Traning report on PLC Upgradation from siemens S5-100U to Siemens S7-300U.

1. SUMMER TRAINING PROJECT
AT
TATA MOTORS, JAMSHEDPUR
Project Title: UPGRADATION OF PLC FROM SIEMENS S5-100U TO S7-300
SUBMITTED TO THE
ENGINE FACTORY DIVISION
TATA MOTORS, JAMSHEDPUR
Compiled by,
1. SAYANTAN BHOWMICK (CAMELLIA SCHOOL OF ENGINEERING & TECHNOLOGY, KOLKATA)
2. SHIVA NAG (SKYLINE INSTITUTE OF TECHNOLOGY, GREATER NOIDA)
3. SAHEB PAL (ASANSOL ENGINEERING COLLEGE, ASANSOL)
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2. A C K N O W L E D G E M E N T
It is really a matter of great pleasure to acknowledge the invaluable guidance, enormous
assistance and excellent co-operation extended to me by TATA MOTORS Jamshedpur in the
completion of my project.
To start with, I would like to express my gratitude towards all the people who have contributed
their precious time and effort to help me in the project. I would like to thank Mr. Rakesh Sarangi
(AGM) Electronics Division as Project Supervisor; Mr. Sandip Ravan (MANAGER & Project Guide) &
Mr. Abhirup Mukherjee (Jr. OFFICER) for their guidance, support, motivation and encouragement
throughout the project period. Their readiness for consultation at all times, their valuable remarks,
their concern and assistance have been invaluable.
I would also like to express my heartfelt thanks to my friends and my project partner.
Last but not the least; I would also extend my sincere gratitude to Department of Electronics, Tata
Motors Jamshedpur for availing the facilities required for my project analysis.
I also express my heartiest gratitude to all the people of Tata Motors for their constant help
and support. This work would not have been possible without the support and help from them.
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3. D E C L A R A T I O N
We do hereby declare that we, Sayantan Bhowmick studying Electrical and
Electronics Engineering at Camellia School Of Engineering & Technology, Kolkata,
Saheb Pal studying Electronics and Communication Engineering at Asansol
Engineering College, Asansol and Shiva Nag studying Electronics and
Communication Engineering at Skyline Institute Of Technology, Greater Noida
has undergone the summer training programme at TATA MOTORS LTD.
Jamshedpur from 21st June, 2014 to 19thJuly, 2014. During the course of this
training we have successfully completed the project titled as :
UPGRADATION OF PLC FROM SIEMENS
S5-100U TO S7-300
She / He have followed all the policies, the safety guidelines and the code of
conduct of the company.
Mr.Rakesh Sarangi Mr.Sandip Ravan
AGM, Manager,
Central Maintenance Electronics (Engine Factory)
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Date:

4. CONTENTS
S.No. Description Page No.
1. Introduction 5
2. Tata Motors Limited
Company Profile 5
Important Milestones 6
3. Tata Motors: The Jamshedpur Plant 7
I. The Central Tool Room (CTR) & Capital
Equipment Manufacturing(CEM) Division 8
Ii. The Cab And Cowl Factory 8
Iii. The Central Paint Shop(CPS) 9
Iv. The Prima(Vehicle Factory III) 10
V. Truck Factory (Vehicle Factory I & II) 12
Vi. The Foundry 13
Vii. The Engine Factory 14
1. Machine Shop Area 15
2. Assembly Area 16
3. Engine Testing Area 16
4. UPGRADATION OF PLC FROM SIEMENS S5-100U TO S7-300 17
5. Programmable Logical Controller 17
6. PLC Programming 21
7. S5 To S7 Migration 22
I. Migration Strategies 22
A. I/O Strategy 22
B. CPU Strategy 24
C. TIA Strategy 30
II. Special Situations 31
III. Installation Requirements 33
8. Introduction To M50- 0432 34
9. Advantages Of Siemens S7 PLC Over Siemens S5 PLC 37
10. Conversion Of Siemens S5-100U PLC Ladder To S7-300 PLC 38
11. Bibliography 39
12. Conclusion 40
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5. INTRODUCTION
TATA MOTORS LIMITED: An Overview
COMPANY PROFILE
Tata Motors Limited is India's largest automobile company, with consolidated revenues of INR 1,
92,590 crores (USD 32.23 billion) in 2013-14. It is the leader in commercial vehicles in each segment,
and among the top three in passenger vehicles with winning products in the compact, midsize car and
utility vehicle segments. It is the world's fourth largest truck and bus manufacturer.
Established in 1945, Tata Motors' presence indeed cuts across the length and breadth of India. Over
6.5 million Tata vehicles ply on Indian roads, since the first rolled out in 1954. The company's
manufacturing base in India is spread across Jamshedpur (Jharkhand), Pune (Maharashtra), Lucknow
(Uttar Pradesh), Pantnagar (Uttarakhand), Sanand (Gujarat) and Dharwad (Karnataka). Following a
strategic alliance with Fiat in 2005, it has set up an industrial joint venture with Fiat Group
Automobiles at Ranjangaon (Maharashtra) to produce both Fiat and Tata cars and Fiat powertrains.
The company's dealership, sales, services and spare parts network comprises over 3,500 touch points;
Tata Motors also distributes and markets Fiat branded cars in India.
Tata Motors, the first company from India's engineering sector to be listed in the New York Stock
Exchange (September 2004), has also emerged as an international automobile company presence is
being expanded in other markets.
Tata Motors is equally focused on environment-friendly technologies in emissions and alternative
fuels. It has developed electric and hybrid vehicles both for personal and public transportation. It has
also been implementing several environment-friendly technologies in manufacturing processes,
significantly enhancing resource conservation.
Through its subsidiaries, the company is engaged in engineering and automotive solutions,
construction equipment manufacturing, automotive vehicle components manufacturing and supply
chain activities, machine tools and factory automation solutions, high-precision tooling and plastic
and electronic components for automotive and computer applications, and automotive retailing and
service operations.
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6. IMPORTANT MILESTONES
It has been a long and accelerated journey for Tata Motors, India's leading automobile manufacturer.
Presented below is a list of some of the significant milestones in the Company's journey towards
excellence and leadership.
1945: Tata Engineering and Locomotive Company (renamed Tata Motors in 2003) is established to
manufacture locomotive and engineering products.
1954: Collaboration with Daimler Benz AG, West Germany, for manufacture of medium commercial
vehicles.
The first vehicle rolled out within 6 months of the contract.
1977: First commercial vehicle manufactured in Pune.
1991: Launch of the 1st indigenous passenger car Tata Sierra.
1995: Mercedes Benz car E220 launched.
1998: Tata Safari - India's first sports utility vehicle launched.
Indica, India's first fully indigenous passenger car launched
2004: Tata Motors is listed on the world's largest bourse, the New York Stock
Exchange, the second group company to do so after VSNL
2009: Tata Motors announces commercial launch of the Tata Nano; Tata Nano draws over 2.03
lakh bookings; first 100,000 owners of the Tata Nano chosen; delivers first Tata Nano in the country in
Mumbai.
2012: Tata Motors signs cooperation agreement with DRB-HICOM's Defence Technologies (DEFTECH)
Tata Motors showcases Anti-Terrorist Indoor Combat Vehicle concept at DEFEXPO India 2012
Tata Motors unveils Tata Safari Storme, Tata Ultra, Tata LPT 3723 new vehicles at Auto Expo
2012
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2013
 Tata Nano becomes the first Auto Brand in India to cross 3 million fans on Facebook
 The Tata Indigo eCS enters Limca Book of Records
 Tata Motors' Jamshedpur plant rolls out its two millionth truck
 Tata Nano offered industry first phenomenon - Swipe your credit card and drive home a Nano
 Tata Motors launches the world-class range of Tata PRIMA trucks in Sri Lanka

