Bosch Rexroth in Indian Education Sector:

Bosch leads Indian Industry Institute partnership in the Field of Automation

technologies, with Financial and technological participation by Bosch Rexroth. Bosch Rexroth
has set up 40+ Centers established across the country in form of master centres, Centre of
competences and Skill development centers to provide hands on training to the students on the
actual technological products in the field of Automation Technologies. The areas covered are
Hydraulics, Pneumatics, PLC’s, Sensorics, AC Servo Drives, CNC Control systems,
Mechatronics and Robotics.

RASHMI S 3
 BUFFER STORE SIMULATION USING PLC

1.3 DAYANANDA SAGAR UNIVERSITY

FIG 1.3 DAYANANDA SAGAR UNIVERSITY

Dayananda Sagar Institutions founded in the 60s by visionary, late Sri Dayananda Sagar
committed to take knowledge to the people, transforms today’s students into responsible
citizens and professional leaders of tomorrow. Dayananda Sagar University created by an Act
of the Karnataka State in 2014, built on this adorable legacy and inspired by its own milestones,
meeting the needs of quality higher education in this part of the world [2].

DSU is a proud member of the Dayananda Sagar Institutions family. DSI has morphed
into global education power house, spread over five campuses, catering to the education needs
of over 17,000 students. Operating under the aegis of the Mahatma Gandhi Vidya Peetha Trust
in Bengaluru, DSI has enabled the transformation of tens of thousands of young Indian and
international citizens into professionals in diverse specializations.

Besides our high-calibre teaching staff, the students are given a challenging academic
environment with well-equipped lecture theatres, laboratories, excellent libraries and computer
networking facilities. DSU also has exceptional infrastructure for students who possess a

RASHMI S 4
 BUFFER STORE SIMULATION USING PLC

passion for sports and games. The hostel facilities, encompassing cultural and recreational
needs, cater to both local and international students.

Research, Innovation and Incubation (spread over 25,000sft of industry quality labs)
form the core of DSU. So it isn’t surprising that DSU has taken the next logical step: Laying
the foundation to transform the entrepreneurial dream of every young Indian and global citizen
into a reality. Enabling this transformation is the active support of industry leaders, industry
bodies and a dedicated 4 lakh square feet modern ready-to-move-in infrastructure.

Vision of DSU: To be a Centre of excellence in education, research & training, innovation &
entrepreneurship and to produce citizens with exceptional leadership qualities to serve national
and global needs.

Mission of DSU: To achieve our objectives in an environment that enhances creativity,

innovation and scholarly pursuits while adhering to our vision.

RASHMI S 5
 BUFFER STORE SIMULATION USING PLC

CHAPTER 2

DEPARTMENT INFORMATION

2.1 AUTOMATION LAB BY BOSCH REXROTH:

2.1.1 Objectives:

• Industry Academic partnership in the Field of Automation technologies, with

technological participation by Bosch Rexroth.
• Works on the Concept of Technological institute in a technical institute, with its own
resources – Laboratories, Techwares, licensed software, Curriculum and Syllabus.
• To bridge technology gaps between Industry and academics.
• Act as a center to transfer current technologies to students and evolve into a research
and innovation center.
• Inclusive approach: Polytechnic, UG programs, PG programs & Skill development.
• Focus on Training, Skill Development, and Knowledge transfer, Projects, Application,
Research and Innovation.
• Improve employability and Entrepreneurship

RASHMI S 6
 BUFFER STORE SIMULATION USING PLC

2.1.2 Centre of Competence for Automation Technologies:

The Centre of Competence for Automation Technologies has been set up in Dayananda
Sagar University, Bangalore in Collaboration with Rexroth Bosch Group. The centre will work
as an independent centre serving as Centre of competence and Skill development. By this centre
a clear well-structured course program on skill development to +2 and Degree holders in
Science background with emphasis on hands on approach for developing skill and competence.
Centre being an independent will act on the concept of an Institute in an institute. This centre
will act as the regional centre in automation technologies to train the Faculty and Students of
nearby colleges – Vocational institutes, Polytechnics and Engineering in its Region.

This centre will increase the employability of students undergoing training. Further this
centre will facilitate the training for the industry personnel in the regions. Industry projects
with will be extended to the students.

