## Posts Tagged ‘wire coil’

### 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.

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### Transformers – Alternating Current Does the Trick

Sunday, December 12th, 2010

 If you’ve seen the movie The Prestige, you know just how “tricky” electricity can be, and if you haven’t seen it yet, you’ve yet to see a great movie.  In it, Hugh Jackman uses the magical properties of electricity to pull off a magic trick the likes of which the world has never seen.  But that’s all I’ll say about that… see the movie.      In 1886, a young American inventor named William Stanley did some serious thinking about Michael Faraday, the British scientist we introduced last week, and his work with electricity and magnetism.  Stanley figured out how to put it all together.  The result was the world’s first electrical transformer.      What fueled Stanley’s curiosity?  Like most good inventors, he perceived a need and sought to fill it.  At the time George Westinghouse was developing his alternating current (AC) electric utility power system, the same basic system we use today.  As Westinghouse’s chief engineer, Stanley was given the task of figuring out a way to efficiently change voltage levels on an AC power grid.  The industrial revolution was in full swing, and for various industrial purposes factories needed to operate on voltage levels different from those produced by the Westinghouse generators.      Stanley approached the task before him with the benefit of knowledge supplied by Faraday’s experimentation.  He knew that Faraday was able to cause current to flow through a wire by moving a magnet near it back and forth.  This phenomenon occurred because lines of magnetic flux were varying over time with respect to the wire through the magnet’s movement.  Being aware of the vicissitudes of alternating current, the way it varies in intensity and direction, Stanley was able to conclude that any lines of magnetic flux generated by AC current flowing through a coiled wire would also tend to vary over time.  Armed with this knowledge, Stanley replaced the DC battery used in Faraday’s experiment with an AC generator.  This modified setup is shown in Figure 1.  Figure 1 – Faraday’s Experiment Modified With An AC Power Source      In the modified setup the switch is closed, causing the AC power flowing through the first coiled wire to create lines of magnetic flux in the iron rod.  These lines of flux continually vary and thus induce AC flow in the second coil.  The action taking place is duly recorded by a Galvanometer needle, which keeps moving so long as the switch remains closed.       Stanley also knew that the voltage created in the second coiled wire was dependent on how many turns, or loops, of wire were present in it compared to the number of turns of wire in the first coil.  He made the observation that if less turns were present in the second coiled wire as compared to the first, less voltage would also be emitted from the second coiled wire.  This demonstrates the phenomenon of changing voltage with respect to supply delivered by the AC generator to the first coil.      Putting these findings together, Stanley was able to develop the first practical electrical transformer, whose basic design is shown in Figure 2.  Here we see that the iron rod from Faraday’s experiment has been replaced with an iron transformer core resembling a squared off doughnut.   Figure 2 – A Basic Electrical Transformer      Next time we’ll get into the math behind this discussion, and we’ll see how Stanley’s transformer worked. _____________________________________________