Professional Documents
Culture Documents
BACHELOR OF TECHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING
BY
PRASHANTH.K
(10241A0227)
SRUJAN.P
(10241A0243)
PRUDHVI.M
(10241A0239)
RAJAGOPALAN.G
(10241A0217)
2013-2014
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
GOKARAJU RANGARAJU INSTITUTE OF ENGINEERING AND
TECHNOLOGY, Hyderabad, Andhra Pradesh.
CERTIFICATE
This is to certify that the project report entitled Lift Control Using Siemens
PLC that is being submitted by K.Prashanth , P.Srujan , M.Prudhvi ,
G.Rajagopalan in partial fulfilment for the award of the Degree of Bachelor of
Technology in Electrical and Electronics Engineering to the Jawaharlal
Nehru Technological University is a record of bonafide work carried out by her
under my guidance and supervision. The results embodied in this project report
have not been submitted to any other University or Institute for the award of any
graduation degree.
Project Guide:
V.V.S Madhuri
Dr.M.Chakravarthy
HOD-EEE,
GRIET.
Asst. Professor
EEE, GRIET.
External Examiner
ACKNOWLEDGEMENT
This is to place on record our appreciation and deep gratitude to the persons without
whose support this project would never see the light of day.
We wish to express our propound sense of gratitude to Mr. P. S. Raju, Director,
G.R.I.E.T for his guidance, encouragement, and for all facilities to complete this project.
We are highly indebted to Mr. P. M. Sarma, DEAN (R & D), G.R.I.E.T for his
guidance and constant supervision as well as for providing necessary information regarding
the project & also for his support in completing the project.
We are humbled by the encouragement received from Dr. M. Chakravarthy, HOD,
EEE Department, G.R.I.E.T throughout the project.
We also express our sincere thanks to Sri P.P.C.Prasad, Associate Professor,
Mechanical Department, G.R.I.E.T for extending his help.
We have immense pleasure in expressing our thanks and deep sense of gratitude to
our guide V.V.S Madhuri , Assistant Professor, Department of Electrical and Electronics
Engineering, G.R.I.E.T for her guidance throughout this project.
We express our gratitude to Mr. E. Venkateshwarlu, Associate Professor, Department
of Electrical and Electronics Engineering , G.R.I.E.T for his valuable recommendations and
for accepting this project report.
Finally we express our sincere gratitude to all the members of faculty and our friends
who contributed their valuable advice and helped to complete the project successfully.
BATCH A-9:
K.Prashanth
-10241A0227
P.Srujan
- 10241A0243
M.Prudhvi
- 10241A0239
G.Rajagopalan
- 10241A0217
ABSTRACT:
This paper describes the use of SIEMENS S7-1200 Programmable Logic Controller to
instruct a four-floor elevator system. PLCs have proven to be able to withstand harsh
environments and this made them very popular in industrial process control. Though
practically elevators are not controlled by PLC, still we employed it, because elevator is an
appropriate system where we can explore a lot of features of the PLC. The PLC system just
makes things easier for the design and maintenance engineer. The PLC Systems are very
useful for Industrial Automation, alone which can replace many number of equipments like
contactors, switches etc. PLC systems are very practical technologies and their mastery will
no doubt boost the student skills in his daily technical life since the system is approached
from both hardware and software design perspectives. As it is a mere model while shifting to
a practical elevator some of the modules must be replaced.
.
CONTENTS
Page No.
