ELECTRICAL
HARDWARE
CONTROL
CONTROL
The out put on &off by the help of input
device. that is called control.
Definition: Control is a set of
technologies that achieves desired
patterns of variations of operational
parameters and sequences for machines
and systems by providing the input
signals.
Example on control
One example of a simple control circuit
is a circuit that turns a light on and off. In this
circuit, the control component is often a
single-pole switch.
Need of controlling
device
?
Types of control
Normally in industry we are using different
types of control.
1. On-off control.
2. Sequential control.
3. Feed back control.
4. Motion control.
5. Logical control.
On-off control
It is the simplest method
of control where desire out
put may be on/off depending
upon the input signal stage ,
whether it will allow or block
the signals.
Sequential control
A control system in which the
individual steps are processed in a
predetermined order, progression from one
sequence step to the next being
dependent on define condition being
satisfied. such a system may be time-
dependent, in which the step transition
conditions are functions of time only ; on
external event dependent, where the
conditions are function of input signals
only ; or combination of this(and perhaps
more complex conditions).
Feed back control
A control system which monitors it effect
on the system . It is controlling and modifying its
output accordingly.
Motion control
It is a sub-field of automation, in which
the position and / or velocity of machines are
controlled using some type of devices such
as hydraulic motion, pneumatic motion,
linear actuator or an electric motor, generally
a servo.
Logical control
In control the output devices operate
by the help of logical instruction ,
programming language by microprocessor ,
microcontroller & PLC
Factor
All the control system depending upon two loop.
Open loop system.
Closed loop system.
Open loop system
Open loop systems have no access to the real
time data about the performance o of the system
and therefore no immediate corrective action can
be taken in case of system disturbance. This
system is normally applied only to the case where
the output is almost constant and predictable
therefore an open loop system is unlikely to be
used to control a machine.
Closed loop system
In case of closed loop system feed back devices
closely monitor the output and any disturbance will
be corrected in the first instance. Therefore high
system accuracy is achievable . this system is more
power full that the open loop system and can be
applied to case where the out pout is subjected to
frequent change.
Types of signal
Signal-
A signal is an electric current or
electromagnetic field used to convey data
from one place to another.
Signal are divided in to 2 types:
Analog signal.(Continues signal)
Digital signal.(Discreet signal)
Analog signal.
Analog signal is any type of continue signal
which represent has a physical measurement
denoted as sine wave .
Here the time variable features is present .
Digital signal.
Digital signal is any type of discreet signal
which represent has a physical measurement
denoted as square wave .
Here the time value is constant.
History of process
control
Manual control.
Hardware logic control.
Electronic control using logic
gate.
Programmable logic control.
Manual control
All the action related to process control and
automation is taken by a operator.
Measure draw backs here is a human
error .which affects on quality of final product
.
The manual control has its own limitation on
mass production. so it can not provide quality
goods with and affordable price.
The safety or efficient use of raw materials
are totally depending upon accuracy of
human action.
EXAMPLE OF MANUAL
CONTROL
Manual Control circuits use
components that require human
interaction in order to operate.
switch
AC
source
EXAMPLE OF MANUAL
CONTROL
Manual Control circuits use
components that require human
interaction in order to operate.
switch
AC
source
Hardware logic control
This was the consider to be the first step
towards automation.
Here contactor and relay together with timer
and counter were used in achieving the
desired level of automation .
This method served the tasks for many years
but still it had certain limitation .
1.Bulky and complex wirings.
2.involes lot of rewiring to implement
changes in control circuit.
3.the work is started only when the
task is fully defined , so it takes a longer
time.
Example
Electronic control
using logic gate
Here the digital logic gate replaced the relays
and contactors in the control circuit. The
mechanical timers were replaced by
electronics timer.
So the benefits are :
Reduce space
Energy saving
Less maintenance
Grater reliability
So this method of automation was popular for quite some
time
Programmable logic
control
With the development of microprocessor the
process of control and automation was totally
changed.
Instead of doing the control in physical
wirings using the plc it is done by a program.
Due to the use of program it is called as
programmable logic controller.
Now a days these types of controllers are
rapidly used to control the process.
