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Learn what is timer in PLC and its types. There are 3 types of timer in PLC - On delay, Off delay and Retentive On/Off timer.

To know more, visit : https://www.gotosage.in/

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What is a Contactor?

A contactor is an electrical device that is used to turn on and off an electrical circuit. It is regarded as a unique sort of relay. The main difference between a contractor and a relay is that the contractor is utilized in applications that require a larger current carrying capacity, whilst the relay is used in situations that require a lower current carrying capacity. Contactors are small and easy to install in the field. These electrical devices usually have many contacts. When the contactor coil is powered, these contactors are generally open and give operating power to the load. For the most part, contactors are used to regulate electric motors.

Contactors come in a variety of shapes and sizes. Each type has its own set of characteristics, capabilities, and uses. Contactors can handle currents ranging from a few amperes to thousands of amperes, as well as voltages ranging from 24 VDC to thousands of volts. Moreover, these electrical devices come in a multitude of sizes, – from small hand-held devices to all those measuring a meter or yard on one side (approximately).

The contactor is most commonly used in high-current load applications. Contactors are well-known for their capacity to manage currents of more than 5000 amperes and high power of more than 100 kW. When a large motor current is interrupted, it produces arcs. These arcs can be decreased and controlled with a contractor.

Contactor Components-

The contactor is made up of three essential components:

1. Coil or Electromagnet: This is the most essential part of the contactor. The coil or electromagnet of the contactor offers the required driving force to close the contacts. An enclosure protects the coil or electromagnet and its contacts.

2. Enclosure: Contactors, like any other device, have an enclosure that provides insulation and protection against personnel touching the contacts. Polycarbonate, polyester, Nylon 6, Bakelite, thermosetting polymers, and other materials are used to construct the protective enclosure. In most instances, an additional enclosure is built to the open-frame contactor to protect it from severe weather, explosion threats, dust, and oil.

3. Contacts: This is another vital part of this electrical device. The contacts are currently performing the contactor's carrying role. In a contactor, there are mainly three types of contacts: contact springs, auxiliary contacts, and power contacts. Each type of contact has a certain function to perform.

Different Types of Contactor Devices-

1. Knife Blade Switch- In the late 1800s, the knife blade switch was introduced. It was most likely the very first contactor used to control (start or stop) electric motors. The switch was made out of a metal strip that slid across a contact. This switch had a lever that could be used to pull the switch down or up. The knife blade switch had to be lowered into the closed position by standing next to it back then. However, there was an issue with this way of switching. Because it was difficult to manually open and close the switch fast enough to avoid arcing, the contacts wore out quickly. As a result, the soft copper switches began to rust, increasing susceptibility to moisture and filth. The size of the motors became larger over time, requiring the use of larger currents to operate them. As a result, operating such high current carrying switches could be dangerous, posing a major safety concern. Despite the number of technical advances, the knife blade switch was never fully developed due to the challenges and risks of dangerous operation as well as the contacts' short life.

2. Manual Contactor- Engineers created a new contactor device after the knife blade switch became potentially unsafe to use. This contactor device included several functions that the knife blade switch lacked. This device was described as a manual controller.

These characteristics included:

Operation is risk-free.

A unit that is not visible and is appropriately enclosed

Smaller in size

Contacts with single breaks have been replaced by contacts with double breaks. 

3. Magnetic Contactor- The magnetic contactor is operated electromechanically and does not require human interaction. This is one of the most advanced contactor designs available, and it can be remotely operated. As a result, it reduces the dangers of running it manually and placing operational staff in danger. The magnetic contactor only requires a small amount of control current to open or close the circuit. In industrial control applications, this is the most common type of contactor.

How Does the Contactor Work?

The electromagnet is activated by the current that flows through the contactor. The contactor core moves the armature due to the magnetic field produced by the excited electromagnet. The circuit between the fixed contacts and the movable contacts is completed by a normally closed (NC) contact. This allows current to flow from the contacts to the load. The coil de-energizes and closes the circuit when the current is released. Contactor contacts are recognized for their quick opening and closing action.

To know more, visit: https://www.gotosage.in/

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Learn what is a contactor and its components. There are 3 essential components of contactors- Coil or Electromagnet, Enclosure and Contacts.

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What is Direct Online Starter?

The DOL starter is a kind of motor starter that connects the electric engine straightway to the line voltage. It’s the simplest and cheapest approach to start an induction motor. In the DOL launch, the outstations of the motor are connected to the powerful force through a contactor and overload safeguard device.

