Higher Technological Institute

Mechatronics Engineering Department

Training Summer Course at

HA Consulting Group
Submitted to:
Dr. Aml Ebrahem

By
Maged Khiry Mohamed
ID: 20140667
3rd Training
 Acknowledgment
 I would like to express my appreciation towards HA training
staff to give me the opportunity to train there and being
generous with us and help me throughout the manufacturing
stages during the training period, and provide us with all kinds
of data.
 He expressed his gratitude also to the official of the training:
Eng. Hassan Ali to provide us with a better climate so that we
can contain and receive knowledge and each one stood beside
me during training.
 Finally, I like to thank Dr. Aml on his guidance and help him

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 ABSTRACT
 In this report we showed what we have learned in summer
course.

 In this term we learned about Car Assembly and its

requirements as: different kind of machinery for production,
steps and levels of production lines in each departments and
the precaution of the industrial safety.

 This report introduces the topics of training and gained

knowledge. Main finding of training period exists in the
company is being as one its engineers and leave their life, gain
experience and knowledge about a lot of things such as:
Theory of industrial control, classic and plc conrol.

Data used in the report have shown

 Which has written or recorded or filmed during the
training and the use of the Internet to get some of this
data.
 Finally, we have to admit that this training was very big
gain from the knowledge.

III
 Contents
Chapter (1): Introduction ................................................................................................................ 1
1. Control Circuits:.................................................................................................................... 1
2. Manual Control ..................................................................................................................... 1
3. Automatic Operation............................................................................................................. 2
4. Control Elements .................................................................................................................. 2
Chapter (2): Electrical Symbols ..................................................................................................... 3
1. Contact Symbols ................................................................................................................... 3
I. Normally Open Contact ................................................................................... 3
II. Normally Closed Contact .............................................................................. 4
III. Switch Symbols ............................................................................................. 4
IV. Pushbutton Symbols ...................................................................................... 5
V. Coil Symbols ................................................................................................. 5
VI. Overload Relay .............................................................................................. 6
VII. Indicator Light Symbols ............................................................................. 7
Chapter (3): Control Components .................................................................................................. 8
1. Fuse ....................................................................................................................................... 8
2. Circuit Breakers .................................................................................................................... 8
3. Overload Relays .................................................................................................................... 9
4. Contactors ........................................................................................................................... 10
5. Relays .................................................................................................................................. 12
6. Timer ................................................................................................................................... 13
Chapter (3): PLC .......................................................................................................................... 14
1. PLC definition..................................................................................................................... 14
2. PLC Function. ..................................................................................................................... 14
3. Basic PLC operation ........................................................................................................... 14
4. plc station considerations .................................................................................................... 15
I. Hard ware ....................................................................................................... 16

IV
 II. Central Processing Unit (CPU) ................................................................... 16
III. System Busses ............................................................................................. 16
IV. Memory ........................................................................................................ 17
V. I/O Sections ................................................................................................. 17
VI. Power Supply ............................................................................................... 17
VII. Programming Device ................................................................................ 17
5. Plc Tools ............................................................................................................................. 17
I. Counters. ......................................................................................................... 17
II. Comparators. ................................................................................................ 18
III. Markers. ....................................................................................................... 19
6. Terminology ........................................................................................................................ 19
I. Sensor ............................................................................................................. 19
II. Actuator ....................................................................................................... 19
III. Discrete inputs ............................................................................................. 20
IV. Ladder logic diagram ................................................................................... 21
V. Function block diagram ............................................................................... 21
VI. Statement list ............................................................................................... 22

