Industrial Automation: Electrical Considerations & Motor Basics

1. ISE 370 Industrial AutomationInstructor: Thomas Koon Electrical Consideration for Industrial Automation Paul Blythe - Binghamton University

2. Topics of Discussion • Basic Electric Systems • Factory Automation Concerns • Motors • Machine Vision Basics Paul Blythe - Binghamton University

3. Electric Current Paul Blythe - Binghamton University

4. A.C. Systems – Single Phase • Three Load voltages may be obtained: • 120V single phase 2 wire • 240v single phase 2 wire • 120/240V single phase 3 wire Paul Blythe - Binghamton University

5. AC Waveform 3 Phase Paul Blythe - Binghamton University

6. Three Phase Systems • Delta Connected System • No Neutral • Line to Line Voltages Only • Easier to Balance Paul Blythe - Binghamton University

7. Wye Connected System Load Voltages Obtained From 480V System • 277 volt single phase two wire (L-N) • 480V single Phase, two wire • 480V single Phase, three wire • 480/277 V three phase, four wire Paul Blythe - Binghamton University

8. Three Phase Systems • What is the line to neutral voltage Paul Blythe - Binghamton University

9. Three Phase Systems Paul Blythe - Binghamton University

10. Three Phase Systems • Remember to balance your load • Step 1: Determine the loads' VA ratings. • Step 2: Put one-third of the 3-phase load on Phase A, one-third on Phase B, and one-third on Phase C. • Step 3: Put one-half of the single-phase, 208V load on Phase A and Phase B, or Phase B and Phase C, or Phase A and Phase C. Paul Blythe - Binghamton University

11. Electrical Code Summary Paul Blythe - Binghamton University

12. Industrial Automation Paul Blythe - Binghamton University

13. Common Industrial Protocol (CIP) • Common Industrial Protocol (CIP) is an open industrial protocol for industrial automation applications.. • Collection of manufacturing automation applications – control, safety, synchronization, motion, configuration and information. • It allows users to integrate these manufacturing applications with: • Enterprise-level Ethernet networks • Internet • EtherNet/IP, DeviceNet, CompoNet and ControlNet. Paul Blythe - Binghamton University

14. Some Automation Considerations Paul Blythe - Binghamton University

15. Automation Consideration Paul Blythe - Binghamton University

16. Operator Safety Light Curtain is the most common safety device on automated machines Presence Sensing Device Stop Machine Motion Paul Blythe - Binghamton University

17. RS Logix 5000 Controller Paul Blythe - Binghamton University

18. Ladder Logic Programming Paul Blythe - Binghamton University

19. What is an Electric Motor? • Electromechanical device that converts electrical energy to mechanical energy • Mechanical energy used to e.g. • Rotate pump impeller, fan, blower • Drive compressors • Lift materials • Motors in industry: 70% of electrical load Paul Blythe - Binghamton University

20. How does an electric motor work? Paul Blythe - Binghamton University

21. Electric Motors Alternating Current (AC) Motors Direct Current (DC) Motors Synchronous Induction Separately Excited Self Excited Single-Phase Three-Phase Series Compound Shunt Type of Electric Motors Paul Blythe - Binghamton University

22. DC Motors • Field pole • North pole and south pole • Receive electricity to formmagnetic field • Armature • Cylinder between the poles • Electromagnet when current goes through • Linked to drive shaft to drive the load • Commutator • Overturns current direction in armature Paul Blythe - Binghamton University

23. DC Motors • Speed control without impact power supply quality • Changing armature voltage • Changing field current • Restricted use • Few low/medium speed applications • Clean, non-hazardous areas • Expensive compared to AC motors Paul Blythe - Binghamton University

24. AC Motors • Electrical current reverses direction • Two parts: stator and rotor • Stator: stationary electrical component • Rotor: rotates the motor shaft • Speed difficult to control • Two types • Synchronous motor • Induction motor Paul Blythe - Binghamton University

25. AC Motors – Synchronous motor • Constant speed fixed by system frequency • DC for excitation and low starting torque: suited for low load applications • Can improve power factor: suited for high electricity use systems • Synchronous speed (Ns): F = supply frequency P = number of poles Ns = 120 f / P Paul Blythe - Binghamton University

26. AC Motors – Induction motor • Most common motors in industry • Advantages: • Simple design • Inexpensive • High power to weight ratio • Easy to maintain • Direct connection to AC power source Paul Blythe - Binghamton University

27. AC Motors – Induction motor Components • Rotor • Squirrel cage: conducting barsin parallel slots • Wound rotor: 3-phase, double-layer, distributed winding • Stator • Stampings with slots to carry 3-phase windings • Wound for definite number of poles Paul Blythe - Binghamton University

28. Electromagnetics Rotor Stator AC Motors – Induction motor How induction motors work • Electricity supplied to stator • Magnetic field generated that moves around rotor • Current induced in rotor Rotor produces second magnetic field that opposes stator magnetic field Rotor begins to rotate Paul Blythe - Binghamton University

29. Variable Speed AC MotorSelection decisions Both steel and cast iron construction Enclosed or open enclosures Non-vent or fan cooled Foot or face mounting. Paul Blythe - Binghamton University

30. Example of 75HP, 1800 RPM Motor Applications • Extruders • Forest Products Paul Blythe - Binghamton University

31. Machine Vision Illumination Basics Thoughts for Today: • Light is governed by the laws of physics • Reliable lighting (not ambient) is important for a successful installation • Shiny surfaces (specular) are particularly challenging • Use Scientific Methods to Analyze and Diagnose Paul Blythe - Binghamton University

32. Machine Vision Basics • The Two Cornerstones • Structure or Geometry • Illumination wavelength or color Paul Blythe - Binghamton University

33. Source Comparisons Paul Blythe - Binghamton University

34. Optical Characteristics of an LED Paul Blythe - Binghamton University

35. Cameras Analog and digital Color and monochrome UV, visible, and IR Area scan and line scan CCD and CMOS Connectivity and interfaces Other things to consider Paul Blythe - Binghamton University

36. Cameras • Area and Line Scan Cameras • Line scan cameras produce high resolution at much lower price • Requires movement of the camera or object • More limited lens selection due to array size • UV, Visible, and IR • Standard cameras • Sensitivity is possible down to 200 nm • Near, Mid, and Far IR generally require different materials for the imager • These materials still have a high cost • Need different material for the optics in these ranges Paul Blythe - Binghamton University

37. CCD and CMOS • CCDs provide higher quality images • CMOS offers lower cost by leveraging economies of scale • Design of CMOS allows for • Anti blooming control • Real area of interest scanning • Increased onboard processing • Higher speeds • CMOS generally needs to be done in larger runs • CCDs will continue hold the lower volume markets Paul Blythe - Binghamton University

38. Thank You ? Paul Blythe - Binghamton University