Integrated Center of Competence with Skill development center will serve the needs as
Center of competence for engineering stream and Skill development for +2 onwards Science
background students. The technologies dealt in this centre will be Hydraulics, Pneumatics,
PLC’s, Sensorics, AC Servo drives, CNC Control systems and Mechatronics. The centre will
be able to accommodate a batch of 20 students for hydraulics, pneumatics, PLC and
Mechatronics. Also a batch of 10 students for Sensorics and a batch of 5 students for AC servo
drive and CNC.

Hydraulics:

HYDRA is Greek word means “Water or Fluid”. “Hydraulics is the name given to
the branch of physics which treats with the properties, motions and behaviour of Fluid or
Water”. Hydraulics is one of the drives which is selected based on its salient features wherever
found suitable and more efficient. There are only two basic motions in the world; LINEAR and
ROTARY.

Pneumatics:

PNEUMA means “Breath or Wind” in Greek word”. “Pneumatics is the name given
to the branch of physics which treats with the properties, motions and behaviour of Air”. The
Media Selection Criteria are Speed of Operation, Reliability, Service Life, Sensitivity to
Environment, Ease of Maintenance, Available Expertise, Training Requirements.

RASHMI S 7
 BUFFER STORE SIMULATION USING PLC

2.1.3 Programmable Logic Controllers:

The PLC is an Industrial Computer. It is capable of Storing Instructions to implement

control functions such as sequencing, timing, counting, arithmetic, data manipulation and
communication. The I/O interfaces provide the connection between the PLC and the
information providers (inputs like pushbuttons, sensors,…) and the controllable devices
(outputs like valves, relays, lamps,…).

Sensorics:
Sensor is a device that measures a physical quantity and converts it into a signal which
can be read by an observer or by an instrument. For example, a mercury thermometer converts
the measured temperature into expansion and contraction of a liquid which can be read on a
calibrated glass tube. A thermocouple converts temperature to an output voltage which can be
read by a voltmeter. For accuracy, all sensors need to be calibrated against known standards.

2.1.4 Agenda of the Centre:

• Technology modules for Automation: Industrial Hydraulics, Industrial Pneumatics,

PLC’s Sensorics, Electric Drives and controls and Mechatronics.
• Hardware’s, Teachwares Licensed software.
• Faculty development programs in 2 stages.
• Layout Design and Engineering detailed drawings for the Center.
• Erection and commissioning of the Center.
• Curriculum development; Modules, Syllabus, Courses, Contents and customization.
• Joint Certification program.
• Performance Audit once a year.
• Periodic Up gradations on Technologies.
• Project programs at the Center for the Students of UG, PG.
• Joint Certification: Bosch and the Center certificate for students.
• Hydraulic oil (HLP68 grade) for Hydraulic training system.

RASHMI S 8
 BUFFER STORE SIMULATION USING PLC

2.1.5 Profile of the Supervisor:

MS. K. SUDHA DEEPTHI is heading the centre of competence for automation

technologies. She is an assistant manager & certified trainer for this centre. She has 7 years of
teaching experience along with industrial experience. In 2014, she was trained by Rexroth
Bosch in various automation technologies such as hydraulics, pneumatics, programmable logic
controllers, mechatronics, robotics, sensorics, cnc motion control and drives. Since, 2014 she
is associated with Rexroth Bosch and she was also in charge of a centre of excellence for
automation technologies in JNTU, Hyderabad, where she used to conduct training programs
for faculty, students and research scholars. She served JNTU, Hyderabad centre of excellence
for automation technologies which was collaborated with Rexroth Bosch till October, 2015.

RASHMI S 9
 BUFFER STORE SIMULATION USING PLC

CHAPTER 3

TASK PERFORMED

3.1 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A PLC is a computer specially designed to operate reliably under harsh industrial

environments – such as extreme temperatures, wet, dry, and/or dusty conditions. It is used to
automate industrial processes such as a manufacturing plant’s assembly line, an ore processing
plant, or a wastewater treatment plant.

