A Training report on

multivibrator and PROGRAMMABLE LOGIC CONTROL

at

Jay ushin limited

Submitted in the partial fulfilment of the requirement for the award of degree of

Bachelor of Technology ECE

(Session: 2009-2013)

Submitted To:
Mrs. Priyanka Jangra

Submitted By:
Sandeep Saini 2509152 ECE-A

University Institute of Engineering and Technology Kurukshetra University, Kurukshetra 136119

DECLARATION

I, Sandeep Saini, a student of Bachelor of Technology ECE, in the Department of Electronics, University Institute of Engineering and Technology, Kurukshetra University, Kurukshetra, under class Roll No.2509152, for the session 2009-2013 hereby, declare that the project report entitled Surface Mounting Technology has been completed by me after 6th semester. The matter embodied in this report has not been submitted earlier for award of any degree or diploma to the best of my knowledge and belief.

Date: 21.08.2012

Sandeep Saini

ACKNOWLEDGEMENT

Industrial training is an indispensable part of any curriculum. It provides the students with an opportunity to gain experience on the practical application of our knowledge.

I express my gratitude to all the people at Minda Industries Limited who helped me during the past one month. The exposure and experience gained at Aggressive Electronics has been unique. I would like to thank Ms. Subham Yadav(for giving me this opportunity to work in their departments and guiding me through the projects for his constant guidance and support.

I would also like to express my sincere gratitude to Mr.Rajesh sharma , Training In charges their able guidance and keen interest in my training.
.

SANDEEP SAINI UIET KU KURUKSHETRA

CHAPTER NO 1
COMPANY PROFILE
1.1 INTRODUCTION Jay-Ushin Ltd. a JPM Group company was incorporated as a Joint Venture company with U-Shin Ltd, Japan for manufacture of auto electrical, mechanical & electronic components for four wheelers in 1986. It is a leading OEM manufacturer of automotive assemblies in India. Its products include lock sets, latches, switches & body parts. The company is a major OE supplier to almost all makers of four wheeler as well as two wheelers in India includes Maruti Suzuki Limited, Hyundai Motors India Ltd., General Motors, Honda Siel, Honda Motor Cycle & Scooters Division, Mahindra & Mahindra and Tata Motors Ltd.. U-Shin Ltd. engages in the design, development, manufacture, sale, and export of various system devices and control machines for automotive, industrial machinery, and home security units. It also offers mechanical, electrical systems, and components for automotive, industrial machinery, and home security unit. The company operates in three divisions: Automotive Parts, Industrial Equipments, and Home Security Unit. The Automotive Parts division offers steering lock unit, lock sets, keyless entry, door latches, heater control panels, door handles, switches, and sensors. The Industrial Equipments division provides equipments for agricultural/constructive/industrial machines, equipments for telecommunication, meter gauge for medical use, harness, cable wire, lump, operator's seat, electric fuel pump, electric measurement, and communication device. The Home Security Unit division offers security system for home, hotel, and office buildings; touch keys; handle sets; and electronic locks. The

company, formerly known as YUHSHIN SEIKI KOGYO CO., LTD., was founded in 1926 and is headquartered in Tokyo, Japan.

1.2 JPM GROUP COMPANIES Annu Industries Limited Jay Ace Technologies Limited Jay Auto Components Limited Jay FE Cylinders Limited Jay Iron & Steel Limited Jay Nikki Industries Limited Jay Ushin Limited JNJ Electronics Limited JNS Instruments Limited JPM Automobiles Limited JPM Tools Limited

1.3 MANAGEMENT STRUCTURE

J.P. Minda Ashwani Minda Anil Minda Shiv Raj Singh Ashok Panjwani Yukichi Harada Chairman Managing Director Technical Director Director Director Director

 Virendra kumar

Director

1.4 PLANT FEATURES OF JAY USHIN LTD. Established in 1986

Joint Venture with Ushin Limited,Japan Plant Location-Gurgaon(Haryana) in 1989 Chennai(Tamil Nadu) in 1997

Manesar(Haryana) in 2001 Number of Employees- 1600

1.5 FACILITIES & TECHNOLOGIES Product and Tool Design Tool Room Production Engineering Die Casting Machines Injection Moulding Machines Press Shop Assembly Test Lab