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FIGURE 1: MANUAL CONTROL ........................................................................................................... 1
FIGURE 2:3.AUTOMATIC OPERATION .................................................................................................. 2
FIGURE 3:CONTACT SYMBOLS ............................................................................................................ 3
FIGURE 4:NORMALLY OPEN CONTACT ................................................................................................. 3
FIGURE 5:NORMALLY CLOSED CONTACT............................................................................................... 4
FIGURE 6:SWITCH SYMBOLS .............................................................................................................. 4
FIGURE 7:PUSHBUTTON SYMBOLS ...................................................................................................... 5
FIGURE 8:COIL SYMBOLS .................................................................................................................. 5
FIGURE 9:COIL EXAMPLE .................................................................................................................. 6
FIGURE 10:OVERLOAD RELAY ............................................................................................................ 6
FIGURE 11:INDICATOR LIGHT SYMBOLS ................................................................................................ 7
FIGURE 12:FUSE............................................................................................................................. 8
FIGURE 13:CIRCUIT BREAKERS ........................................................................................................... 8
FIGURE 14:OVERLOAD RELAYS........................................................................................................... 9
FIGURE 15:MOTOR CIRCUIT WITH AN OVERLOAD RELAY. ......................................................................... 10
FIGURE 16:CONTACTOR ................................................................................................................. 10
FIGURE 17:CONTACTOR CIRCUIT ...................................................................................................... 11
FIGURE 18:RELAY ......................................................................................................................... 12
FIGURE 19:RELAY PINOUT .............................................................................................................. 12
FIGURE 20:RELAY OPERATION ......................................................................................................... 12
FIGURE 21:TIMER ......................................................................................................................... 13
FIGURE 22:PLC STRUCTURE ............................................................................................................ 15
FIGURE 23: PLC BASED SYSTEM ....................................................................................................... 15
FIGURE 24:PLC COMPONENT .......................................................................................................... 16
FIGURE 25:UP DOWN COUNTER ...................................................................................................... 18
FIGURE 26:COMPARATOR............................................................................................................... 18
FIGURE 27:INPUT INTERFACE ........................................................................................................... 19
FIGURE 28:OUTPUT INTERFACE........................................................................................................ 20
FIGURE 29:DISCRETE INPUTS ........................................................................................................... 20
FIGURE 30:LADDER DIAGRAM ......................................................................................................... 21
FIGURE 31:FUNCTION BLOCK DIAGRAM ............................................................................................. 21
FIGURE 32:STATEMENT LIST ............................................................................................................ 22

VI
 Chapter (1): Introduction
1. Control Circuits:
 Control, as applied to control circuits, is a broad term that means anything
from a simple toggle switch to a complex system of components (which may
include relays, contactors, timers, switches, and indicating lights). Every
electrical circuit for light or power has control elements. One example of a
simple control circuit is a light switch that is used to turn lights on and off. Of
course, there are many other devices and equipment systems in industrial
applications. Motor control, for example, can be used to start and stop a motor
and to protect the motor, associated machinery, and personnel. In addition,
motor controllers might also be used for reversing, changing speed, jogging,
sequencing, and pilot-light indication. Control circuits can be complex,
accomplishing high degrees of automatic, precise machine operation.

2. Manual Control

Figure 1: Manual Control

 Control is considered to be manually operated when someone must initiate an

action in order for the circuit to operate. For example, someone might have to
flip the switch of a manual starter to start and stop a motor.

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3. Automatic Operation

Figure 2:3.Automatic Operation

 While manual operation of machines is still common practice, many machines

are started and stopped automatically. Frequently there is a combination of
manual and automatic control. A process may have to be started manually, but
may be stopped automatically.

4. Control Elements
 The elements of a control circuit include all of the equipment and devices
concerned with the circuit function: enclosures, conductors, relays, contactors,
pilot devices, and overcurrent protection devices. The selection of control
equipment for a specific application requires a thorough understanding of
controller operating characteristics and wiring layout. The proper control
devices must be selected and integrated into the overall circuit design.

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 Chapter (2): Electrical Symbols
 Language has been developed in order to transfer ideas and information. In
order to understand the ideas and information being communicated, an
understanding of the language is necessary. The language of controls consists
of a commonly used set of symbols which represent control components.

1. Contact Symbols
 Contact symbols are used to indicate an open or closed path of current flow.
Contacts are shown as normally open (NO) or normally closed (NC). Contacts
shown by this symbol require another device to actuate them.

Figure 3:Contact symbols

I. Normally Open Contact

 For example, in the following illustration the circuit is first shown in the de-
energized state. The contacts are shown in their normally open (NO) state.
When the relay is energized, the contacts close, completing the path of current
and illuminating the light. The contacts have been highlighted to indicate they
are now closed.

Figure 4:Normally Open Contact

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 II. Normally Closed Contact
 In the following illustration the contacts are shown as Example normally
closed (NC), meaning the contacts are closed when the relay is de-energized.
A complete path of current exists and the light is on. When the relay is
energized, the contacts open turning the light off.

