Classic Control

Introduction:
Control something is meant to control that thing, in order to do the work that you want to
do, for example, if I want to turn it on or off, I close or open its electrical switch to light or
not.
And there are two types of control
1-manual control.
2-automatic control.
In the previous example (room lamp) shows manual control and here must be the
presence of the individual or worker to carry out the required control process as for
automatic control, it is that type of control that does not require the presence of an
individual or worker in order to do a specific job, but the system automatically performs
something when something else happens and this is what is explained in PLC.

What is Automation?
Automation is the use of control systems such as computers, controllers to control
industrial machinery and processes, to optimize productivity in the production of goods
and delivery of services. Automation is a step beyond mechanization. Whereas
mechanization provides human operators with machinery to assist them with the
muscular requirements of work, automation greatly decreases the need for human
sensory and mental requirements.

Advantages of Automation:
1. Replacing human operators in tasks that involve hard physical or monotonous work
Also task done in dangerous environments.
2. Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc. 3. Automation may improve in economy of enterprises, society or most
of humanity.

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Disadvantages of Automation:
1. Current technology is unable to automate all the desired tasks.
2. The research and development cost of automating a process may exceed the cost
saved by the automation itself.
3.The automation of a new product or plant requires a huge initial investment in
comparison with the unit cost of the product.

Component of control system:

1. AC or DC sources
2. circuit breakers
3. switches
4. timers
5. contactor
6. relay
7. counters
8. sensors
9. over load

Electrical Sources:
AC DC
. Single phase (L , N) 220 V . Always use 24 V
. Three phase (R , S , T) . Greatly reduces the wiring cost
beside (L , N) to almost half the original cost

control circuit: low power lines

power circuit: high power lines

Fig (1)

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Types of electrical contacts:

Fig (2) Fig (3)

Contact seam consists of two points like fig (2) the normally open is natural and its
abbreviation (NO) and the other type in fig (3) normally close that passes the electric
current and abbreviation (NC).
The type of seam can be confirmed using an electric avometer.

Types of switches:
1-Toggle switch: A permanent separation or connection device that does not return to
normal after the effect on it disappears.
2-push bottom: A temporary separation or connection device with an unstable position,
meaning that it changes when a mechanical effect occurs on it and returns to its normal
position when this effect disappears including the NO push bottom (start), NC push
bottom (stop).

Circuit Breaker:

o Definition: A circuit breaker is a manually or automatically operated

electrical switch designed to protect and control power systems by
interrupting fault currents.
o How Circuit Breakers Work: By detecting faults like overloads or short
circuits, circuit breakers interrupt the current flow, activate arc quenching
methods, and can be reset to reinstate the flow of electricity.

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Contactors:
Construction:
Contactors consist of various components designed to withstand the rigors of electrical
switching. The main parts include the coil, contacts, and an enclosure.
Components of a Contactor:
1. Coil
The coil is the electromagnet that, when energized, generates a
magnetic field. This magnetic field pulls the contacts together,
closing the circuit.
2. Contacts:
Contacts are conductive pieces that open or close to control the
flow of current. They are typically made of materials capable of
withstanding arcing and wear.
Fig (5)

3. The contactor frame:

is the housing that holds it all together, protects the contactor’s components, and allows
the contactor to be mounted. The frame protects users against accidentally touching
any conductive parts, as well as offering robust protection against overheating,
explosion, and environmental hazards like dirt and moisture ingress.

Operating Principal:
when the electromagnetic coil has a current passed through it, a magnetic field is
created. This causes the armature within the contactor to close and, either open, or
close the electrical contacts.
If the contactor is designed as normally open (NO), energising the coil with voltage will
close the contacts together, and allow power to flow around the circuit. When the coil is
de-energised, the contacts will open, and the circuit will open. This is how most
contactors are used. A normally closed (NC) contactor works the opposite way. The
circuit is made when the contactor is de-energised.
As contactors operate entirely via electromagnetism, it is one of the more efficient and
reliable designs since electromagnetic switching only requires a small amount of power.
It also enables the full remote operation of the contactor.