1.6 CUSTOMERS OF JAY-USHIN LTD. TWO WHEELERS CUSTOMER

FOUR WHEELERS CUSTOMER

1.7 MILESTONES OF JAY-UHIN LTD. 1959:- Started manufacturing auto components with Hindustan motors, fiat & Bajaj.

 1986:- Joint venture with U-SHIN LTD. (Japan) & established JAYUSHIN LTD. & start supplies to Maruti Udyog Ltd. 1998:- Start of Chennai plant, supply to Hyundai motors, and incorporation of JPM tools ltd. and award of ISO 9001 certification by TUV, Germany. 1999:- T.A. with NS INC. of Japan for instrument cluster. 2001:- Converted to J.V. with NIPPON SEIKI as JNS instrument ltd. 2004:- Award of ISO/TS: 16949:2002 to JAY-USHIN LTD. QCDDM award from HMSI. 2005:- Award of 100 PPM from HYUNDAI motors ltd. 2006:- Start of Manesar plant, start of Pune plant and QCDDM award from HMSI. 2008:- Quality & delivery award from HMSI three star awards from Hyundai. 2009:-Incorporation of Jay Ace Technologies Limited, Roorkee Established Jay FE Cylinders Limited in Collaboration JFE Containers & Marubeni Automotive, Japan Established Jay Nikki Industries Limited in Joint Venture with Nikki Co. Limited, Japan & Marubeni Automotive, Japan 2010:-Jay Auto Start of Automated Paint Shop JNJ Electronics Start of SMT Production Incorporation of JPM Renewable Energy Limited

CHAPTER NO 2
AIM:- INTRODUCTION TO PCB
2.1 PRINTED CIRCUIT BOARDS
Printed Circuits are found in virtually all electronic equipment in manufactured in the last twenty years. They are perhaps the most custom designed and manufactured components in that equipment, and are very often thge most expensive single component. Printed circuit boards are dielectric substrates with metallic circuitry photochemical formed upon that substrate. There are three major types classification: 2.1.1 Single sided boards: Dielectric substrates with circuitry on one side only. There may or may not be holes for components and tooling drills into them. 2.1.2 Double sided boards: Dielectric substrates with circuitry on both sides. An electrical connection is established by drilling holes through the dielectrics and plating copper through the holes. 2.1.3 Multilayer boards: Two or more pieces of dielectric material with circuitry formed upon them are stacked up and bonded together. Electrical connections are established from one side to the other and to the inner layer circuitry by drilled holes which are subsequently plated through with copper.

The dielectric substrate most commonly used is made from fiberglass sheets which have copper foil bonded onto both sides with epoxy resin; this is called epoxy/fiberglass laminate. Other materials are glass with polyimide, Teflon or

triazine resins; and paper covered with phenolic resin. All of these substrates have copper foin bonde to both sides with the resin.

7447 The '47ls feature active low outputs designed for driving common anode VLEDs or incandescent indicators directly. The '47 circuits incorporate automatic leading and/or trailing edge zero blanking control (RBI and RBO). Lamp test (Lt) of these types may be performed at any time when the BI/RBO node is at high level. All types contain an overriding blanking input (bi) which can be used to control the lamp intensity by pulsing or to inhibit the outputs. Inputs and outputs are entirely compatible for use with TTL logic outputs. Decim al 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 BI RBI LT LT RBI D C B A BI/RB O H H H H H H H H H H H H H H H H L L H

H H H H H H H H H H H H H H H H X H L

H X X X X X X X X X X X X X X X X L X

L L L L L L L L H H H H H H H H X L X

L L L L H H H H L L L L H H H H X L X

L L H H L L H H L L H H L L H H X L X

L H L H L H L H L H L H L H L H X L X

10

74190 The '190 is synchronous, reversible up/down counters having a complexity of 58 equivalent gates. It is a BCD counter. Synchronous operation is achieved by having All flip flops clocked simultaneously so that the outputs change coincident with each other when so instructed by the steering logic. This mode of operation eliminates the output counting spikes normally associated with asynchronous counters. The outputs of the four master slave flip flops are triggered on a low to high transition of the clock input if the enable input is low. Level changer at the enable input should be made only when the clock input is high. The direction of the count is determined by the level of the down/up input. When low, the counter count up and when high is counts down. A false clock may occur if the down/up changes while the clock is low. A false ripple carry may occur if both the clock and the enable are low and the down/up input is high during a load pulse.