Figure 5:Normally Closed Contact

III. Switch Symbols

 Switch symbols are also used to indicate an open or closed path of current
flow. Variations of this symbol are used to represent limit switches, foot
switches, pressure switches, level switches, temperature-actuated switches,
flow switches, and selector switches. Like contacts, switches require another
device or action to change their state. In the case of a manual switch, someone
must manually change the position of the switch.

Figure 6:Switch Symbols

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 IV. Pushbutton Symbols
 There are two basic types of pushbuttons: momentary and maintained. A
normally open momentary pushbutton closes as long as the button is held
down. A normally closed momentary pushbutton opens as long as the button
is held down. A maintained pushbutton latches in place when the button is
pressed.

Figure 7:Pushbutton Symbols

V. Coil Symbols
 Coils are used in electromagnetic starters, contactors, and relays. The purpose
of contactors and relays is to open and close associated contacts. Letters are
used to designate the coil; for example, “M” frequently indicates a motor
starter and “CR” indicates a control relay. The associated contacts have the
same identifying letter. Contactors and relays use an electromagnetic action
(which will be described later) to open and close these contacts. The
associated contacts can be either normally open or normally closed.

Figure 8:Coil Symbols

 Coil Example Using in the following example, the “M” contacts in series with
Normally Open Contacts the motor are controlled by the “M” contactor coil.
When someone closes the switch, a complete path of current flow exists

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 through the switch and “M” contactor coil. The “M” contactor coil actuates
the “M” contacts which provide power to the motor.

Figure 9:Coil Example

VI. Overload Relay

 Symbols Overload relays are used to protect motors from overheating
resulting from an overload on the driven machinery, low line voltage, or an
open phase in a three-phase system. When excessive current is drawn for a
predetermined amount of time, the relay opens and the motor is disconnected
from its source of power.

Figure 10:Overload Relay

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 VII. Indicator Light Symbols
 An indicator light (sometimes referred to as a pilot light) is a small electric
light used to indicate a specific condition of a circuit. For example, a red light
might be used to indicate a motor is running. The letter in the center of the
indicator light symbol indicates the color of the light.

Figure 11:Indicator Light Symbols

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 Chapter (3): Control Components
1. Fuse

Figure 12:Fuse

 In electronics and electrical engineering, a fuse is an electrical safety device

that operates to provide overcurrent protection of an electrical circuit. Its
essential component is a metal wire or strip that melts when too much current
flows through it, thereby interrupting the current. It is a sacrificial device;
once a fuse has operated it is an open circuit, and it must be replaced or
rewired, depending on type.

2. Circuit Breakers

Figure 13:Circuit Breakers

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 Circuit breaker is an automatic circuit protection system. Breakers are
installed in an electrical panel (breaker box) and each circuit is attached to a
singular breaker. The breaker will monitor the circuit and in the event of a
complication such as an overload, the breaker will immediately shut off that
circuit. This is often colloquially called a “breaker trip” or “tripping a
breaker” and it commonly happens when appliances or equipment acts up or
too many high-power draw tools are placed (plugged into) a single circuit.

 Specifications of circuit breakers:

1.Operating voltage of the circuit:
It determines the insulating requirements.
2. Normal operating or maximum load current:
It determines requirements of the normal or load-carrying parts.
3. Maximum abnormal or fault current that must be interrupted:
It determines the mechanical requirements of the breaker itself and of its
supporting structure.

3. Overload Relays

Figure 14:Overload Relays

 Overload relays are designed to meet the special protective needs of motor
control circuits. Overload relays:
• allow harmless temporary overloads (such as motor starting) without
disrupting the circuit

9
 • will trip and open a circuit if current is high enough to cause motor damage
over a period of time
• can be reset once the overload is removed.
 Current flows through the overload relay while the motor is running. Excess
current will cause the overload relay to trip at a predetermined level, opening
the circuit between the power source and the motor. After a predetermined
amount of time, the overload relay can be reset. When the cause of the
overload has been identified and corrected, the motor can be restarted.

Figure 15:motor circuit with an overload relay.

4. Contactors

Figure 16:Contactor

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 A contactor is an electrically-controlled switch (relay) used for switching an
electrical power circuit. A contactor is typically controlled by a circuit, which
has a much lower power level than the switched circuit, such as a 24-volt coil
electromagnet controlling a 230-volt motor switch.
 Contactors come in many forms with varying capacities and features. Unlike a
circuit breaker, a contactor is not intended to interrupt a short circuit current.
Contactors range from those having a breaking current of several amperes to
thousands of amperes and 24 V DC to many kilovolts.

