Summer Internship Training Re...-1.pdf and electronics engineering

Summer Internship Training Report on
Automation System
NAME- ASHOK KUMAR
REG NO- 23408075003
BRANCH- ELECTRICAL AND ELECTRONICS ENGINEERING
COLLEGE- GOVERNMENT POLYTECHNIC JAGANNATHPUR

1. WELCOME

2. SummerInternshipTrainingReporton
AutomationSystem
NAME-ASHOKKUMAR
REGNO-23408075003
BRANCH-ELECTRICALANDELECTRONICSENGINEERING
COLLEGE-GOVERNMENTPOLYTECHNICJAGANNATHPUR

3. Abstract
Automationdescribesawiderangeoftechnologiesthatreducehumaninterventioninprocesses.Ingeneralusage,automationcanbedefinedasa
technologyconcernedwithperformingaprocessbymeansofprogrammedcommandscombinedwithautomaticfeedbackcontroltoensureproper
executionoftheinstructions.Theresultingsystemiscapableofoperatingwithouthumanintervention.Thedevelopmentofthistechnologyhasbecome
increasinglydependentontheuseofcomputersandcomputer-relatedtechnologies.Inour4weeksofvocationaltrainingin“Developmentofautomation
systemandmaintenance”,welearnedaboutthosethingsandtechnologieswhichishelpfulinmakingasystemorprocessautomated.Weanalysed
differentcircuitsandICswhichcontributetoanautomationsystem.WedidsomeprojectsonthosecircuitssuchasblinkingLEDatvarioustimeintervals
automatically,drivingthemotorwiththehelpofamicrocontrollerandcontrollingitsspeed.Wealsolearnedsmarthomeautomationwhichallowsusto
remotelycontrolourelectricalapplianceswiththehelpofoursmartphone.

4. Introduction
AboutCompany
AeronspireisoneofIndia’sgrowingelectronicsproductmanufacturers,embeddedsystemprovidersandprovidesawidevarietyofautomationsystem
developmentandmaintenance.
Aeronspirehasateamofqualifiedprofessionalsintheembeddedsystemdevelopmentandembeddedsystemprogrammingareas.Ourtopmanagement
expertshavehands-onexperienceinthedesignanddevelopmentofmicrocontroller-basedsystemsandwirelesscommunicationsystems.Wedevelop
manyembeddedsystemsforindustry/real-timeapplications.
Aeronspiremainlyprovidesautomationsolutionsforindustries,homesandoffices.Aeronspiremanufacturesallkindsofelectronicsproductsaccordingto
yourrequirementsespeciallybasedonembeddedsystems.Weprovideserviceofelectronicsprojectswhichyouneedtocompletewithqualityandcost
perfection.Aeronspireservicescoverseveralmicrocontrollerarchitecturesandtheirdevelopmenttechniques.
Aeronspirebringstheideasofallnewtechnologiestoyou.Itprovidesthesolutiontoallourtechnicalproblemsbyourengineers.Wecompletelycompileall
rareandhard-to-worktechnologiesatoneplaceandscreenoutoneofthemwhichgivesthebestsolutiontoourrequirements.
Buildingonthestrengthscreatedthroughcollaborativedevelopmentandmanufacturing,Aeronspirecontinuestocommittoqualityproductsandreliable
services.

5. Introduction
SafetyConditions
Completesafetyofthetraineewasintroducedduringtheprocessoftraining.
Separatedandproperdistributionofpowersupplyconnectionssothatthereisno
possibilityofshortcircuit.
1
Theautomationsystemdevelopmentinvolvedcertainhigh-temperatureareas.Full
heatprotectivecaseswereprovidedtotheworkertoavoidanyaccidentaldamage.
3
Beforerunninganyprototypecircuit,itwasalwaysverifiedtwotimeswithcomplete
precautionsincludingconnectioncheckingtoavoidanyaccidentaldamages.
5
Eachconnectionwascompletelyinsulated.Thetrainingfloorwascoveredwitha
completelyinsulatedmaterialtoavoidanyaccidentaldamage.
Safetyglasseswereprovidedwheneverwewererequiredtoexposetoflamesduring
cuttingofcertainmaterials.
Handlingofeverycomponentanddesigningofeverysystemwasdoneunder
completesupervision.
2
4
6

