VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI

INTERNSHIP REPORT ON

“CONTROLLING THE MOVEMENT OF PISTON USING

ELECTRO-PNUEMATICAL PLC”

Submitted by

KARTHIK.N 1RN17ME041

in partial fulfilment of the requirement for the award

of the Bachelor Degree in Mechanical
Engineering
Under the Guidance of
Mrs. CHETANA S B
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

RNS INSTITUTE OF TECHNOLOGY, BENGALURU-560 098
2020-21

i
 RNS INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
BENGALURU-560098

CERTIFICATE

This is to certify that Mr. KARTHIK.N (1RN17ME041) has successfully

completed Internship in partial fulfilment of VII Semester to award the Bachelor Degree in
Mechanical Engineering of the Visveswaraya Technological University, Belagavi during
the year 2020-21. The Internship Report has been approved as it satisfies the academic
Requirements in respect of Internship prescribed for the Bachelor of Engineering Degree.

Mrs. CHETANA S B Dr. T. SREENIVASAN Dr. M. K. VENKATESHA

Assistant Professor & Guide Professor & Hod Principal

Examiners

Sl. No. Name Signature Date

1.

2.

ii
 On Organisation/Industry Letter Head

CERTIFICATE

This is to certify that Mr. KARTHIK.N (1RN17ME041), student of RNS

INSTITUE OF TECHNOLOGY, Bengaluru-98 has successfully completed Internship
from………………. to…………….in our Organisation/Industry in…………………
department/section under the supervision of……………………………

Signature:

Name:

Designation:

Date:

Seal

iii
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task would
be incomplete without the mention of the people who made it possible, whose constant
guidance and encouragement crowned the efforts with success.

I would like to thank the Management of RNS Institute of Technology for providing such a
healthy environment for the successful completion of project work. I would like to express
our thanks to the Director Dr. H N Shivashankar and the Principal Dr. M K Venkatesha
for their encouragement that motivated us to successfully complete the project work.

It gives me immense pleasure to thank Dr. T Sreenivasan, Professor and Head of

Department, Mechanical Engineering for his constant support and encouragement. I wish to
express our deepest sense of gratitude to our project guide Mr. SANTOSH and Mrs.
DOLLY S for their constant support and guidance throughout the project. Last, but not the
least, we would like to hereby acknowledge and thank our parents who have been a source of
inspiration and also instrumental in the successful completion of our project.

KARTHIK.N
(1RN17ME041)

iv
 CONTENTS

Certificate ii
Industry Certificate iii
Acknowledgement iv
1. Introduction 1-5
1.1 Basic Characteristics of
Hydraulics 1
1.2 Applications 2

1.3 Basic Symbols 2

1.4 Hydraulic Fluids 3

1.5 Hydraulic Pumps 3

1.6 Pressure valves 4

1.6.1 Pressure Relief Valve 4

1.7 Cylinder 4

1.7.1 Single Acting Cylinder 4

1.7.2 Double Acting Cylinder 4
1.8 Advantages and Limitations 5

2. Pneumatics 6-8

2.1 Introduction 6

2.2 Controlling the Movement of Pistons Pneumatically using PLC

6

2.3 Applications of Pneumatics

7
2.3.1 Manufacturing Applications 7
2.4 Compressed air Generation and Supply 8
9-10
3. PLC
3.1 Basics of PLC 9

3.1.1 Where is PLC used? 9

3.1.2 How does PLC work? 9
3.2 Controlling the Movement of Pistons using PLC
9
3.2.1 What is a Relay? 9
3.2.2 How does a relay work? 10
3.3 Controlling the Movement
of Pistons Hydraulically using PLC
10
3.3.1 What is PLC Logic? 10
4. Software Details 11-12

4.1 Software used 11

4.2 Details of Indra Logic 11

4.3 Basic Ladder Diagram used in PLC programming

11
5. Project Details 13-15

5.1 Problem Statement 13

5.2 Components Used 13

5.3 Software Used 13

5.4 Description 13

5.5 Ladder Diagram 14

5.6 Wiring Diagram 14

5.7 PLC CIRCUIT 15

5.8 Applications 15

16
Conclusions
References 17

List of Figures

Fig No. Description Page No.

