J.S.

INSTITUTE OF
MANAGEMENT &
TECHNOLOGY

1
Summer
Training
Seminar
Prepared by:
Gaurav Khanna,
0725531017,
2
4th ECE
Ordnance Equipment Factory, Kanpur

Welcomes

3
 Milestones
1859 Established as Government H & S Factory.
1862 Tannery was set up.
1960 Composite Boot Plant established.
1969 Rechristened as OEF, Kanpur.
1992 Ventured into International Market
1998 Established production of Electrical Safety Shoe
&Tail Unit of 1000 Lbs Bomb for IAF.
2004 Shoe Oxford for Air Force.
2004 Shorts P. C. Khaki.
2006-07 Bag Harness, Bag Kit Disruptive W/P with
Stroller [Duffle Bag].
2007-08 Boot Paratrooper, Boot High Ankle,
Synthetic Camouflage Net, Tank Water
Collapsible 230 L [Improved Version].
4
FACTORY LAYOUT
 Heritage Building

• The Quila was built by Almasa Ali, Minister of Nawab Asaf-ud- Daula.
• Used by Nana Rao Peshwa during the First War of Independence 1857.
• Capt. John Stewarts of East India Co. established Commissary of Ordnance in 1859.
• First Tannery was established in 1862.
 Heritage Building
•The Building was constructed by Raja of Oudh.
• An underground tunnel connects the building with Bithoor.
• The Anchor used by boats of Nana still exists.

7
Total Area of the Factory

30 Hectares

Total Area of Estate

66 Hectares

8
Exhibition Ground
Assets

9
Product Profile

10
 Product Profile
Textile Division Leather Division Engineering Division
%V.O.P ( 80% ) ( 15% ) ( 5% )
• Bag Sleeping • Boot D.V.S. • Components for
• Mattress Kapok • Industrial & Textile & Leather
• Net Mosquito Electrical Safety Division
• Capes Waterproof Shoes • Spares for weapon
• Vehicle & Storage • Saddlery items • Tail Units
Cover • Gloves Leather • HSOB
• Tents • Shoe Oxford • Ammunition Boxes
• Infantry Combat & Carriers
Kit (ICK)
• N. B.C. Equipment
• Water Holding &
Carrying Equipt
• Bag Kit

11
 Technology Share
5
15

80 Textile Leather Engineering

12
 T. P. M. Ladies Shop

13

Production of Mattress Kapok

Hot Air Conveyor Vacuum Dryer M/C

Auto Spray Lasting Operation

14
 15
Power Press CNC Machine
Quality Management

16
Wrap Reel Laboratory Chemical Test Laboratory

17

Tensile Strength Testing Waterproofness testing for Sole Leather

Flame Retardancy Test Colour Fastness to light. Bursting Strength Testing

18
Hardness Testing of Micro Processor based
Tensile Strength Tester Test Sample Preparation
Latex Foam
 Quality Management

ISO 9001 – 2000 Certified.

Well established Quality Assurance System.
Started self-certification for Shorts Men PC
Khaki w.e.f. 01.04.2002.
At present 9 items are self certified.
Laboratory is accredited to ISO-17025 by
NABL, New Delhi vide their Certificate No.
T-0663, dtd. 01.06.2004.
Responsibility for input material inspection
taken over from DGQA w.e.f. 1st July 2005.
Final Rejection in production is NIL.
19
20
 What does PLC stand for?
■ PLC - programmable logic controller
■ PLC implements logic control functions by means of a
program.

21
Features

22
 PLC History
PLCs were first introduced in the
1960’s. The primary reason for
designing such a device was
eliminating the large cost involved in
replacing the complicated relay based
machine control systems. Bedford
Associates (Bedford, MA) proposed
something called a Modular Digital
Controller (MODICON) to a major US
car manufacturer. The MODICON 084
brought the world's first PLC into
commercial production.
23
Structure of a PLC

24
Comparing traditional and programmable control systems
■In traditional control, the
switches S1, S2 and S3
must close for K1 to be
turned on - the wiring
makes the rule
■In PLC systems, the
program is written to
perform the logic “when
S1 is closed AND S2 is
closed AND S3 is closed,
THEN turn on K1” - the
program makes the rule

It is much simpler to
change program then
wiring! 25
 How does a PLC differ from a computer?
■ A computer is optimized for calculation and display tasks
■ A computer is programmed by specialists
■ A PLC is designed for (logic) control and regulation tasks
■ A PLC is programmed by non-specialists
■ A PLC is well adapted to industrial environment

Why are PLCs so common?