6. ObjectiveofTraining
Theobjectiveofjoiningthistrainingprogrammeistogetexperienceinanactualworkingenvironmentandgainpracticalknowledgeandskillswhichinturnwillmotivate,develop
andbuildourconfidence.
Thistrainingwasdesignedtodevelopskillsintheapplicationoftheorytopracticalwork.
Thistraininghelpedustobuildgoodcommunicationskillswithagroupofworkersandlearnproperbehaviorofcorporatelifeinindustrialsectors.
Todevelopteamworkspirit.
Todevelopskillsandtechniquesdirectlyapplicabletoourcareers.
Togethands-onexperiencetodesignautomationsystemsforindustrialandorganizationalrequirements.
Tolearntoimplementsoftwareintohardwaretomakethesystemsautomated.
Thistrainingreallyhelpedustoenhanceourcreativityskillsandsharingideas.
Thetraininggivesawholenewexperienceofdesigningcircuitsfromscratchandimplementingourideasgeneratedintophysicalexistence.

7. PowerDistributionSysteminAutomationSystem
Powerdistributionisanimportantaspectwhileconsideringautomationsystems.Theprimaryreasonforthisisthatdifferentelectronicscomponents
requireseparatevoltagelevels.ThesupplyavailabletousisACsupply.ButmostoftheelectronicssystemsworkonDCsupply.Also,theprocessorsandICs
generallyrequirea5VDCsupply.Therefore,werequireconversionofpower.Theconversionbasicallyrequirestransformer,regulator.Themachinesthat
performheavy-dutyoperationsgenerallyrequireACpowersupplyandtheintegratedsystemsusedtocontrolthesemachinesoperateonDCpowersupply.
Carefulpowerdistributionalongwithaconsistentsystemisveryimportantindevelopingautomationsystem.Properconsiderationshouldbetakenwhile
workingwithbothtypesofpowerinacommonsystemtoprovidesafetyfromshortcircuitandminimizingelectromagneticinterferencetoensuresmooth
functioningofautomatedsystems.Powerdistributioninanindustrialsetupdirectlyimpactstheoverallperformanceofproductivityandefficiencyof
industries.Anyminormistakeinthepowerdistributionsystemmayleadtolargelossofmachinesaswellastime.Sometimesevenminormistakesareso
dangerousthatitbecomesnearlyimpossibletobearthelosses.
Thepowerdistributionsystemnotonlyrequiresproperdistributionbutalsocompleteisolationofsystems.Sothatincaseofanyfailures,thelossis
minimizedandrestrictedtoacertainpartonly.Somecommonlyusedcomponentsinpowerdistributionsystemsarediscussedbelow:

8. ConversionofACSupplytoDC
Thepurposeofusingatransformerinpowersupplyistomakeelectricalpoweraccessibleasit
travelsfromapowerutilitytoanoffice,home,worksiteorotherlocation.Formanyyears,linear
AC/DCpowersupplieshavebeentransformingACpowerfromtheutilitygridintoDCvoltagefor
runninghomeappliancesorlighting.Theneedforsmallersuppliesforhigh-powerapplications
meanslinearpowersupplieshavebecomerelegatedtospecificindustrialandmedicaluses,
wheretheyarestillneededbecauseoftheirlownoise.Butswitchingpowersupplieshavetaken
overbecausetheyaresmaller,moreefficient,andarecapableofhandlinghighpower.