EXAMPLES OF
AUTOMATED PLANTS
EXAMPLES OF
AUTOMATED PLANTS
EXAMPLES OF
AUTOMATED PLANTS
EXAMPLES OF
AUTOMATED PLANTS
EXAMPLES OF
AUTOMATED PLANTS
CONTROLING DEVICE
(IN PUT)
Basically in industries different method
controls are there such as:
Mechanical control.
Electromechanical control.
Electronics control.
Hydraulic & pneumatic control.
WHAT IS SWITCH
A switch is a type of device
that can break and make a
controlling
circuit ,interrupting the
signal or diverting it from
one point to another point.
different switching
device
Steps to be followed to find out a switching
device.
1. Contact parts of switch.
2. Actuation mechanism.
3. State of switch.
CONTACT PARTS OF SWITCH
Every switch having incoming path(pole) & out going
path(throw).
If the incoming path & out going path is connected with
each other then i.e. called NC(Normally Closed) contact.
If the incoming path & out going path is disconnected with
each other then i.e. called NO(Normally Open) contact.
A common contact(C) is a combination contact
composed of a normally closed & a normally open contact
operated by the same device, with common electrical
connection resulting in only three connection terminal.
ACTUATION MECHANISM.
The force that is required to activate a switch
is called actuation mechanism.
According to digital input device different
type actuation applied .
Manual force
Mechanical force
Electrical force
Spring return force
STATE OF SWITCH.
It is represent switch having which state,
whether the switch is in ON STATE OR OFF
STATE, means ON POSITION OR OFF
POSITION.
TYPES OF SWITCH
Toggle switch
Push button switch
Selector switch
Limit switch
Relay
Contactor
Timer
Sensor
Types of switch Types of switch according to
according to actuation construction
manual force:- toggle switch Mechanical switch:-
push button toggle switch
switch
push button
selector switch switch
mechanical force
selector switch
limit switch
electrical force limit switch
relay Electro mechanical switch
contactor relay
timer contactor
sensor timer
spring return force
toggle switch sensor
push button switch
selector switch
limit switch
relay
contactor
TOGGLE SWITCH
Toggle switch
A switch that uses a toggle joint with a
spring to open or close an electrical circuit as
an attached leaver is pushed or shifted
through a small force .
It is different type
1.spst(single pole single throw)
2.spdt(single pole double throw)
3.dpst(double pole single throw)
4.spco(single pole change over/ center off)
5.dpdt(double pole double throw)
6.qpdt(quarter pole double throw)
single pole
SPST single throw
single pole
SPDT double throw
double pole
DPST single throw
BIKE
single pole
LEFT/RIGHT
SPCO change over/ INDICATOR
OPERATING
center off
SWITCH
double pole
DPDT double throw
4 COMMON
quarter pole
TYPE RELAY
QPDT double throw SWITCH
INTERNAL PARTS OF TOGGLE SWITCH
PUSH BUTTON SWITCH
PUSH BUTTON SWITCH
It is a one type of momentary switching
device.
The deactivation is done using an internal
spring.
The maintained pushbutton activates when
pressed, but remains activated when it is
released. Then to deactivate it , it must be
pressed a second time. For this reason, this
type of switch is sometimes called a push-
push switch.
The on/off switches on most desktop
computers and laboratory oscilloscopes are
maintained pushbuttons.
PUSH BUTTON SWITCH
It is a one type of momentary switching device.
Types of push button (DEPENDING UPON CONTACT)
1. NO CONTACT TYPE.
2. NC CONTACT TYPE.
Types of push button (DEPENDING UPON CONSTRUCTION)
1. PLAIN HEADED TYPE.
2. MUSHROOM HEADED TYPE.
Types of push button (DEPENDING UPON OPERATION)
1. START PROCESS
COMMON STOP
2. STOP PROCESS
EMERGENCY STOP KEY TO RELEASE
PULL TO RELEASE
OR
PALM TYPE
Types of push button (DEPENDING UPON OPERATION AS PER COLOR CODE)
1. GREEN –START PROCESS
2. YELLOW-INCH PROCESS
3. RED-STOP PROCESS
. MUSHROOM HEADED TYPE.
. PLAIN HEADED TYPE.