7. MANUFACTURING – AT TATA MOTORS
Tata Motors owes its leading position in the Indian automobile industry to its strong focus on
indigenization. This focus has driven the Company to set up world-class manufacturing units with
state-of-the-art technology. Every stage of product evolution-design, development, manufacturing,
assembly and quality control, is carried out meticulously. Our manufacturing plants are situated at
Jamshedpur in the East, Pune and Sanand in the West and Lucknow and Pantnagar in the North.
TATA MOTORS, JAMSHEDPUR
Established in 1945, the Jamshedpur unit was the company’s first unit and is spread over an
area of 822 acres. It consists of 6 major divisions- Truck Factory (vehicle factory I & II), Engine Factory,
Cab and Cowl Factories, Foundry, Prima (vehicle factory III) and Central Tool Room (CTR) and Forge
Division. The divestment in March 2000 hived off the Axle and Engine plants into independent
subsidiaries viz. HVAL and HVTL respectively.
The Truck Division boasts of two assembly lines. The main assembly line, measuring 180 m in length
has 20 work stations with a vehicle rolling out every 8 minutes. The other line is dedicated to special
purpose vehicles and for meeting the requirements of the Indian Army.
The Cab & Cowl Factory is equipped with state-of-art facilities like Centralized Paint Shop and
automated painting set up, Robot painting, BIW Fabrication of day & sleeper cabs for trucks,
Articulates (Tractor/ Trailer), BIW Fabrication of Cowls for buses, and other miscellaneous
applications.
The fully equipped Foundry, that the unit is supported by, supplies high-grade SG Iron castings for
automobile components and excavators, and is rated as one of the cleaner, better and highly
automated foundries in the world.
The Engine Factory is responsible for the in-house manufacture of Tata 697/497 Naturally Aspirated
and Turbo Charged engines, and the 6B series engines manufactured at Tata Cummins.
Forge Division is equipped with a semi-automated forging line with 40,000 mkg Beche Hammer and
state-of-the-art presses from Kurimoto of Japan. It produces critical forgings like crankshafts, front
axle beams and steering parts for the automobile plant.
TML Drivelines Limited., a wholly owned subsidiary of Tata Motors, is currently the market leader in
medium and heavy commercial vehicles axles in India with an installed capacity of over two lakh axles
per annum.
A signatory to the UN Global Pact, it also takes various initiatives in human rights protection,
labor standards, environmental issues, modern effluent treatment facilities, sanitation drives, soil and
water conservation programs, tree plantation drives, etc.
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8. 8
THE PLANT:
The Central Tool Room (CTR) & Capital Equipment Manufacturing(CEM)
Division:
The CEM has two main LOB(line of business) first being fixture and the other being dies.
There are two types of dies, forging & sheath metal dies (SMD)
It is a PC based shop; the CAD/CAM Lab is used to design the dies. It is then fed to a processor, which
develops a program as per the machine specification, which is then fed into the machine which is
thereby executed for dies or fixtures.
Dies and fixtures with top bottom both are manually finished and sent to the forge division. Generally
front axle and crankshaft dies are made in CEM.
Going into the field of electronic the most important aspect of control devices in the CEM Division is
the CNC (Computerized Numeric Control)
As CNC is used for controlling various machines such as auxicutting, milling, grinding machine, SPM
(Special Purpose Machine).
TYPES of CNC USED
1) SIEMENS- obsolete now
2) FAGOR- SIP6 machine
3) NIIGATA
4) FIDIA
The CTR section is responsible for the designing of the cabs and making the dies. As one of the
most modern forging set-ups in the country, the Forge Division is equipped with a semi-automated
forging line with 40,000MKg Beche Hammer and state-of-the-art presses from Kurimoto of Japan.
It produces critical forgings like crankshafts, front axle beams and steering parts for the
automobile plant. The new forging line, installed in April 1984, has the capacity to forge front axle
beams at 90 seconds per piece and crankshafts at 120 seconds per piece. Mechanical presses help
produce a variety of heavy forgings. The sophisticated FIDIA digit 165 CC Graphite Milling Machine
links shop floor machines to the design workstation. The Forge has been certified as ISO 9002 and
QS 9000 by the BVQI.
The Cab and Cowl Factory
The fabrication and the fitment of the cab/cowl are done in the Cab and Cowl Factory of the
plant. Different procedures of manufacturing are used for different models of trucks. Fabrication
refers to the process in which the steel structure is made with al l the welding which are then tested
and painted and then sent for the fitment, which refers to the process in which the other parts and
auxiliary items are fitted in like the seats the dashboard, the headlights and blinkers, the mirrors etc.
The CAB and COWL factory for the world truck division it is sub divided into the following
sections:
1. Fabrication line
2. EDAG 2516 fabrication line