9. ConversionofACSupplytoDC
VoltageRegulator
Avoltageregulatorisasystemdesignedtoautomaticallymaintainaconstantvoltage.ElectronicvoltageregulatorsarefoundindevicessuchascomputerpowersupplieswheretheystabilizetheDCvoltagesusedbytheprocessorandother
elements.Inautomobilealternatorsandcentralpowerstationgeneratorplants,voltageregulatorscontroltheoutputoftheplants.
Itisalsoknownasaboardmounttransformer,circuitboardtransformer,orPCBtransformer.APCBmounttransformerdoesnothaveasophisticatedcoolingmechanism,soittendstocomewitharatingforminimumandmaximumtemperaturesat
whichitshouldrun.Aslongasyoudiligentlymaintainitwithinthesestipulatedranges,yourPCBmounttransformersshouldlastyoudecades.APCBmounttransformerconsistsofaprimaryandsecondarycoilwire.Italsoincludesametalcore,
mountingbrackets,anoutercasing,andconnectingterminals.Itisdesignedwithlightmaterialtobemountedeasilyoverachassisoracomputerboard.Thetransformersaremostlyintegratedcircuitsandaremanufacturedusingsemiconductor
fabricationtechnology.APCBtransformerhasasimpleandcompactdesignthatmakesitpracticalforapplicationsthatrequirelittlespaceforcomponents.ThesizeofaPCBmounttransformerisexceedinglysignificantforfunctionality.Thecore
functionofatransformerisconvertingandtransferringpowerfromonecircuittoanother.Itispracticallyusedtoreduceorincreasethevoltageorcurrentofasignal.
Thedeviceconsistsoftwonon-interactinginductingcircuitsknownastheprimaryandsecondarycircuits.Onceavoltageisappliedtotheprimarycircuit,amagneticfieldisproducedthatinducesaseparatemagneticfieldinthesecondarycircuit,
generatingavoltageinthesecondary.
Thesecondary'sinducedvoltagevaluedependsontheratioofthenumberofwindingturnsinthesecondarytotheturnnumbersintheprimary.Determiningandspecifyingyourintendedapplicationisvitalwhenchoosingaboardmounttransformer.
Thisispartlybecausethedesignandcharacteristicsoftransformersdependontheiruse.
Forexample,amedicaltransformershouldfeaturealargeisolationtoprotecthealthpersonnelandpatientsfrompossibleelectricshocks.Moreover,apowertransformershouldberatedtomanagelargepoweramounts.
Whenchoosingaboardmounttransformer,youshouldnotethattheformfactorisvitalsincetransformersareintegratedwithcomputerboards,andthespaceavailableisoftenrestricted.Theotherfewparametersvitaltospecifywhenchoosinga
PCBmounttransformerincludeprimaryvoltagerating,secondaryvoltagerating,powerrating,andoperatingtemperature.

10. ConversionofACSupplytoDC
IntroductiontoMicrocontroller
Inthisproject,an8051microcontrollerisusedtoprogramthecodetodrivethelinefollower
accordingtothelogicswritteninthecode.Ithasan8-bitprocessorthatsimplymeansthatit
operateson8-bitdataatatime.Itisamongthemostpopularandcommonlyused
microcontroller.Asitisan8-bitmicrocontrollerthushasan8-bitdatabusand16-bitaddressbus.
Alongwiththat,itholds4KBROMwith128bytesRAM.