■ They are cost-effective
■ They are flexible, reliable and compact
■ They have significant advantages over traditional control systems based on relay
or pneumatics

Where are PLCs used?

■ In every industry where automation is involved, from individual machines to
whole processes
26
 What tasks do PLCs perform?
■ The logic control tasks such as interlocking, sequencing, timing
and counting (previously undertaken with relays or pneumatics)
■ In addition, PLCs can perform a variety of calculation,
communication and monitoring tasks

27
 PLC Input/Output Devices
Outputs & Power Supply
Communication
Ports (RS-485)

Inputs

28
 Input Devices / Output Devices
 Pushbuttons Valves
 Motor Starters
 Selector Switches
 Solenoids
 Limit Switches  Control Relays
 Alarms
 Level Switches
 Lights
 Photoelectric Sensors  Fans
 Horns
 Proximity Sensors Relays
 Motor Starter Contacts -120 VAC/VDC
-240 VAC
 Relay Contacts
-24 VAC/VDC
 120/230 VAC Triac
-120/230 VAC
 24 VDC Transistor MOSFET
-Sourcing -24 VDC

-Sinking 29
 Thumbwheel Switches
 PLC Operating Cycle
START

Housekeeping Input Scan

Internal checks on The status of external inputs
memory, speed and (terminal block voltage) is written
operation. Service to the Input image (“Input file”).
any communication
requests, etc.

Output Scan Program Scan

The Output Image data
is transferred to the
external output
circuits, turning the
output devices ON or
OFF.
Each ladder rung is scanned
using the data in the Input file.
The resulting status (Logic
being solved) is written to the
Output file (“Output Image”).

30
Typical PLC Operating Cycle
 Input scan – inputs are read by
processor and stored in memory.
 Program scan – control program is
executed Input values stored in
memory are used in the control logic
calculations to determine values of
outputs.
 Output scan – output values are
updated to agree with calculated
values.
 Time to perform the three steps (scan
time) varies between 1 and 25 msec.
31
 PLC Programming
Graphical languages:

1. Ladder logic diagrams – most widely used

2. Function block diagrams – instructions composed of
operation blocks that transform input signals
3. Sequential function charts – series of steps and
transitions from one state to the next (Europe)

Text-based languages:

1. Instruction list - low-level computer language

2. Structured text – high-level computer language

32
 Programming through standard computer
■ Most PLC manufacturers offer software packages that allow a standard
computer to be used as a programming terminal

33
 BOOLEAN ALGEBRA
The techniques can model a logical system with
a single equation.

The equation can then be simplified and/or

manipulated into new forms.

The three basic operators are AND, OR and

NOT; more complex operators include exclusive
or (EOR), not and (NAND), not or (NOR).

Truth tables are a simple method for showing all

of the possible combinations that will turn an
output on or off.
34
Logic Symbols, Truth Tables, and Equivalent Ladder/PLC Logic
Diagrams

35
Rules To Implement Ladder Logic From
Boolean Equation

When simplifying Boolean equations that are to be

implemented in ladder logic there are a few basic rules.

1. Eliminate NOTs that are for more than one variable. This
normally includes replacing NAND and NOR functions with
simpler ones using DeMorgan’s theorem.

2. Eliminate complex functions such as EORs with their

equivalent.

