Control of Machines. Revised second edition

Cover
......Page 1
Preface......Page 8
Contents......Page 10
1.1 General Idea of Controls
......Page 18
1.3 Introduction to Magnetic Control
......Page 19
1.4 Advantages of Magnetic Control
......Page 21
1.5 Semi-Automatic and Automatic Control of Modern Machinery
......Page 22
1.6.1 Development of Two-wire and Three-wire Control
......Page 23
1.6.2 Remote Control Operation of a Motor......Page 25
1.6.3 Interlocking of Drives......Page 26
2.1 Introduction
......Page 28
2.2 Fuses, Switches and Fuse Switch Units
......Page 29
2.3 Moulded Case Circuit Breaker and Miniature Circuit Breaker (MCCB & MCB)
......Page 31
2.4.1 Solenoid Type Contactor......Page 33
2.4.2 Clapper Type Contactor......Page 34
2.4.3 Lock-out Type Contactor......Page 36
2.4.4 Inductive Accelerating Contactors......Page 37
2.5 Contactor Ratings
......Page 38
2.6 Relays
......Page 39
2.6.1 Voltage Relays......Page 40
2.6.2 D.C. Series Current Relay......Page 41
2.6.3 Frequency Responsive Relay......Page 42
2.6.4 Latching Relays......Page 43
2.7.1 Bimetallic Thermal Overload Relay
......Page 45
2.7.3 Magnetic Dash Pot Oil Filled Relay
......Page 47
2.8 Time Delay Relays (Timers)
......Page 49
2.8.2 Pneumatic Timer
......Page 50
2.8.3 Motor Driven Timers
......Page 52
2.8.4 Electronic Timer
......Page 53
2.9 Phase Failure Relay (Single Phasing Preventer)
......Page 54
2.10 Push Button Switches
......Page 56
2.11 Selector Switches
......Page 57
2.13 Limit Switches
......Page 59
2.13.1 A Simple Limit Switch
......Page 60
2.13.3 Heavy Duty Limit Switches
......Page 62
2.14 Solenoid Valves
......Page 63
2.15 Pressure Switches
......Page 65
2.16 Pressure Transducer
......Page 67
2.17 Temperature Switches (Thermostats)
......Page 68
2.18 Float Switch
......Page 69
2.19 Control Transformer
......Page 71
2.20 Symbols for Various Components
......Page 72
2.21 Control Diagrams
......Page 73
3.1 Introduction
......Page 80
3.1.1 Motor Current at Start and During Acceleration
......Page 81
3.1.2 No-load Speed and Final Speed of Motor
......Page 82
3.1.3 Starting of Motor
......Page 83
3.2.1 Manual Primary Resistor Type Starter
......Page 84
3.2.2 Semi-automatic Stepless Resistance Starter
......Page 86
3.2.3 Automatic Primary Resistor Type Starter
......Page 87
3.3 Increment Resistance Starter
......Page 88
3.4 Line-Reactor Reduced Voltage Starter
......Page 90
3.5. Auto-Transformer Reduced Voltage Starters
......Page 92
3.5.1 Manual Auto-transformer Starter
......Page 93
3.5.2 Automatic Auto-transformer Starter (Open Circuit Transition)
......Page 94
3.5.3 Auto-Transformer Voltage Starter (Closed Circuit Transition)
......Page 96
3.6 Part Winding Motor Starter
......Page 99
3.6.1 Two Step Starting
......Page 100
3.6.2 Three Step Starting
......Page 101
3.7 Star-Delta Starter
......Page 102
3.7.1 Manual Star-delta Starter
......Page 104
3.7.2 Push-button Operated Manual Star-delta Starter......Page 105
3.7.3 Semi-automatic Star-delta Starter 
......Page 106
3.7.4 Automatic Star-delta Starter (Open Circuit Transition)
......Page 108
3.7.5 Automatic Star-delta Starter (Closed Circuit Transition)
......Page 109
3.8 Starters for Multi-Speed Motors
......Page 112
3.8.1 Starter for Two-Speed, Two Winding (Separate Winding) Motor
......Page 114
3.8.2 Two Speed One Winding (Consequent Pole) Motor Starter......Page 116
3.9 Reversing the Direction of Rotation of Induction Motors
......Page 119
3.10 Plug Stopping of Motor
......Page 120
3.11 Dynamic Braking
......Page 121
4.1 Introduction
......Page 126
4.2 Motor Acceleration
......Page 128
4.3 Manual Face Plate Starter
......Page 130
4.4 Manual Starter Using Master Controllers
......Page 132
4.5.1 Definite Time Limit Starter
......Page 133
4.5.2 Current Limit Acceleration Starter
......Page 137
4.5.3 Secondary Frequency Acceleration Starter
......Page 138
5.1.2 Series Motor......Page 141
5.2 Principles of DC Motor Acceleration
......Page 142
5.3.2 Three-point Starter
......Page 146
5.3.3 Four-point Starter
......Page 147
5.4 Types of Starters for Automatic Acceleration
......Page 148
5.4.1 Direct-on-line Starter
......Page 149
5.4.2 Current Limit Acceleration Starters
......Page 150
5.4.3 Definite Timer Acceleration Starters
......Page 154
5.5 Reversing of DC Motors
......Page 157
5.6 Jogging Operation of Motor
......Page 160
5.7 Dynamic Breaking of Motor
......Page 161
5.8 Plugging Circuit for DC Motor
......Page 163
6.1 Types of Single Phase Motors
......Page 166
6.2.1 Reversing Direction of Rotation of Universal Motor
......Page 167
6.2.2 Speed Control of Universal Motor
......Page 169
6.3 Shaded Pole Motor......Page 170
6.4.1 Standard Split Phase Motors
......Page 172
6.4.3 Starters for Capacitor Type Split Phase Motors
......Page 174
6.4.4 Starter for Two Value Capacitor Type Split-phase Motors
