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Last summer my wife and I did a lot of work in the garden. Many holes were dug, bags of garden soil lifted, and plants planted. It’s a new garden, and my wife has very big plans for it, so needless to say there was a lot of work to be done. On more than one occasion we would end the day moaning about our body aches and how we had overdone it. The next day we would hurt even worse, and we’d end up taking time off to recuperate. Pain is your body’s way of telling you that it needs attention, and you’d better listen to it or you may have an even heavier price to pay down the road. Electric motors can get overworked, just like our bodies. Motors are often placed into situations where they are expected to perform tasks beyond their capability. Sometimes this happens through poor planning, sometimes due to wishful thinking on the user’s part. Motors can sustain damage when stressed in this way, but they don’t have a pain system to tell them to stop. Instead, motors benefit by a specific type of electric relay known as an overload relay. But before we get into how an overload relay works, let’s get a better understanding of how overloads happen. Suppose we’re back in the telephone factory discussed in previous blogs, watching a conveyor belt move phones through the manufacturing process. An electric motor drives the conveyor belt by converting electrical energy into mechanical energy. Everything is moving along normally when all of a sudden a machine malfunctions. Telephones start piling up on a belt, and the pile up gets so bad the belt eventually gets jammed and its motor overloaded. If the electricity flow to the motor isn’t shut down promptly by means of a nearby emergency stop button or an astute operator sitting in central control, then an even bigger problem is in the making, that of a potential fire. When electricity is applied to motors they begin to operate, and their natural tendency is to want to keep operating. They do so by continuously drawing energy from the electric current being supplied to them. The greater the workload demand on the motor, the more current it requires to operate. When motors become overloaded as in the scenario presented above, they continue to draw energy unless forced to a stop. The result is an overabundance of current flowing through the motor and no outlet for its task of converting electrical energy into mechanical energy. And where is all that pent up energy to go? It becomes heat energy trapped inside the motor itself, and this heat can build up to the point where the motor becomes damaged or even bursts into flames. Next time we’ll look at how overload relays work to keep electric motors from overheating, just as our body’s pain sensors protect us from overdoing it.
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Posts Tagged ‘electricity flow’
Industrial Control Basics – Electric Relay Example
Saturday, January 14th, 2012| When a starving monkey is faced with two buttons, one representing access to a banana, the other cocaine, which will he push? The cocaine, every time. The presence of buttons usually indicates a choice must be made, and electric relays illustrate this dynamic.
Last week we looked at a basic electric relay and saw how it was used to facilitate a choice in electricity flow between two paths in a circuit. Now let’s see what happens when we put a relay to use within a basic industrial control system making use of lit bulbs.
Figure 1
Figure 1 shows an electric relay that’s connected to both hot and neutral wires. At the left side is our pushbutton and the hot wire, on the right two bulbs, one lit, one not, and the neutral wire. No one is depressing the pushbutton, so an air gap exists, preventing current from flowing through the wire coil between the hot and neutral sides. With these conditions in place the relay is said to be in its “normal state.” The relaxed spring positioned on the relay armature keeps it touching the N.C. contact. This allows current to flow between hot and neutral through the armature and the N.C. contact. When these conditions exist the red bulb is lit, and this is accomplished without the need for anyone to throw a switch or press a button. In this condition the other lamp will remain disengaged and unlit. Now let’s refer to Figure 2 to see what happens when someone presses the button.
Figure 2
When the button is depressed the air gap is eliminated and the coil and wire become magnetized. They will attract the steel armature closer to them, the spring to expand, and the armature to engage with the N.O. contact. Under these conditions current will no longer flow along a path to light the red bulb because an air gap has been created between the armature and N.C. contact. The current instead flows through the N.O. contact, lighting the green bulb. It will stay lit so long as someone holds the button down. If our monkey were faced with the scenarios presented in Figures l and 2 and a banana was placed in the position of the red bulb, the cocaine in the position of the green, he might find that the regular delivery of bananas that takes place when the relay is in the N.C. contact position is enough to keep him happy. In this state he might be so full of bananas he won’t want to expend the energy to engage the button into the N.O. contact position for the delivery of cocaine. Next time we’ll revisit the subject of ladder diagrams and see how they are used to denote the paths of electric relays. ____________________________________________ |
Industrial Control Basics – Manual Control
Monday, December 12th, 2011| You’ve probably heard the saying, “asleep at the switch.” It’s usually associated with some sort of disaster, found later to have been caused by human error. Someone wasn’t paying attention, and something very bad happened. The meltdown of the Soviet nuclear power plant Chernobyl in 1986 comes to mind. You may be surprised to learn that the saying has its origins in the world of industrial controls, or more specifically, manual controls, as we’ll see in this article.
Last week when we opened our discussion on manual controls, we talked about how they work just as their name implies, that is, someone must manually press a button or throw a switch in order to initiate a factory operation. In other words, a manual control requires human intervention to initiate an action, such as pushing the start button. The machine will then continue to run until a person hits the stop button. Let’s go now on a virtual field trip into a telephone factory to see how a basic manual control system works. It has a conveyor belt operated by an electric motor, and this motor is connected by wires and a power switch to a 120 volt power source of alternating current. Figure 1 illustrates what we mean. It shows that when the power switch is in the open position, a physical air gap exists within the electrical circuit. This prevents electricity from flowing through the wire because electricity can’t jump over gaps.
Figure 1 – Open Power Switch Enter a human into the scenario, someone who grabs the power switch handle and manually closes it, eliminating the air gap. See Figure 2.
Figure 2 – Closed Power Switch When the power switch is closed, a metal conductor bridges the gap, causing electricity to flow through the metal conductor to the electric motor in the circuit. This brings life to the conveyor belt. As long as the power switch remains closed, the conveyor belt will continue to operate. That’s it, that’s a basic manual control system. It’s simple to operate, but it does have one major flaw. It requires constant monitoring by a human. Aside from opening and closing a power switch, humans are required to monitor operations, in case something goes wrong. The operator watching over an industrial machine performs the same function as the pilot on a plane, that is, to start-stop operations, and to intervene in case of an emergency. Computers fly modern jets. Pilots serve as trouble shooters when the unanticipated disaster situation occurs, because computers can’t yet creatively problem solve. Next time we’ll introduce the element of an automatic control system, which will virtually eliminate the need for human intervention and with it human error. ____________________________________________ |