These counters are fully programmable, that is, the outputs may be preset to either level by placing a low on the load input and entering the desired data at the data inputs. The output will change to agree with the data inputs independently of the clock input. This feature allows the counters to be used as modulo N dividers by simply modifying the count length with the preset inputs. The clock, down/up, and load inputs are buffered to lower the drive requirement which significantly reduces the number of clock drivers etc required for long parallel words. Two outputs have been made available to perform the cascading function: ripple clock and maximum / minimum count. The latter output produces a high level output pulse at the with a duration approx. equal to one complete cycle of the clock when the counter overflows or underflows. The ripple clock output produces a low level output pulse equal in width to the low level portion of the clock input if p[parallel enabling is used. The

11

maximum/minimum count output can be used to accomplish look ahead for high speed operation.

Note: 1. The blanking input (bi) must be open or held high at a high logic level when output functions 0 through 15 are desired. The ripple blanking input(RBI) must be open or high if blanking of a decimal zero is not desired. 2. When a low logic level is applied directly to the blanking input (BI), all segments are off regardless of the level of any other input. 3. When ripple blanking input(RBI) and inputs A,B,C,D are at low level with the lamp test input high , all segment outputs go off and the ripple blanking output(RBO)

7476 The '76 contain two independent negative edge triggered JK flip flops with individual flip flops with individual JK, clock, preset and clear inputs. The 76 and 76h are positive edge triggered flip flops .Jk input is loaded into the master while the clock is high and transferred to the slave on the high to low transition. For these devices the J and K inputs must be stable while the clock is high. The ls76a contains two independent negative edge triggered flip flops. The J and K inputs must be stable one setup time prior to the high to low clock transition for predictable operation. The preset and clear are asynchronous active low inputs. When low they override the clock and data inputs forcing the outputs to the steady state levels as shown in the function table. PRE L H L CLR H L L CLK X X X J X X X K X X X Q H L H Q L H H

12

H H H H

H H H H

L H L H

L L H H Q0 H L Toggle

Q0 L H

13

CHAPTER NO 3
Aim-: To study an astable multivibrator
3.1 MULTIVIBRATOR
A multivibrator is an electronic circuit used to implement a variety of simple two-state systems such as oscillators, timers and flip-flops. It is characterized by two amplifying devices (transistors, electron tubes or other devices) cross-coupled by resistors and capacitors. The most common form is the astable or oscillating type, which generates a square wavethe high level of harmonics in its output is what gives the multivibrator its common name. The multivibrator originated as a vacuum tube (valve) circuit described by William Eccles and F.W. Jordan in 1919. There are three types of multivibrator circuit:

astable, in which the circuit is not stable in either stateit continuously oscillates from one state to the other. monostable, in which one of the states is stable, but the other is notthe circuit will flip into the unstable state for a determined period, but will eventually return to the stable state. Such a circuit is useful for creating a timing period of fixed duration in response to some external event. This circuit is also known as a one shot. A common application is in eliminating switch bounce. bistable, in which the circuit will remain in either state indefinitely. The circuit can be flipped from one state to the other by an external event or trigger. Such a circuit is important as the fundamental building block of a register or memory device. This circuit is also known as a flip-flop.

14

In its simplest form the multivibrator circuit consists of two crosscoupled transistors. Using resistor-capacitor networks within the circuit to define the time periods of the unstable states, the various types may be implemented. Multivibrators find applications in a variety of systems where square waves or timed intervals are required. Simple circuits tend to be inaccurate since many factors affect their timing, so they are rarely used where very high precision is required.

