| My daughter will be studying for her driver’s license exam soon, and I can already hear the questions starting. “What does that sign mean? Why does this sign mean construction is ahead?” Symbols are an important part of our everyday lives, and in order to pass her test she’s going to become familiar with dozens of them that line our highways.
Just as a triangle on the highway is a symbol for “caution,” industrial control systems employ a variety of symbols in their diagrams. The pictures are shorthand for words. They simplify the message, just as hieroglyphics did for our early ancestors who had not yet mastered the ability to write. Ladder diagrams and the abstract symbols used in them are unique to industrial control systems, and they result in faster, clearer interpretations of how the system operates. Last week we analyzed an electric circuit to see what happens when we put a relay to use within a basic industrial control system, as found in Figure 1.
Figure 1Now let’s see how it looks in an even simpler form, the three-rung ladder diagram shown in Figure 2. Figure 2In industrial control terminology the electric relays shown in ladder diagrams are often called “control relays,” denoted as CR. Since a ladder diagram can typically include many different control relays, they are numbered to avoid confusion. The relay shown in Figure 2 has been named “CR1.” Our ladder diagram contains a number of symbols. The symbol on the top rung which looks like two parallel vertical lines with a diagonal line bridging the gap between them represents the N.C. contact. This symbol’s vertical lines represent an air gap in the N.C. contact, the diagonal line is the relay armature which performs the function of bridging/closing the air gap. This rung of the ladder diagram represents the contact when the relay is in its normal state. In the middle ladder rung the N.O. contact symbol looks like two parallel vertical lines separated by a gap. There is no diagonal line running through it since the relay armature doesn’t touch the N.O. contact when this particular relay is in its normal state. The wire coil and steel core of this relay are represented by a circle on the bottom ladder rung. The contact and coil symbols on all three rungs are labeled “CR1” to make it clear that they are part of the same control relay. Other symbols within Figure 2 represent the red and green bulbs we have become familiar with from our initial illustration. They are depicted as circles, R for red and G for green, with symbolic light rays around them. The pushbutton, PB1, is represented as we have discussed in previous articles on ladder diagrams. Just as road sign symbols are faster than sentences for drivers speeding down a highway to interpret, ladder diagrams are faster than customary illustrations for busy workers to interpret. Next time we’ll expand on our electric relay by introducing latching components into the control system that will allow for a greater degree of automation. ____________________________________________ |
Posts Tagged ‘steel core’
Industrial Control Basics – Electric Relay Operation
Monday, January 9th, 2012| It’s a dark and stormy night and you’ve come to the proverbial fork in the road. The plot is about to take a twist as you’re forced to make a decision in this either/or scenario. As we’ll see in this article, an electric relay operates in much the same manner, although choices will be made in a forced mechanical environment, not a cerebral one.
When we discussed basic electric relays last week we talked about their resting in a so-called “normal state,” so designated by industrial control parlance. It’s the state in which no electric current is flowing through its wire coil, the coil being one of the major devices within a relay assembly. Using Figure 3 of my previous article as a general reference, in this normal state a relaxed spring keeps the armature touching the N.C. switch contact. While in this state, a continuous conductive path is created for electricity through to the N.C. point. It originates from the wire on the left side, which leads to the armature pivot point, travels through the armature and N.C. contact points, and finally dispenses through the wire at the right leading from the N.C. contact. Now let’s look at an alternate scenario, when current is made to flow through the coil. See Figure l, below.
Figure 1Figure 1 shows the path of electric current as it flows through the wire coil, causing the coil and the steel core to which it’s attached to become magnetized. This magnetization is strong, attracting the steel armature and pulling it towards the steel core, thus overcoming the spring’s tension and its natural tendency to rest in a tension-free state. The magnetic attraction causes the armature to rotate about the pivot point until it comes to rest against the N.O. contact, thus creating an electrical path en route to the N.O. wire, on its way to whatever device it’s meant to energize. As long as current flows through the wire coil, its electromagnetic nature will attract the armature to it and contact will be maintained with the N.O. juncture. When current is made to flow through the wire coil, an air gap is created between the armature and the N.C. contact, and this prevents the flow of electric current through the N.C. contact area. Current is forced to follow the path to the N.O. contact only, effectively cutting off any other choice or fork in the road as to electrical path that may be followed. We can see that the main task of an electric relay is to switch current between two possible paths within a circuit, thereby directing its flow to one or the other. Next time we’ll examine a simple industrial control system and see how an electric relay can be engaged with the help of a pushbutton. ____________________________________________ |
Industrial Control Basics – Introduction to Electric Relays
Tuesday, January 3rd, 2012| I’ve always considered science to be cool. Back in the 5th grade I remember fondly leafing through my science textbook, eagerly anticipating our class performing the experiments, but we never did. For some reason my teacher never took the time to demonstrate any. Undeterred, I proceeded on my own.
I remember one experiment particularly well where I took a big steel nail and coiled wire around it. When I hooked a battery up to the wires, as shown in Figure 1 below, electric current flowed from the battery through the wire coil. This set up a magnetic field in the steel nail, thereby creating an electromagnet. My electromagnet was strong enough to pick up paper clips, and I took great pleasure in repeatedly picking them up, then watching them unattach and fall quickly away when the wires were disconnected from the battery. Figure 1
Little did I know then that the electromagnet I had created was similar to an important part found within electrical relays used in many industrial control systems. An example of one of these relays is shown in Figure 2. Figure 2
So, what’s in the little plastic cube? Well, a relay is basically an electric switch, similar to the ones we’ve discussed in the past few weeks, the major difference being that it is not operated directly by human hands. Rather, it’s operated by an electromagnet. Let’s see how this works by examining a basic electrical relay, as shown in Figure 3.
Figure 3
The diagram in Figure 3 shows a basic electric relay constructed of a steel core with a wire coil wrapped around it, similar to the electromagnet I constructed in my 5th grade experiment. If the coil’s wires are not hooked up to a power source, a battery for example, no electric current will flow through it. When there is no current the coil and steel core are not magnetic. For purposes of our illustration and in accordance with industrial control parlance, this is said to be this relay’s “normal state.” Next to the steel core there is a movable steel armature, a kind of lever, which is attached to a spring. On one end of the armature is a pivot point, on the other end is a set of electrical switch contacts. When the relay is in its normal state, the spring’s tension holds the armature against the “normally closed,” or N.C., contact. If electric current is applied to the wire leading to the pivot point on the armature while in this state, it will be caused to flow on a continuous path through the armature and the N.C. contact, then out through the wire leading from the N.C. contact. In our illustration, since the armature does not touch the N.O. contact, an air gap is created that prevents electric current from traveling through the contact from the armature. Next week we’ll see how these parts come into play within a relay when electric current flows through the coil, turning it into an electromagnet. ____________________________________________ |