Abstract
Table of Contents
1. Introduction
2. Programmable Logic Controller
2.1 PLC history
2.2 PLC characteristics
2.3 How PLC works
2.4 PLC programming language
2.5 Human Machine Interface
2.6 PLC Applied in Elevator System Applications
3. Variable Frequency Drive
4. Induction Machine
5. Construction of Elevator
5.1 Hardware Design
5.2 Design of Elevator Cabin
5.3 Counter Weight Balance
5.4 Rope Strength
6. Software Design
7. System Debug
7.1 Hardware debug
7.2 Software debug
Result
Summary
References
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5
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CHAPTER-1
INTRODUCTION
INTRODUCTION:
Due to the cause of rapid population growth at the cities and multi-stored buildings, the
need of elevators is being increased. With the rising life standards and attention to human and
with the technologic developments, elevator systems are getting better, more fast, stronger and
better quality elevators are produced. Previously, most systems were focused on the mounting of
elevators, especially after the 1980s the need for elevator maintenance and fault staff have been
started to increase. For instance, automatic doors have being used instead of splash doors,
microprocessor electronic cards have being used instead of cards with relay, double-speed or
speed-controlled elevators have being used instead of one-speed elevators. Such developments
provide to improve the quality in elevator systems, develop and diverse the used setting and
maintenance or repair tools and Instruments and therefore facilitation of the work compared to
previous years and increase the reliability of elevator. Some of the drawbacks of the traditional
system are
The control system have high failure rate that were mainly due to numerous contacts,
complexity of wiring circuit. In addition, electrical contacts were easy to burn out, which
could result in poor contact.
Electrical controller and hardware wiring based on common method were difficult to
achieve a more complex control function.
Electromagnetic actuator and contact action were so slow, mechanical and
electromagnetic have large inertia. Therefore, the control precision of system was
difficult.
Some of the developments that have made to overcome the disadvantages of previously used
elevators are
The traditionally used relays and IC boards have been replaced by PLC for easy and
cheap controlling of machines used in the elevator.
Also by the use of PLC we can integrate monitoring softwares like Intouch, Citech, etc.
In order to control the motion of the elevator cabin smoothly AC motors are used
because of its advantage of easy controlling and fast acceleration and deceleration.
To achieve high speed nine-phase Permanent Magnet Synchronous Motor has been used.
To reduce the size of the machine room and for smooth operation Linear Induction Motor
has been used.
In some cases Linear Switched Reluctance Motor (LSRM) has been used because of the
absence of windings both in stator as well as in the rotor even though it is having some
disadvantages like difficulty in motor controlling and generation of ripples.
Block diagram:
Based upon the need the blocks have been developed and drawn as block diagram
Figure1
CHAPTER-2
PROGRAMMABLE LOGIC CONTROLLER (PLC)
Communications abilities began to appear in approximately 1973. The first such system
was Modicon's Modbus. The PLC could now talk to other PLCs and they could be far away from
the actual machine they were controlling. They could also now be used to send and receive
varying voltages to allow them to enter the analog world. Unfortunately, the lack of
standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks. Still, it was a great decade for the
PLC.
The 80's saw an attempt to standardize communications with General Motor's
manufacturing automation protocol (MAP). It was also a time for reducing the size of the PLC
and making them software programmable through symbolic programming on personal computers
instead of dedicated programming terminals or handheld programmers. Today the world's
smallest PLC is about the size of a single control relay.
The 90's have seen a gradual reduction in the introduction of new protocols, and the
modernization of the physical layers of some of the more popular protocols that survived the
1980's. The latest standard (IEC 1131-3) has tried to merge plc programming languages under
one international standard. We now have PLCs that are programmable in function block
diagrams, instruction lists, C and structured text all at the same time! PC's are also being used to
replace PLCs in some applications. The original company who commissioned the MODICON
084 has actually switched to a PC based control system.
Industrial communication:
The SIMATIC S7-1200s integrated PROFINET interface provides seamless
communication with the SIMATIC STEP 7 Basic engineering system for programming, with
SIMATIC HMI Basic Panels for visualization, with additional controllers for PLC-to-PLC
communication and with third-party devices for advanced integration options.
Integrated technology:
The name SIMATIC has been a reliable symbol in the field of automation for many
years. They have integrated proven and innovative technology functions into the new controller
ranging from counting and measuring, speed, position and duty cycle control to simple process
control functionality. This wide variety of functionality guarantees the ability to solve a wide
array of applications based on technology that has proven its validity in the field for many years.
Up to 3 communication modules can be added to any of the SIMATIC S7-1200 CPUs. The
RS485 and RS232 communication modules provide the connection for performing point-to-point
serial communication.
High-speed inputs & outputs:
The new SIMATIC S7-1200 controller comes with 6 high-speed counters. Three inputs at
30 kHz are integrated for counting and measuring.