PALM TYPE
KEY TO RELEASE PULL TO RELEASE
TOTAL VIEW OF PUSH BUTTON
SWITCH TERMINOLOGY
Momentary contact switch:-a switch in which the shorting
bar return from its operated position to its normal or free
position when the actuating force is removed
Break-before-make switch (BBM/NC):-a switch in which
the moving contact breaks the connection with the first
circuit before making contact with the second ;also called
non-shorting switch
Make before brake switch (MBB/NO):-a switch in which
the contacts makes connection whit second circuit before
breaking contact whit the first ; also called shorting switch.
Alternate action (push-push) switch:-a switch in which
the operable position is maintained after the first actuation
, and then disengaged with the second operation.
.
Maintained contact switch:- (PULL TO RELEASE TYPE
PUSH BUTTON / Key to Release):- a switch in which the
actuator remains in a position until it is
actuated to another position where it also
remains until actuated .
Joy stick action switch:-A lever switch which
operates with momentary action in 4 directions.
SYMBOL
(Momentary Pushbutton Switches)
SYMBOL
(Momentary Pushbutton Switches)
(Maintained Switch)
SELECTOR SWITCH
SELECTOR SWITCH
A selector switch is also known as a rotary
switch.
SYMBOL
LIMIT SWITCH
LIMIT SWITCH
Limit switches are usually not operator
accessible. Instead they are activated by
moving parts on the machine. They are
usually mechanical switches.
Example :
• Refrigerator door that turns on the
light inside
• Cam switches
• Door open & close
RELAY
RELAY
It is the Device which uses a small amount of current
to control a large amount of current.
A switch that can be turned on and off by electricity
(instead of by a person).
Uses magnetic properties of materials and the
magnetic forces due to electric current flow.
A relay is an electrical switch that opens and closes
contacts under control of another electrical circuit.
The switch is operated by an electromagnet
(Solenoid) to open or close one or many sets of
contact points.
It was invented by Joseph Henry in 1835.
A relay is able to control an output circuit of higher
power than the input circuit which is at lower
power.
A RELAY LOOKS LIKE…..
Lever
(Magnetic Material)
NC
Contact
Solenoi
d Coil NO
Contact
Sprin
g
Common
Contact
OPERATION
When a current flows through the
coil, the resulting magnetic field
attracts an armature that is
mechanically linked to a moving
contact.
The moving contact is supported by
a spring, which keeps the common
contact normally connected to the
NC and when the coil get activated
and a magnetic field is produced,
the moving contact get attracted.
Resulting a closed path between NO
contact and Common contact.
The movement either makes or
Inside a Relay
Magnetic force deflects
the lever downward
Spring force restores when the coil is energized
the lever when the
coil is not energized
Normally closed
contact
Common contact
NC
NO
Normally open
Connections to coil contact
Inside a Relay Magnetic force deflects
the lever downward
Spring force restores when the coil is energized
the lever when the
coil is not energized
Normally closed
contact
Common contact
NC
NO
Normally open
Connections to coil contact
Inside a Relay Magnetic force deflects
the lever downward
Spring force restores when the coil is energized
the lever when the
coil is not energized
Normally closed
contact
Common contact
NC
NO
Normally open
Connections to coil contact
Inside a Relay Magnetic force deflects
the lever downward
Spring force restores when the coil is energized
the lever when the
coil is not energized
Normally closed
contact
Common contact
NC
NO
Normally open
Connections to coil contact
WIRING DIAGRAM OF A RELAY
CONTACTS OF RELAY
Normally-open contacts connect the circuit
when the relay is activated. The circuit is
disconnected when the relay is inactive.
Normally-closed contacts disconnect the
circuit when the relay is activated.The
circuit is connected when the relay is
inactive.
Change-over contacts control two circuits:
one normally-open contact and one
normally-closed contact with a common
terminal.
Relays are used to :
1) To control a high-voltage
circuit with a low-voltage
signal.
2) To control a high-current circuit
AC coil relay
with a low-current signal.
3) To detect and isolate faults on
transmission and distribution lines by
opening and closing circuit breakers
(protection relays).
CONTACTOR
CONTACTOR
Definatio
n
A contactor is an electrical
device used for controlling
power flow.
It is activated by a control
input which is at lower
voltage / current than that
of control output .
APPLICATIO
N
Contactors are used in applications
ranging from the light switch to the most
complex automated industrial
equipment.
It is used by electrical equipment
that is frequently turned OFF and
ON such as lights, heaters, and motors.