PLCs share many features of the personal computer you have at home. They both have
a power supply, a CPU (Central Processing Unit), inputs and outputs (I/O), memory, and
operating software (although it’s a different operating software). The biggest differences are
that a PLC can perform discrete and continuous functions which a PC cannot do, and a PLC is
much better suited to rough industrial environments. A PLC can be thought of as a ‘ruggedized’
digital computer which manages the electromechanical processes of an industrial environment.

PLCs plays a crucial role in the field of automation, using forming part of a larger
SCADA system. A PLC can be programmed according to the operational requirement of the
process. In the manufacturing industry, there will be a need for reprogramming due to the
change in the nature of production. To overcome this difficulty, PLC based control systems
were introduced.

3.2 PLC BASICS

PLCs were invented by Dick Morley in 1964. Since then PLC has revolutionized the
industrial and manufacturing sectors. There is a wide range of PLC functions like timing,
counting, calculating, comparing and processing of various analog signals. The main advantage
of PLC over a “hard-wired” control system is that you can go back and change a PLC after
you’ve programmed it, at little cost (just the cost of the programmer’s time). In a hard-wired
control system, you’re essentially having to rip out wires and start from scratch (which is more
expensive and takes longer). Let’s look at an example to better understand this advantage.

RASHMI S 10
 BUFFER STORE SIMULATION USING PLC

Imagine you have a light connected to a switch. In general, the light operates under two
conditions – ON and OFF. Now you are given a task that when you turn ON the switch, the
light should glow only after 30 seconds. With this hard-wired setup – we’re stuck. The only
way to achieve this is to completely rewire our circuit to add a timing relay. That’s a lot of
hassle for a minor change.

This is where a PLC comes into the picture, which doesn’t require any additional wiring
and hardware to make sure a change. Rather it requires a simply change in code, programming
the PLC to only turn on the light 30 seconds after the switch is turned ON. So, by using a PLC,
it is easy to incorporate multiple inputs and outputs. This is just a simple example – a PLC has
the ability to control much larger and more complex processes. A PLC can be customized
depending on the application and needs of the user.

RASHMI S 11
 BUFFER STORE SIMULATION USING PLC

3.3 PHYSICAL STRUCTURE OF PLC

The structure of a PLC is almost similar to a computer’s architecture .

Programmable Logic Controllers continuously monitors the input values from various
input sensing devices (e.g. accelerometer, weight scale, hardwired signals, etc.) and produces
corresponding output depending on the nature of production and industry. A typical block
diagram of PLC consists of four parts namely:

• Power Supply Module

• Central Processing Unit (CPU) and memory
• Input & Output Module
• Communication Interface Module

RASHMI S 12
 BUFFER STORE SIMULATION USING PLC

Power Supply Module:

This module is used to provide the required power to the whole PLC system. It converts
the available AC power to DC power which is required by the CPU and I/O module. PLC
generally works on 24V DC supply. Few PLC uses an isolated power supply.

CPU Module and Memory:

CPU module has a central processor, ROM & RAM memory. ROM memory includes
operating system, driver and application program. RAM memory is used to store programs and
data. CPU is the brain of PLC with an octal or hexagonal microprocessor. Being a
microprocessor based CPU, it replaces timers, relays, and counters. Two types of processors
as a single bit or word processor can be incorporated with a PLC. One bit processor is used to
perform logic functions. Whereas word processors are used for processing text, numerical data,
controlling and recording data. CPU reads the input data from sensors, process it and finally
sends the command to controlling devices. DC power source, as mentioned in the previous
discussion is required voltage signals. CPU also contains other electrical parts to connect cables
used by other units.

Input and Output Modules:

PLC has an exclusive module for interfacing inputs and output, which is called an input
& output module. Input devices can be either start and stop push buttons, switches, etc and
output devices can be an electric heater, valves, relays, etc. I/O module helps to interface input
and output devices with a microprocessor. The output module of PLC works similar to the
input module but in the reverse process. It interfaces the output load and processor.

Communication Interface Module:

To transfer information between CPU and communication network, intelligent I/O
modules are used. These communication modules help to connect with other PLCs and
computers which are placed at a remote location.

RASHMI S 13
 BUFFER STORE SIMULATION USING PLC

3.4 WORKING OF A PLC

The working of a PLC can be easily understood as a cyclic scanning method known as scan
cycle. A PLC Scan Process includes the following steps

• The operating system starts cycling and monitoring of time.

