This document provides an overview of a training on PLC circuit design and basic programming. It covers the contents of the training, including basic circuits, PLC fundamentals, ladder logic programming, and a project to program a spherical bolt greasing machine. The document describes the major PLC components, the operating cycle, inputs and outputs, programming methods including ladder logic, and provides diagrams of the electrical drawings and PLC programming for the greasing machine project.

1. PLC Circuit Design And
Basic Programming
at BOSCH Lmt., Jaipur
Manish Kumar
11EBKEX028

2. Contents covered in the Training
 Basic circuits used in industry
 Basic of PLC
 Ladder logic programming
 PLC circuit designs
 Project
Spherical bolt greasing machine
Electrical drawing of machine
PLC programming of machine

3. Content
 Introduction of PLC
 Programming in PLC(Ladder logic)
 PLC circuit design
 Project
Spherical bolt greasing Machine

4. Introduction
 A Programmable Logic Controller (PLC) is an industrial
computer that accepts inputs from switches and sensors,
evaluates these in accordance with a stored program, and
generates outputs to control machines and processes.
PB1
LS1
INPUTS
M1
M2R
LOGIC OUTPUTS
M1
SOL
Block Diagram of a Control System

5. Major Components of a Common PLC
PROCESSOR
POWER
SUPPLY
I M
N O
P D
U U
T L
E
O M
U O
T D
P U
U L
T E
PROGRAMMING
DEVICE
From
SENSORS
Pushbuttons,
contacts,
limit switches,
etc.
To
OUTPUT
Solenoids,
contactors,
alarms
etc.

6. Major Components of a Common PLC
 POWER SUPPLY
Provides the voltage needed to run the primary PLC components
 I/O MODULES
Provides signal conversion and isolation between the internal logic-level signals inside
the PLC and the field’s high level signal.
 PROCESSOR
Provides intelligence to command and govern the activities of the entire PLC systems.
 PROGRAMMING DEVICE
used to enter the desired program that will determine the sequence of operation and
control of process equipment or driven machine.

7. What' happens in an operating cycle
Based on the data in
the output image file
the PLC energises or
de-energises it’s output
circuits,controlling
external devices.
1.Input
Scan
2. Program
Scan
3. Output
Scan
START
-
- -
-
PLC
OPERATING
CYCLE
TYPICALLY
1 to 25 ms.
During the input scan PLC
examines the external input
devices -On or Off.
The status of the inputs is
temporarily stored in an input
image memory file.
The PLC scans the instructions in the ladder
logic program,uses the input status from the
input image file & determines if an output will
be energised.The resulting status of the outputs
is written to the output image memory file.

8. Inputs and outputs of PLC
INPUTS
 Pushbuttons
 Selector Switches
 Limit Switches
 Level/Pressure/Temperature
Sensors
 Photoelectric Sensors
 Motor Starter Contacts
 Relay Contacts
 Transducers/Transmitters
 Encoder
OUTPUTS
 Relay
 Motor Starters
 Solenoids Valves
 Control Relays
 Alarms
 Lights
 Fans

9. Programming in PLC
 Ladder Logic
 Structured Text
 Sequential functional chart
 Functional Block Diagram
 Instruction List

10. Programming in PLC
 Ladder Logic
 Structured Text
 Sequential functional chart
 Functional Block Diagram
 Instruction List

11. Ladder logic
 Ladder Logic is a graphical system of symbols and terms.
 Those who are not familiar with relay wiring. Diagram, can easily learn it.
 In ladder logic, we have to translate all of the items we're using into symbols
the PLC understands

12. PLC CIRCUIT DESGIN

13. The various components used in the panel are as
follows PLC
 SMPS
 PLC S7-200
 Connectors
 Wires
 Main switch
 Selector switch
 Push buttons
 Emergency switch
 Relay
 Sensors
Outside view of the panel

14. Spherical Bolt greasing Machine
 A spherical bolt greasing machine
is made to reduce the
manufacturing cost of spherical
bolt. Previously what is happing the
spherical bolt was manufactutered
in the BOSCH ,but it is sent to
Bangalore for harding of the
component by doing the cadmium
and magnesium coating on it. This
increasing the cost of the
component. The BOSCH, Jaipur
researched that the lubricating the
component ,it can be used in the
assemblyeasily and it is reducing
the cost of the component and this
machine is made for this purpose.
 In this machine the PLC circuit
Desgin panel is used.
Spherical bolt greasing machine

15. ELECTICAL DRAWING OF MACHINE
Power Diagram
 Main switch from power
supply
 SMPS is switch mode power
supply
 MCB is miniature circuit
breaker
5.2.1POWER DIAGRAM
Power diagram of the spherical bolt greasing machine