Two high-speed pulse train outputs at 100 kHz are integrated for controlling the speed
and position of a stepper motor or a servo drive. They can alternatively be used as pulse-widthmodulated outputs for controlling the speed of a motor, position.
Memory:
Up to 50 KB of integrated work memory is provided with a floating boundary between
the user program and user data. Up to 2 MB of integrated load memory and 2 KB of integrated
retentive memory are also provided. The optional SIMATIC Memory Card provides an easy way
to transfer programs to multiple CPUs. This card can also be used for storing miscellaneous files
or to update the firmware of the controller system.
Signal modules:
Up to eight signal modules can be connected to the largest CPUs for the support of
additional digital and analog I/Os. With the addition of a signal board, you can increase the
number of digital or analog I/Os on the controller to custom-fit your needs without increasing
the controllers footprint. The SIMATIC S7-1200 system comes in three different models, CPU
1211C, CPU 1212C and CPU 1214C, that may each be expanded to exactly fit your machine
requirements. One signal board can be added inside the front of any CPU to easily expand the
digital or analog I/Os without affecting the physical size of the controller. Signal modules can
be connected to the right side of the CPU to further expand the digital or analog I/O capacity.
CPU 1212C accepts two and CPU 1214C accepts eight signal Modules. CPU 1214C has a width
measuring only 110 mm and both the CPU 1212C and CPU 1211C are only 90 mm wide.
Together with the small footprint of the communication modules and signal modules, this
modular and compact system saves valuable space and offers you the highest level efficiency and
flexibility during the installation process.
High-speed outputs for speed, position or duty cycle control, two high-speed outputs are
integrated into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulsewidth-modulated outputs. When configured as a PTO, a 50 percent duty cycle pulse train is
provided at a rate of up to 100 kHz for the open-loop speed and position control of stepper
motors and servo drives. Feedback for the pulse train outputs is provided internally using two of
the high-speed counters. When configured as a PWM output, a fixed cycle time output with a
variable duty cycle is provided for controlling the speed of a motor, position of a valve, or duty
cycle of a heating element.
CPU 1212C
DI 8x24 V DC, DQ 6x24 V DC or 6xRLY, AI 2x10 Bit 010 V DC
DC/DC/DC 6ES7 212-1AD30-0XB0
AC/DC/RLY 6ES7 212-1BD30-0XB0
DC/DC/RLY 6ES7 212-1HD30-0XB0
Fig: 2.2
Input Scan: Detects the state of all input devices that are connected to the PLC
Program Scan: Executes the user created program logic.
Output Scan: Energizes or de-energize all output devices that are connected to the PLC.
Housekeeping: This step includes communications with programming terminals, internal
diagnostics etc...
1. CHECK INPUT STATUS:
First the PLC takes a look at each input to determine if it is on or off. In other words, is
the sensor connected to the first input on? , Then the second input? , Then the third and so on
It records this data into its memory to be used during the next step.
2. EXECUTE PROGRAM:
Next the PLC executes your program one instruction at a time. Maybe the program says
that if the first input was on then it should turn on the first output. Since it already knows which
inputs are on/off from the previous step it will be able to decide whether the first output should
be turned on based on the state of the first input. It will store the execution results for use later
during the next step.
3. UPDATE OUTPUT STATUS:
Finally the PLC updates the status of the outputs. It updates the outputs based on which
inputs were on during the first step and the results of executing your program during the second
step.
Based on the example in step 2 it would now turn on the first output because the first
input was on and your program said to turn on the first output when this condition is true. After
the third step the PLC goes back to step one and repeats the steps continuously. One scan time is
defined as the time it takes to execute the 3 steps listed above.
The basic elements of a PLC include input modules or points, a central processing unit
(CPU), output modules or points, and a programming device. The type of input modules or
points used by a PLC depends upon the types of input devices used. Some input modules or
points respond to digital inputs, also called discrete inputs, which are either on or off. Other
modules or inputs respond to analog signals. These analog signals represent machine or process
conditions as a range of voltage or current values. The primary function of a PLCs input
circuitry is to convert the signals provided by these various switches and sensors into logic
signals that can be used by the CPU.
