CDL GOVT.

POLYTECHNIC COLLEGE
NATHUSARI CHOPTA (SIRSA)
SYNOPSIS OF THE PROJECT WORK
1. TITTLE OF THE PROJECT

Overload Detect Circuit

2. INTRODUCTION

An overload detection circuit is designed to identify and respond to

excessive electrical current flowing through a circuit. it helps prevent
damage to components and ensures safety, typically, it involves
sensor protective devices that monitor current levels. When an
overload occurs, the circuit triggers a response, such as shutting down
power or activating a protective, mechanism. to safe guard the
potential damage.

3. RATIONAL FOR THE STUDY

A rational study of an overload circuit involves examining its design,

and principles with a focus on ensuring the reliability and safety of
electrical systems. Here are key aspects to consider in a rational study
of an overload circuit:
1. Design Principles:
 Current Rating:
 The overload circuit should be designed to handle the maximum
current expected in normal operation. The current rating is a critical
parameter, and it should be set based on the capacity of the electrical
system or device it protects.
 Sensitivity and Response Time:
 The circuit should be sensitive enough to detect overcurrent
conditions promptly. The response time is crucial to prevent damage,
and it should be well-calibrated to ensure a rapid reaction to
abnormal current levels.
 Adjustability:
 In some cases, it might be beneficial to have an adjustable current
threshold, allowing for flexibility based on specific application
requirements.
2. Components and Sensors:
 Current Sensors:
 The type of current sensor used, such as current transformers or
shunt resistors, should be selected based on the characteristics of the
 circuit and the accuracy required.
 Tripping Mechanism:
 The choice of a tripping mechanism, whether it's a circuit breaker,
relay, or other protective device, should align with the application's
needs. Thermal overload relays are commonly used to trip circuits
based on temperature rise due to prolonged overcurrent conditions.

4. METHODOLOGY
● Theory of control and Working
he theory of control in electrical systems involves regulating or
managing the behaviour of a system to achieve a desired output or
performance. Control systems are crucial in maintaining stability,
accuracy, and efficiency in various applications. There are two main
types of control systems:
1. Open-Loop Control System:
 In an open-loop control system, the control action is not dependent
on the system's output. It provides a predefined input to the system,
and the system operates without feedback. This type of control
system is simple but lacks the ability to correct errors.
2. Closed-Loop Control System:
 In a closed-loop control system (also known as feedback control), the
system monitors its output and adjusts the input based on the
feedback. This allows the system to respond to changes and maintain
the desired output.
Working of Overload Circuit:
An overload circuit is a protective mechanism designed to prevent
damage to electrical devices or systems when they experience
excessive current beyond their rated capacity. Overloads can occur
due to various reasons such as short circuits, electrical faults, or
excessive load.
Here's how an overload circuit typically works:
1. Current Sensing:
 The overload circuit includes a current-sensing device such as a
current transformer or a shunt resistor. This device monitors the
current flowing through the circuit.
2. Comparison with Set Threshold:
 The sensed current is compared with a predetermined threshold
value. This threshold is set based on the rated capacity of the circuit
or device.
3. Tripping Mechanism:
 If the sensed current exceeds the predetermined threshold, the
overload circuit activates a tripping mechanism. This mechanism can
take various forms depending on the application, such as a circuit
breaker, a relay, or a thermal overload relay.
4. Disconnection or Alarm:
 Upon activation, the tripping mechanism either disconnects the
power supply to the circuit or triggers an alarm to alert the operator.
The disconnection prevents further damage to the system caused by
the excessive current.
5. Manual or Automatic Reset:
 Some overload circuits have a manual reset, requiring the operator to
reset the circuit after addressing the cause of the overload. Others
may have an automatic reset feature after a certain cool-down period.
In summary, the theory of control involves managing system
behaviour, while the working of an overload circuit focuses on
protecting electrical systems from damage caused by excessive
current. The overload circuit acts as a safety mechanism by detecting
overcurrent conditions and taking appropriate actions to prevent
equipment failure or fire hazards

 Advantage:-
Here are some advantages of overload protection:
1. Equipment Protection: The primary purpose of overload protection is to
safeguard electrical equipment and devices from damage. When the current
exceeds safe levels, the protection mechanism kicks in, either by tripping a
circuit breaker or blowing a fuse. This interrupts the flow of current,
preventing overheating and potential damage.
2. Fire Prevention: Overloaded circuits can generate excessive heat, posing a
fire hazard. Overload protection helps prevent the risk of fires by
disconnecting the power supply when the current exceeds safe limits.
3. Enhanced Safety: Overload protection enhances the safety of electrical
systems by reducing the risk of electrical shocks and other hazards. It
ensures that circuits operate within their designed capacity, minimizing the
potential for accidents.
4. Longer Equipment Lifespan: Continuous exposure to high currents can
significantly reduce the lifespan of electrical equipment. Overload
protection helps extend the life of devices and components by preventing
them from operating under stressful conditions.
5. Reduced Downtime: Without overload protection, electrical systems
would be more susceptible to damage and failures. By preventing damage,
overload protection contributes to reduced downtime and maintenance
costs.