16. PLC Inputs
 I1 is the start no switch
 I2 is the stop nc switch
 I3 is NC auto switch
 I4 is NC emergency push button
switch
 I5 read switch of cylinder back
 I6 is read switch of cylinder forward
 I7 is flow sensor for lubrication is
coming or not
 I8 is the proximity sensor at compent
is at loading
 I9 is proximity sensor at the
component at lubrication point

17. PLC OUTPUT DIAGRAM
 R1,R2,R3 arerealy coil connected at the
PLC output
CONTROL DIAGRAM
K1 is the connector supply of vibrator
K2 is the connector supply of the lubrication
unit motor
Valve is the supply of the solinoide vavle of
cylinder
Output of PLC
Control circuit of spherical bolt machine

18. FLOW CHART OF MACHINE WORKING
Flow chart of machine

19. Inputs and Outputs
Inputs Description
I0.0 START NO PUSH BUTTON
I0.1 STOP NC PUSH BUTTON
I0.2 AUTO SLECTOR NC SWITCH
I0.3 EMERGENCY NC SWITCH
I0.4 NO READ SWITCH OF CLYINDER BACKWARD
I0.5 READ SWITCH OF CLYINDER FORWARD
I0.6 NO FLOW SENSOR
I0.7 NC SENSOR AT COMPONENT AT LOADING CLYINDER
I1.1 NC SENSOR AT LUBRICATION POINT OUT
Output Description
Q0.0 VIBRICATOR
Q0.1 LUCRICATION MOTOR
Q0.2 PNEUMATIC CYLINDERS
Memory bit Description
M0.1 CLYINDER SET
M15.0 START AUTO SET
M15.1 SET START
M15.2 SET EMERGENCY
SM0.0 CALL SUBROUTINE BIT

20. Ladder logic program of machine
Ladder logic of main program
Inputs Description
I0.0 START NO PUSH BUTTON
I0.1 STOP NC PUSH BUTTON
I0.2 AUTO SLECTOR NC SWITCH
I0.3 EMERGENCY NC SWITCH
I0.4 NO READ SWITCH OF CLYINDER BACKWARD
I0.5 READ SWITCH OF CLYINDER FORWARD
I0.6 NO FLOW SENSOR
I0.7 NC SENSOR AT COMPONENT AT LOADING CLYINDER
I1.1 NC SENSOR AT LUBRICATION POINT OUT

21. (a)Ladder logic of auto program
Inputs Description
I0.0 START NO PUSH BUTTON
I0.1 STOP NC PUSH BUTTON
I0.2 AUTO SLECTOR NC SWITCH
I0.3 EMERGENCY NC SWITCH
I0.4 NO READ SWITCH OF CLYINDER BACKWARD
I0.5 READ SWITCH OF CLYINDER FORWARD
I0.6 NO FLOW SENSOR
I0.7 NC SENSOR AT COMPONENT AT LOADING CLYINDER
I1.1 NC SENSOR AT LUBRICATION POINT OUT

22. (b) Ladder logic of auto program
Inputs Description
I0.0 START NO PUSH BUTTON
I0.1 STOP NC PUSH BUTTON
I0.2 AUTO SLECTOR NC SWITCH
I0.3 EMERGENCY NC SWITCH
I0.4 NO READ SWITCH OF CLYINDER BACKWARD
I0.5 READ SWITCH OF CLYINDER FORWARD
I0.6 NO FLOW SENSOR
I0.7 NC SENSOR AT COMPONENT AT LOADING CLYINDER
I1.1 NC SENSOR AT LUBRICATION POINT OUT

23. Conclusion
 The technical internship program was aimed at providing a practical
experience and exposure. It was directed towards enhancing the knowledge
about the upcoming technologies and how they are actually used.
 The basic role was understanding the Automation. It is the use of control
systems such as PLC, SCADA,HMI, etc. to control industrial machinery and
processes, replacing human operators which greatly reduces the need for
human sensory and mental requirements.
 I made a logic for a machine named SPERICAL BOLT GREASING MACHINE in
PLC which aims to achieve automation of a lubrication of the spherical bolt
one of the component of VE pump which is the main product manufactured
at BOSCH.

24. References
 SIMATIC S7-200 CPUs
 http://w3.siemens.com/mcms/programmable-logic-controller/en/simatic-s7-
controller/s7-200/cpu/Pages/Default.aspx
 http://www.wikipedia.com/
 http://w3.siemens.com/mcms/simatic-controller-software/en/step7/step7-micro-
win/Pages/Default.aspx
 http://www.google.com/

25. Thank You