3.2 ASTABLE MULTIVIBRATOR

This circuit shows a typical simple astable circuit, with an output from the collector of Q1, and an inverted output from the collector of Q2. Suggested values which will yield a frequency of about 0.24Hz:

R1, R4 = 10K R2, R3 = 150K C1, C2 = 10F Q1, Q2 = BC547 or similar NPN switching transistor

and

, so

15

3.3 BASIC MODE OF OPERATION

The circuit keeps one transistor switched on and the other switched off. Suppose that initially, Q1 is switched on and Q2 is switched off. State 1:

Q1 holds the bottom of R1 (and the left side of C1) near ground (0V). The right side of C1 (and the base of Q2) is being charged by R2 from below ground to 0.6V. R3 is pulling the base of Q1 up, but its base-emitter diode prevents the voltage from rising above 0.6V. R4 is charging the right side of C2 up to the power supply voltage (+V). Because R4 is less than R2, C2 charges faster than C1.

When the base of Q2 reaches 0.6V, Q2 turns on, and the following positive feedback loop occurs:

Q2 abruptly pulls the right side of C2 down to near 0V. Because the voltage across a capacitor cannot suddenly change, this causes the left side of C2 to suddenly fall to almost -V, well below 0V. Q1 switches off due to the sudden disappearance of its base voltage. R1 and R2 work to pull both ends of C1 toward +V, completing Q2's turn on. The process is stopped by the B-E diode of Q2, which will not let the right side of C1 rise very far.

This now takes us to State 2, the mirror image of the initial state, where Q1 is switched off and Q2 is switched on. Then R1 rapidly pulls C1's left side toward +V, while R3 more slowly pulls C2's left side toward +0.6V. When C2's left side reaches 0.6V, the cycle repeats.

16

3.4 MULTIVIBRATOR FREQUENCY

The period of each half of the multivibrator is given by t = ln(2)RC. The total period of oscillation is given by: T = t1 + t2 = ln(2)R2 C1 + ln(2)R3 C2

where...

f is frequency in Hertz. R2 and R3 are resistor values in ohms. C1 and C2 are capacitor values in farads. T is period time (In this case, the sum of two period durations).

For the special case where

t1 = t2 (50% duty cycle) R2 = R3 C1 = C2

17

3.5 INITIAL POWER UP

When the circuit is first powered up, neither transistor will be switched on. However, this means that at this stage they will both have high base voltages and therefore a tendency to switch on, and inevitable slight asymmetries will mean that one of the transistors is first to switch on. This will quickly put the circuit into one of the above states, and oscillation will ensue. In practice, oscillation always occurs for practical values of R and C. However, if the circuit is temporarily held with both bases high, for longer than it takes for both capacitors to charge fully, then the circuit will remain in this stable state, with both bases at 0.6V, both collectors at 0V, and both capacitors charged backwards to -0.6V. This can occur at startup without external intervention, if R and C are both very small. For example, a 10 MHz oscillator of this type will often be unreliable. (Different oscillator designs, such as relaxation oscillators, are required at high frequencies.)

3.6 PERIOD OF OSCILLATION

Very roughly, the duration of state 1 (low output) will be related to the time constant R2*C1 as it depends on the charging of C1, and the duration of state 2 (high output) will be related to the time constant R3*C2 as it depends on the charging of C2. Because they do not need to be the same, an asymmetric duty cycle is easily achieved. However, the duration of each state also depends on the initial state of charge of the capacitor in question, and this in turn will depend on the amount of discharge during the previous state, which will also depend on the resistors used during discharge (R1 and R4) and also on the duration of the previous state, etc. The result is that when first powered up, the period will be quite long as the capacitors are initially fully discharged, but the period will quickly shorten and stabilise.

18

CHAPTER NO 4
Aim-: To study plc
4.1 INTRODUCTION
There is nothing particularly new about the concept of a programmable controller (General Motors first proposed the concept nearly thirty years ago). Recently, however, technology has moved on apace and now Programmable Logic Controllers (PLC's) are the unsung heroes of a huge variety of industrial processes - from brewing beer to manufacturing tin cans, and from handling baggage to docking a super-tanker. This section describes the principle and operation of the PLC, including the ladder logic that is often used to program such devices.