11. IntroductiontoMicrocontroller
PinDescription
VCC
Supplyvoltage.
GND
Ground.
Port0
Port0isan8-bitopen-drainbidirectionalI/Oport.Asanoutputport,eachpincansinkeightTTLinputs.When1sarewrittentoport0pins,thepinscanbeusedashighimpedanceinputs.
Port1
Port1isan8-bitbidirectionalI/Oportwithinternalpull-ups.Theportcansink/sourcefourTTLinputs.When1sarewrittentoPort1pinstheyarepulledhighbytheinternalpull-upsandcanbeusedasinputs.
Port2
Port2isan8-bitbidirectionalI/Oportwithinternalpull-ups.ThePort2outputbufferscansink/sourcefourTTLinputs.When1sarewrittentoPort2pinstheyarepulledhighbytheinternalpull-upsandcanbeusedasinputs.
Port3
Port3isan8-bitbidirectionalI/Oportwithinternalpull-ups.ThePort3outputbufferscansink/sourcefourTTLinputs.When1sarewrittentoPort3pinstheyarepulledhighbytheinternalpull-upsandcanbeusedasinputs.
RST
Resetinput.Ahighonthispinfortwomachinecycleswhiletheoscillatorisrunningresetsthedevice.
ALE/PROG
AddressLatchEnableoutputpulseforlatchingthelowbyteoftheaddressduringaccessestoexternalmemory.ThispinisalsotheprogrampulseinputduringFlashprogramming.

12. IntroductiontoMicrocontroller
PortPinAlternateFunctions
1
P3.0RXD(serialinputport)
3
P3.2INT0(externalinterrupt0)
5
P3.4T0(timer0externalinput)
7
P3.6WR(externaldatamemorywritestrobe)
PSEN:ProgramStoreEnableisthereadstrobetoexternalprogrammemory.WhentheAT89C51isexecutingcodefromexternalprogrammemory,PSENisactivatedtwiceeachmachinecycle,
exceptthattwoPSENactivationsareskippedduringeachaccesstoexternaldatamemory.
EA/VPP:ExternalAccessEnable.EAmustbestrappedtoGNDinordertoenablethedevicetofetchcodefromexternalprogrammemorylocationsstartingat0000HuptoFFFFH.Note,however,that
iflockbit1isprogrammed,EAwillbeinternallylatchedonreset.EAshouldbestrappedtoVCCforinternalprogramexecutions.Thispinalsoreceivesthe12-voltprogrammingenablevoltage(VPP)
duringFlashprogramming,forpartsthatrequire12-voltVPP.
XTAL1:Inputtotheinvertingoscillatoramplifierandinputtotheinternalclockoperatingcircuit.
XTAL2:Outputfromtheinvertingoscillatoramplifier.
2
4
P3.1TXD(serialoutputport)
P3.3INT1(externalinterrupt1)
6
P3.5T1(timer1externalinput)
8
P3.7RD(externaldatamemoryreadstrobe)

13. Enable 1.2Vcc Input1 Input4 Output1 Output4 GND
2GND GND Output2 Output3 Input2 Input3 Vcc2
PortPinAlternateFunctions
MotorDriverControlCircuit
Motorshavespecialneedsinmachinecontrol.Foreverymotor,aproperformofelectricalcontrolisrequired,fromsimpleon/offtomorecomplexvariablespeedapplications.Motorcontroldevices
includemanualmotorstarters,motorcontactors,andstarterswithoverloadprotection.Amotorcircuitmustincludebothovercurrent(shortcircuit)andoverloadprotection.Thistypicallyconsistsof
branch-circuitprotection,suchasproperlyratedfuses,andamotorstarterwithoverloadprotectiondevices,suchasthermaloverloads,butadditionalprotectionmaybeneeded.
AmotordriverICisanintegratedcircuitwhichisusuallyusedtocontrolmotorsinautonomousrobots.MotordriverICsactasaninterfacebetweenthecontrollerinrobotsandthemotorsintherobot.
ThisICconsistsof16-pinswhichareusedtocontrolasetoftwoDCmotorsinstantaneouslyinanydirection.Itmeans,byusinga2x3DserieswecancontroltwoDCmotors.Aswell,thisICcandrive
smallandmicromotors.
PinCharacteristics
Enable1
WhenthisisHIGH,theleftpartoftheICwillworkand
whenitislow,theleftpartwon’twork.
GND
Groundpins.
VCC2
Thisisthevoltagewhichwillbesuppliedtothemotor.
OUTPUT4
Thispinshouldbeconnectedtooneoftheterminalsof
themotor.
Enable3,4
WhenthisisHIGH,therightpartoftheICwillworkandwhenitislow,therightpartwon’twork.
INPUT1
WhenthispinisHIGH,thecurrentwillflowthrough
output1.
TheDCmotorisaninductiveload.So,itdevelopsabackEMFwhensuppliedbyavoltage.Therecanbefluctuationsofvoltagewhileusingthemotorwhensuddenlywetakeareversewhilethemotor
wasmovinginsomedirection.Atthispoint,thefluctuationinvoltageisquitehighandthiscandamagetheIC.Thus,weusefourcapacitorsthathelptodampentheextremevariationincurrent.
OUTPUT2
Thispinshouldbeconnectedtooneoftheterminalsof
themotor.
VCC1
ThisisthepowersourcetotheIC.So,thispinshouldbe
suppliedwith5V.
OUTPUT3
Thispinshouldbeconnectedtooneoftheterminalsof
themotor.
OUTPUT1
Thispinshouldbeconnectedtooneoftheterminalsof
themotor.
INPUT2
WhenthispinisHIGH,thecurrentwillflowthrough
output2.
INPUT4
WhenthispinisHIGH,thecurrentwillflowthrough
output4.
INPUT3
WhenthispinisHIGH,thecurrentwillflowthrough
output3.