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3. PLC and drive panel
4. PDI gate
5. Sludger
For the plant (treatment) there are several lines stated below:
1. TILT(709) CAB TRIM SHOP
2. SFC TRIM SHOP
3. LP(1210) COWL TRIM SHOP
4. HCV(1516) CAB TRIM SHOP
There are different types of PLC (programmable logic controller) used for the automation of
the machines in the shop. SCADA (supervisory control and data acquisition) is also used for
monitoring the performance of the machines.
World Truck cabs are manufactured in fully robotic assembly lines inside the vehicle factory III.
The various segments used for making the cab are supplied from CTR. The robots are pre-taught on
procedures to be followed for assembling the parts (roof, doors, and body). Spot-welding during the
assembling of the parts is done by ABB robots and that of the doors of the cab is done by a Fanuc
robot.
Since the World Truck cabs are completely assembled by robots, the finishing is of superior
quality. Other models are manufactured by partially using robots and partially assembled manually.
The finishing is not as superior as that of World Truck-since manual welding differs from the
perfection of robotic welding.
The Central Paint Shop
After the cab/cowl’s steel structure is completely assembled, it is shifted to the painting area in
the shop.
The process of Painting involves the following steps:
 The cab/cowl is washed with high speed jet of water to remove all the dust particles.
 Then it is passed through jets of chemicals to eliminate the dirt. In an electro-dipping tank, the
cab/cowl is dipped while a current of 700V DC passes through the tank. The paint gets charged
and attached to the body of the cab/cowl, hence the primer is done.
 Next it is sent through a heating oven to strengthen the primer coat. The cab/cowl is given
sandpaper finishing, thus smoothening the surface before the painting.
 In the next stage, a line of robots are taught to paint the cab/cowl according to the colors input
given by the operator.
 At the end, the painted cab/cowl is again passed through the oven to dry the paint.
After these processes, the cab/cowl is ready for fitment.
Fitment of the cab:

10. This final process involves the attachment of seats, handles, lights, steering wheel and other
necessary parts to the cabins. The cabs or cowls move on a conveyor that runs through a stretch that
is divided into marked regions. The conveyor moves with such as speed, that the cab/cowl remains in
a certain marked region for three minutes. Within these three minutes, the assigned operator has to
finish attaching the parts of the cabin that he is responsible for. At the end of the process a quality
check is done.
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The PRIMA (Vehicle Factory III)
The Prima section of the plant handles the making of World Trucks solely. The welded and
assembled structure of the cabin is brought in from Truck III and long members are supplied from
Truck I. The remaining procedures involved to make a World Truck are carried out here. Asia’s longest
conveyor belt system is installed in Prima along with a unique Glass Glazing Robot, which due to its
complex programming is not used in any other industry.
There are three lines – assembly line, trim line and frame line.
The long members are brought in position under the gantry system by a motor driven conveyor
system. The motor is driven by a Mitsubishi VFD.
A variable-frequency drive (VFD) is a type of adjustable-speed drive used in electro-mechanical
drive systems to control AC motor speed and torque by varying motor input frequency and voltage.
The gantry system hoists the long member and shifts it to the Vinar conveyor system. There
are 3 kinds of conveyors – slat conveyor, single chain and double chain conveyor.
An Electrified Monorail System, that is, an overhead conveyor system is installed inside the
shop. The conveyor is brought down at lower levels for loading and unloading purposes. An overhead
conveyor basically consists of a track, chain, drive unit, and take up unit, oiler and carriers. The track is
supported from roof, floor or wall as per site conditions. The chain is guided in the track and moved
by a drive unit. The take up unit is provided to adjust the chain tension. The carriers are fixed to the
chain at a predefined pitch. The component to be conveyed is loaded on the custom designed carrier.
The oiler lubricates the chain. The Electrified Monorail System is controlled by CNC.
The long members are first fitted with the appropriate parts on the upturned long members.
Then an Inversion System turns these long members to their original position. The inversion system is
monitored by PLC and consists of overhead conveyors carrying suspension trolleys. A barcode is fitted
along the entire overhead system. A laser reader installed on the suspension trolleys sends the
position signal to the PLC.
Acting on this, the PLC sends the required instructions for the trolleys to move towards the
load, invert the load at a particular position and stop to load or unload. The suspension trolleys pick
up the load and invert them using motor run pulleys. In total six motors are used in the trolleys.

11. An Axle Alignment System is used to check the position of the axles. If the axles are not aligned
perfectly, the truck shall move in a tilted angle even when the steering is kept straight. To avoid this,
laser signals are projected on the lines of the front and rear axle and analog measurements are taken.
These measurements are sent through Bluetooth to the computer analyzing the procedure. If the
axles form opposite ends of a rectangle, the axles are aligned correctly.
A Glass glazing robot is installed, which is one of its kinds. The robot applies a sealant along the
perimeter of the glass which is installed as the windshield in the trucks. The programming of this
robot is of complex nature due to its delicate job of accurate measurements while applying the
sealant on the glass. When the robot is working, even a slight deviation from these measurements
may result in the cracking of the glass.
At the end of the process, a Dynamometer Test is done to measure the amount of horsepower
and torque the engine produces and the proper functioning of the brakes. When running a chassis
dynamometer test, the vehicle to be tested is driven onto the dynamometer platform that simulates
resistance through the use of automated wheels. A computer instructs the driver of the chassis on the
speed of the vehicle and the time of applying the brakes. A variable-frequency drive (VFD) is used in
the analyzing system.
Thus the trucks are manufactured under extreme care so that the customers get what they pay
for. Quality checks at appropriate junctions are provided for this purpose.
Assembly Line of PRIMA
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Truck Factory (Vehicle Factory I & II)
The truck factory is also basically an assembly line and is more or less like the assembly line in
the Prima which was discussed above, the differences being that the truck factory manufactures
many models of vehicles and also the long members are also made and assembled inside this factory.
There are three assembly lines in this plant; first the Frame Shop where the long members are
assembled, second, the assembly line 1 and third, assembly line 2. The finished product of the frame
shop is the starting point of the two assembly lines.
Assembly Line of Vehicle Factory I and II
Frame Shop:
The making of the long members starts from the large metal sheet rolls which are the raw
materials. They are supplied mainly by Tata Steel. They are first decoiled by a decoiler machine
from KOHLER which is used to decoil or straighten the 5mm and 7mm coils to make them into
sheets. Then they are sent to the 5000 press which consists of two dies for different operations i.e.
notching and bending.