Although DOL starter is the most frequent starting approach accessible on the demand, it’s meaningful to reflect that it has some limitations. The starting current of an induction engine is 6 to 8 times higher than the rated current when straightway connected to the power supply voltage. The control of current and torque isn’t achievable. For this reason, large power motors cannot be competent to start with this system.

A wiring diagram of Direct Online Starter :

The DOL starter attaches the engine immediately to the main supply line of the device connected, the motor draws a high amount of current compared to the full loading current of the motor (up to 6-8 times advanced). The valuation of this bulky current decreases as the motor reaches its rated speed.

A DOL starter can exclusively be implemented in situations when the high flow current of the engine doesn’t generate an intolerable voltage drop in the force circuit. However, a star-delta starter should be used rather, if a high voltage drop needs to be avoided. Direct online starters are generally used to start fragile engines, especially 3 phase squirrel cage induction engines.

The protection offered by DOL Starter-

The Motor starters not exclusively give the safe starting current but also give protection to keep the engine all right during operation. It’s crystal clear that the DOL starter provides the full line voltage but it does give the following protection.

The overcurrent condition can generate damage to the engine, power lines and can be a threat for operators. Such a quantum of current is too hazardous for a brief occasion.

In the DOL starter, we apply a circuit breaker or fuses for security against overcurrent. They unclose the circuit and break the current inflow in a moment until the challenge in the system is resolved. The fuse or circuit breaker is precisely named with its degree kept in mind. Because we don’t demand the fuse to break up but to permit the starting current as well as the heavy load current. The overcurrent breaker’s standing is kept a bit advanced than the rated starting current of the motor.

Overload Protection-

The condition where the load connected to the motor increases beyond its limitation and the engine draws an extreme quantum of current is called overload condition. During load, the current inflow is beyond the safe boundaries which damages the cables as well as the motor windings. It melts the windings and may invoke fire threats. To safeguard the motor from overloading, we apply an overload relay that trips the power supply and protects the system from overheating. The overload relay monitors the current and breaks the current inflow when it exceeds some limit for a period of moment. The tripping mechanism may differ and depends on the operation of the motor.

Different Types of Overload Relays used for motor protection-

1. Thermal Overload Relay- This class of overload relay works on the principle of expansion due to the heat generated by the current inflow. A bimetallic strip is employed with distinguishable thermal expansion to break up or form the circuit grounded on the temperature.

2. Magnetic Overload Relay- Similar relays of this type work on the principle of the magnetic field generated by the current inflow through a coil. An intolerable current drawn by the engine (that is a predetermined quantum) generates enough magnetic field to trips the contact outstations and breaks the current supply.

3. Electronic Overload Relay- An electronic relay is a solid-state device without any portable region or connections. It utilizes current detectors to cover the motor current and has an adjustable setting that allows the tripping at a wide range of current rankings.

Construction of DOL Starter-

A DOL or Direct Online starter has exclusively two push buttons; Green and Red, where the green button is employed for starting and the red is employed for stopping the motor. The green button connects the outstations and closes the circuit while the red button disconnects the outstations and breaks the circuit.

The DOL starter is manufactured of a circuit breaker or MCCB or fuse, a load relay, and a contactor or coil. The circuit breaker is used for security against short circuits while the overload relay protects the engine from overfilling. The contractor is utilized for starting and stopping the engine where the green and red buttons are compounded.

Parts of DOL Starter-

1. Circuit Breaker or Fuse- The circuit breaker or fuse is straightway compounded to the power mains and it’s used for protection against short circuits. It trips the power supply in case of a short circuit to safeguard the system from any possible hazards.

2. Magnetic Contactors- A magnetic contactor is an electromagnetic switch that operates electromagnetically to exchange the power supplied to the engine. It connects and disconnects multiple connections accessibly by supplying remote control over the operation. The magnetic field generated by the coil is harnessed for switching the terminals. The passing current through the coil magnetizes the iron core that’s encircled by the coil. The magnetic force pulls on the armature to close or open the connections.

3. Overload Relay- OLR or load relay is the last part used in the DOL starter and it’s used for protection against overloading of the motor. It breaks the current inflow when it exceeds a certain limit but it also tolerates the high starting current. So the OLR is precisely named in such a way that its tripping current limitation doesn’t tumble below the starting current range.

Principle of DOL Starter-

The Direct Online starter works on full voltage or across-the-line methodology where the engine is directly compounded to the full voltage supply. Since there’s no voltage deduction, the starting current is genuinely high which leads to high starting torque.

When the engine starts, it’ll drag a huge current generally 5 to 6 times that of its rated full speed current. The huge current draw will effectuate a dip in the line voltage. The gradational increment in the speed will drop the current drawn from the lines but not below a certain speed (typically at 75). Once the engine reaches its rated speed, the current drawn and the line voltage will return to normal.