1.1 Symbols used in Hydraulics

1.2 Types of Cylinder,

Reservoirs and Valves

4.1 PLC Ladder

5.1 PLC Ladder Diagram (Acc.

To project)

5.2 Wiring Diagram

5.3 PLC circuit

CHAPTER 1
INTRODUCTION
Hydraulics
The word hydraulics is based on the Greek word for water, and originally covered the study
of the physical behaviour of water at rest and in motion. Use has broadened its meaning to
include the behaviour of all liquids, although it is primarily concerned with the motion of
liquids.

Pneumatics
A pneumatic system is a system that uses compressed air to transmits and control energy.
Pneumatic systems are used extensively in various industries. Compressed air is the air from
the atmosphere which is reduced in volume by compression thus increasing its pressure.

1.1 Basic Characteristics of Hydraulics

Hydraulic systems have many desirable features. However, one disadvantage is the original
high cost of the various components. This is more than offset by the many advantages that
make hydraulic systems the most economical means of power transmission. The following
paragraphs discuss some of the advantages of hydraulic systems: -

• Efficiency: Discounting any losses that can occur in its mechanical linkage,
practically all the energy transmitted through a hydraulic system is received at the
output end where the work is performed.
• Dependability: The hydraulic system is consistently reliable. Unlike the other
systems mentioned, it is not subjected to changes in performance or to sudden
unexpected failure.
• Control Sensitivity: The confined liquid of a hydraulic system operates like a bar of
steel in transmitting force. However, the moving parts are lightweight and can be
almost.

• Flexibility of Installation: Hydraulic lines can be run almost anywhere. Unlike

mechanical systems that must follow straight paths, the lines of a hydraulic system
can be led around obstructions.
 • Low Space Requirement: The functional parts of a hydraulic system are small in
comparison to those of other systems; therefore, the total space requirement is
comparatively low

1.2 Applications
• Industrial Trucks Travel drives
• Flight Simulators
• Machine tools and transfer lines
• Lifting and conveying devices
• Metal-forming presses
• Metallurgical and Rolling Industry

1.3 Basic Symbols

Figure: 1.1 Symbols used in Hydraulics

 Figure: 1.2 Types of Cylinder, Reservoirs and Valves

1.4 Hydraulic Fluids

In a hydraulic system, the fluid assumes the task of force transmission. This means that
certain demands must be placed on the fluid.

The fluid should:

• Be easy to filter
• Be neutral against metal guides, seals and paints • Feature good lubrication properties
• Be resistant to aging not be detrimental to health
• Be easy to dispose of after use
• Be incompressible for the transmission of forces
1.5 Hydraulic Pumps
The function of a pump is to convert mechanical energy into hydraulic energy. It is the heart
of any hydraulic system because it generates the force necessary to move the load.
Mechanical energy is delivered to the pump using a prime mover such as an electric motor.
Partial vacuum is created at the inlet due to the mechanical rotation of pump shaft. Vacuum
permits atmospheric pressure to force the fluid through the inlet line and into the pump. The
pump then pushes the fluid mechanically into the fluid power actuated devices such as a
motor or a cylinder.

1.6 Pressure valves

Pressure valves are represented using squares. The flow direction is indicated by an arrow.
The valve ports can be labelled P (pressure port) and T (tank connection) or A and B. The
position of the valve within the square indicates whether the valve is normally open or
normally closed.

1.6.1 Pressure Relief valve

In the normally closed position, the control pressure is detected at the input. This pressure
acts on a valve via the control passage coming from the input on a piston surface which is
held against the control pressure by a spring. If the force resulting from the pressure and the
effective piston surface exceeds the spring force, the valve opens. In this way, it is possible to
set the limiting pressure to a fixed value.