The CPU evaluates the status of inputs, outputs, and other variables as it executes a
stored program. The CPU then sends signals to update the status of outputs. Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices. The programming device is used to enter or change the PLCs program
or to monitor or change stored values. Once entered, the program and associated variables are
stored in the CPU. In addition to these basic elements, a PLC system may also incorporate an
operator interface device to simplify monitoring of the machine or process.
In our case the input module will be composed of an array of switches that help us to
input Logic ones or Logic zeros to the PLC; the output module is made of LEDs to display the
status of the system; our programming device is the SIEMENS provided STEP 7 MicroWin and
the operator interface is a WinCC based Human Machine Interface, herein referred to HMI
Fig: 2.3
10
Fig : 2.5
alternative and parallel branching. Each step represents a processing status of a control program,
which is active or inactive. A step consists of actions which, identical to the transitions, are
formulated in the IEC 1131-3 languages. Actions themselves can again contain sequence
structures. This feature permits the hierarchical structure of control program. The sequential
function chart is therefore an excellent tool for the design and structuring of control programs.
Since Ladder Diagram is the most used method to program PLCs and particularly our method in
this project, a closer look at how some of the hardware functions are achieved is necessary.
12
13
5. The OR Rung:
The OR is a logical condition that is easy to represent in Ladder Logic. Suppose a switch
is wired to Switch1, a second switch is wired to Switch2, and a light bulb is wired. Through
Light1 in such a way that the light is OFF when Light1 is OFF, and ON when Light1 is ON. In
this instance, we want to the light to turn ON if either Switch1 OR Switch2 is ON. If Switch1 is
ON - power flows to Light1 turning it ON. If Switch2 is ON - power flows through the Switch2
contact, and up the rail to Light1 - turning it ON. If Switch1 AND Switch 2 are ON - Light1 is
ON. The only way Light1 is OFF is if Switch1 AND Switch2 are OFF.
AND logic
Fig. 2.9
2.4.4 Register allocation:
OR logic
OR logic
In this section, we allocate some specific registers that will be used in our project. Also
their functions will be introduced briefly.
Position register: this register tells us the current location of the lift vehicle.4 bits are
reserved and bit3 ,bit 2 ,bit 1 and bit0 relate to 1F,2F,3F and 4F respectively.MB0 provided by
the S7 1200 system has been used for this purpose.
Destination Registers (Updest and Downdest): When a destination request PB is pushed, a
corresponding bit is set in the appropriate destination register. 4 bits are reserved and bit3, bit 2,
bit 1 and bit0 relate to 1F, 2F, 3F and 4F respectively.MB1 and MB2 provided by the S7 1200
system have been used Updest and Downdest respectively. A particular register can be called
using %MBxx , where xx is the number of the register.
2F, 3F and 4F respectively. Bit 1, 2, 3 and 4 of the MB5 Register have been used to control the
1F, 2F, 3F and the 4F respectively.
Motion control:
The function of these bits is to tell whether the lift vehicle is in motion or not. Also,
when it is in motion, we need to know if it is moving up or down. Bit 0 of MB3 has been used
for motion control and bit1 of the same byte has been used for motion direction control.
On top of the above mentioned registers and bits, a great number of other registers have been
used for other purposes such as latching, temporary storage and the like. Numerous timers and in
particular 10 ms resolution timers have been used for delay purposes. For example passage from
floor to floor has been achieved using timer delays.
16
CHAPTER-3
VARIABLE FREQUENCY DRIVE (VFD)
17
18
.
Fig: 3.1
For the speeds below rated speed for large variation of voltage, small change in speed
occurs. Therefore normally v/f control is used. In this method, voltage and frequency are
varied with respect to each other, so that the ratio is maintained constant. Therefore the flux
density will be maintained constant. But this method requires A Converter- Inverter circuit at the
stator side.