A contactor can be used as a controller
in a electrical control circuits, or as an
actuator in Power circuits.
CONSTRUCTION
It is composed of three different
systems.
1) The contact: This system is the current
carrying part of the contactor.This
includes Power contacts, Auxiliary
contacts & contact springs.
2) The electromagnet: This system
provides the driving force to close the
contacts.
CONSTRUCTION
3) The enclosure: This system, is a frame
housing the contact and the electromagnet.
Enclosures are made of insulating
materials like Bakelite, Nylon 6, and
thermosetting plastics to protect and
insulate the contacts and to provide some
measure of , protection to personnel coming
in contact.
Open-frame contactors may have a
further enclosure to protect against dust,
oil, explosion hazards and weather.
CHARACTERISTI
CS
Contactors used for starting
electric motors are commonly fitted with
overload protection to prevent damage
to their loads.
When an overload is detected the
contactor is tripped removing power
downstream from the contactor.
CHARACTERISTI
CS
Some contactors are motor driven rather
than relay driven and high voltage
contactors (greater than 1000 volts)
often have arc suppression systems
fitted (such as a vacuum or an inert gas
surrounding the contacts).
CHARACTERISTI
CS
Contactors are often used to provide
central control of large lighting
installations, such as an office building
or retail building.
To reduce power consumption in the
contactor coils, latching contactors are
used, with two coils.
One coil, momentarily energized, closes
the power circuit contacts; the second
opens the contacts.
CHARACTERISTI
CS
A basic contactor
Will have a coil input (which may be
driven by either an AC or DC supply
depending on the contactor design).
And generally a minimum of two
poles(Double Pole,DP) or three
poles(Tripple Pole Nutral,TPN) contact
points which are controlled when coil
gets a power supply.
OPERATING PRINCIPLE
A contactor is a type of electrical relay.
Unlike general-purpose relays, contactors are designed to
be directly connected to high-current load devices, not
other control devices.
Relays tend to be of much lower capacity and are usually
designed for both Normally Closed and Normally Open
applications.
Devices switching more than 15 amperes or in circuits
rated more than a few kilowatts are usually called
contactors.
Apart from optional auxiliary low current contacts, a
contactor only has Normally Open contacts fitted in
general .
When current passes through the electromagnet, a
magnetic field is produced which attracts ferrous objects,
in this case the moving core of the contactor is attracted
to the stationary core.
Since there is an air gap initially, the electromagnet coil
draws more current initially until the cores meet and
reduct the gap, increasing the inductive impedance of the
circuit.
For contactors energized with alternating current, a small
part of the core is surrounded with a shading coil, which
slightly delays the magnetic flux in the core.
The effect is to average out the alternating pull of the
magnetic field and so prevent the core from buzzing at
twice line frequency. For contactors energized with
alternating current, a small part of the core is surrounded
with a shading coil, which slightly delays the magnetic
flux in the core.
The effect is to average out the alternating pull of the
magnetic field and so prevent the core from buzzing at
twice line frequency.
TIMER
TIMERS
Timers are a critical part
of industrial automation and
are necessary in sequential
processes where a machine
follows a set operational
sequence with some steps
assigned a specific time
span.
TIMERS
In relay ladder logic the timers
are called timing relays because
a contact closure is associated
with the timing function.
Knowledge of timing relays is
important because relay ladder
logic implementations continue
to be used in small control
applications and where higher
current levels must be switched.
TIMERS
Timing relay provides:
on-delay and off-delay
timing
Timed Contacts:
Time delay relay contacts
are specified as either
normally
open (NO) or normally
TIMERS
Timed Contacts:
With the additional
requirement that the delay
operates in the direction of
closing or in the direction of
opening.
TIMERS
Timed Contacts:
The four basic
types of time delay
relay contacts
fall into two groups:
on delay and off
delay.
TIMERS
On-delay timing relays.
The normally open
and normally closed
timed contacts for on-
delay timing relays
have special names.
TIMERS
The normally open are
called normally open,
time close(NOTC)
contacts,
The normally closed
are called normally
closed, timed open
TIMERS
Normally open, timed closed
(NOTC):
When the timing relay coil is
energized, the timed normally
open (NO) contacts remain open
until after the time delay value.