14. IntroductiontoSensors
Asensorisadevicethatdetectsandrespondstosometypeofinputfromthephysicalenvironment.Theinputcanbelight,heat,motion,moisture,pressure
oranynumberofotherenvironmentalphenomena.Theoutputisgenerallyasignalthatisconvertedtoahuman-readabledisplayatthesensorlocationor
transmittedelectronicallyoveranetworkforreadingorfurtherprocessing.
SensorsplayapivotalroleintheInternetofThings(IoT).Theymakeitpossibletocreateanecosystemforcollectingandprocessingdataaboutaspecific
environmentsoitcanbemonitored,managedandcontrolledmoreeasilyandefficiently.IoTsensorsareusedinhomes,outinthefield,inautomobiles,on
airplanes,inindustrialsettingsandinotherenvironments.Sensorsbridgethegapbetweenthephysicalworldandlogicalworld,actingastheeyesandears
foracomputinginfrastructurethatanalyzesandactsuponthedatacollectedfromthesensors.
Asensorisadevicethatidentifiestheprogressionsinelectricalorphysicalorotherquantitiesandinawaytodeliverayieldasanaffirmationofprogressin
themeasuredquantity.Intheindustrialautomationsection,sensorsplayaveryimportantroletomaketheproductsintelligentandhighlyautomatic.These
allowonetodetect,analyze,measureandprocessvariouschangeslikechangeinposition,length,height,appearanceanddisplacementthatoccursinthe
productionsites.Thesesensorsalsoplayapivotalroleinpredictingandpreventinganyfutureevents,thus,cateringtotheneedsofmanysensing
applications.Thefollowingarethevarioustypesofsensorsusedinindustrialautomation:Proximitysensors,Visionsensors,Ultrasonicsensors,Position
sensors,Photoelectricsensors,Temperaturesensors,Inclinationsensors,etc.Thesesensorsalsoplayapivotalroleinpredictingandpreventingnumerous
potentialproceedings,thus,cateringtotherequirementsofmanysensingapplications.

15. LinearPositionSensor
Thisplaysanimportantroleintheautomationcontrol,whereaccurate(precision)positioningisrequired.Itmeasuresthelinearpositionofadevice.Avery
goodexampleofthistypeofsensoristheLinearVariableDifferentialTransformer(alsoknownasLVDT).Itisatypeoftransformerthatisusedtosense
andmeasurelineardisplacement.

16. AngularPositionSensor
Thissensor,oftenreferredtoasarotarysensor,calculatestheorientationofanobjectwithrespecttoaspecificreferencepositionashasbeenexpressed
bythedegreeofrotationnecessarytochangefromonerotationtotheotheraboutaspecificaxis.Itmeasurestherelationestablishedbetweenaposition
withrespecttoanotherposition.Theseareused,wherelongtermreliabilityisrequired.