13. Then the next machine being used is by SOENEN, it is used for the purpose that if some holes get
missed during notching operation in the 5000 press then this finds out and rectifies it. After all this
the final product is loaded and sent to LMCD. In LMCD it is unloaded and goes to the pre wash
area where it is washed with hot water to remove dust, oil and make it completely moisture free
to avoid rust. Then it is sent to the shot-blasting system which coats a layer over it to make it shiny
and smooth.
Now the job is sent to the pre-treatment area for degreasing and water rinse and then to the
cathodic electro coat system. From here it goes to the oven for drying up the paint and then to the
pre assembly line and frame assembly.
13
Assembly Line1 & Assembly Line2:
Consists of pre assembly line and frame assembly line. Different parts of the job are assembled
together and sent to line-1 and line-2 where the whole truck is assembled with different parts
coming from different division and finally the heavy and light truck are ready to move out.
The Foundry:
The fully equipped Foundry, that the unit is supported by, supplies high-grade SG Iron castings
for automobile components and excavators, and is rated as one of the cleaner, better and highly
automated foundries in the world. It has an annual capacity of 42,000 MT of Good castings and
makes, both, Gey and SG cast Iron Casting. It manufactures all critical automobile castings. For
example Cylinder Block, Cylinder Head etc.
It has a sophisticated Kunkel Wagner High Pressure Moulding line of a rated production
capacity of 90moulds/hour. This is supported by a sand cooler and sand mixer from Kunkel Wagner.
Its melting shop has Medium Frequency Induction Furnaces for melting and Channel Furnaces for
holding. The pouring is done by a Channel Press Pour coupled with a Steam Inoculation Dispenser.
The core shop has a state-of-the-art Cold Box Machine, making four cores per minute.It has
Furnace in the Foundry division

14. elaborated sand and metallurgical laboratories. In 1993 the foundry was ISO 9002 certified by
the Bureau VERITAS Quality International, which was later followed by the more stringent QS 9000
certification from the BVQI in the year 2000. Currently it is certified as TS: 16949 by BVC.
Robots assembling the cask
14
The Engine Factory:
Description of engine division – As engine is the heart of an automobile, Engine division is heart of
TATA motors.
Engine Dispatch Line

15. The Engine Factory is responsible for the in-house manufacture of Tata 697/497. Naturally
Aspirated and Turbo Charged engines, and the 6B series engines manufactured at Tata Cummins.
An engine is manufactured by the assembly of five main parts; the five C’s of an engine are as follows:
15
1. Cylinder Block
2. Cylinder Head
3. Crankshaft
4. Camshaft
5. Connecting rod
The Engine division at Tata Motors, Jamshedpur is sub divided into three sections:
1. Machine shop section
2. Assembly section
3. Testing section
1. MACHINE SHOP AREA
A. CYLINDER BLOCK
In cylinder block line, cylinder blocks are manufactured. These blocks are fitted in all tata engines.
Cylinder block castings are received from foundry division of tata motors in cylinder block line; mainly
multi-spindle milling, drilling, rough boring and tapping operation are carried out.
B. CRANKSHAFT LINE
Crank shaft machining line is the heart of engine machine shop because crank shaft is main part which
provides motion to all parts of the engine crankshaft. Forgings are received from forge division of tata
motors in crank shaft cmvr.
C. CAMSHAFT LINE
Cam shaft is the part of the engine responsible for opening and closing of inlet and outlet valves. Its
machining is done in order to provide finishing to the camshaft obtained from the foundry.
D. CYLINDER HEAD

16. The head of the engine is mounted on top of the cylinder block. Its machining includes processes like
face milling, boring, washing, polishing, etc.
2. ASSEMBLY AREA
After machining, the different parts of the engine are assembled together in the assembly area.
Before being assembled, the various parts are washed in the washing area. The assembly line area
consists of three assembly lines:
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1. Short block assembly line
2. Head assembly line
3. Main assembly line.
Also, there is a separate, highly sophisticated assembly area for the manufacturing of high quality VS4
engines.
3. ENGINE TESTING AREA
Once the engine parts are assembled to form an engine, it is sent for testing in the engine test beds.
The test beds are designed to test various parameters of the engine under running conditions. Some
of the parameters tested are engine ambient temperature, lubricant oil temperature and pressure,
etc.

17. UPGRADATION OF PLC FROM SIEMENS
S5-100U TO S7-300
PC
Processor
Memory
Peripherals External Dev ices
17
PROGRAMMABLE LOGIC CONTROLLER
Automation control systems
A programmable logic controller (PLC) or programmable controller is a digital computer used for
automation of electromechanical processes, such as control of machinery on factory assembly lines,
amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general -
purpose computers, the PLC is designed for multiple inputs and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to
control machine operation are typically stored in battery-backed-up or non-volatile memory.
PLC Architecture
I/O
Modules
Power
Supply
Program
Loader
Printer
Cassette
Loader
EPROM
Loader
Switches
Machines
FEATURES:
The main difference from other computers is that PLCs are armored for severe conditions (such as
dust, moisture, heat, cold) and have the facility for extensive input/output (I/O) arrangements. These
connect the PLC to sensors and actuators. PLCs read limit switches, analog process variables (such as
temperature and pressure), and the positions of complex positioning systems. Some use machine
vision. On the actuator side, PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic
relays, solenoids, or analog outputs
USER INTERFACE:
PLCs may need to interact with people for the purpose of configuration, alarm reporting or everyday
control. A human-machine interface (HMI) is employed for this purpose. HMIs are also referred to as

18. man-machine interfaces (MMIs) and graphical user interface (GUIs). A simple system may use buttons
and lights to interact with the user. Text displays are available as well as graphical touch screens.
More complex systems use programming and monitoring software installed on a computer, with the
PLC connected via a communication interface.
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PROGRAMMING:
PLC programs are typically written in a special application on a personal computer, and then
downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the
PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a single PLC
can be programmable to replace thousands of relays.
Under the IEC 61131-3 standard, PLCs can be programmable using standards-based programming
languages. A graphical programming notation called Sequential Function Charts is available on certain
programmable controllers. Initially most PLCs utilized Ladder Logic Diagram Programming, a model
which emulated electromechanical control panel devices (such as the contact and coils of relays )
which PLCs replaced. This model remains common today.
IEC 61131-3 currently defines five programming languages for programmable control systems:
function block diagram (FBD), ladder diagram (LD), structured text (ST; similar to the Pascal
programming language), instruction list (IL; similar to assembly language) and sequential function
chart (SFC). These techniques emphasize logical organization of operations.
Basic Components of a PLC System
There are five basic components in a PLC system:
 The PLC processor or controller
 I/O (Input /Output) modules
 Chassis or backplane
 Power supply
 Programming software that runs in a PC
In addition to these 5, most PLCs also have:
 A network interface
Processor, Controller, or CPU
trol program and data in its memory

19. –For example: Turn a light on, start a fan, adjust a speed, or temperature
19
SIMATIC S7-300 CPU 313C-2 DP
Standalone PLC
I/O Modules
electrical signals that the PLC can understand.
field devices can understand, such as a motor starter, or a hydraulic solenoid valve.
Input Modules

20. 20
-20mA,
to signals which the controller can understand.
there are different types of input devices, there is a wide variety of input modules available, including
both digital and analog modules.
Output Modules
operate. Since there are different types of output devices, there is a wide variety of output cards
available, including both digital and analog cards.
Power Supply
A power supply is needed to provide power to the PLC and any other modules. Power supplies
come in various forms:
alone power supplies that connect to the PLC or I/O through a power cable
Programming Software
Software that runs on a PC is required to configure and program PLCs.