4.2 WHY PLCS

19

PLCs provide a rugged, low-cost yet versatile means of controlling a seemingly endless variety of industrial processes. When compared with other methods (such as the use of industrial PCs or dedicated microcontrollers, PLCs offer the following notable advantages:

easily programmed and reprogrammed rugged enough to withstand a harsh electrical and mechanical environment modular - permitting easy removal and replacement in the event of failure flexible - allowing rapid reconfiguration of both hardware and software reliable and cost effective.

The first ever specification for a PLC was produced by General Motors in 1968 where a group of production engineers and designers were searching for a flexible solution to the need to control a number of complex linked manufacturing processes. Today, PLCs are manufactured by such well known names as Allen-Bradley, Mitsubishi, Siemens, General Electric, and Hitachi.

20

4.3 PLC ARCHITECTURE

21

The diagram shows the block schematic of a typical PLC system. The heart of the PLC is a central processing unit (CPU) and its immediate support devices, ROM, RAM and timers/counters. In addition, two dedicated areas of RAM (known as the process input image and process output image) help keep track of the state of all of the system's inputs and outputs (more about this later). In addition, most PLCs incorporate some on-board I/O. This allows the controller to be used in simple applications without the need for any external I/O modules. A series interface provides a means of programming the PLC (either by means of a hand-held programmer or by downloading programmes from a remote PC). Alternatively, a specialised programming interface may be provided leaving the serial port free to permit data transfer to/from a remote computer. External I/O is made possible by means of a number of modules connected to a common data path (or 'bus') linked to the controller. These modules contain the necessary interface circuitry (including level-shifting, optical-isolation, analogue to digital conversion and digital to analogue conversion, as appropriate).

4.4 PROGRAM OPERATION

22

During normal operation, following system initialisation, a PLC executes a continuous scan - reading the states of the inputs, processing the inputs (by carrying out arithmetic and logical operations), and updating the states of all the outputs. The complete program scanning cycle takes from a few tens of ms to several hundred of ms depending on the PLC used and the number of I/O modules that are connected to it. During normal operations, the CPU continuously generates a Process Input Image (PII) in an area of RAM. This may sound complicated but it is simply a set of data stored in read/write memory that reflects the state of each of the inputs to the PLC. The Process Output Image (POI), on the other hand, contains data that corresponds to the state of each of the outputs that the PLC generates. These two data tables are read and updated on each cycle of the program logic.

23

4.5 PROGRAMMING

PLCs can be programmed by using:

hand-held programming keypads fitted with dedicated LCD displays specialised programming devices (based on a PC) portable lap-top PCs running specialised software.

Various programming instructions are available to the programmer including a number of different types of input and output, timers and counters. Programming instructions can be entered using various methods, including:

ladder logic diagrams logic statement lists Symbolic logic diagrams

These PLC programming methods are, in fact, interchangeable. Indeed, some manufacturers allow the programmer to choose which method of programming he or she wishes to use. Since ladder logic is most closely allied to the origins of PLCs (i.e. switches and relays) we will take some time to explain how this works in the screens that follow.

24

Part of a simple program written using ladder logic is shown in the diagram. The ladder logic diagram relates to a PLC in which there are five inputs and two outputs. The inputs are arranged on the left of each 'rung' of the ladder whilst the outputs are shown on the right of each corresponding 'rung'. The inputs are:

Ready (the contacts close when the system is ready for operation) Start (the contacts close when the start button is pressed) Stop (the contacts open when the stop button is pressed) Overheat (the contacts close when the motor is overheated) Guard open (the contacts close when the machine guard is raised)

The outputs are:

Motor ON (the contacts close to operate the motor) Audible warning (the contacts close to operate the audible alarm)

25

When reading a ladder logic diagram, you should work from left to right, and from top to bottom. It also helps to imagine that the diagram is a circuit - with current following from left to right. Only when there is a path for current through the input switches and contacts will an output be produced.

4.6 LADDER LOGIC FNS

Ladder logic is a widely used programming method for PLCs. Ladder logic diagrams may be entered by pressing appropriate buttons on a hand-held programmer, by means of function keys on a PC-based programmer, or by drawing and placing symbols on a screen. Click on the buttons to display the various ladder logic functions available to the programmer and their equivalents in terms of switch/relay logic, logic symbols, and conventional truth tables

26

27

28

29

30

31