17. PotentiometricPositionSensors
Theseuseresistiveeffectasthesensingprinciple.Itiswear-freeasthesedonothaveany
contactingparts.Inthesetypesofsensors,thepositionmarkerisattachedtothemovingpartof
theapplication,whosepositionneedstobemeasured.

18. IntroductiontoSoftwareUsedforDevelopingAutomation
System
Oneoftheimportantpartsinmakinganembeddedsystemisloadingthesoftware/programwedevelopintothemicrocontroller.Usually,itiscalled
“burningsoftware”intothecontroller.Before“burningaprogram”intoacontroller,wemustdocertainprerequisiteoperationswiththeprogram.This
includeswritingtheprograminassemblylanguageorClanguageinatexteditorlikeNotepad,compilingtheprograminacompilerandfinallygenerating
thehexcodefromthecompiledprogram.Earlierpeopleuseddifferentsoftware/applicationsforallthesethreetasks.Writingwasdoneinatexteditorlike
Notepad/Wordpad,compilingwasdoneusingaseparatesoftware(probablyadedicatedcompilerforaparticularcontrollerlike8051),convertingthe
assemblycodetohexcodewasdoneusinganothersoftwareetc.Ittakesalotoftimeandworktodoalltheseseparately,especiallywhenthetaskinvolves
lotsoferrordebuggingandreworkingonthesourcecode.

19. KeilμVision
WiththeµVisionProjectManagerandRun-TimeEnvironment,wecreatesoftwareapplicationsusingpre-builtsoftwarecomponentsanddevicesupport
fromSoftwarePacks.Thesoftwarecomponentscontainlibraries,sourcemodules,configurationfiles,sourcecodetemplates,anddocumentation.Software
componentscanbegenerictosupportawiderangeofdevicesandapplications.TheKeilµVisionDebuggeraccuratelysimulateson-chipperipherals(I²C,
CAN,UART,SPI,Interrupts,I/Oports,A/DConverter,D/AConverter,andPWMModules)ofyour8051device.Simulationhelpsyouunderstandhardware
configurationsandavoidstimewastedonsetupproblems.Thissoftwarecreatesexecutablehexfileswhichcanbeloadedtothemicrocontrollerwithaset
ofinstructionstoperformourdesiredtasks.

20. Willar
Thisisthesoftwarethroughwhichyouload&burntheHEXfilecreatedbyKeilontothetarget
chip.

21. Conclusion
Automationplaysanincreasinglyimportantroleintheglobaleconomyandindailyexperience.Engineersstrivetocombineautomateddeviceswith
mathematicalandorganizationaltoolstocreatecomplexsystemsforarapidlyexpandingrangeofapplicationsandhumanactivities.Automationprovides
100%accuracyallthetime.Sothefailuresandmismatchesinproductionarecompletelyeliminated.Itmakesthesystem’sefficiencyhigherthanmanualas
wellasitcontrolswastages.Sotheoverallsavingsincrease.Itprovidessafetytohumanbeings.Bythatindustrycanachievethesafetymeasures.Itmakes
theoperationfasterthanmanualwhichcauseshigherproductionandproperutilizationofutilities.Itincreasestheproductionbywhichthecostofeach
productdecreasesandtheindustry'sprofitincreases.Itprovidessmoothcontrolonsystemresponse.Itprovidesrepeatabilitysothatthesamekindof
productsareeasiertomanufactureatdifferentstageswithoutwastingtime.Itprovidesqualitycontrol,sothattheproductsbecomereliablewhich
improvesindustrialreputationinthemarket.Itprovidesintegrationwithbusinesssystems.Itcanreducelaborcosts,sothefinalprofitincreases.Industrial
automationisaverycompulsoryneedofindustriesintoday’sscenariotoneedmarketcompetition.

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23. ThankYou