21. 21
Network Interface
Most PLCs have the ability to communicate with other devices. These devices include
computers running programming software or collecting data about the manufacturing process, a
terminal that lets an operator enter commands into the PLC or I/O that is located in a remote
location from the PLC. The PLC will
communicate with the other devices through a network interface
PLC Control Panel
Typically, PLCs are installed in enclosures, on a “panel”
PLC PROGRAMMING
Every PLC has associated programming software that allows the user to enter a program into
the PLC.
own programming software.
Before a PLC can perform any control task, it must be programmed to do so. The most popular
language used to program a PLC is ladder logic. In a conveyor system, we have several “requirements”
to accomplish; for example, timing and counting parts on the conveyor. Each of these requirements
must be programmed into the PLC so that it knows how to respond to different events.
The programmer develops the program, and connects their personal computer to the PLC through a
network or cable and then downloads the program to the PLC.
Example of a ladder logic program

22. SIMATIC S5 to S7 Migration
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I. Migration Strategies
A. I/O Strategy
B. CPU Strategy
C. TIA Strategy
A. I/O Strategy
i. When to Use
When migrating the I/O from S5 to ET200 is a relatively low risk solution for
upgrading portions of an automation system to the latest technologies,
reducing field wiring, and reclaiming panel space for future expansion.
ii. Overview
After the above items are complete, the I/O configuration can be generated and
downloaded to the IM 308C memory module. The necessary program logic
code changes must then be generated. Many customers with large systems will
replace the I/O in stages.
iii. Planning
Planning is a critical step towards the success of any project. The more
complex a project is, the more planning is required to insure its overall success.
Planning a conversion from S5 I/O to ET200 I/O requires:
1 Getting the right tools
Profibus I/O requires SIMATIC COM PROFIBUS software for the
configuration of the I/O and its subsequent integration into the S5
programming software.
A IM 308C card with memory module will be required. A Siemens E Prom
burner to download the Com Profibus program to the IM308C memory
module is also needed. Be sure to check availability of the IM 308C.
2. Choosing the ET200 Hardware
In choosing the SIMATIC ET200 hardware, there are three possible
implementation approaches. The first two approaches (explained in the
following sections a and b) are chosen when S5 I/O and ET200 I/O are to
be used together in a single system. The third approach (section c) is
chosen when all the existing I/O in the system will be converted to ET200,
along with additional ET200 I/O that may also be added.

23. a. Retaining the existing I/O
In regards to implementation effort, the easiest is to expand the I/O points
simply by adding ET200 I/O to an existing S5 system. Using COM
PROFIBUS software, the new ET200 I/O is selected from the ET200
catalog and the Profibus drops are populated.
It is suggested that ET200M be used as the I/O type although if desired
the ET200S or ET200L could be used. In planning bear in mind that each
Profibus drop can contain only 8 modules. It may require several drops at
a physical location to obtain the required I/O points.
b. Converting the S5 Remote I/O to Profibus
The original remote I/O might be ET100U or remote racks interfaced
using cables. In both cases to replace the I/O with S7 I/O the ET200 type
must be used. Again the ET200M is the suggested choice. The Com
Profibus software must be used to develop the file for the IM308C
memory module.
The original I/O in the remote racks may be sizable, care must be taken
to insure that only 8 new ET200M modules are used at each logical
Profibus drop. It will probably be necessary to have several Profibus
drops at each physical drop. It is suggested to start the remote drop
addresses at 4. Step 7 usually reserves drop 1 for a OP, drop 0 for a
programmer, drop 2 for a CPU, and drop 3 for a drive.
c. Converting the S5 I/O to ET200 I/O
This option has a more complex implementation, although it results in a
more uniform and easier-to-maintain system since all the I/O will be of
one type, the ET200. Any digital or analog I/O in the main rack will have
to be replaced with ET200 I/O. The type ET200M is the suggested type. A
remote drop address would be required for these modules. One might
consider leaving the main rack I/O as S5 type unless failures have
occurred and replacements are not available. Converting to ET200M
doesn’t seem to add anything except for standardization.
For the remote racks follow the information as documented in b. above.
Other options for ET200 I/O include ET200S and ET200L. These families
of I/O include many specialty modules such as motor starters, VFD
drives, and PLC Controllers that are already built into the unit. These
compact I/O families make it easy to expand a machine where panel
space is limited.
3 Making Code Changes
PLC code must be written to read the inputs and write the outputs of the
newly added I/O. This is done through S5 in the same manner as with S5
I/O. As with any system that has newly added HW and SW, testing of the
modified system should be planned as part of the implementation.
23

24. There probably are address changes of the old I/O when converted to S7
because of additional drops etc. The S5 software includes a software
feature that allows “Rewire” of the address. Make use of this feature
either on a single step or the entire revised I/O map. For ease of locating
the I/O physically the I/O may be mapped using a different group for eachlocation. I.e. byte address’s
10 through 19 for drop 4, 20 through 29 for
drop 5, etc.
4 Documentation
The integrated program documentation capabilities of S5 can be used to
incorporate the new I/O and code. Each rung of ladder logic can be
described in detail. New I/O can be given descriptors (also called
symbols or tags). Drawing for panel wiring must be updated to show both
the new I/O and any changes to the exiting I/O. Documentation is
essential to maintaining the system.
iv. Execution
Good planning and documentation prior to the start of the effort is essential to a
successful execution phase of the implementation. As explained in previous
sections, the basic steps will include choosing the implementation method, and
creating the Profibus configuration with the COM PROFIBUS software. Enter
the new control code into the PLC program using S5. While programming, be
sure to document the code. Test the I/O and the new control code. When
testing and documentation have been completed, online production can be
restarted.
24
B. CPU Strategy
i. When to use
There are obvious reasons for migrating from the S5 controller to an S7
controller. A primary reason may be due to insufficient memory in the S5 CPU.
Other reasons include taking advantage of one or more of the many new
technologies available in S7, moving to a Structured programming
environment, or taking advantage of additional programming languages and/or
S7 option packages.
ii. Migration Steps
1. Training, the first step
The first step is to attend a “STEP 7 Programming I” training course.
These courses are scheduled periodically at Siemens training locations
throughout the US. The schedule, syllabus, and locations can be found
at http://www.sea.siemens.com/sitrain. Training will significantly reduce