• The CPU starts reading the data from the input module and checks the status of all the
inputs.
• The CPU starts executing the user or application program written in relay-ladder logic
or any other PLC-programming language.
• Next, the CPU performs all the internal diagnosis and communication tasks.
• According to the program results, it writes the data into the output module so that all
outputs are updated.
• This process continues as long as the PLC is in run mode.

FIG 3.4 SCHEMATIC OF WORKING OF A PLC

RASHMI S 14
 BUFFER STORE SIMULATION USING PLC

3.5 INDRACONTROL L20 PLC

• Processor – STM ST40

• Supply voltage – 24V DC
• Bandwidth – 166MHz
• Digital inputs – 16
• Digital outputs – 16
• Analog inputs – 2
• Analog outputs – 2
• Communication interface – Ethernet TCP/IP
• Permissible temperature – +5 °C ... +55 °C
• Firmware used – 03V09.1

RASHMI S 15
 BUFFER STORE SIMULATION USING PLC

3.6 PLC PROGRAMMING

There are 5 languages that are all a part of the IEC (International Electrotechnical
Commission) Section 61131-3 Standard. This IEC Standard allows some ground rules that
standardize PLC’s and their languages. Let’s take a deeper look into all these PLC
Programming Languages.

The 5 most popular PLC Programming Languages are:

1. Ladder Diagram (LD)
2. Sequential Function Charts (SFC)
3. Function Block Diagram (FBD)
4. Structured Text (ST)
5. Instruction List (IL)

FIG 3.6 PLC PROGRAMMING LANGUAGES

RASHMI S 16
 BUFFER STORE SIMULATION USING PLC

3.7 LADDER LOGIC/ LADDER DIAGRAM:

Ladder Diagram was originally modeled from relay-logic which used physical devices,
such as switches and mechanical relays to control processes. Ladder Diagram utilizes internal
logic to replace all, except the physical devices that need an electrical signal to activate them.

FIG 3.7 RELAY-LOGIC REPRESENTED AS LADDER DIAGRAM

The ladder diagram consists of two vertical lines representing the power rails.
Circuits are connected as horizontal lines, i.e., the rungs of the ladder, between these two
verticals.

FIG 3.8 RUNGS OF THE LADDER

RASHMI S 17
 BUFFER STORE SIMULATION USING PLC

In drawing a ladder diagram, certain seven conventions are adopted:

Convention 1 //
The vertical lines of the diagram represent the power rails between which circuits are
connected. The power flow is taken to be from the left-hand vertical across a rung.

Convention 2 //
Each rung on the ladder defines one operation in the control process.

Convention 3 //
A ladder diagram is read from left to right and from top to bottom, Figure 3 showing the
scanning motion employed by the PLC. The top rung is read from left to right. Then the
second rung down is read from left to right and so on.

When the PLC is in its run mode, it goes through the entire ladder program to the end, the
end rung of the program being clearly denoted, and then promptly resumes at the start. This
procedure of going through all the rungs of the program is termed a cycle. The end rung
might be indicated by a block with the word END or RET for return, since the program
promptly returns to its beginning.

RASHMI S 18
 BUFFER STORE SIMULATION USING PLC

Convention 4 //
Each rung must start with an input or inputs and must end with at least one output. The
term input is used for a control action, such as closing the contacts of a switch, used as an
input to the PLC. The term output is used for a device connected to the output of a PLC, e.g.,
a motor.

Convention 5 //
Electrical devices are shown in their normal condition. Thus, a switch, which is normally
open until some object closes it, is shown as open on the ladder diagram. A switch that is
normally closed is shown closed.

Convention 6 //
A particular device can appear in more than one rung of a ladder. For example, we might
have a relay that switches on one or more devices. The same letters and/or numbers are used
to label the device in each situation.

Convention 7 //
The inputs and outputs are all identified by their addresses, the notation is used depending
on the PLC manufacturer. This is the address of the input or output in the memory of the
PLC.

FIG 3.10 Standard IEC 1131-3 symbols that are used for input and output devices.

RASHMI S 19
 BUFFER STORE SIMULATION USING PLC

Ladder Diagram Advantages:

The main advantages of the Ladder Diagram language are:
1. The rungs allow it to be organized and easy to follow.
2. It also lets you document comments that are readily visible.
3. It supports online editing very successfully.

