Industrial training on "INDUSTRIAL AUTOMATION" at National Small Industries Corporation, Howrah

1. Industrial Training Report on:
Industrial Automation
Training Centre:
National Small Industries Corporation, Howrah.
Date: 03-07-2017 to 28-07-2017
Guided by:
Mr. Sanjay Ghosh, Ms. Alpona Ghosh
Report by:
ARNAB PODDER
Roll No. – 07 (7th
Semester)
Dept. - Electronics and Instrumentation Engineering
Academy of Technology,
Adisaptagram, Hooghly.

2. Certificate
This is to certify that the work presented in this Industrial Training
Report has been prepared by- ARNAB PODDER (Roll No. – 07) under the
supervision of Mr. Sanjay Ghosh and Ms. Alpona Ghosh , being
Seventh Semester, B.Tech student of Electronics and Instrumentation
Engineering department of Academy of Technology, Adisaptagram, at the
Training Centre- National Small Industries Corporation, Howrah, from 03-
07-2017 to 28-07-2017.
…………………… ………………………
Mr. Sanjay Ghosh Mr. Palash Bhowmick
(GUIDE) (HEAD OF TRAINING DEPARTMENT)
……………………
Ms. Alpona Ghosh
(GUIDE)
(I)

3. STATEMENT BY THE CANDIDATE
I hereby state that this training report has been prepared by
me, is a record of my Industrial Training on the topic Industrial
Automation. The report is being submitted to fulfil the
requirements of Course EI781 of the curriculum of Academy of
Technology, Adisaptagram, Hooghly, India, 712121 under the
affiliation of Maulana Abul Kalam Azad University of Technology
(formerly known as WBUT).
………………………
ARNAB PODDER
Roll No. - 07
7th
Semester
(EIE)
(II)

4. ACKNOWLEDGEMENT
It is our privilege to express our sincerest regards to our guide, Mr. Sanjay
Ghosh and Ms. Alpona Ghosh for their valuable inputs, able guidance,
encouragement, whole-hearted cooperation and constructive criticism throughout
the duration of our training. We deeply express our sincere thanks to our Head of
Training Department Mr. Palash Bhowmick for encouraging and allowing us to
present the report on the topic “INDUSTRIAL AUTOMATION” at the National
Small Industries Corporation, Howrah, premises for the partial fulfilment of the
requirements leading to the award of B.Tech degree. We take this opportunity to
thank all our lecturers who have directly or indirectly helped in our project. Last
but not the least we express our thanks to our friends for their cooperation and
support.
(III)

5. INDEX
Contents Page No.
1. About NSIC---------------------------------------------------1-2
2. Abstract-----------------------------------------------------------3
3. Level of Engineering-------------------------------------------4
4. Familiarisation of Electronic Components----------------5
5. RFID-------------------------------------------------------------6-7
6. Infrared Sensor------------------------------------------------8-9
7. Multivibrator--------------------------------------------------10-11
8. Relay-----------------------------------------------------------12-13
9. Motion Sensor---------------------------------------------------14
10. Advantages of Industrial Automation----------------------15
11. Disadvantages Industrial Automation --------------------16
12. Conclusion-------------------------------------------------------16
13. References -------------------------------------------------------16