25. the learning curve on S7. There are also other courses such as the S7
PID Loop class covering the STEP 7 PID blocks, the optional Standard
PID blocks and the optional Modular PID blocks. Taking this class will
help in the deciding which S7 PID option package is the best fit for the
application. With adequate training, it is easier to plan the conversion and
successfully execute the conversion and migration plans.
2. How to replace S5 CPU
The SIMATIC S7 PLC’s are separated into 3 families, S7-200, S7-300,
and S7-400. SIMATIC S7-200 is a compact micro programmable logic
controller (PLC) designed for lowered end applications. With a system
that has a very small program, it would be cost effective to use an S7-200
PLC rather then a S7-300 PLC. However, there is no software converter
to use for a migration to a S7-200. SIMATIC S7-300 is a modular mini
controller designed for mid range applications. SIMATIC S7-400 is
designed for high end/ high performance applications. The critical factor
is to choose the correct S7 CPU. There are two parameters to focus on.
The first is CPU memory size. Choose an S7-300 or S7-400 CPU with a
memory size equivalent to the memory size of your S5 Controller plus any
additional memory to cover expansion or 20% excess capacity. The
excess will vary depending on how much of the S5 CPU memory the
program actually uses. The second important parameter is CPU I/O
addressing capacity. Refer to Appendix A for a CPU reference chart that
shows the amount of memory in the S5 CPU and the comparative S7
CPU.
a. Retaining the Existing I/O
To reuse the existing (non Profibus) I/O, ET200U could be
used. S5-100U I/O is converted to ET200U by adding a IM318
interface card to the I/O rack. Unfortunately, these cards are
mature and only available as spare part (not available for
sale).
b. Interface Modules on the Main Rack
Since replacing the PLC CPU also requires changing the PLC
entire back plane, any modules that were previously used in
the S5 rack must also be replaced. This includes all I/O
modules, function modules, and communication modules.
c. Interface Modules in Local Expansion Racks
In legacy S5 applications, there may have been more than one
tier of modules (local expansion racks) connected to the main
rack. In these cases, all the modules will have to be replaced
with S7 modules. If using the S7-300 family, a similar
25

26. architecture can be achieved using the IM360, IM361, and
IM365 modules to expand the main rack. If using the S7-400
family, the IM460 and IM461 are used. Another possible thing
to consider is to move the modules to a remote rack and use
the IM463 interface as shown below. This might be cost
effective since you could reuse the S5 I/O modules. The
following sketch shows remote racks of S5 type connected to
a S7 main rack through the IM463. Note this could be a
possible setup for both intermediate performance and high
performance systems. The IM463 interface is very easy to
program. Very similar to a DP coupler in that it has S5
addresses assigned on one side and S7 addresses assigned
on the other side. Experience has proven that the correct
length of the 721 cable is important. There is a switch on the
front of the IM463 module which must be set to the length of
the 721 cable. There are 4 choices for length. Again, the
other way to migrate the system would be to convert the
remote racks and all of the modules to ET200M. It may be
wise to make several estimates of hardware conversions, and
choose the most cost effective approach.
Since replacing the PLC CPU also requires changing the PLC
entire back plane, any modules that were previously used in
the S5 rack must also be replaced. This includes all I/O
modules, function modules, and communication modules.
c. Interface Modules in Local Expansion Racks
In legacy S5 applications, there may have been more than one
tier of modules (local expansion racks) connected to the main
rack. In these cases, all the modules will have to be replaced
with S7 modules. If using the S7-300 family, a similar
architecture can be achieved using the IM360, IM361, and
IM365 modules to expand the main rack. If using the S7-400
family, the IM460 and IM461 are used. Another possible thing
to consider is to move the modules to a remote rack and use
the IM463 interface as shown below. This might be cost
effective since you could reuse the S5 I/O modules. The
following sketch shows remote racks of S5 type connected to
a S7 main rack through the IM463. Note this could be a
possible setup for both intermediate performance and high
performance systems. The IM463 interface is very easy to
program. Very similar to a DP coupler in that it has S5
addresses assigned on one side and S7 addresses assigned
on the other side. Experience has proven that the correct
length of the 721 cable is important. There is a switch on the
26

27. front of the IM463 module which must be set to the length of
the 721 cable. There are 4 choices for length. Again, the
other way to migrate the system would be to convert the
remote racks and all of the modules to ET200M. It may be
wise to make several estimates of hardware conversions, and
choose the most cost effective approach.
d. Function Modules and Communication Modules
In both S5 and S7 systems, the Function Modules (FM’s) and
Communication Processors (CP’s) reside in the main rack. It
is possible to reuse some of the FM’s used in the intermediate
and high end PLC’s when using the S7-400 system. To
accomplish this, new COM software and an adapter case is
required. However, in researching this fact for this paper, it
was discovered that the adaptor cases are no longer available
and cannot be ordered anymore. Therefore, if you do not
already own the adaptor cases, you will have to migrate your
FM’s. As for CP’s, there is no possibility of reusing the S5
modules. The migration of these modules should be checked
with the hotline personnel for the latest availability and usage.
e. Digital and Analog I/O
Appendix B and C provide a cross reference of S5 to S7 I/O.
These cross reference tables are set up with the best replacement items for most of the features of
the original S5
module. Some of the features may not be in the choices
therefore use the tables as a starting point buy check the latest
ST50 and ST70 catalogs once your list has been established.
The tables were set up for ET200M remote racks. If
replacement for the main racks or local expansion racks of an
S7-400 system is desired, use the ST50 and ST70 catalogs
directly.
f. Robot Control SIROTEC RCM 1P
If a robot control system was used for 3 axis handling
applications, one migration opportunity is the S7-300 CPU
317T (6ES7317-6TJ10-0AB0) with the option software
package S7 Technology (6ES7864-1CC30-0YX0). The
downloadable template “Simple 3D-Interpolation with cam
disks” covers exactly such applications for servo drives connected to
the Profibus DP (mainly Siemens: SINAMICS S120,
SIMODRIVE 611U, Master drives MC) or analog with the
SIMATIC IM174 module (6ES7174-0AA00-0AA0, 4 channels
incremental or SSI encoder inputs and 4 channels analog
27