Ladder Diagram Disadvantages:

The main disadvantage is that there are some instructions that are not available, which might
make it more difficult for programming such as motion or batching.

FIG 3.11 DISADVANTAGE OF A LADDER DIAGRAM

RASHMI S 20
 BUFFER STORE SIMULATION USING PLC

3.8 STANDARD FUNCTIONAL BLOCKS

As already discussed, many controlling operations can be done using PLCs. The two
main components used for PLC programming are timers and counters.

DIFFERENT TYPES OF TIMERS:

➢ On-Delay Timer (Ton): When input (IN) goes high, output (Q) will go high only after
the pre-set time (PT) has elapsed. When input goes low, output will go low
immediately.
➢ Off-Delay Timer (Toff): When input (IN) becomes high, simultaneously output (Q)
becomes high. When input becomes low, output becomes low after the pre-set time
(PT) is elapsed.
➢ Pulse Timer (TP): If input (IN) is low, output (Q) is low. When input goes high, output
will remain high till the pre-set time (PT) & after that it will be reset even if input is
high.

FIG 3.12 DIFFERENT TYPES OF TIMERS

FIG 3.13 LOGIC FOR WORKING OF TIMERS

RASHMI S 21
 BUFFER STORE SIMULATION USING PLC

DIFFERENT TYPES OF COUNTERS:

➢ Down Counter (CTD): When input (CD) has the rising edge, counter value (CV) is
decremented by 1. So when the counter value becomes equal to the pre-set value (PV)
which is zero, output (Q) becomes high. Some initial value is given to Load which is
been shifted to CV.
➢ UP Counter (CTU): When input (CU) has the rising edge, counter value (CV) is
incremented by 1. When CV becomes equal to the pre-set value (PV) which is loaded
with some initial value except zero, output (Q) becomes high. Reset is used to reset the
counter value to zero.
➢ Up-Down Counter (CTUD): It can act as Up Counter as well as Down Counter.So it
can perform both the functions.

FIG 3.14 DIFFERENT TYPES OF COUNTER

FIG 3.15 LOGICFOR WORKINGOF COUNTERS

RASHMI S 22
 BUFFER STORE SIMULATION USING PLC

CHAPTER 4

OUTCOME OF PHASE 1

BUFFER STORE SIMULATION USING PLC

4.1 PROBLEM STATEMENT:

RASHMI S 23
 BUFFER STORE SIMULATION USING PLC

4.2 PLC CODE GENERATED:

RASHMI S 24
 BUFFER STORE SIMULATION USING PLC

4.3 LADDER DIAGRAM

CASE 1: Both H1 and H2 will be ON when the count is below 10.

CASE 2: H1 is ON till the count reaches 15 and H2 is off as soon as the count reaches 10.

RASHMI S 25
 BUFFER STORE SIMULATION USING PLC

CASE 3: H1 AND H2 both are OFF when the count exceeds 15.

RASHMI S 26
 BUFFER STORE SIMULATION USING PLC

CHAPTER 5

FUTURE WORK
I have implemented some functions such as Boolean expressions, combinational
circuits, some simple real-time applications using ladder logic. Some of the remaining concepts
related to developing complex circuits will be studied in the upcoming stages. Further, some
complex real – time applications will be considered for implementation in PLC. These
functions will be implemented with some additional considerations such as deadlines,
controlling of different units and some physical signals. A prototype will be developed with
the above mentioned consideration.

RASHMI S 27
 BUFFER STORE SIMULATION USING PLC

REFERENCES
[1] http://www.boschrexroth.com/en/xc/

[2] http://www.dsu.edu.in/index.php/innovation-labs/

[3] “PLC Training Basic concepts” by Rexroth Bosch Group.

[4] “Sample programs for PLC Training” by Rexroth Bosch Group.

[5] https://realpars.com/plc-programming-languages/

[6] https://www.electrical4u.com/programmable-logic-controllers/

[7] https://www.myodesie.com/wiki/index/returnEntry/id/2962

RASHMI S 28
 BUFFER STORE SIMULATION USING PLC

RASHMI S 29