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Relay:
A Relay is a simple electromechanical switch. While we use normal switches to close or
open a circuit manually, a Relay is also a switch that connects or disconnects two
circuits. But instead of a manual operation, a relay uses an electrical signal to control an
electromagnet, which in turn connects or disconnects another circuit.
consists of an:
1. Electromagnet
2. Mechanically movable contact
3. Switching points and
4. Spring

Relay Working Principle: Fig (6)

Fig (7)

• Relay works on the principle of electromagnetic induction.

• When the electromagnet is applied with some current, it induces a magnetic field
around it.
• Above image fig (7) shows working of the relay. A switch is used to apply DC
current to the load.
• In the relay, Copper coil and the iron core acts as electromagnet.
• When the coil is applied with DC current, it starts attracting the contact as shown.
This is called energizing of relay.
• When the supply is removed it retrieves back to the original position. This is
called De energizing of relay.

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What's the Difference Between Contactors and Relays?

Aspect Contactors Relays

Purpose High-power switching (motors, heaters) Low-power control circuits

Current Rating 10 to 100 of amps Generally, under 20 amps

Voltage Rating Up to 1000 volts Usually under 250 volts

Size Large small

Arc Suppression Yes, for high current Not typically required

Auxiliary Contacts A few Muche

Timers:
A time relay is a device, usually electromechanical, that opens or closes a circuit after a
preset period. Timed relays can be used to delay the energizing of a circuit, delay the
de-energizing of a circuit, and perform timing in either directions or a combination of
both. The time delay can be adjustable or fixed, depending on the needs of the
application. The time delay is usually adjustable using a knob, dial, multi-position switch,
or other means. This allows the user to change the time delay without having to replace
the entire relay. a time delay relay can also be used to repetitively energize and
deenergize a circuit at preset intervals. These types of timer relays are often used in
applications such as water sprinklers, where the circuit is powered for a set period, then
left without power for a set period.

Type of timers:
o Timer on delay
o Timer off delay

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Timer on delay:
The on-delay time delay relay is the most common type of time relay. As the name
suggests, this type of relay will start the timing action when an input voltage is applied,
and energize the output after the set timing. In order to de-energize the output, this input
voltage must be removed, after which the on time delay relay will reset.
On-delay time delay relays are used in applications where it is necessary to ensure that
a certain process has taken place before starting another process.

For example:
Fig (8)

• Burglar alarms that need to delay the sounding of the alarm to allow authorized
persons time to leave the premises.
• In industrial systems to stagger the startup of large motors so that the power
supply is not overloaded.
• To operate door locks that must wait a few seconds after the power is applied to
make sure that the door is closed before locking it.

Timer off delay:

The off-delay time delay relay is the second most common type of time delay relay. This
type of timer relay requires a trigger to start timing after it has received an input voltage.
Its output will, therefore, be energized upon the application of the trigger, after which the
trigger is removed so the timing can start. After the set timing duration, the output will
de-energize. The off-delay time delay relays fit into applications where it is necessary to
ensure that a certain process has taken place before stopping another process
for example:
• Elevator doors that must close after a certain
amount of time.

Fig (9)

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Counters:
The counter is a digital device and the counter output includes a preset state based on
clock pulse applications. The counter outputs can be used to count the number of
pulses and there are counters that reset themselves.

Type of counters:
o Counter up
o Counter down
o Counter up/down

Counter-Up
A counter-up, or up-counter, increments its count whenever it detects a particular input
signal, such as a pulse or clock signal. This type of counter starts from an initial count,
typically zero, and increases in a stepwise manner each time a designated event
occurs. Once it reaches a preset maximum count, the counter may reset to zero or stay
at the maximum count, depending on its configuration.
The up-counter is commonly used in processes where events or steps must be counted
sequentially. For example, it is widely applied in manufacturing automation, where a
specific count of completed parts triggers the next process step. Traffic light systems
and elevator control mechanisms also use up-counters to manage sequential phases.