Also, keep in mind, the jumping current may harm the windings of the motor. Therefore, motors having a low power rating are connected through the DOL starter.

Advantages of DOL Starter-

1. Simple to design

2. Easy to operate and maintain

3. Cheapest and Economical

4. Provides 100% starting torque

5. Troubleshooting and understanding the system is easier.

6. Connects the delta winding of the motor.

Disadvantages of DOL Starter-

1.  Starting current is very high.

2. Starting current can damage the motor

3. The high inrush of current causes a voltage drop in the lines that can be connected to other appliances.

4.  High starting is torque unnecessary in many cases.

5.  High starting torque produces mechanical stress which reduces the life span of the motor.

6. There is no control over the starting current and torque.

Features of DOL Starter-

1. Provides high starting current.

2. Provides high starting torque.

3. Produces voltage dip in the power mains.

4. Simplest controlling mechanism.

5. Suitable for low power rated motor.

Applications of DOL Starter-

1. The DOL starters are used in motors having low power ratings.

2. Starting current does not cause huge dips in the line voltage.

3. DOLs are used for small water pumps, conveyor belts, compressors, and fans.

To know more, visit : https://www.gotosage.in/ 

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What is Direct Online Starter?

This info graphic explain what is DOL and its principle. The DOL starter is a kind of motor starter that connects the electric engine straightway to the line voltage. It's the simplest and cheapest approach to start an induction motor. 

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What is Star-Delta Starter?

Star-Delta Starter is the most commonly used method that reduces the starting current and starting torque of an electrical motor.  The star/delta are used in an attempt to reduce the start current applied to the motor for reducing the trouble and intervention on the electrical supply.  Star/delta are consist of three contactors- An overload relay or circuit breaker and a timer. For the functioning of the delta starter, a motor must be connected to the delta.  In the star-delta starter, starting current is 33% during direct online start, and starting torque is reduced by about 33% of the torque available at a direct online starter. 

Types of Star-Delta Starter -

There are 3 types of star-delta starter:

1. Manual Star-Delta Starter - 

Manual star delta is a perfect solution for Oil mills, Flour mills and Agro Industries. It gives assurance of same dependability and protection.

2. Semi-Automatic Star-Delta Starter -

These starters work with a 3-push button system. The third push yellow button is used to change the sequence of the running motor from Star to Delta. To protect against overloading and single phasing problem bimetallic thermal overload Relay is fitted in these starters.

3. Fully Automatic Star Delta Starter (wye delta) -

These starters work automatically with the help of the timer fitted inside the starter. The time period can be adjusted between 7 to 15 sec.

Star-Delta Starter working principle: 

1. When Star/Delta motor starts working, the start-up of the three-phase induction motor is applied by a changeover of windings.  2. All 6 winding connections are attached to the main supply with the help of Star-Delta Switch and, jumpers in the motor terminal box are excluded.  3. The windings of the motor are connected throughout the operating connection.  4. The winding voltage (WV) must be equal to the phase voltage of the three-phase system. 5. In a star connection, the mains voltage (ULN) on the individual motor windings is lower by a factor of 0.58.

Advantages of Star-Delta Starter: 

Star Delta-Starter are widely used because of their low price. 

There is no limit on operating them. 

The components of star/delta do not require much space. 

It reduces mechanical stress on the motors. 

The operating function of star/delta is simple.

Disadvantages of Star-Delta Starter: 

The star/delta can only be applied to motors where the six leads and terminals can be accessed. 

Once the starting torque is reduced to 33% it cannot be adjusted. 

There are many devices and much wiring. 

It requires higher maintenance. 

When the starting current is reduced to approximately one-third of the rated current, the starting torque is also reduced to one-third.

To know more, visit : https://www.gotosage.in/

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This infographic explains what is Star-Delta Starter and its three different types. Star/Delta Starter comes under the PLC program. Manual Star Delta Starter, Semi-Automatic Star Delta Starter and Fully Automatic Star Delta Starter, these three types are explained in an above image. 

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What is Level Sensor and How does it work?

 What is Level Sensor? 

A level sensor is a tool that is used to monitor, maintain and measure liquid levels that flow in an open system or closed system. Once the liquid level is measured, these sensors helps in converting received data into an electric signal. Level sensors are primarily used in the manufacturing and automotive industries, but are also used in many household appliances.

There are two Types of  Level Sensors- 

1. Point Level Sensor- 

Point level sensors are used in measuring the liquid at a certain point in a tank or a chamber. These sensors are mainly used to managed high and low levels of liquid. Most of the time, they work as a switch to engage a function when the tank level is either rises or falls to a certain level. The sensor detects when the liquid has reached the expected point and it moves as a switch to activate the necessary response.