1.7 Cylinders
A hydraulic cylinder is a mechanical actuator that is used to give a unidirectional
force through a unidirectional stroke. Cylinders are classified as either single-acting or
double-acting.

1.7.1 Single acting cylinder

Single acting cylinders just have one port, i.e. only the full piston surface can be pressurized
with hydraulic fluid. These cylinders are returned either by the effect of external forces –
indicated by the symbol with the open bearing cap – or by a spring. The spring is then also
drawn into the symbol.

1.7.2 Double acting cylinder

Unlike single acting hydraulic cylinders, double acting hydraulic cylinders have hydraulic fluid
on both the base and the rod sides of the piston with force being delivered in both directions
allowing both retraction and extension without the need of an external force. More common
than single acting hydraulic cylinders, double acting hydraulic cylinders work at any angle and
nearly every application where hydraulic power is needed.

1.8 Advantages and Limitations

Advantages:

• High force density, compact construction.

• Easy reversal of movement.
• Good controllability
• Easy movement conversion.
• Simple overload protection

Limitations:

• Temperature dependency
• Leakage problems
• Compressibility
• Manufacturing costs
CHAPTER 2
PNEUMATICS

2.1 Introduction
The principles of pneumatics are the same as those for hydraulics, but pneumatics transmits
power using a gas instead of a liquid. Compressed air is usually used, but nitrogen or other
inert gases can be used for special applications. With pneumatics, air is usually pumped into a
receiver using a compressor. The receiver holds a large volume of compressed air to be used
by the pneumatic system as needed. Atmospheric air contains airborne dirt, water vapor, and
other contaminants, so filters and air dryers are often used in pneumatic systems to keep
compressed air clean and dry, which improve reliability and service life of the components
and system. Pneumatic systems also use a variety of valves for controlling direction, pressure,
and speed of actuators.

2.2 CONTROLLING THE MOVEMENT OF PISTONS

PNEUMATICALLY USING PLC
The choice of medium depends on the application. Some of the general, broad rules followed
in the selection of a working medium are listed below.

• When the system requirement is high speed, medium pressure (usually 6 to 8 bar) and
less accuracy of position, then pneumatic system is preferred.

• If the system requirement is high pressure and high precision, a fluid system with oil
is good.

• When the power requirement is high like in forging presses, sheet metal press, it is
impossible to use air system. Oil hydraulics is the only choice Air is used where quick
response of actuator is required.

• If temperate variation range in the system is large, then use of air system may run into
condensation problems and oil is preferred.

• If the application requires only a medium pressure and high positional accuracy is
required then hydro –pneumatic system is preferred
• Air is non-explosive; it is preferred where fire/electric hazard are expected. Oil
systems are more prone to fire and electrical hazards and are not recommended in such
applications.

• Because air contains oxygen (about 20%) and is not sufficient alone to provide
adequate lubrication of moving parts and seals, oil is usually introduced into the air stream
near the actuator to provide this lubrication preventing excessive wear and oxidation.

2.3 Applications of Pneumatics

Pneumatic systems are used in many applications. New uses for pneumatics are constantly
being discovered. In construction, it is indispensable source of power for such tools as air
drills, hammers, wrenches, and even air cushion supported structures, not to mention the
many vehicles using air suspension braking and pneumatic tires. In manufacturing, air is used
to power high speed clamping, drilling, grinding and assembly using pneumatic.