Counter-Down
A counter-down, or down-counter, operates in the opposite direction by decrementing its
count with each pulse or event. This counter starts from a predefined maximum value
and counts down to zero. When it reaches zero, it may reset to the initial maximum
value or hold at zero, depending on the system requirements.
Down-counters are useful in scenarios where it is essential to track the remaining steps
or resources. For instance, they are found in countdown timers in digital clocks, where
they mark the time remaining. In process control.

Combination of Counter-Up and Counter-Down in Control Systems

Combining counter-up and counter-down mechanisms allows for a more flexible control
system, particularly when both incrementing and decrementing functions are necessary.
Many control applications involve a reversible counter that can switch between counting
up and down based on conditional inputs or states, providing versatile counting and
tracking capabilities. For example, in a conveyor belt system, an up-counter might track
items added to a belt, while a down-counter simultaneously tracks items leaving the
belt.

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 Programmable Logic Controller (PLC):
Is a digital computer used for automation of industrial processes, such as control of
machinery on factory assembly lines It is a solid-state user programmable control
system with functions to control logic, sequencing, timing, arithmetic data manipulation
and counting capabilities. It can be viewed as an industrial computer that has a central
processor unit, memory, input output interface and a programming device. The central
processing unit provides the intelligence of the controller. It accepts data, status
information from various sensing devices like limit switches, proximity switches,
executes the user control program stored in the memory and gives appropriate output
commands to devices such as solenoid valves, switches etc.
A constant demand for better and more efficient manufacturing and process machinery
has led to the requirement for higher quality and reliability in control techniques. With
the availability of intelligent, compact solid-state electronic devices, it has been possible
to provide control systems that can reduce maintenance, down time and improve
productivity to a great extent. One of the latest techniques in solid state controls that
offers flexible and efficient operation to the user is programmable controllers.

Features of PLC:
• It is designed for multiple inputs and output arrangements, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact.
• Almost any production process can greatly enhance using this type of control
system, the biggest benefit in using a PLC is the ability to change and replicate
the operation or process while collecting and communicating vital information.

Types of PLC Programming logic controller (PLCs):

has several types: Based on the size of the module and it can be classified according
to is working. Based on Size:
• Micro PLC or Small PLC
• Medium PLC or Mini
• Large PLC or Rack

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Different PLC Manufactures:
• Siemens
• FATEK
• Delta
• Omron
• Panasonic
• GE Fanuc

Criteria of choosing PLC:

• Cost
• No. of I/O
• Memory Capacity
• Processing Speed of CPU
• No. of Timer, Counters

PLC operation:
There are three basic steps in the operation of all PLCS which continually take place in
a repeating loop.
1. Input Scan: Detects the state of all input devices that are connected to the PLC.
2. Program Scan: Executes the user created program logic.
3. Output Scan: Energizes or de-energize output devices that are connected to the PLC.
Depending on the PLC design

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PLC scan cycle:
The completion of a cycle of the controller is called a Scan. The scan time needed to
complete a full cycle by the controller gives the measure of the speed of execution for
the PLC.
SCAN TIME taken by PLC to execute these three steps (Checking Input status,
Executing Program, Updating Output Status) is denoted by its scan time.
Scan is read code from top to bottom.

SCAN TIME taken by PLC to execute these three steps

(Checking Input status, Executing Program, Updating
Output Status) is denoted by its scan time.

Fig (10)

Ladder logic:
is one form of drawing electrical logic schematics, and is a graphically language very
popular for programming PLCS. Ladder logic was originally invented to describe logic
made from relays. The name is based on the observation that programs in this
language resemble ladders, with two vertical "rails" and a series of horizontal "rungs"
between them.

Fig (11)

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Sensors:
Sensors are fundamental components in automatic control systems, used to gather data
from the environment or system and feed it to controllers to make informed decisions.
Different types of sensors serve various purposes, each uniquely designed to measure
specific variables such as temperature, position, pressure, light, and motion.