2. Continuous Level Sensor- 

Continuous level sensors are used to give liquid level detection through every point in the tank or a chamber. In simple words, it is a transmitter that calculates liquid within a specified range that controls the same amount of liquid within the limited area. These sensors come in both vertical and horizontal mount transmitters that are perfect for monitoring the liquids in tight and restricted areas.

 How does level sensor works- 

1. Level sensors are put into a certain depth in the liquid to be measured. After putting these sensors into the liquid, the pressure on the sensor’s front surface transfers into the liquid level height.  2. The calculation formula for measuring the level of liquid is- P=ρ.g. H+Po.  3. Here, P stands for Pressure on the liquid surface of the sensor, ρ stands for the density of the liquid to be measured, g is for local acceleration of gravity, H is for depth at which sensor drops into the liquid and Po is the atmospheric pressure on the liquid surface.

To know more, Visit: https://www.gotosage.in/

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What is Sensor and What are the types of Sensors?

What is Sensor?

A sensor is a device that helps to make advancements in electronic quantities and physical quantities and other quantities. It shall result in making progress by affirming yield. In Industrial automation, sensors play very important role by making the products intellectual and unusually automatic.

Different Types of Sensors used in Industrial Automation- 

Temperature     Sensor

Pressure     Sensor

MEMS     Sensor

Torque     Sensor     

1. Temperature Sensor- 

A temperature sensor is a device that helps in collecting the information regarding the temperature from a resource and it changes in such a form which can be understood by another device. 

Digital temperature and humidity & temperature sensors are two main sensors that are used in automation.

Digital     Temperature Sensor: 

Digital temperature sensors are silicon-based temperature sensing ICs that gives the exact output through the digital representation of temperatures they are measuring. This helps in making simple control system’s design.

Humidity     and Temperature Sensor: 

These devices are used to give the actual humidity condition within the air at any given time or a place. Such devices are of most use where the air condition is extreme or it need to be controlled that are caused by different reason. By using these sensors, it gives a surety of high consistency and exceptional long standing stability.

2. Pressure Sensor- 

Pressure sensor is a device that catches the pressure and manages to change it into an electronic signal where the quantity depends upon how much pressure appealed.

3. MEMS Sensor-

MEMS sensors helps in converting measured mechanical signals into electrical signals.

 Acceleration and Motion MEMS are two types used most in Industrial Automation.

4. Torque Sensor- 

Torque sensors is defined as transducer used for torque measurement (torque sensing) that transforms an input mechanical torque into an electrical output signal. This sensor is also commonly known as Torque transducer, Torque cell, Torque tester, Torque gauge and Moment sensor. 

To know more, Visit: https://www.gotosage.in/ 

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PLC/SCADA Training At Sage Automation

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PLC SCADA Training at SAGE India

PROGRAMMABLE LOGIC CONTROLLER (PLC)

What is a PLC?

A Programmable Logic Controller, or PLC, is a ruggedized PC utilized for industrial automation. These controllers can automate a particular cycle, machine work, or even a whole creation line. A PLC is a Computer specially intended to operate reliably under harsh industrial conditions – like outrageous temperatures, wet, dry, and/or dusty conditions. PLCs are utilized to automate industrial cycles, for example, a manufacturing plant assembly line, a metal handling plant, or a wastewater treatment plant. A PLC shares some of its features with a PC that we use at home although it uses a different operating software.

How does a PLC Work?

● A PLC Scan Process incorporates the accompanying advances

● The operating framework starts cycling and checking of time.

● The CPU starts reading the data from the information module and checks the status of all the data sources.

● The CPU starts executing the client or application program written in relay-ladder logic or any other PLC-programming language.

● Then, the CPU plays out all the internal diagnosis and communication tasks.

● According to the program results, it composes the data into the yield module so that all yields are updated.

● This cycle proceeds as long as the PLC is in run mode

A PLC program is normally composed on a computer and afterward is downloaded to the controller

Most PLC programming offers programming in Ladder Logic, or "C". Ladder Logic is the conventional programming language. It mirrors circuit graphs with "rungs" of logic read passed on to the right. Each rung addresses a particular activity constrained by the PLC, beginning with information or series of data sources (contacts) that outcome in a yield (curl). On account of its visual nature, Ladder Logic can be simpler to execute than numerous other programming dialects.

"C" writing computer programs is a later development.

Some PLC producers supply control programming.