6. About NSIC:
National Small Industries Corporation Limited (NSIC) is a Mini Ratna PSU
established by the Government of India in 1955. It falls under Ministry of Micro, Small
& Medium Enterprises of India. NSIC is the nodal office for several schemes of
Ministry of MSME such as Performance & Credit Rating, Single Point Registration,
MSME Databank, National SC ST Hub, etc.
HISTORY: It was established in 1955 to promote and develop micro and small scale
industries and enterprises in the country. It was founded as a Government of India
agency later made into a fully owned government corporation.
OPERATION: National Small Industries Corporation Ltd. (NSIC), is an ISO 9001-
2008 certified Government of India Enterprise under Ministry of Micro, Small and
Medium Enterprises (MSME).
NSIC operates through countrywide network of offices and Technical Centres in the
Country. To manage operations in African countries, NSIC operates from its office
in Johannesburg, South Africa. In addition, NSIC has set up Training cum Incubation
Centre & with a large professional manpower, NSIC provides a package of services
as per the needs of MSME sector.
NSIC has recently partnered with Rubique, to facilitate lending for MSME segment.
Rubique & NSIC will work together to create an interface which will ease credit
facilitation for MSMEs by allowing quicker decision making and evaluation and to
widen the product offerings will bring their respective bank/FI tie-ups under one
umbrella for MSME.
OBJECTIVES: Government of India to promote small and budding entrepreneurs of
post independent India, decided to establish a government agency which can
mediate and provide help to small scale industries (SSI). As such they
established National Small Industries Corporation with objectives to provide
machinery on hire purchase basis and assisting and marketing in exports. Further,
SSI's registered with NSIC were exempted from paying Earnest money and
provided facility of free participation in government tendered purchases. Also for
training persons the training facilities centres and for providing assistance in
modernising the small industries several branches of NSIC were opened up by
government over the years in several big and small towns, where small industries
were growing.
NSIC also helps in organising supply of raw materials like coal, iron, steel and other
materials and even machines needed by small scale private industries by mediating
with other government companies like Coal India Limited, Steel Authority of India
Limited, Hindustan Copper Limited and many others, who produce this materials to
provide same at concessional rates to SSIs. Further, it also provides assistance to
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7. small scale industries by taking orders from Government of India owned enterprises
and procures these machineries from SSI units registered with them, thus providing
a complete assistance right from financing, training, providing raw materials for
manufacturing and marketing of finished products of small scale industries, which
would otherwise not be able to survive in face of competition from large and big
business conglomerates. It also helps SSI by mediating with government owned
banks to provide cheap finance and loans to budding small private industries of
India.
Nowadays, it is also providing assistance by setting up incubation centres in other
continents and also international technology fairs to provide aspiring entrepreneurs
and emerging small enterprises a platform to develop skills, identify appropriate
technology, provide hands-on experience on the working projects, manage funds
through banks, and practical knowledge on how to set up an enterprise.
BRANCHES: NSIC Service Centres are located at the following places
Name of Centre Focus Area
Aligarh (UP) Lock Cluster & Die and Tool making
Chennai Leather & Footwear
Howrah General Engineering
Hyderabad Electronics & Computer Application
New Delhi Machine Tools & related activities
Rajkot Energy & Energy Conservation activities
Rajpur (Pb) Domestic Electrical Appliances
Ramnagar (UK) Electronics & Computer Hardware and
application
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2