 Disadvantage
Here are some disadvantages:
1. Inertia in Response:
 Overload circuits may have a certain response time before they trip
to protect the system. In some cases, this inertia in response time
might allow a brief surge of overcurrent, potentially causing damage
before the protection mechanism activates.
2. Sensitivity to Transients:
  Overload circuits can be sensitive to transient spikes or short-
duration overcurrent events. This sensitivity might lead to false trips
if not adequately filtered or if the circuit is not designed to account
for transient conditions.
3. Complexity and Cost:
 Implementing sophisticated overload protection systems can be
complex and may increase the overall cost of the electrical system.
Balancing cost-effectiveness with the required level of protection is a
challenge.
4. Temperature Considerations:
 Thermal overload relays, a common type of overload protection, rely
on temperature rise as an indicator of overcurrent conditions.
However, this method assumes a linear relationship between current
and temperature, which may not hold true in all situations.
5. Limited Protection Range:
 Overload circuits are designed for a specific current range, and they
may not provide effective protection for very high or very low
current levels. For extremely high currents, other protection
mechanisms such as short-circuit protection may be necessary.

 Application
Here are some common applications of overload circuits:

1.Motor Protection:
Overload circuits are extensively used in motor control panels to protect
electric motors from overheating due to prolonged overcurrent conditions. This is
crucial for preventing motor burnout and extending the lifespan of motors.
2. Transformer Protection:
Transformers are vulnerable to overcurrent conditions that can result from short
circuits or other faults. Overload circuits help protect transformers by
disconnecting them from the power source when excessive current is detected.
3. Power Distribution Systems:
Overload protection is integrated into power distribution systems to safeguard
against overloads caused by faults, short circuits, or sudden increases in load. This
ensures the integrity of the distribution network and prevents damage to
connected equipment.
4.Circuit Breakers:
Overload protection is a fundamental feature in circuit breakers. Circuit breakers
automatically disconnect the electrical circuit when they sense an overload,
preventing damage to wiring and connected devices.
5.Control Panels and Cabinets:
Industrial control panels and cabinets often contain electronic components and
sensitive devices. Overload circuits protect these components from damage
caused by excessive current, ensuring the reliability of control systems.
 Future Scope
Here are some potential areas of future development and innovation in the field
of overload circuits:

1.Smart Overload Protection:

Integration with smart technologies and the Internet of Things could lead to
more intelligent overload protection systems. These systems may be capable of
real-time monitoring, remote control, and predictive maintenance, enhancing
overall system efficiency.
2.Machine Learning and Artificial Intelligence:
The incorporation of machine learning algorithms and artificial intelligence (AI)
could enable overload circuits to adapt dynamically to changing load conditions.
These systems may learn from historical data, predict potential overloads, and
optimize protection strategies.
3.Condition Monitoring and Predictive Maintenance:
Future overload circuits may incorporate advanced condition monitoring
capabilities, allowing them to assess the health of electrical components
continuously. Predictive maintenance algorithms could anticipate potential
overloads and recommend preventive measures.

 COMPONENTS

SNO COMPONENTS NAME PRICE

1. C.T (Current Transformer) 380-/
2. Relay 190-/
3. Single phase transformer 370-/
4. Printed circuit board 140-/
5. Buzzer 80-/
6. Comparator 90-/
7. Rectifier 110-/
8. Bulb holder 40-/
9. Transistor 90-/
10. Bulb 100W, 200W Bulb 80-/
11. Wires 100-/
TOTAL 1670-/

5. PLACE AND LAB

C.D.L GOVT POLYTECHNIC COLLEGE NATHUSARI CHOPTA
(SIRSA)

6. PROBLEMS
Material Availability
Cost of Materials is very high in local markets
 Parts are not available

PREPARED BY: - APPROVED BY:-

1.SONU GUPTA (210290922033) ER.VIPIN AHUJA (H.O.D)
2.YASH MITTAL (210290922038) ER.SANDEEP MEHTA
3.VIKRAM SINGH (210290922037) (SR.LECTURER)
4.ROHIT VERMA (210290922028)
5.VISHAL BHARGAV (210290900123)