Figure 17:Contactor Circuit

 The top three contacts switch the respective phases of the incoming 3-phase
AC power, typically at least 480 Volts for motors 1 horsepower or greater.
The lowest contact is an “auxiliary” contact which has a current rating much
lower than that of the large motor power contacts, but is actuated by the same
armature as the power contacts. The auxiliary contact is often used in a relay
logic circuit, or for some other part of the motor control scheme.

11
5. Relays

Figure 18:Relay

 Relays are widely used in control circuits. They are used for switching
multiple control circuits, and for controlling light loads such as starting coils,
indicator lights, and audible alarms.

Figure 19:Relay Pinout

Figure 20:Relay Operation

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 Relay Operation The operation of a control relay is similar to a contactor. In
the example below, a relay with a set of normally open (NO) contacts is used.
When power is applied from the control circuit, an electromagnetic coil is
energized. The electromagnetic field pulls the armature and movable contacts
toward the electromagnet closing the contacts. When power is removed,
spring tension pushes the armature and movable contacts away from the
electromagnet, opening the contacts.

6. Timer

Figure 21:Timer

 When the process needs to stop at defined time or at desistance that reached after an
exact time, timer will be used in this case which control many several processes at the
same time.
 Word “timer” has many different manufacturing like (mechanical, electronical and air
timer). Classic control interests at mechanical timer which contains coil with inner gear
box that controlled by time setting scale.
 Simply, timer inner components like two switches that works oppositely (one open the
other close and vice versa).
 There are two types of mechanical timer (on delay and off delay).
 On delay mechanical timer: when the power on, it counts down the time settled and
then change all the open inner switches to off state and all the off inner switches to the
on state.
 Off delay mechanical timer: when the power is on, all the on inner switched will be at
off state and all the off inner switches will be at on state during the power in connected
to the device. When the power is off, the timer count the time settled to return to the
initial inner switches state.
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 Chapter (3): PLC
1. PLC definition.
 A programmable logic controller, PLC, or programmable controller is a digital
computer used for automation of typically industrial electromechanical
processes, such as control of machinery on factory. PLCs are used in many
machines, in many industries. PLCs are designed for multiple arrangements of
digital and analog inputs and outputs, extended temperature ranges, immunity
to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile
memory.

2. PLC Function.
 The functionality of the PLC has evolved over the years to include sequential relay
control, motion control, process control, distributed control systems, and networking. The
data handling, storage, processing power, and communication capabilities of some
modern PLCs are approximately equivalent to desktop computers

3. Basic PLC operation

 PLCs consist of input modules or points, a Central Processing Unit (CPU),
and output modules or points. An input accepts a variety of digital or analog
signals from various field devices (Sensors) and converts them into a logic
signal that can be used by the CPU. The CPU makes decisions and executes
control instructions based on program instructions in memory. Output
modules convert control instructions from the CPU into a digital or analog
signal that can be used to control various field devices (actuators). A
programming device is used to input the desired instructions. These
instructions determine what the PLC will do for a specific input. An operator
interface device allows process information to be displayed and new control
parameters to be entered.

14
 Figure 22:PLC structure

 Pushbuttons (sensors), in this simple example, connected to PLC inputs, can

be used to start and stop a motor connected to a PLC through a motor starter
(actuator).

Figure 23: PLC based system

4. plc station considerations

 to set up an PLC station, there are basic five considerations to follow:
I. Hard ware.
II. Software.
III. Symbol.
IV. Simulation.
V. Online.

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 I. Hard ware
 Hardware Components of a PLC System
 Processor unit (CPU), Memory, Input/Output, Power supply unit,
Programming device, and other devices.