8. Abstract:
Automation takes a step further mechanization that uses a particular machinery
mechanism aided human operators for performing a task. Mechanization is the
manual operation of a task using powered machinery that depends on human decision
making.
On the other hand, automation replaces the human involvement with the use of logical
programming commands and powerful machineries.
Industrial Automation is the replacement with computers and machines to that
of human thinking. The word Automation gives the meaning ‘self-dictating’ or
‘a mechanism move by itself’ that has been derived from the Greek
words Auto and Matos where auto means self while Matos means moving.
In a brief, industrial automation can be defined as the use of
set technologies and automatic control devices that results the automatic operation
and control of industrial processes without significant human intervention and
achieving superior performance than manual control. These automation devices
include PLCs, PCs, PACs, etc. and technologies include various industrial
communication systems.
.
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9. Levels in Engineering -
The different levels of engineering are-
DEVICE LEVEL
CIRCUIT LEVEL
SYSTEM LEVEL
NETWORK
OR VIRTUAL
LEVEL
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10. Familiarisation of Electronic Components -
The practical samples of different electronic components were shown and
explained.
The components are listed as below-
 Potentiometer ( Trim and pre-set )
 Transmitter and Receiver ( Infrared )
 DPDT and SPDT switch
 Resistance ( wire wound, ceramic, polyester, cylindrical, single inline package)
 Zener Diode
 LED
 Relay (Electro-magnetic, PCB mounted)
 Magnetic Reed Switch
 Crystal Oscillator
 IC, Microcontroller and IC Base
 Seven Segment Display
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11. RFID -
Radio-frequency identification (RFID) uses electromagnetic fields to
automatically identify and track tags attached to objects. The tags contain
electronically stored information. Passive tags collect energy from a nearby RFID
reader's interrogating radio waves. Active tags have a local power source such as a
battery and may operate at hundreds of meters from the RFID reader. Unlike
a barcode, the tag need not be within the line of sight of the reader, so it may be
embedded in the tracked object. RFID is one method for Automatic Identification and
Data Capture (AIDC).
RFID tags are used in many industries, for example, an RFID tag attached to an
automobile during production can be used to track its progress through the assembly
line; RFID-tagged pharmaceuticals can be tracked through warehouses;
and implanting RFID microchips in livestock and pets allows for positive identification
of animals.
Here at NSIC a prototype of the working of RFID was demonstrated. I got to see
a car which switched on by the RFID tag or card when placed in front of the sensor.
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12. Advantages of RFID –
 An RFID smart card-based fare collection system may reduce operation costs in
the long run.
 Public transportation authorities will be able to monitor ridership in real-time and
will minimize delays by committing extra resources (buses or trains) to specific
congested routes.
 RFID does not require line of sight. The reader can communicate with the tag via
radio waves. An individual can potentially be identified and charged the right fare
by simply carrying the RFID smart-card in his/her pocket.
 RFID equipment damage occurs much less frequently than is the case with
magnetic strips or bar codes present on CharlieTickets.
 The combination of all above mentioned advantages will result in improved
convenience and boost public transportation ridership.
Disadvantages of RFID -
 In the short run, costs of diffusion and implementation for an RFID smart card-
based fare collection system can be rather high.
 An RFID-based fare collection system has the potential of seriously invading
people's privacy
 RFID technology ultimately involves software that allows each user to be
identified by a central database. This infrastructure will certainly be under attack
by hackers.
 Poor read rate can occur if the reader and receiver are not properly aligned.
 In cases when multiple tags and readers are at work simultaneously, double
charges may occur.
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13. Infrared Sensor -
Infrared radiation is an electromagnetic wave with wavelength of 700nm to 1
mm. It is emitted by objects with temperature above 0 kelvin. Furthermore intensity
and wavelength of infrared radiation depends on the temperature of the object.
The infrared sensors are the sensors that detect/measure infrared radiation or
change in the radiation from outer source or inbuilt source. Also sensors that uses
the property of infrared radiations to detect the changes in surrounding are termed
as infrared sensors.
o There are two types of infrared sensor based on its function:
 Thermal Infrared sensor.
 Quantum infrared sensor.
o These are the types of infrared sensors based on the working mechanism:
 Active Infrared Sensors.
 Passive Infrared sensors.
Here at NSIC a prototype of the working of Infrared Sensor was demonstrated.
I got to see a circuit containing IR sensor which when receiving the input signal
changes the status of the relay switches. The input was given with the help of a pocket
laser and the output was observed.
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14. Advantages of Infrared Sensor –
Infrared detectors has the ability to be applied to a large area, They are
operating in the real time , They pick up the movement, so, They are very useful in a
variety of circumstances , They are used by many fire departments and they help the
firefighters to see through the smoke .Infrared detectors can receive the infrared
light which is irradiated from both living and non-living objects which is very important
for many of the applications that infrared sensors are used for .Infrared sensors can
detect the infrared light from far distances over a large area, They detect the
movement , making them ideal for the security purposes, They help the humans see
what the other devices do not allow them to see, such as the leaks in underground
pipes .
Disadvantages of Infrared Sensor –
As Infrared detectors detect the infrared images based on the temperature
variants of the objects, They cannot detect differences in the objects which have a
very similar temperature range, So, They leads to the inaccuracy in many
circumstances. The infrared sensors are incapable of distinguishing between the
objects which irradiate similar thermal energy levels, Infrared Sensors are extremely
expensive that limits their use in many sectors. So, they are not as widely used as
they could be.
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15. Multivibrator –
A multivibrator is an electronic circuit used to implement a variety of simple two-