PHYSICAL STRUCTURE OF A PLC

Programmable Logic Controllers consistently monitor the input esteems from different input detecting gadgets (for example accelerometer, weight scale, designed signs, and so forth) and produce corresponding output contingent upon the idea of creation and industry. A commonplace square outline of PLC comprises of five sections to be specific: ● Rack or chassis

● Power Supply Module

● Central Processing Unit (CPU)

● Input and Output Module

● Communication Interface Module

CERTIFIED PLC PROGRAMMER COURSE AT SAGE AUTOMATIONS

SAGE Automations India offers the best and an all-round certification course in PLC that can help all kinds of engineers, working professionals and freshers to level up their skill in the field of automation.

COURSE HIGHLIGHTS:

➔Complete understanding of all the aspects of the Programmable Logic Control (PLC) ➔ PLC Learning with a 90% practical and 10 % theory ➔ Award winning TTIM training platform Ideal for :Working professionals with prior work knowledge & experience, who currently require a skill upgrade in PLC technology

WHY SAGE AUTOMATIONS?

For most Universities in India, the prospectus doesn't cover the Automation subjects in detail. Engineering students need some extra exposure and skills as far as ideas and application to become industry-prepared. The courses at Sage India are intended to make your work prepared and are application-oriented along these lines to how any Automation organization would do their task. Consequently, this will assist you with beginning working straightforwardly on projects when you go into the Automation Industry. Check out our automation courses now to gain an edge in the working industry!

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SAGE Automation India is a leading institute which provides training courses in the field of automation to engineers across the globe. We help engineers to upskill their work in the field of automation and become Industry leaders.

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Just like how the human body has five senses that send information to the brain for it to take actions, in the same way Instrumentation is the process of gathering data on the field and the processing it!

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What are Pneumatic systems

Pneumatic systems are systems that use gas or pressurized air to move cylinders, motors or other mechanical parts. Pneumatics applications are relevant to a wide variety of industries, including construction, healthcare, mining, the automotive industry, and many others. Specific pneumatic applications can include:

●      Transportation: Air brakes for trains or buses, air engines, and compressed air-powered vehicles

●      Healthcare: Dental drills, vacuum pumps, and pressure regulators

●      Construction: Pneumatic jackhammers and nail guns

●      Home Systems: Heating and air conditioning control

●      Music: Pipe organs, player pianos

Common Pneumatic Issues:

Because some pneumatic devices are more complex machines than others, there are several issues that might arise with your pneumatic systems, including:

●      Actuator moving too slowly

●      Pressure too low

●      Too much air choke

●      Air seal leaks

●      A dirty or damaged filter

●      Directional control valve not changing direction

●      Cylinder drift

Advantages of pneumatic systems

Pneumatic systems are widely used in different industries for the driving of automatic machines. Pneumatic systems have a lot of advantages.

●       High effectiveness – There is an unlimited supply of air in the atmosphere to produce compressed air. Also, there is the possibility of easy storage in large volumes. The use of compressed air is not restricted by distance, as it can easily be transported through pipes. After use, compressed air can be released directly into the atmosphere without the need of processing.

●       High durability and reliability – Pneumatic system components are extremely durable and cannot be damaged easily. Compared to electromotive components, pneumatic components are more durable and reliable.

●       Simple design – The designs of pneumatic system components are relatively simple. They are thus more suitable for use in simple automatic control systems. There is a choice of movements such as linear movement or angular rotational movement with simple and continuously variable operational speeds.

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Visit: http://www.gotosage.in/

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THE BEST ‘INDUSTRIAL AUTOMATION’ TRAINING CENTER

As Bill Gates once said, “Automation applied to an inefficient operation, will magnify the inefficiency”

This sums up an important message of how the process of “Industrial Automation” is not a silver bullet and does not fix up broken processes. Automation only does as you tell it, if you command it to complete a broken or faulty process, it will.

Industrial Automation is an interesting and vast ocean to dive in, but it's really important to have your training done in the right way.

To run operations efficiently in automation without any faulty process, advanced training with a high level of expertise is required. The latest trends in industrial automation include rise in use of analytics, growing use of PLCs, PACs, and increased cloud-based supervisory control and data acquisition (SCADA) systems. These trends will influence the industrial automation control market, according to a report.

A well updated training center like “Sage Automation India” thrives to provide advanced knowledge about industrial automation right from the basis of automation to complex automation concepts. It also has a flexible syllabus when it comes to keeping up with the trends included in plc/scada.

Sage Automation India the best plc/scada training center in Thane, India offers certified courses with experience on live projects and opportunities to work internationally. 

Enroll yourself to acquire certified courses of your choice at Sage Automation India.

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PLC Automation Training in Thane, Mumbai

PLC programming classes in Thane, Mumbai provided by Sage Automation India