19
Fig: 3.2
Feature
Benefits
Fig: 3.3
21
Soft starting
Capability for speed reversal / regenerative Desired torque during braking, therefore better
product quality
braking
improved braking characteristics
Higher efficiency
Flux optimisation (motor flux automatically Improved motor efficiency
adapted to load)
Reduced motor noise
Power loss ride through
Reduced number of drive trips
Better process availability
Table 3.1
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CHAPTER-4
INDUCTION MACHINES
INDUCTION MACHINES:
23
Fig:
4.1
0.3 KW
Speed
:
Rated voltage
Rated current
Duty - s1
Connection
Frequency
Efficiency
IP 55
A0C 50
1390 RPM
:
415 V
:
1.02A
:
:
:
Star
50 hz
70%
25
CHAPTER-5
CONSTRUCTION OF ELEVATOR
CONSTRUCTION OF ELEVATOR:
5.1 Hardware Design:
26
This chapter discuss about the design of an elevator by the calculation of certain
parameters which defines the operation of the elevator. To meet the objectives of the project that
has been derived from the previously completed theoretical studies a machine model has been
designed. Then to validate and to implement the simulated model as a prototype certain
calculations have been carried out to determine some critical parameters. The parameters
includes the size of the cabin, maximum number of persons can be accommodated into the
elevator, strength of the rope, type of motor used, motors power rating and torque rating. The
important part of the system is the controller the type of controller used here is PLC.
Electromagnetic actuator and contact action were so slow, mechanical and electromagnetic
components have large inertia. Therefore the control precision of system was difficult. So there
is a need to go for modern type of controllers like PLC. In this type of control there is provision
to monitor the entire system by means of SCADA.
27
Table: 5.1
Rope Calibration
5.4 Sensors:
Reed Switch is used as a sensor to determine the position of the lift. The reed switch is
an electrical switch operated by an applied magnetic field. It was invented at Bell Telephone
Laboratories in 1936 by W. B. Ellwood. The reed switch contains a pair (or more) of
magnetizable, flexible, metal reeds whose end portions are separated by a small gap when the
switch is open. The reeds are hermetically sealed in opposite ends of a tubular glass envelope.
The contacts may be normally open, closing when a magnetic field is present, or normally closed
and opening when a magnetic field is applied. The switch may be actuated by a coil, making a
reed relay or by bringing a magnet near to the switch. Once the magnet is pulled away from the
switch, the reed switch will go back to its original position.
28
Fig. 5.2
Since the contacts of the reed switch are sealed away from the atmosphere, they are
protected against atmospheric corrosion. The hermetic sealing of a reed switch make them
suitable for use in explosive atmospheres where tiny sparks from conventional switches would
constitute a hazard.
One important quality of the switch is its sensitivity, the amount of magnetic field
necessary to actuate it. Sensitivity is measured in units of Ampere-turns, corresponding to the
current in a coil multiplied by the number of turns. Typical pull-in sensitivities for commercial
devices are in the 10 to 60 AT range. The lower the AT, the more sensitive the reed switch. Also,
smaller reed switches, which have smaller parts, are more sensitive to magnetic fields, so the
smaller the reed switch's glass envelope is, the more sensitive it is. They usually range in length
from 2.0 inches long to as small as 0.025 inches long.
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CHAPTER-6
SOFTWARE DESIGN
31
SOFTWARE DESIGN:
The programming for PLC is done on SIMATIC STEP 7 Basic (TIA Portal) which is a
price-optimized subset of STEP 7 Professional controller software.
TIA Portal Basic has task-oriented, intelligent and intuitive editors that enable it to serve
as one common engineering framework for the SIMATIC S7-1200 controller and SIMATIC
HMI Basic Panel; which will help to achieve many engineering efficiencies in daily work giving
a competitive advantage.
Compact automation solutions also require scalability and flexibility, and this is achieved
for your application through the integrated PROFINET interface on the controller S7-1200 for
programming, HMI connections, distributed I/O's and distributed drive architectures.
32
Fig: 6.1
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34
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CHAPTER-7
SYSTEM DEBUGGING
36
Debugging:
System Debug:
In computers, debugging is the process of locating and fixing or bypassing bugs (errors)
in computer program code or the engineering of a hardware device. To debug a program or
hardware device is to start with a problem, isolate the source of the problem, and then fix it. A
user of a program that does not know how to fix the problem may learn enough about the
problem to be able to avoid it until it is permanently fixed. When someone says they've
debugged a program or "worked the bugs out" of a program, they imply that they fixed it so that
the bugs no longer exist.
