1. Monitoring of Machine’s status in Engine Plant
Office
(Capacity Improvement)
Project Report
Submitted to: Assistant manager
Miss Soha Shafqat
Submitted by: M.Umair Zafar (U.E.T Lahore)
Gohar Rehman (G.C.T Faisalabad)

2. Contents
Introduction
Our Analysis
Methods
Control Points
Shop wise bottleneck machines
Methods description
Circuit diagrams
Conclusion

3. In this project we have to analyze engine’s plant bottle neck machines
send it to plant’s office so that A.M’s can observe their least production machines
status from their offices and then take necessary actions to meet their production
demands.
Basically we are interested in establishing an indication
controlled by machines status.
We analyzed from the study of crankshaft bottle neck machine’s electric manual
that:
From these points we observe that actually we are interested in red led status
because when it glows machine is not giving them production. So, from this we
conclude that we have to transfer machine’s red led status in plant’s office by some
technology or scheme. So, we have to proposed this strategy.
From our analysis we proposed four solutio
 We can transmit signal from machines to office through wireless electricity
i.e. by wifi.
Introduction
In this project we have to analyze engine’s plant bottle neck machines
send it to plant’s office so that A.M’s can observe their least production machines
status from their offices and then take necessary actions to meet their production
Basically we are interested in establishing an indication box in office that is
controlled by machines status.
Our Analysis
We analyzed from the study of crankshaft bottle neck machine’s electric manual
From these points we observe that actually we are interested in red led status
machine is not giving them production. So, from this we
conclude that we have to transfer machine’s red led status in plant’s office by some
technology or scheme. So, we have to proposed this strategy.
Methods
From our analysis we proposed four solutions to the problem:
We can transmit signal from machines to office through wireless electricity
In this project we have to analyze engine’s plant bottle neck machines status and
send it to plant’s office so that A.M’s can observe their least production machines
status from their offices and then take necessary actions to meet their production
box in office that is
We analyzed from the study of crankshaft bottle neck machine’s electric manual
From these points we observe that actually we are interested in red led status
machine is not giving them production. So, from this we
conclude that we have to transfer machine’s red led status in plant’s office by some
We can transmit signal from machines to office through wireless electricity

4.  Secondly, we can transmit signal through digital communication i.e. by
transmitters receivers.
 Thirdly, we can send signals by direct wire and annunciator system.
 Fourthly, we can use PLC based system with HMI.
We provide brief description of all these methods then upon this discussion we
finalize our best recommended solution, which would be most preferable for
engine plant office.
Control Points
In present case we give complete analysis on one shop bottle neck machine i.e.
crankshaft shop. In this shop least productive machine is TC 200.
From this machine, we use two control points i.e. from red and orange
LED’s controlling relays. From this, we can observe complete status i.e. handling
and stop time of bottle neck machines.
In TC 200 control signal is taken from the two following pins:
 A21 for red Led status
 B21 for orange Led status
Shop wise bottleneck machines
Crankshaft Shop:
This shop bottleneck machines are TC 200 and Cylindrical Grinder.
TC 200 Control Points are:

5.  A21 for red Led status
 B21 for orange Led status
It is a turning machine of CG 125 line. It is 2 axis CNC machine and its cycle
time is 57 seconds.
Cylindrical Grinder Control Points:
 A22 for red Led status
 B22 for yellow Led status
It is grinding machine that does facing after hardening. Its cycle time is 44
seconds.
Crankcase Shop Bottleneck Machines:
It has Kira case 1 machine as bottleneck machine whose control points are:
 A17 for red Led status
 B17 for orange Led status
Its cycle time is 76 seconds. It is in 125 line and has 4 axis movement as X, Y, Z
and A axis. It is doing facing, threading and drilling.
Cylinder head Shop Bottleneck Machines:
It has machining centre TVT 301s and KPC 30b as bottleneck machines.
TVT 301s machine control point:
Control points are:
 A09 for yellow Led status
 B08 for red Led status
It is doing facing and 7.5 mm drill. It is also 4 axis CNC machine. Its cycle time is
49 seconds.