Type of sensors:
1. Temperature Sensors
Description: Temperature sensors measure the heat levels in an environment or
system.
Working Principle: Thermocouples work by producing a voltage relative to the
temperature difference between two junctions. Thermistors and RTDs change their
resistance with temperature.

2. Optical Sensors
Description: Optical sensors detect light or changes in light levels, used for various
applications like motion detection or color sorting.
Working Principle: Optical sensors detect changes in light intensity, either through
absorption or reflection, often generating an electrical signal when triggered.

3. Proximity Sensors
Description: These sensors detect the position or presence of an object.
Working Principle: Inductive sensors detect metallic objects through magnetic fields,
while capacitive sensors sense changes in capacitance to detect various materials.
Ultrasonic sensors use sound waves, and optical sensors use light to detect objects’
presence or distance.

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Proximity Sensors connecting:
Proximity sensors are commonly connected using either a 3-wire or 5-wire
configuration, depending on the application requirements, such as Normally Closed
(NC) or Normally Open (NO) modes. Here’s a summary of each wiring type and how it
works.
A 3-wire proximity sensor: This configuration is most commonly used for simple NC or
NO setups.
Wiring Terminals:
o Vcc (Power): Connected to the positive supply voltage.
o GND (Ground): Connected to the negative supply or ground.
o Output: Connected to the control input of the system (like a PLC or
microcontroller).
• Operation:
o Normally Open (NO): In this mode, the output remains open (no voltage)
until the sensor detects an object. Once detected, the output is triggered
and connected to ground, allowing current to flow to the control system.
o Normally Closed (NC): In this mode, the output stays closed (connected to
ground) by default, allowing current flow. When an object is detected, the
output disconnects from ground and opens the circuit.

Fig (12)
Proximity sensors are connected to the control circuit rather than the power circuit
because they are designed to signal or control system logic, not to handle or switch high
power directly.
o Low Power Requirements
o Safety
o Isolation from High Current

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Practical Training of classic control:

Overview of Practical Sessions:

The practical sessions were conducted in a fully equipped laboratory, designed to
facilitate hands-on experience in performing electrical experiments. Each trainee
was assigned an individual electrical panel, allowing us to practice and
implement our circuits independently.

The practical sessions provided a structured and comprehensive introduction to

classic control systems, with a strong emphasis on accuracy, independent
problem-solving, and real-time troubleshooting. This hands-on experience has
significantly enhanced my understanding of circuit design and fault management,
equipping me with valuable skills for future applications.

Experiments in Classic Control:

The classic control training included 15 experiments, each increasing in difficulty.
Some of these experiments were covered in lectures, while others introduced
new wiring techniques that required independent work. The laboratory was
supervised by qualified personnel who offered external assistance, although after
the fifth experiment, trainees were expected to work without help.
Each experiment required connecting various components as instructed to
achieve a specific task. Time constraints were strictly enforced; each lab session
had a set completion time, and skipping experiments was not permitted. This
systematic approach ensured a progressive understanding of each task before
moving to the next.

Troubleshooting Exercises:
After completing the initial ten experiments, the remaining five incorporated fault
diagnosis and troubleshooting exercises. This segment was designed to test our
understanding of circuit functionality and fault resolution skills. In these final
experiments, once the circuit was assembled and verified by the lab engineer, I
would leave the room while the instructor introduced deliberate faults into the
circuit. Upon re-entering, my task was to identify and correct these faults. The
types of faults introduced included:

1. Reversed connections on the contactor and timer.

2. Insulation on the main power line.
3. Short circuit faults.

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Practical experiments:

1.Star Delta FW REV

First, we connect the control circuit, and the laboratory engineer makes sure that
there is no error in the wiring so that (short circuit) does not occur. Then we
connect the power circuit, and the laboratory engineer turns it on after verifying it.

