Industrial

Electronics II

Course outline
Industrial Control devices and transducers

Power Electronic switching and semiconductor switches

Cooling and Protection of electronic switches

Power Rectification

Chapter 1: Industrial Control device

Mechanical switches

Proximity switches

Control relays and contactors

Overload relays

Solenoids & control valves

Timing & counting devices

Relay logic control

Transducers performance

Thermocouples & Thermistors

 Displacement- pressure- and flow transducers

Strain gages

Photoelectric devices

Optical shaft encoders

Capacitive- ultrasonic- and thickness sensors

Humidity transducers.

INTRODUCTION

Various types of mechanical control devices are used in industry. A typical industrial electronic system
will combine both semiconductor and mechanical control devices. Mechanical switching is often used
for manual control of a system.

MECHANICAL SWITCHES

Mechanical switches are used in industrial electronic control to initiate or interrupt the flow of current
in a circuit. The most common types of switches used in industry are pushbuttons, toggle switches, limit
switches, float switches, and pressure switches.

Pole & throw

The term pole is used to describe the number of completely isolated circuits that are allowed to pass
through a switch at a given time.

The term throw is used to describe the total number of individual circuits that each pole is capable of
controlling.

Tableau 1

Pushbutton

A typical pushbutton is a momentary device that will maintain current flow only as long as the button is
pressed.

Pushbuttons are available in normally open (NO) and normally closed (NC) configurations.

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Limit switches
Limit switches are switch mechanisms usually operated by the motion of part of a machine such as a
slide or cam.
This type of switch Is designed to convert mechanical motion into an electrical signal. There are four
basic configurations,

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The most popular types of limit switches has both NO and NC contacts.

Tableau 2

Limit switches (cont.)

The lever connected to a limit switch is called an actuator. There is a wide variety of actuators available
for the many different industrial applications of limit switches.

Three of the more common types are,

the push-roller
wobble-stick
catwhisker.

Image

Rotary switches & toggle switches

Rotary switches are actuated by a twisting motion, usually involving the manual turning of a knob. These
switches can have many pairs of terminals or as few as two.

The main advantage of the rotary switch is that it has the capability to perform simultaneous and
sequential switching of many sets of contacts with the operation of a single actuator.

Switching inductive loads

Switches that control inductive loads usually have high current ratings "to prevent contact arcing.

The development of an arc between opening contacts can be suppressed by slowing the rate of the
collapsing field by using an RC snubber in parallel with the switch. Another popular is to use a
freewheeling diode.
PROXIMITY SWITCHES

Many industrial applications require that the presence, or absence, of an object be sensed without
physical contact being made. Devices used for this purpose are called proximity switches.

Inductive proximity switches are used to detect the presence of metal parts. They are also used in some
applications to sense position and motion.

Capacitive proximity switches can detect the presence of metal objects or non-metallic materials such as
wood, paper, glass, rubber, water, and any other material with a dielectric constant of 1.2 or greater.

Optical sensors

A light source, such as an LED, acts as a transmitter of infrared light. The receiver is often a photodiode
which detects the presence or absence of light from the source.

The disadvantage of this method of detection is that it is only effective when the object being sensed
has a reflective surface.

Ultrasonic sensors ??

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CONTROL RELAYS

A relay is a electromechanical switch.

Relays have only two possible operating states: ON or OFF.
Relays are classified according to their use as control relays, power relays, or sensing relays.
A relay is essentially a switch that can be actuated from a remote location.
Relays use one or more pairs of contacts to make or break control circuits.

Image

CONTROL RELAYS (cont.)

Ratings : There are many considerations involved in the correct selection of a control relay for a
particular application. These considerations include factors as speed of operation and relay sensitivity.
Although typical control relays operate in the 5ms to 20ms range. Relays with switching speeds as fast as
100us are available.
Pull-in current (Make rating)
Sealed current Break rating
 Continuous rating

Derating – why ??

CONTROL RELAY circuits

Interlocking :

Figure

CONTROL RELAY circuits

Seal-in :

Figure

Contactor

When a relay has a current-handling capability above 15 A. it is classified as an electro-magnetic

contactor.

In other words, an electromagnetic contactor is a high-power relay with heavy-duty contacts for
switching industrial loads.

Overload relays
Are used to protect motors from short-circuit conditions. Overload relays are designed to allow a relay
to remain closed during startup periods when the inrush current rises very high but can provide
overload protection if excessive current flow occurs after the motor has been started.
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Solenoids

A solenoid is an electromechanical output device that is used extensively in industrial control circuits.
Solenoids are very common in robots with hydraulic controls.

Hydraulic components

Cylinder Rotary actuator

TIMING AND COUNTING DEVICES

Time Delay Relay (TDR) - provides a time delayed switching action.

Types of counting devices:
Electromechanical
Electro pneumatic
Mechanical
Electronic

RELAY LOGIC CONTROL CIRCUITS

Relay logic is a method of controlling industrial electronic circuits by using relays and contacts.

The schematic diagrams for relay logic circuits are often called line diagrams, because the inputs and
outputs are essentially drawn in a series of lines.

RELAY LOGIC CONTROL CIRCUITS

Basic format for relay logic diagrams

1. The two vertical lines that connect all devices on the relay logic diagram are labeled L1 and L2. The
space between L1 and L2, represents the voltage of the control circuit.
2. Output devices are always connected to L2. Any overloads that are to be included must be shown
between the output device and L2 : otherwise, the output device must be the last component before L2.
3. Control devices are always shown between L1, and the output device. Control devices may be
connected either in series or in parallel with each other.
4. Devices which perform a stop function are usually connected in series, while devices that perform a
start function are connected in parallel.
5. Electrical devices are shown in their normal conditions.

Steps in designing a relay logic diagram

1. Define the process to be controlled.

2. Draw a sketch of the operation process. Make sure all the components of the system are present in
the drawing.
3. Determine the sequence of operations to be performed. List the sequence of operational steps in as
much detail as possible. Write out the sequence in sentences, or put them in table form.
4. Write the relay logic diagram from the sequence of operations.

A STOP/START station is used to control two pilot lights. When the START button is presses, the Contact
relay energizes and its associated contact changes state. The GREEN light is now ON and the RED is OFF.
When the STOP button is pressed, the contacts return to their resting state, the red pilot light is ON,
and the green switches OFF.

When the start button is pressed, CR1 is energized and the holding contact around the START button is
sealed in. The solenoid valve SV1, is in parallel with the control relay so both output devices remain ON
via the holding contact when START button is released. The solenoid caused the cylinder to extend and
activate limit switch LS1. When LS1 is opened, power is interrupted to both CR1 and SV1, causing the
seal-in contact to drop out and the hydraulic cylinder to retract. As the cylinder retracts, LS1 recloses,
and the circuit returns to its original resting state.

When the system is off, the workpiece rests against the limit switch LS1, holding the NC contacts in the
open state.

Practical : experiment 1

Homework :
Problems 5.14 – 5.16 & 5.19 – 5.21