28. outputs or stepper outputs with pulse/direction interface).
g. Closed Loop Control System SIMADYN D
Most of the SIMADYN D 16/32 bit applications could be
migrated to the S7-400 application module FM 458-1DP
(6DD16070AA2) with their expansion modules for
communication and I/O. Programs written in the UNIX based
STRUC L or STRUC G normally can be converted to a STEP
7/CFC/D7-SYS program with about 20% manual coding left.
Depending of the former complexity of the closed loop control
demands a second migration solution can be a SIMATIC TDC
system.
After determining the correct CPU, it is necessary to obtain STEP 7 and
the S7 optional programming packages that may be required. Again, the
S7 training course is the quickest way to obtain a clear understanding of
the S7 programming concepts.
All S7 projects require STEP 7. STEP 7 includes the S5 conversion tool.
STEP 7 includes 3 basic programming languages, Ladder Logic, Function
Block Diagram, and Instruction List. In addition to these languages, there
are several option packages available to extend the capabilities of the
basic software.
S7 SCL (Structured Control Language) is an S7 option package that
looks similar to a high level “Pascal” like language. It is very useful for
complex subroutines or advance math calculations.
S7 Graph is also a S7 option package. S7 Graph allows programming of
sequential control systems graphically.
Another S7 option package to consider is S7 PLC Sim. PLC Sim is a
simulator program that runs on the same PC where STEP 7 is running.
The STEP 7 program output is transferred to PLC Sim and executes the
code as though it were running and being monitored in the actual PLC.
PLC Sim allows the program’s memory and I/O to be manipulated and
tested prior to its real world installation. With PLC Sim, there is also an
option for Visual Basic programs to be written to provide a custom user
interface that can simulate the actual PLC operation visually.
STEP 7 and the S7 optional packages can be purchased and added as
they are needed. If you plan on buying multiple options specified above,
you may want to consider the STEP 7 Professional package which
includes the options STEP 7, SCL, Graph and PLC Sim. Your Siemens
representative can help you get the tools and training you need.
3. How to convert a program
There are two approaches to converting the S5 program logic to STEP 7
program logic. Both approaches require that the programmer performing
the conversion attend at least one STEP 7 training course. The first
28

29. approach is to use the S5 to S7 conversion tool that’s included with STEP
7. The other option is to manually convert the program. In the first
section the S7 conversion tool is discussed.
a. Automatic Conversion
Preparing for a Program Conversion
Before starting to convert a S5 505 program, it is highly recommended
that you attend “S7 Programming I” training classes offered by Siemens
Energy & Automation.
The S5 to S7 Conversion tool is designed to convert S5 source programs
into S7 Statement List text files suitable to be edited and/or compiled by
the STEP 7 Program Editor. Any program converted must be carefully
analyzed and tested after conversion to ensure proper operation. The
primary requirement for conversion is a complete understanding of the
application. All functionality required by the application must be verified.
This must be done with caution as a prime safety consideration.
Any S5 programs to be converted must be accessible on the personal
computer (PC) where the S5 to S7 Conversion tool is installed. S5 programs may be copied using
standard DOS or Windows file copy
techniques.
Overview of a Program Conversion
The S5 to S7 Converter reads information from the associated S5 files
and creates text files containing the equivalent STEP 7 commands.
Complete conversion is not possible because operand and architectural
differences prohibit this. As a result, any program converting must be
carefully analyzed and tested after conversion to ensure proper operation.
Similar to the S5 programming software, the STEP 7 programming
package has several editors that allow several different programming
languages to be used. The LAD (Ladder Editor), the STL/AWC
(Statement List Editor), the FBD (Function Block Diagram), and the SCL
(Sequential Control Language) are examples of different
program/language editors available with the STEP 7 software. STEP 7
has the ability to toggle between editors such that the program logic can
be displayed in either language simply by selecting to toggle from one
language to another. The output text files created by the S5 to S7
conversion tool are used as input to STEP 7. The resulting output
generated by the conversion tool, for the S5 Ladder logic is statement list
(STL). When possible, the conversion tool constructs STL so that the
rungs may be displayed graphically as ladders. When difficulties are
encountered converting a S5 construct, the converter generates Warning
Messages and enters them in the AWL / SCL and LIS files.
29
Steps In a Program Conversion

30. The S5 to S7 Converter program allows you to choose the S5 source file
you want to convert, the destination directory, and several other options.
The conversion process creates text files and STEP 7 imports text source
files. You might want to create a directory to hold both the S5 program
and the conversion output. Each output directory only holds one
conversion file set, since names used for output files are standardized.
Once the S5 program is converted, you need to create a STEP 7 project
to hold it. Use the SIMATIC Manager to import the conversion files from
the destination directory into the source object of your STEP 7 project.
You may want to create the S7 project before the conversion. Once the
project is created, insert the appropriate object, a SIMATIC 300 Station or
a SIMATIC 400 Station. Open the S7 Hardware Station Configuration
and configure the CPU and I/O. This will help you complete the I/O
Mapping portion of the Converter.
Before running the conversion software program, it is suggested that you
print out the parameter blocks DB 1 and DX0 from the S5 program. The
information (parameters) for the S7 program are loaded into the property settings of the CPU out of
the Hardware subdirectory. These blocks can
then be deleted out of the S5 program. Below you will see several screen
shots of the conversion using the convert program.
Open the SIMATIC > STEP 7 > Converting S5Files to begin the
conversion. See Figure 1. The S5 file is chosen, after which the OK
button is pressed.
b. Manual Conversion
As indicated in the Automatic section above one would probably use the
automatic conversion and then manually convert blocks that had many
errors in then. There is a library section of canned blocks that give many
of the S5 functions and should be looked at as possible starting point for
needed blocks.
30
C. TIA Strategy
i. When to use
A TIA or Totally Integrated Automation Strategy is used on new
installations similar to previous SIMATIC S5 installations. With TIA,
SIMATIC STEP 7 is the programming environment, SIMATIC S7 is the
controller and ET200 is the I/O used. This is applicable for new
installations and OEM equipment. It combines the application knowledge
from the SIMATIC S5 with the new technologies of SIMATIC S7
ii. Migration Steps
The Migration steps are similar to the steps outlined in this document.
Refer to Appendix A to select the CPU. Refer to appendix B and C to