Fig (13) control circuit

Fig (14) power circuit

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 2. Start1 m1 10s off
Start2 m2 10s off
If you stop m1 before the end of time, m2 starts and completes the time and vice
versa

Fig (15)

3.Start m1 on 5s m1+m2
Stop m1 on m2 off 5s all off

Fig (16)

Fig (17)

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PLC Practical Training:

Overview of PLC Programming and Practical Sessions:

In this part of the training, we focused on setting up and programming a PLC circuit,
which was then connected to a laptop. The programming was done using Siemens
software, and we used Ladder Logic language to write the code. Essentially, this code
mirrored the connections we previously made in classic control circuits, but it was now
implemented in a digital environment on the computer, making the process significantly
faster. However, the conceptual challenges were more demanding, as while coding itself
was quick, the real challenge lay in developing the right logic for each experiment.
Compared to classic control, the PLC offered far greater flexibility as it wasn’t limited by
a specific number of physical components. This allowed us to explore a broader range
of solutions and design ideas.

Hands-On PLC Experiments:

The practical training included 20 hands-
on PLC experiments of varying difficulty
levels, all conducted in the laboratory. Fig (18)

These experiments were not covered in the lectures, providing an opportunity to learn
independently and test our understanding of PLC programming. In certain experiments,
the lab engineer introduced specific conditions, such as using only one timer or
restricting the use of counters. These requirements encouraged us to think creatively
and find alternative methods to achieve the desired outcomes.
Simulation Exercises and Collaboration:
In addition to the lab exercises, we completed 10 simulation experiments at home using
computer-based simulation software. These simulations mimicked the operation of a
complete manufacturing plant, and our task was to write and run code to perform
specific tasks within this virtual environment. This part of the training was instrumental in
fostering teamwork, as we collaborated to develop ideas and build comprehensive code
solutions capable of running a complex, fully simulated factory. Working together on
these simulations improved our problem-solving skills and reinforced our understanding
of PLC logic in real-world applications.

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 Practical experiments:

1. 3 Phase Motor Control using PLC Ladder Logic

Fig (19)

2. Bottle Filling

Fig (20) Fig (21)

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Motor Drive Practical Training:
During this section of the training, I focused on studying various types of motor drives
through a set of five experiments, each progressively increasing in difficulty. Each
experiment utilized a different type of motor drive to provide comprehensive exposure
and practical understanding. The motor drives I worked with included
• INVT
• SAVCH
• Schneider
• Delta
Each motor drive type had a unique catalog that required thorough reading and
comprehension before proceeding with the experiments. The experiments involved
programming each motor drive and connecting it to an electrical circuit along with the
motor. This practical approach allowed me to understand both the theoretical and
practical aspects of motor drive operation, including programming and integration within
electrical systems.

What motor drive can do?

• AC drives provide a very wide speed range. Also, they can provide multiple ways
to control this speed.
• the motor can provide the torque required.
• the motor can control in current out.

Fig (22)

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Conclusion:
This training provided extensive knowledge in the field of automation, with a strong
focus on hands-on experience. Intensive practical sessions on various electrical panels,
PLC devices, and motor drives offered invaluable skills that enhanced my
understanding and prepared me for real-world applications. Through this experience, I
gained a solid foundation, making me well-equipped to pursue a career in this field

Reference:

• Training notes
• https://ladderlogicworld.com/ladder-logic-symbols/
• https://drive.google.com/file/d/1BDPyrAY4KrRLBn5cVxlMoCENfwH99
Nym/view?usp=sharing

• https://drive.google.com/file/d/1LyjxNVDSn7kMJIiJBvD2wJ_eQEMZ9
Vqo/view?usp=drive_link

• https://drive.google.com/file/d/1fB8rDKgnsdKrewpRoFz1i7EFDQHuQ
qrj/view?usp=sharing

• https://drive.google.com/file/d/1wI2Q6EALOPjDf-
Cf76wfCf48gMrLE_s4/view?usp=drive_link

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