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 Devices
• 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.
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.
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,

The most popular types of limit switches has

both NO and NC contacts.
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.
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 ??
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.
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 :
CONTROL RELAY circuits

Seal-in :
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.
Types : Thermal & Magnetic
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.

Reference : Colin D. Simpson

Hydraulic components

Cylinder Rotary actuator

Reference : Colin D. Simpson

TIMING AND COUNTING DEVICES
Time Delay Relay (TDR) - provides a time delayed
switching action.

Types of counting devices:

Electromechanical
Electro pneumatic
Mechanical
Electronic

Reference : Colin D. Simpson

TDR’s - TDOFF
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

Reference : Colin D. Simpson

Problem 5-19

Reference : Colin D. Simpson

Problem 5-20

Reference : Colin D. Simpson

Problem 5-21