state devices such as relaxation oscillators, timers and flip-flops. It consists of
two amplifying devices (transistors, vacuum tubes or other devices) cross-coupled
by resistors or capacitors
The three types of multivibrator circuits are:
 Astable multivibrator, in which the circuit is not stable in either state —it
continually switches from one state to the other. It functions as a relaxation
oscillator.
 Monostable multivibrator, in which one of the states is stable, but the other
state is unstable (transient). A trigger pulse causes the circuit to enter the
unstable state. After entering the unstable state, the circuit will return to the
stable state after a set time. Such a circuit is useful for creating a timing period of
fixed duration in response to some external event. This circuit is also known as
a one shot.
 Bistable multivibrator, in which the circuit is stable in either state. It can be
flipped from one state to the other by an external trigger pulse. This circuit is also
known as a flip-flop. It can store one bit of information, and is widely used in
digital logic and computer memory.
Here at NSIC the working of a multivibrator using NE555 was shown and we
also made the circuit as shown below in fig no. 4 on a dot Vero board.
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16. Here in place of LED we also used relays and also connected externally
connected 9V buzzers to the relays and observed the outputs and thus we observed
how different apps can be connected to the outputs of the multivibrator.
The components that we required to make the multivibrator are-
 Dot Vero board
 2 LED
 1MΩ potentiometer
 IC Base
 NE555 IC
 10µF, 63V capacitor
 3 resistors ( 22KΩ, 1KΩ, 1KΩ)
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17. Relay –
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such
as solid-state relays. Relays are used where it is necessary to control a circuit by a
separate low-power signal, or where several circuits must be controlled by one
signal. The first relays were used in long distance telegraph circuits as amplifiers:
they repeated the signal coming in from one circuit and re-transmitted it on another
circuit. Relays were used extensively in telephone exchanges and early computers
to perform logical operations.
Here at NSIC practical demonstration of a Relay based automation system
was shown which when scaled up used in industries such as lumber industry, where
relay is used to automate the working of saw, conveyor belt as well as lifting and
moving mechanism working in synchronization with each other.
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18. Advantages of Relay -
 Electromagnetic relays have fast operation and fast reset.
 They can be used for both ac and dc systems for protection of ac and dc
equipment.
 Electromagnetic relays operating speeds which has the ability to operate in
milliseconds are also can be possible.
 They have the properties such as simple, robust, compact and most reliable.
 These relays are almost instantaneous. Though instantaneous the operating
time of the relay varies with the current. With extra arrangements like dashpot,
copper rings etc. slow operating times and reset can be possible.
Disadvantages of Relay –
 High burden level instrument transformers are required (CTs and PTs of high
burden is required for operating the electromagnetic relays compared to static
relays).
 The directional feature is absent in electromagnetic relays.
 Requires periodic maintenance and testing unlike static relays.
 Relay operation can be affected due to ageing of the components and dust,
pollution resulting in spurious trips.
 Operation speed for an electromagnetic relays is limited by the mechanical
inertia of the component.
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19. Motion Sensor–
A motion detector is a device that detects moving objects, particularly
people. Such a device is often integrated as a component of a system that
automatically performs a task or alerts a user of motion in an area. They form a vital
component of security, automated lighting control, home control, energy efficiency,
and other useful systems.
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20. Advantages of Industrial Automation–
Lower operating cost: Industrial automation eliminates healthcare costs and paid leave and
holidays associated with a human operator. Further, industrial automation does not require
other employee benefits such as bonuses, pension coverage etc. Above all, although it is
associated with a high initial cost it saves the monthly wages of the workers which leads to
substantial cost savings for the company. The maintenance cost associated with machinery
used for industrial automation is less because it does not often fail. If it fails, only computer
and maintenance engineers are required to repair it.
 High productivity
Although many companies hire hundreds of production workers for a up to three shifts
to run the plant for the maximum number of hours, the plant still needs to be closed
for maintenance and holidays. Industrial automation fulfills the aim of the company by
allowing the company to run a manufacturing plant for 24 hours in a day 7 days in a
week and 365 days a year. This leads to a significant improvement in the productivity
of the company.
 High Quality
Automation alleviates the error associated with a human being. Further, unlike human
beings, robots do not involve any fatigue, which results in products with uniform
quality manufactured at different times.
 High flexibility
Adding a new task in the assembly line requires training with a human operator,
however, robots can be programmed to do any task. This makes the manufacturing
process more flexible.
 High Information Accuracy
Adding automated data collection, can allow you to collect key production
information, improve data accuracy, and reduce your data collection costs. This
provides you with the facts to make the right decisions when it comes to reducing
waste and improving your processes.
 High safety
Industrial automation can make the production line safe for the employees by
deploying robots to handle hazardous conditions.
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21. Disadvantages of Industrial Automation–
Disadvantages of Industrial Automation
 High Initial cost
The initial investment associated with the making the switch from a human
production line to an automatic production line is very high. Also, substantial
costs are involved in training employees to handle this new sophisticated
equipment.
Conclusion–
Industrial automation has recently found more and more acceptance from
various industries because of its huge benefits, such as, increased productivity,
quality and safety at low costs.
Reference–
 wikipedia.org
 google.co.in
 rfidintro.wikifoundry.com
 electricalquestionsguid.com
 online-science.com
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