......Page 175
6.4.5 Starter for a Two Value Capacitor Motor Using a Current Relay and an AutoTransformer
......Page 176
6.4.7 Plug Reversing of Capacitor Start Motors
......Page 177
6.4.8 Speed Control of Split Phase Motors
......Page 178
6.4.9 Speed Control of Permanent Split Capacitor Motors
......Page 179
7.1 Construction and Operation of a Synchronous Motor
......Page 182
7.2 Manual Push Button Synchronising Starter
......Page 183
7.4 Automatic Starter Using Polarised Field Frequency Relay
......Page 184
8.2 Co-Ordination of Fuse, Over-Load Relay and Contactor/Circuit Breaker Operating Characteristics
......Page 188
8.3.1 Overload and Short Circuit Protection
......Page 189
8.3.2 Over Temperature Protection
......Page 192
8.3.3 Under Voltage Protection
......Page 193
8.3.4 Phase Failure and Phase Reversal Protection
......Page 194
8.4.1 Field Failure Protection Circuit for dc Shunt Motors
......Page 195
8.4.2 Field Acceleration Protection Circuit
......Page 196
8.4.3 Field Deceleration Protection Circuit
......Page 198
9.2 Planer Machine
......Page 201
9.3 Skip Hoist Control
......Page 204
9.4 Automatic Control for a Water Pump
......Page 206
9.5 Lifting Magnet
......Page 208
9.6 Control of Electrical Oven
......Page 210
9.7 Overhead Crane
......Page 213
9.8 Battery Trolley
......Page 219
9.9 Battery Operated Truck
......Page 222
9.10 Air Compressor
......Page 225
9.11 Walking Beam
......Page 229
9.12 Conveyor System
......Page 234
9.13 Elevator
......Page 239
10.1 Introduction
......Page 248
10.2.2 Loose Connections
......Page 249
10.2.3 Faulty Contacts
......Page 250
10.2.5 Combination Problems
......Page 251
10.2.7 Grounding
......Page 252
10.2.8 Momentary Faults
......Page 253
10.3 General Procedure for Troubleshooting
......Page 254
11.1 Introduction 
......Page 259
11.2 Advantages of Static Control over Magnetic Relay Control......Page 260
11.3 Disadvantages of Static Control over Magnetic Relay Control
......Page 261
11.4.1 AND Gate......Page 262
11.4.2 OR Gate
......Page 263
11.4.4 NOR Gate
......Page 265
11.4.6 Exclusive OR gate
......Page 266
11.5 Solid State Timer
......Page 267
11.6 Memory Elements (Off-Return Type)
......Page 268
11.6.2 JK Flip Flop
......Page 270
11.7 Retentive Memory Element
......Page 271
11.8 Development of Logic Circuits
......Page 272
11.9.1 Capacitive Switch Filters
......Page 276
11.9.2 Bounce Eliminators
......Page 277
11.9.3 Signal Converters
......Page 278
11.10 Output Devices for Solid State Logic
......Page 280
11.11 Solenoid Valve Operated Cylinder Piston Assembly
......Page 281
11.12 Control of Three Stage Air Conditioning System
......Page 282
11.13 Speed Control of Wound Rotor Induction Motor
......Page 284
11.14 Control of Planer Machine
......Page 286
11.15 Control of Three Conveyors
......Page 289
11.16 Shift Register
......Page 291
11.17 Conveyor System Using a Shift Register
......Page 292
11.18 Counter
......Page 294
11.19 Decoder
......Page 295
11.20 Loading of Castings Into Annealing Furnace Using Decade Counter and Decoder
......Page 296
11.21 Mono Shot
......Page 298
11.22 Clock
......Page 299
11.23 Automatic Filling of Silos Using a Clock and a Monoshot
......Page 300
11.24 Down Counter
......Page 302
11.25 Encoder
......Page 303
11.26 Product Dispersion Conveyor System Using a Down-Counter, an Encoder, a Mono-Shot and a Timer
......Page 304
12.1 Introduction
......Page 308
12.2.1 Fixed I/O
......Page 311
12.2.2 Modular I/O
......Page 312
12.3 Discrete Input Modules
......Page 313
12.3.1 AC Discrete Input Module
......Page 314
12.3.2 DC Discrete Input Module
......Page 315
12.4.1 AC Output Module......Page 316
12.4.3 Rating of Output Modules......Page 318
12.5 Analog I/O Modules
......Page 319
12.7 Processor Unit
......Page 320
12.7.2 Memory Types
......Page 324
12.7.4 Output Image Table......Page 325
12.7.6 Variable Data Memory......Page 326
12.8.1 Dedicated Desktop Programmers
......Page 327
12.8.3 Computer Programmers
......Page 328
12.8.4 Advantages of Using Personal Computers for Programming
......Page 329
12.9.1 Introduction
......Page 330
12.9.2 Physical Components Versus Program Components
......Page 332
12.9.3 Examine ON Instruction
......Page 333
12.9.6 Latching Instruction
......Page 334
12.9.8 Programming Stop Push-buttons
......Page 335
12.9.10 Overload Contacts
......Page 337
12.9.11 Master Control Relay Instruction
......Page 338
12.9.12 Branch Open and Branch Close Instructions
......Page 340
12.9.13 Timer Instruction
......Page 342
12.9.14 Counter Instruction
......Page 344
12.9.15 Sequencer Instruction
......Page 346
12.9.16 Basic Operation of Time Driven Output Sequencer Instruction
......Page 348
12.10.2 Relay Ladder Logic Diagram
......Page 349
12.10.4 Explanation for the Ladder Program
......Page 351
References and Suggestions for Further Study 
......Page 355