MCT312 – Industrial Automation

Lecture 4

Dr. Nancy Emad El-Hady

[email protected]
Hardware Components for Automation
(Cont.)
 Recap - Limit Switch
• Limit switch is a mechanical device that uses physical contact to
detect the presence or absence of an object.

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Limit Switch

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Recap - Other Mechanically-operated Switches

Paddle-type flow switch

Float level switch

Bimetal temperature switch

Pressure switch

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 Manually-operated Switches
• Manually operated switches are controlled by hand. These include
toggle switches, pushbutton switches, knife switches, and selector
switches.

NO push button NC push button Selector switch

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 Electric Motors

Induction motor Stepper motor Servo motor

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 Electric Motors
• Three-phase Induction Motor

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Electric Motors

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Solenoid

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 Pneumatic Cylinders
• Double-Acting Cylinder Operation

Compressed air Exhaust Exhaust Compressed air

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Directional Control (DC) Valve

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 Directional Control (DC) Valve

• 3/2 DC valve is a 3 port and 2 position direction.

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 Motion Sequence representation of Cylinders
• Position step motion diagram:

• Sign Conventions:
o Forwards: + ve sign
o Backwards: –ve sign

• Cylinders can be named A, B, C, D, etc.

• The forward motion of cylinder A can be denoted by A+

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 Exercise
1. An electromagnet control relay is basically a(n)
a) electromagnet used to switch contacts.
b) electromagnet used to relay information.
c) manually operated control device.
d) pressure-operated control device.

2. In the relay illustration, the contact No. 1 is a(n)

a) NO fixed contact. c) NO movable contact.
b) NC fixed contact. d) NC movable contact.

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 Exercise
3. A contactor
a) is another name for a relay.
b) is designed to handle heavy power loads.
c) always has an overload relay physically and electrically attached.
d) is a physically small relay.

4. A limit switch is usually actuated by

a) hand.
b) pressure.
c) contact with an object.
d) an electromagnet

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 Exercise
5. In the hardwired relay schematic shown, when the switch
is closed, CR coil is

a) energized, and the red and green lights are both on.
b) de-energized, the red light is off, and the green light is on.
c) energized, the red light is on, and the green light is off.
d) energized, the red light is off, and the green light is on.

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Industrial Automation Circuits
 Industrial Automation Circuits
• The electrical circuits being utilized for the study and
implementation of an industrial manufacturing plant can be divided
into the following categories:

o Power circuits
o Automation circuits
o Wiring diagrams

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 Power Circuits
• Power circuits (also called main circuit) indicate the type of power
supply for the utilized motors and all other related power devices.

Switch

fuse

contactor

Overload
relay

Power circuit of a direct starting motor.

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 Automation Circuits
• Automation circuits (also called control circuits, or auxiliary circuits)
represent the operational logic and control of the power devices.

The simplest form of an automation Automation circuit for a start/stop operation of

circuit which is equivalent to a full the previously depicted motor
manual operation.

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 Remarks for Automation Circuits
❖ Every automation circuit is secured by a general safety fuse.

❖ In the case of control panels for human operators, all the

automation circuits should be of low.

❖ The automation circuits are being designed in parallel branches

between the R and N lines.

❖ Every branch of an automation circuit can consist of a series,

parallel, or a mixed type combination of switching contacts.

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 Remarks for Automation Circuits
❖ Every branch of an automation circuit can contain an unlimited
number of switching contacts, but always only one coil should be
able to get energized.

❖ It is never permissible to have serial connections of relay coils in the

same branch.

❖ It is permissible to have a parallel connection of two or multiple

coils in the same branch.

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 Basic Automation Circuits Symbols
• Multiple standards have been defined from national and
international regulations, such as NEMA, DIN, BS, ANSI, IEC, etc.

Mostly used basic symbols for switching contacts and automation devices
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 Wiring Diagram
• Wiring diagrams are circuits representing both the power circuit and
the automation circuit.

• It represents the actual positioning of all the devices and

components in the industrial installation.

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 Design of Automation Circuits

Empirical Systematic
methods methods

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 Empirical methods -
Industrial Automation Synthesis
 Introductory Principles in Designing Automation
Circuits
• The Latch Principle
Let’s consider a machine operating with the help of an electric motor.
The motor is a direct start type and is being controlled by the utilization
of a relay C.

The automation problem can be stated as follows:

‘’What automation circuit can we select to energize or de-energize the

relay C and thus directly control the operation or non-operation of the
motor?’’

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 Latch Principle
• Elementary manual ON-OFF control of a machine.

(a) Permanent stop or operation of a machine

(b) Permanent stop, instantaneous operation of a machine
(c) Permanent operation, instantaneous stop of a machine
(d) Permanent stop or operation of a machine
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 Latch principle - Seal-in circuits
• A seal-in or holding circuit is a method of maintaining current flow
after a momentary switch has been pressed and released.

• In these types of circuits, the seal-in contact is usually in parallel

with the momentary device.

Relay Ladder Diagram

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 Introductory Principles in Designing Automation
Circuits
• The Principle of “Command”

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 Basic Automation Examples Synthesis
• Motor Operation with Thermal Overload Protection
• Operation and Fault Indication
• Machine Operation with Starting Delay
• Sequential Start—Latch of Machines
• Electrical Interlocking Circuits
• Motor with Inversion in Rotation

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Motor Operation with Thermal Overload
Protection

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Operation and Fault Indication

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Machine Operation with Starting Delay

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Sequential Start—Latch of Machines (Chain Latch)

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 Electrical Interlocking Circuits
• An electrical interlocking circuit is used to prevent a piece of
equipment from operating under certain potentially hazardous or
undesirable condition.

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 Motor with Inversion in Rotation

Power circuit of a motor with two directions of rotation. Automation circuit for permanent operation
of a motor with two directions of rotation.

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 Exercise
• Design the Automation circuit of the Garage Door described below.
A garage door is equipped with a motor with reverse capability.
Limit switches (b1, b2) stop the movement of the door automatically
(safety switches) when it reaches the corresponding motion limit.

A photocell (u) is utilized for the detection of humans, in order to

instantly terminate the movement of the door upon human detection.

The automation is achieved by the utilization of a remote control of

two channels (two independent signals), one for every direction of
movement. When the button from the remote control transmitter is
being pressed, a corresponding contact at the receiver (TC1 or TC2)
remains closed, and the door movement should be retained
automatically.
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 Exercise
• Design the Automation circuit of the Garage Door described below.

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