After the time delay, the timed
contacts change state (NO
contacts close) and remain in that
new state as long as the coil is
energized.
When the coil is de-energized,
TIMERS
Normally open, timed closed
(NOTC):
Timing diagrams.(Ex:Delay -
5sec)
TIMERS
Normally closed, timed open
(NCTO):
When the relay coil is
energized, the
timed normally closed (NC)
contacts remain closed until after
the time delay value.
After the time delay, the
timed contacts change state (NC
contacts open) and remain in that
new state as long as the coil is
energized.
TIMERS
Normally closed, timed open
(NCTO):
Timing diagrams.(Ex:Delay -
5sec)
TIMERS
Off-delay timing relays.
The normally open
and normally closed
timed contacts for off-
delay timing relays also
have special names.
TIMERS
Off-delay timing relays.
The normally open
are called normally
open, timed
open(NOTO) contacts,
The normally
closed are called
TIMERS
Normally open, timed
open(NOTO):
When the relay coil is
energized, the timed NO contacts
immediately close and remain in
that new state as long as the coil
is energized.
When the coil is de-
energized, the timed contacts
remain in the changed state (the
TIMERS
Normally open, timed
open(NOTO):
At the end of the time delay
contacts return to their
initial state (NO contacts
open).
Note that the delay starts
after power is removed from
TIMERS
Normally open, timed
Timing diagrams.(Ex:Delay -
open(NOTO):
5sec)
TIMERS
Normally open, timed
open(NOTO):
At the end of the time delay
contacts return to their
initial state (NO contacts
open).
Note that the delay starts
after power is removed from
TIMERS
Normally closed, timed close (NCTC):
When the relay coil is energized,
the timed NC contacts immediately
open and remain in that new state as
long as the coil is energized.
When the coil is de-energized, the
timed contacts remain in the changed
state(NC contacts open) until the set
time delay value is reached.
TIMERS
Normally closed, timed close
(NCTC):
At the end of the time delay
timed contacts return to their
initial state (NC contacts
closed).
Note that the delay starts after
power is removed from the coil.
TIMERS
Normally closed, timed close
Timing diagrams.(Ex:Delay
(NCTC): -
5sec)
Relay Timers
ON Delay
OFF Delay
Wired ON Delay
X1 X2
1. Energy
applied to
power rails
Wired ON Delay - NCTO
X1 X2
1. Energy applied to
power rails
2. Start PB is
pressed
- Coil is energized
- Holding contact
close
- Timer contact
stays closed, lamp
stays on.
- Count begins (5
sec)
Wired ON Delay - NCTO
X1 X2
3. Timer count ends
- Coil is still
energized
- Timer contact open
- lamp goes off.
4. Timer contacts remain
open until the coil is
de-energized
The Normally Closed contact will take 5 seconds To Open when the coil
is energized.
ON Delay - NOTC
X1 X2
1. Power is
applied to rails
The Normally Open contact will take 5 seconds To Close when the coil is
energized.
ON Delay - NOTC
X1 X2
2. Start PB is
pressed
Coil energizes
Holding contacts
close
Timer contacts
stay open
Lamp stays off
Counter starts to
count (5 sec)
The Normally Open contact will take 5 seconds To Close when the coil is
energized.
ON Delay - NOTC
3. Counter finishes
count
Coil stays
energized
Timer contacts
close
Lamp goes on
4. Timer contacts will
open when relay
coil is de-
energized.
The Normally Open contact will take 5 seconds To Close when the coil is
energized.
OFF Delay - NCTC
1. Power is applied to
rails
2. Coil is off, contacts
are closed, lamp is
on
The timer contacts will close 5 seconds after the coil is de-
energized
OFF Delay - NCTC
3. Start PB is pressed
4. Timer contacts open
5. Counter will start to
count only when coil
is de-energized.
OFF Delay - NOTO
1. Power is applied to
rails
2. Coil is off, contacts
are closed, lamp is
on
OFF Delay - NOTO
3. Start is pressed.
4. Contacts close, lamp
on
5. Counter only starts
when coil is de-
energize
TIMERS
Schematic symbols for timing
relays.
SENSOR
Sensor Definitions
WHAT IS A SENSOR?
Used in Industrial Automation:
Electrical
Electrical device
device capable
capable of
of identifying
identifying
change
change within
within an
an automated
automated process.
process.