Debugging is a necessary process in almost any new software or hardware development
process, whether a commercial product or an enterprise or personal application program. For
complex products, debugging is done as the result of the unit test for the smallest unit of a
system, again at component test when parts are brought together, again at system test when the
product is used with other existing products, and again during customer beta test, when users try
the product out in a real world situation. Because most computer programs and many
programmed hardware devices contain thousands of lines of code, almost any new product is
likely to contain a few bugs. Invariably, the bugs in the functions that get most use are found and
fixed first. An early version of a program that has lots of bugs is referred to as "buggy."
Debugging tools (called debuggers) help identify coding errors at various development stages.
Some programming language packages include a facility for checking the code for errors as it is
being written.
Hardware Debug:
The hardware debug phase involved testing each hardware module component for proper
operation. As in any circuit test, we have to make sure that the system is safely powered; we
made sure that the system has a 220V; 50Hz AC power supply and a 24V DC power supply
.These should be connected following standard safety measures. Each Light Emitting Diode has
been tested for proper operation. Here the current limiting resistors must be checked since they
are critical to the operation of the system. If not carefully chosen the LEDs may burn out as a
result of over current.
We should also be sure that the power supply has the capability to power the system. The
power supply used for this system can provide up to 3.5A.This should be more than enough for
our system since each LED needs 8~15 am or current to light properly and the maximum number
of LEDs that can be ON simultaneously is 5. To be practically sure that the hardware module
will work without problem when connected to the actual PLC we have tested it with a simple
program to power one of the output ports that we have connected to the 1F indicator LEDs for
example. With this test successful, the hardware module was approved for proper operation and
we were confident to be able to approach any further dysfunction as the situation requires.
37
Software Debug:
Software debugging is the process by which developers attempt to remove coding defects
from a computer program. It is not uncommon for the debugging phase of software development
to take 60-70% of the overall development time. In fact, debugging is responsible for 80% of all
software project overruns. Ultimately, a great amount of difficulty and uncertainty surround the
crucial process of software debugging.
This is because at each stage of the error detection process, it is difficult to determine
how long it will take to find and fix an error, not to mention whether or not the defect will
actually be fixed. In order to remove bugs from the software, the developers must first discover
that a problem exists, then classify the error, locate where the problem actually lies in the code,
and finally create a solution that will remedy the situation (without introducing other problems!).
Some problems are so elusive that it may take programmers many months, or in extreme cases,
even years to find them. Developers are constantly searching for ways to improve and streamline
the process of software debugging. At the same time, they have been attempting to automate
techniques used in error detection. Over the years, debugging technology has substantially
improved, and it will continue to develop significantly in the near future.
Since we have used the Ladder programming technique in our project we have not come
across any hard-to-solve grammatical error. This is because it is a straightforward technique and
the system warns you at any wrong move you might want to make. Several logical errors have
occurred though; and we had to find a way around this if we wanted our project to be successful.
The approach that worked was to design the software in blocks and run as many tests as
we can. Each time we were going to make a major change, we introduced a new version. This
allowed us to come back to the last best version every time we did something catastrophic.
38
RESULT
39
40
41
42
43
44
Fig (f):
Summary:
This project involves using the S7 1200 PLC to control a four floor elevator system. The basic
functions of the elevator system have been emulated. As part of hardware design, a module for
input/output has been designed and its purpose is to provide us with different status of the
system. The SIEMENS provided software package have been used for software design and the
Ladder programming technique was used ;also, the S7 1200 PLC simulator tool was used for
quick test purposes or in case the PLC hardware was not available. Software and hardware were
tested together and possible remedies have been carried out for problems that occurred.
A Human Machine Inter face can be implemented for the visual display and control of the
PLC working and status.
46
References:
Websites:
[1] www.siemens.com
[2] http://www.plcs.net/chapters/history2.htm
[3] http://www.scribd.com/doc/49006620/Summer-Training-Project-Report-PLC
[4] http://www.plcs.net
[5] www.wikipedia.org
[6] www.allaboutcircuits.com
[7] www.ieeecss.org
Books:
[1] Programmable Logic Controllers, W.Bolton, Elsevier-Newnes, 2009
[2] Electrical machines by J B Gupta
[3] Control Systems by Kothari
47