2.3.1 Manufacturing applications

• Clamping

• Shifting

• Ejection

• Braking

• Locking

• Packaging

• Feeding

• Sorting

• Drilling

• Turning

• Milling
2.4 Compressed air generation and supply
For the continuing performance of control systems and working elements it is necessary to
guarantee that the air supply is:

• clean

• dry

• at the required pressure

If these conditions are not fulfilled, then short to medium term degeneration of the system
will be accelerated. The effect is downtime on the machinery in addition to increased costs
for repair or replacement of parts. The equipment to be considered in the generation and
preparation of air include:

• Inlet

• Air compressor

• Air reservoir

• Air dryer
CHAPTER 3
PLC
3.1 Basics of PLC
It is capable of storing instructions to implement control functions such as sequencing,
timing, counting, arithmetic, data manipulation and communication. The PLC has I/O
interfaces that provide the connection between the PLC and the information providers (inputs
like pushbuttons, sensors, etc.) and the controllable devices (outputs like valves, relays,
lamps, etc.).

3.1.1 Where is PLC used?

• The PLC controls industrial machines in a manufacturing unit.

• They are used in assembly line, robotic devices, and any activity that requires high reliability
control and ease of programming and process fault diagnosis.

• Materials handling, packaging, palletizing, milling, boring, grinding, filling, sorting,

weighing are the different industries using PLC.

3.1.2 How does PLC work?

• In the past the movements of industrial machines were controlled by relay circuits. These
relay-controlled systems were replaced by PLC.

• The primary function of the PLC was to perform the sequential operations that were
previously implemented with relays.

3.2 CONTROLLING THE MOVEMENT OF PISTON USING PLC

3.2.1 What is a relay?
A relay is an electro-magnetic switch.
It contains:

• An iron cores.

• A coil and switch.

• An iron bar connected to the switch.

3.2.2 How does a relay work?

Relays differ in their size, capacity, and corresponding uses. However, although they may
differ in these respects, all relays function in essentially the same way: one circuit is used to
power another.
The specific manner in which this occurs depends on whether the relay is normally open (NO)
or normally closed (NC).
Normally Open Relays
Most relays are normally open; that is, the second, larger circuit is in the off position by
default.
In a normally open relay, power flows through an input circuit, activating an electromagnet.
This generates a magnetic field that attracts a contact to join with the second, larger circuit,
allowing current to flow through. When the source of power is removed, a spring draws the
contact away from the second circuit, stopping the flow of electricity and turning off the end
device.
Normally Closed Relays
The fundamentals of an NC relay are the same as an NO relay: there are two circuits, with the
second being larger, and an electromagnet moves a physical contact between two positions.
But in the case of an NC relay, the default states are reversed. When the first circuit is
activated, the electromagnet draws the contact away from the second circuit. As such, NC
relays keep the larger circuit in the on position by default.

3.3 CONTROLLING THE MOVEMENT OF PISTONS HYDRAUCIALLY

USING PLC
The electromagnetic force pulls in the switch and a current can go through the switch.

3.3.1 What is PLC logic?

• The PLC logic is not a mechanical part of the controller.

• The PLC logic is a software program, which runs on the processor in the PLC.

• This program has to be created with a special programming tool on a PC. ex:
Indra logic or Codesys.

• After downloading the program into the PLC, the control automatically starts the program.

CHAPTER 4

SOFTWARE DETAILS

4.1 Software used: Indira logics

Indra logic Programming Languages PLC supports five different languages:

• Ladder Diagram (LD)

• Functional Block Diagram (FBD)

• Sequential Flow Chart (SFC)

• Instruction List (IL)

• Structural Text (ST)

4.2 Details of Indra logic

INDRAWORKS ML 12V12 PATCH 10, BY REXROTH INDRAWORKS

4.3 Basic ladder diagram used in PLC programming

Ladder logic is widely used to program plc where sequential control of a process or
manufacturing operation is required. Ladder logic is useful for simple but critical control
systems or for reworking old hardwired relay circuits. As programmable logic controllers
became more sophisticated it has also been used in very complex automation systems.