Sometimes…
Sensor = Switch
Sensor Definitions
USE OF SENSOR
Sensors used in general are
Automatic opening doors.
Conveyer start stop.
Safety sensors on garage doors.
Glowing of lamp when car door is
opened.
Sensors used in Manufacturing
Part position verification of
Tools.
Counting products.
Liquid level control.
Sensing of dielectric
materials,insulators.
Personal safety systems.
Sensor Definitions
COMPONENTS OF SENSOR
The three major components:
The sensing side The electrical side
Back-end
Front-end
Housing
Sensor Definitions
TYPES OF SENSORS
Front-end - Sensing
Five technology choices:
Inductive
Optical
Capacitive
Magnetic
Mechanical
Selection base on: Application
Sensor Definitions
SENSORS USED ON
Back-end – Electrical
Options:
Electrical voltage
AC/DC
DC
Output type
Discrete (on-off, like a switch)
Analog
Selection base on: Control System
Sensor Definitions
SENSORS USED ON
The Sensors Housings
Material Options:
Metal (nickel-plated brass)
Stainless steel
Aluminum
Plastic
Shape (mounting style):
Tubular
Block
Selection base on: Environment
Sensor Definitions
SENSORS ON
THE REAL WORLD
Co
io
nt
at
El
r
ic
in
ol
ec
pl
ns
S
tri
Ap
Se
ys
ca
te
l
m
Housing
Environment
Electrical Interface
A DISCRETE
SENSOR IS A SWITCH
Electronics
Sensing Side
Front-end
Electronics
Switch
Power Wires
Electrical Interface
BASIC SENSOR CIRCUIT
Sensors with relay output
Unlike a switch,
Electronics
sensors require
power to operate
-
Electrical Interface
PNP, 3-WIRE
Standard diagram form
The Sensor
1 +
4 Load PNP Output
3 -
The Load
Connector
Pins
Electrical Interface
PNP, 3-WIRE
Watching the current flow
Sensors Power
Output Signal
1 +
4 Load PNP Output
3 -
Electrical Interface
NPN, 3-WIRE
Watching the current flow
Sensors Power
Output Signal
1 +
4 Load NPN Output
3 -
SENSING TECHNOLOGIES
Sensing Technologies
SENSING TECHNOLOGIES
Non- Contact
Contact
Contact
No physical
withcontact
targetwith target
Simplest
Preferred method
method available
for sensing end products
MECHANICAL SWITCHES
On/off operation only
Two general modes
Normally Open (NO)
Normally Closed (NC)
For a wide range of
uses
Sensing Technologies
CONTACT SENSING
c t
n ta
Mechanical switch C o
Contact with plunger
opens electrical contacts
EXAMPLE MECHANICAL SWITCHES
WHEN TO USE MECHANICAL SWITCHES
Where physical contact is possible
Where definitive position is required
PLACES YOU FIND MECHANICAL
PROXIMITY SWITCHES !
Sensing Technologies
NON-CONTACT
Popular sensing technologies
Inductive Sensors
Metal targets
Optical Sensors
Target capable of reflecting or blocking light
Capacitive Sensors
Liquids/solids
Sensing Technologies
INDUCTIVE
• When voltage is applied, an electromagnetic field is
generated and extends out the face of the sensor.
• When metal enters the sensing zone, an eddy current is
induced in the metal.
• The change in eddy current is detected and the sensor’s
output is energized.
INDUCTIVE PROXIMITY SENSOR
Sensor
Coil
Oscillator
Detector
Output
Sensing Technologies
INDUCTIVE
Two basic Sensing types
Flush mount
Shorter range
Sensor can be buried in metal
Non-flush mount
Longer range
Sensor can NOT be buried in metal
OPTICAL SENSORS
Consist of a light source (LED) and light detector
(phototransistor)
Various models: 12-30V DC, 24-240V AC, power
THROUGH BEAM SENSORS
Emitter and receiver are in
two separate housings
facing each other. The
sensor switches whenever
the light beam is
interrupted.
EXAMPLE OPTICAL PROXIMITY II
CAPACITIVE SENSOR
Maximum Distance:
millimeters
Detecting:Dielectric Material
(Metal and non-
metal)
CAPACITIVE SENSOR : OPERATION
Thank you