Figure 24:Plc Component

II. Central Processing Unit (CPU)

 CPU – Microprocessor based, may allow arithmetic operations, logic
operators, block memory moves, computer interface, local area network,
functions, etc.
 CPU makes a great number of check-ups of the PLC controller itself so
eventual errors would be discovered early.
III. System Busses
 The internal paths along which the digital signals flow within the PLC are
called busses.
 The system has four busses:
– The CPU uses the data bus for sending data between the different
elements,
– The address bus to send the addresses of locations for accessing stored
data,
– The control bus for signals relating to internal control actions,
– The system bus is used for communications between the I/O ports and
the I/O unit.
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 IV. Memory
 System (ROM) to give permanent storage for the operating system and the
fixed data used by the CPU.
 RAM for data. This is where information is stored on the status of input and
output devices and the values of timers and counters and other internal
devices. EPROM for ROM’s that can be programmed and then the program
made permanent.
V. I/O Sections
 Inputs monitor field devices, such as switches and sensors.
 Outputs control other devices, such as motors, pumps, solenoid valves, and
lights.
VI. Power Supply
 Most PLC controllers work either at 24 VDC or 220 VAC. Some PLC
controllers have electrical supply as a separate module, while small and
medium series already contain the supply module.
VII. Programming Device
 The programming device is used to enter the required program into the
memory of the processor.
 The program is developed in the programming device and then transferred to
the memory unit of the PLC.

5. Plc Tools
I. Counters.
 Counters in the software form are so important in the industrial process, there
are three types of counters:
I. Count up:
This type of counters counts from 0 to the set value that must reach to out a signal
that servers another process.
II. Count down:
This type of counters counts from the set value to 0 that must reach to out a signal
that servers another process.

17
 III. Count up/down:
This type of counters counts up to reach the set value then out the signal then
countdown to reach 0 and then out another signal and so on.

Figure 25:Up Down Counter

II. Comparators.
 Comparators cannot stand alone, but through counters or output sensor that
sending a present values saved in markers.
 Comparing the present value to the set one then take the action depends on the
type of comparator.

Figure 26:Comparator
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 III. Markers.
 Markers in PLC means a storage that store the values in, there are three types
as shown:
I. M: means 0 or 1(called Bool).
II. MW: used to store 8 bits.
III. MDW: used to store 16 bits.

6. Terminology
 The language of PLCs consists of a commonly used set of terms; many of
which are unique to PLCs. In order to understand the ideas and concepts of
PLCs, an understanding of these terms is necessary.
I. Sensor
 A sensor is a device that converts a physical condition into an electrical signal
for use by the PLC. Sensors are connected to the input of a PLC. A
pushbutton is one example of a sensor that is connected to the PLC input. An
electrical signal is sent from the pushbutton to the PLC indicating the
condition (open/ closed) of the pushbutton contacts.

Figure 27:Input Interface

II. Actuator
 Actuators convert an electrical signal from the PLC into a physical condition.
Actuators are connected to the PLC output. A motor starter is one example of
an actuator that is connected
 to the PLC output. Depending on the output PLC signal the motor starter will
either start or stop the motor.

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 Figure 28:Output Interface

III. Discrete inputs

 A discrete input also referred to as a digital input, is an input that is either in
an ON or OFF condition. Pushbuttons, toggle switches, limit switches,
proximity switches, and contact closures are examples of discrete sensors
which are connected to the PLCs discrete or digital inputs. In the ON
condition a discrete input may be referred to as logic 1 or logic high. In the
OFF condition a discrete input may be referred to as logic 0 or a logic low.

Figure 29:Discrete Inputs

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 IV. Ladder logic diagram
 The left vertical line of a ladder logic diagram represents the power or
energized conductor. The output element or instruction represents the neutral
or return path of the circuit. The right vertical line, which represents the return
path on a hard-wired control line diagram, is omitted. Ladder logic diagrams
are read from left-to-right, top-to-bottom. Rungs are sometimes referred to as
networks. A network may have several control elements, only one output coil.

Figure 30:Ladder Diagram

V. Function block diagram

 Function Block Diagrams (FBD) provides another view of a set of
instructions. Each function has a name to designate its specific task. Functions
are indicated by a rectangle. Inputs are shown on the left-hand side of the
rectangle and outputs are shown on the right-hand side. The function block
diagram shown below performs the same function as shown by the ladder
diagram and statement list.

Figure 31:Function Block Diagram

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 VI. Statement list
 A statement list (STL) provides another view of a set of instructions. The
operation, what is to be done, is shown on the left. The operand, the item to be
operated on by the operation,
 is shown on the right. A comparison between the statement list shown below,
and the ladder logic shown on the previous page, reveals a similar structure.
The set of instructions in this statement list perform the same task as the
ladder diagram.

Figure 32:Statement list

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