The motivation for representing sequential control logics in a ladder diagram was to allow
factory engineers and technicians to develop software without additional training to learn a

language such as Fortran or other general-purpose computer language . Development and

maintenance were simplified because of the resemblance to familiar relay hardware systems.
Implementations of ladder logic may have characteristics, such as sequential execution and
support for control flow features that make the analogy to hardware somewhat inaccurate.

Ladder logic can be thought of as a rule-based language rather than a procedural language.
When implemented with relays and other electromechanical devices, the various rules
execute simultaneously and immediately. When implemented in a programmable logic
controller, the rules are typically executed sequentially by software in a continuous loop.

An example of ladder diagram shown below.

Figure 4.1 PLC Ladder

CHAPTER 5

PROJECT DETAILS

5.1 Problem Statement

Push Button> A+>B+>WAIT FOR 5 SECONDS>B->A-.

5.2 Components used

Air Compressor, Distributors, Two 5/2 DCV solenoid operated detent valve, Push Button,
Two Cylinders, Two Throttle Check valve.

5.3 Software Used

INDRAWORKS ML 12V12 PATCH 10, BY REXROTH INDRAWORKS.

5.4 Description
• The working of our sequence is simple. We have two cylinders, when power is
supplied the first cylinder extends. Immediately after first cylinder the second cylinder
extends and stays at that position for few seconds(5sec). After waiting for 5 sec the
second retracts first followed by the first Cylinder.

• We have used pneumatics for this sequence. We use 2 pneumatics circuit each
equipped with double acting Cylinders, throttle check Valve and 5/2 DCV solenoid
operated detent Valve. Each cylinder is equipped with 2 sensors, one placed at
retracted position of the cylinders and the other at the extended position of the
cylinders. We also use Push Button to start these circuits.
5.5 Ladder Diagram

Figure: 5.1 PLC Ladder Diagram (Acc. To project)

5.6 Wiring Diagram

Figure: 5.2 Wiring Diagram

5.7 PLC CIRCUIT

Figure: 5.3 PLC circuit

5.8 Application
• PLC systems offer number of advantages over hard wired electromechanical relay
control systems. Unlike the electromechanical relays, PLCs are not hardwired to perform
specific functions. Thus, when system operation requirement changes, a software program is
readily changed instead of having to physically rewire relays. In addition, PLCs are more
reliable, faster in operation, smaller in size, and can be readily expanded.

• Thus, electrical circuits combined with PLCs, are employed in industries for
controlling the working of cylinders, motors, compressors, conveyor belts, speed of working
of the tools, etc.

• They are also used to control the timing between the various operations a machine is
performing on a product.
• Codes such as the one described, is used in controlling the light sequence used in a 4-
way traffic signal. PLCs are much faster and much more reliable than normal circuit boards
and are easier to reprogram when changes are needed.

Conclusions
The internship at Bosch Rexroth has been very educative and has also provided us with the
opportunity in order to complete our summer internship under industrial professionals over a
course of 4 weeks in the field of Hydraulics, Pneumatics and PLC Programming. This
program has helped us not only gain knowledge related to industrial grade equipment but also
an insight into working of Hydraulic and Pneumatic components in manufacturing lines and
their integration with PLC Programming as well as knowledge necessary for a fresher with
mechanical background.
References
[1] “Active Motion Control of a Hydraulic Free Piston Engine” by Ke Li, Ali
Sadighi, Zongxuan Sun
[2] “Design, Development and Optimization of Hydraulic Press” by Deepak
Annasaheb More, N.K.Chhapkhane, Ravindra Kolhe
[3] “Design and fabrication of Hydraulic Jack system for four wheelers” by Aditya
Masiwal, Aman Kanungo, Ishan Rawlley
[4] “The Automatic Hydraulic Jack” by Shraddha S. Jadhav, v Prajakta K. Patil, A R Kharat
[5] “Investigation on the design of hydraulic high-speed punching press with a large press
force and a long press stroke” by Wei Song, Shuo Liu, Hongjun Pan