36
A Boolean Equation and Derived Circuit and
Ladder Logic

37
Advantages of PLCs Compared to
Relay Control Panels
 Programming a PLC is easier than wiring a
relay control panel
 PLC can be reprogrammed
 PLCs take less floor space
 Greater reliability, easier maintenance
 PLC can be connected to computer systems
(CIM)
 PLCs can perform a greater variety of control
functions

38
 Areas of Application
· Manufacturing / Machining
· Food / Beverage
· Metals
· Mining
· Power
· Petrochemical / Chemical
· Conveyor control
· Printed circuit board handling equipment
· SCADA(Supervisory Control And Data Acquisition)
· Remote pump/lift station (water/wastewater)
· Flow monitoring for leak detection (Oil & Gas)
· Strapping machinery / trash compactors
· Palletizers
· Compressor control
· Amusement park rides and attractions
· Hard-wired relay panels or Single Board Computers
Many,many more
39
 An application example 1: Gate Control

■ PLC can sense a vehicle at the entrance or exit, and open and close the gate
automatically
■ The current vehicle count is easily determined by programming a simple counter

An application example 2: Conveyor System

■ PLC can be used to start/stop latching logic for motor control

■ Counters can be used for monitoring product amounts
40
41
 Introduction to CNC?
 CNC stands for Computer Numerical Control.

 It is a versatile system that allows you to control the motion of tools and parts
through computer programs that use numeric data.

 CNC can be used with nearly any traditional machine.

 CNC may be defined as the numerical control system where in a dedicated programs
in a computer are used to replace some or all of its control functions.

 In CNC the program is read once by he tape reader as the input device & is stored in
the controller’s random access memory.

Controlling a machine tool by means of prepared program, which consists of

blocks, or series of commands/numbers, is known as numerical control.
Numerical Control [NC] for machine tools was introduced in 1950 by Prof.
John T Parsons. The first CNC machine was built at the Massachusetts
institute of technology [MIT] in 1953 by joint efforts of US Air force, MIT 42
and the Parsons Corporation.
 Basic Functional Blocks Of A CNC Machine

Computer User
Axis servo Interface
controller
Numerical
(key board,monitor)
Control

Programmable
Machine
controller

Servo Slide
Motor Machine Tool
Encoder 44
 Functions Of A Control System
Some important functions, controlled by control
system.
Displacement of machine slides
Angular rotation of circular table
Start / Stop of the main spindle
Changing of spindle speed
Reverse spindle direction
Changing the feed rate of machine slides
Rotate tool turret
Change tool
Coolant ON / OFF
Lock table in position 47
 Machine Tools
Turning center
A sophisticated CNC machine that specializes in turning, boring, drilling,
and threading operations, all at the same location.

Spindle
The part of the machine tool that spins. On the turning center, the spindle
holds the work piece, On the machining center, the spindle holds a cutting tool.

Turret
This holds the tools required for machining.

Usually on a turret in the rear, most lathes have 8 to 12 tools on a single,

indexing turret.

Axis
This is the moving slide, and a turning center has a minimum of two axes.(named X
and Z),controlled by the CNC.
The turret is mounted on the axes in such a way that,The tool can be moved in both
directions.
48
x

Z axis

X axis
z

49
Turning center Operations
 Facing
Turning
Drilling
Boring
Grooving on OD or ID
Face grooving
Chamfering
Thread Cutting
Etc.,,
50
Structure of a CNC program

51
 Evolution
• Punched tape and input through tape
reader.
• Programming directly on the machine.
• Programming through hand held device.
• Programming from centralized PC.

52
 Process of Programming
Part drawing - indicates which are the characteristics
to be machined
Machining plan – how many set ups, fixtures,
tooling, sequence of operation etc.
Part programming – Writing program considering
the machining plan.

53
 Basic Flow For CNC Preparation

Part Machine
Part drawing CNC
programming tool

Programming Operation

54
 How to set the machine
Machine ON Tool offset inputing

Programming
Origin
Find work co ordinate

Fixture Mounting Dry run with out component

/single block

Fixture dialing Cutting in single block

Rapid /feed lesser rate

Locator/clamp fixing
Component inspection
Tool mtg on the holders
Correction of work co ordiante

Measure the tool length Correction of tool offset

Component cutting @
Tool pocketing 100%feed/ speed/Rapid 55
 Advantages of CNC

Flexibility
Accuracy
Speed
Simplified fixture and generic cutting tools
Storage of machining skill in NC programs
Less skilled operators will do
Less fatigue to the operators
Reduced lead time
Greater flexibility
User written programs
Program editing at the machine site

56
57
58