6. KPC_30B machine control point:
Control points are:
 B17 for orange Led status
 A17 for red Led status
Gear Shop Bottleneck Machines:
This shop has GSM-12N as bottleneck machine. Its control points are:
 B11 for yellow Led status
 A11 for red Led status
It is a gear shaper machine having 4 axis. Its cycle time is 56 seconds.
Camshaft Shop Bottleneck Machines:
It has oil hole machine and tapping machine as bottleneck machines.
Oil hole machine:
Its cycle time is 22 seconds and its is doing two holes for oil movement in
camshaft.
Tapping machine Control points:
Its control points are:
 A18 for door opening
 A17 for right door closing
 A16 for left door closing
It does threading in camshaft machine.

7. Methods description
All proposed methods has their own limitations.
 Wireless electricity are based on what's known as radio frequency, or RF.
While less efficient, they work across distances of up to 85 feet. In these
systems, electricity is transformed into radio waves, which are transmitted
across a room, then received by so-called power harvesters and translated
back into low-voltage direct current. So engines plant office distance is
greater than 85 feet so digital communication is needed here.
 Digital communication requires high quality transmitters and receivers
which uses PLL at receivers for accurate detection of signals, that system is
much expensive and not economical for engines plant office.
Also, we analyzed that digital communication system can
be harmful for CNC machines programming and working.
 Direct wires communication system is most efficient and economical in our
present problem due to some facts i.e. ceiling is already there we can easily
wire our system through ceiling of plant. It is much cheap and economical
system. We studied that signal drop is almost same with in 500 meters
range through wires.
 PLC i.e. programmable logic control can also be used with HMI i.e. human
interface. It is much expensive as compared to direct wiring communication
system but it has revolutionary advantages over all previously proposed
methods. By PLC system instead of bottle neck machines one can observe
all machines functionality if PLC system extends to all machines. By
HMI when you need to observe machines you can observe with out any
need to continuously viewing previously proposed annunciator panel box.
By PLC based system many more features can be added by
efficiently making its Ladder diagram. For example, running time of
machines can be calculated, handling time can also be calculated and this
way, production flaws can be checked properly.
Circuit Diagrams

8. Circuit Diagram for direct wiring system is:
Here K1 and K2 are two external relays.
In this system we use an external 1
internal relay signal that controls machines led’s status. Annunciator
diagram for office panel box in direct wiring system is shown below:
Circuit Diagram for direct wiring system is:
Here K1 and K2 are two external relays.
In this system we use an external 1-input 2-output relay that is controlled by
internal relay signal that controls machines led’s status. Annunciator
diagram for office panel box in direct wiring system is shown below:
output relay that is controlled by
internal relay signal that controls machines led’s status. Annunciator
diagram for office panel box in direct wiring system is shown below:

9. Previous direct wire transmission circuit diagram is for crankshaft shop
bottleneck machine i.e. for TC 200, but by Using this same procedure for
other bottle neck machines of engine plant’s shops we can design our system
for all shop machines and observe their status from office.
For PLC based system circuit diagram is shown below:

10. Here
K1= Handling time + Non productive time
K2= Breakdown time (suddenly door open or emergency switch
PLC= Programmable logic control
RS232= Cable for HMI to PLC for communication
HMI= Human interface
Circuit is extended back to machine control points as :
K1= Handling time + Non productive time
K2= Breakdown time (suddenly door open or emergency switch
PLC= Programmable logic control
RS232= Cable for HMI to PLC for communication
HMI= Human interface
Circuit is extended back to machine control points as :
K2= Breakdown time (suddenly door open or emergency switch

12. Conclusion
We proposed four methods for this problem but last two methods are feasible in
our present situation because they didn’t contain wireless communication. Both
direct wiring system and PLC system has their own advantages and efficiencies.
Direct wiring system is cheap but has less features as described earlier. On
the other hand, PLC based system is much expensive but it is more user friendly
and has a lot of interesting features. Through PLC, we can check any machines
data when we needed by HMI display.
Now depending upon observation and analysis we can put any method
efficiently for plant’s capacity.