31. cross reference the SIMATIC S5 I/O to ET200 I/O.
Program conversion can be accomplished with the S5 to S7 Converter or
reprogramming in STEP 7.
II. Special Situations
A. HMI
If the S5 system had Siemens Operator Panels connected to the S5 CPU, there
will be several Data Blocks no longer required and these can be deleted. Their
also will be a FB that can be deleted. The FB number will depend on how the
connection was made i.e. AS511, Ethernet, Profibus etc. a review of the Profibus
manual would be a way to check on this. The Operator Panel connection to the
S7 CPU is done behind the scenes using S7 functions and no code is required.
There are drivers for the S7 that allow for connections through MPI, Profibus and
Ethernet. Once the S7 symbols have been converted they can very easily used
by the new ProTool program if the Operator Panel is integrated into the Step 7
project. It is possible to copy some of the pictures, but you may find out that it is
easier to start from scratch taken advantage of new features of ProTool or
WinCC Flex.
Again with WinCC (SCADA) (Supervisory Control And Data Acquisition) there
are drivers for all the possible connections you might want to use. If the WinCC is
integrated then the Symbols can be used as tags making it easier to convert the
SCADA over to S7 PLC
B. Safety
Safety means protecting personnel, equipment and environment from potential
safety hazards. Hazards arising from functional faults must be prevented before
they occur. Safety Integrated is Siemens safety module in the world of Totally
Integrated Automation and stands for greater cost effectiveness, flexibility and
safety. The complete Safety Integrated safety concept can be seamlessly
integrated in standard automation and offers a one-stop range of Siemens
products to cover all requirements.
C. PROFInet - The open industrial Ethernet standard (PTO) (Profibus Trade
Organization)
Profinet brings together all aspects of automation including; distributed IO,
motion control, distributed automation and connectivity to management systems.
31


32. 32
SIMATIC S7-300 CPU 313C-2 DP

33. 33
Installation Requirements
The above configured SIMATIC S7-300 CPU 313C-2 DP PLC is installed in the Main Panel of M50-
0432 machine used for making crankshafts whichinvolves 4 processes: Pilot Bore Drilling, Tapping,
Camphoring & Finishing.
CPU for installations with high requirements in terms of processing power and response time.
 MPI interface onboard
 PROFIBUS DP master/slave interface
 Technological functions:
- Counting
- Closed loop control
- Frequency measurement
- Pulse width modulation
- Pulse generator
 16 digital inputs
 16 digital outputs

34. INTRODUCTION TO M50- 0432
M50- 0432 Machine
34
CRANKSHAFT:

35. The crankshaft, sometimes abbreviated to crank, is responsible for conversion between
reciprocating and rotational motion. In a reciprocating engine, it translates
reciprocating linear piston motion into rotational motion, whereas in a reciprocating compressor, it
converts the rotational motion into reciprocating motion. In order to do the conversion between two
motions, the crankshaft has "crank throws" or "crankpins", additional bearing surfaces whose axis is
offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder
attach.
It is typically connected to a flywheel to reduce the pulsation characteristic of the four-stroke cycle,
and sometimes a torsional or vibrational damper at the opposite end, to reduce the torsional often
caused along the length of the crankshaft by the cylinders farthest from the output end acting on the
torsional elasticity of the metal.
35
PROCESSES:
1. Pilot Bore Drilling
2. Tapping
3. Camphoring
4. Finishing
1. Pilot Bore Drilling & Tapping
A process for drilling oil holes in a crankshaft at various positions lengthwise and widthwise about a
longitudinal axis of the crankshaft, where the oil holes are perpendicular to and have angled
directions with regards to the longitudinal axis. The process includes the sequential steps of placing
the crankshaft in a horizontal position in a crankshaft holding unit and maintaining the crankshaft in a
horizontal position through the drilling process. The holding unit is then rotated on a vertical axis until
the crankshaft faces the drilling unit. The crankshaft is next rotated along the longitudinal axis of the
crankshaft to position the crankshaft in a position for drilling a hole. The drill tool is then moved on a
second and third axis until the drill tool is situated in order to drill the hole in the crankshaft.

36. In the process of tapping, threads are created inside the drilled bore with the help of taps of specific
diameter and length.
36
2. Camphoring & Finishing

37. Besides maintaining a sufficient micro finish, it is also important that any burrs are removed. Critical
areas where burrs are often found are just inside of the journal’s oil passages. The way to remove
these burrs is by using a process known as chamfering. Chamfering is performed as part of
the crankshaft polishing process and must be performed after most significant crankshaft repairs have
been made. Just before the crankshaft is polished, it is chamfered in the grinding machine. Because
chamfering can also create slight burrs, a polishing belt is all that is needed to remove any burrs left
behind from the surface where the stone has met the journals outside diameter.
When a crankshaft is welded, it almost always needs to be chamfered. Instead of simply cleaning
up the outside of the oil passage after a welded journal has been roughed in, the automotive
machinist will often use a long and narrow stone to clean up the inside of the passageway as well.
Because welding penetrates existing steel, a small amount of weld may enter the passageway that
is easy cleaned out with the right stone and chamfering process.
ADVANTAGES OF SIEMENS S7 PLC OVER SIEMENS S5 PLC
The Siemens S5 PLC is an automation system based on Programmable Logic Controllers. It was
manufactured and sold by Siemens AG. Such automation systems control process equipment and
machinery used in manufacturing. This product line is considered obsolete, as the manufacturer has
since replaced it with their newer Siemens S7 PLC.
PURPOSE FOR UPGRADATION:
- The PLC can operate on double words (4 byte words) and can do floating point math.
- There is a genuine one shot instruction. Actually there are 2 - positive and negative transition.
- There are various new instructions and addressing modes and some changes to existing ones.
- Siemens S5-100U PLC is obsolete now.
- Spare parts not available
-To introduce the option for 4 cyl. Block and 6 cyl. Block using HMI (human machine interface)
- The hardware on the S7 provides a far greater range of CPU's and I/O cards, thereby allowing you to
choose more appropriate hardware for your plant, and hence saving costs.
37

38. CONVERSION OF SIEMENS S5-100U PLC LADDER TO S7-300 PLC
SIEMENS S5-100U (BEFORE):
SIEMENS S7-300 (AFTER):
38

39. BIBLIOGRAPHY
39
 Siemens S7-300 PLC instruction manual
 M50-0432 instruction manual
 Through various sources on Internet
 Ladder programming logic
 Siemens Official Website
I would also like to thank the administration of TATA MOTORS for providing me with this
wonderful opportunity of completing my training here.

40. CONCLUSION
With the active help and support of all the employees in the Electronics department of the Engine
Factory, I was able to complete my project and I am extremely grateful to them while doing this
project I got an insight of the application of my branch in this factory. Unless one undergoes practical
training it is difficult to relate to all that is being taught in theory. Moreover one gets the feel of
working in a factory.
The next important thing that one learns in the training is how to relate himself to his colleagues, his
seniors and the employees of his division. Until and unless a person interacts actively with his co-workers,
he will not be able to dispel his duties well because in an organization an individual alone,
isolated from his workforce cannot complete a job.
Finally I would like to thank Mr. Sandip Ravan & Mr. Rakesh Sarangi for their constant guidance and
help without their support it would not have been possible. I would also like to thank the
administration of TATA MOTORS for providing me with this wonderful opportunity of completing my
training here.
40