| Copyright. All rights reserved. Reg, No. L—27520/2006 No part of this publication may be reproduced in any material form (hard copy as wel soft ‘are version) without the written permission of Copyright holder. TAACT ELECTRONIC AUTOMATION We engineer careers Teknocrat's Academy of Automation & Contro! Technology B-61, MIDC Satpur, Nashik Tel No, 0253-8603022, 6602766 E-mail: nashik@taact.co.in Website: www.taact.co.in (For Private Circulation only)9993999925939333399 1 OITAMOTUA DIMDRTOS.13 a . u Ww f i - Y by - J * SAE eerie UW ened te yea 8 bercrcieote | ew on at Somme nenred Odi 2> ee ee eee eat nid rameremaciiesewy OF Vv U u J U UY Uy Vu Y LTAACT Electronic Automation (3.0) Index Introduction Basics of Switching, Interfacing and Isolation Techniques Sensors for position, velocity, and displacement Sensors for process parameters Electronic transducers Timers Counters Process controllers Application examples of Electronic Automation Teknocrat’s Academy of Automation & Control Technology, Nashik 1TAACT ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 2Re Electronic Automation (3.0) TAACT 1.0 Introduction Electronic automation is about automatic control of industrial machines and ‘manufacturing processes using primarily electronic devices and instruments. Any automatic control system basically comprises of + Sensors * Controllers + Actuators Reference Controller |_—4f Actuator [+f Press ] “ Sensor + Fig.1.1-Block diagram Electronic automation is used in typically following types of industrial applications, * Controt of special purpose machines (SPMs) in the machine tool industry. ‘+ Packing machines for pharmaceutical, cosmetic and food industry. * Plastic / rubber machines like injection molding nvc, extruders, calendars, thermo forming machines. * Control of conveyor systems for bulk ore, coal and sand handling in stec}, thermal and fertilizer plants, * Bottling plants in beverage industry, ‘Sequential operation and control of furnaces. "Batch mixing plants in chemical and food industry. + Metal forming lines i ferrous and non- ferrous industry, like Continuous Casting lines, Cold Rolling Mills and metal furnishing lines, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 3ie Electronic Automation (3.0) TAACT ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 4te Electronic Automation (3.0) A , Fu . . , TAACT 2.0 Basics of Switching, Interfacing and Isolation Techniques ‘An electronic automation system comprises of discrete devices which communicate with each other through different types of signals, generated by various switching techniques. 21 Blectronie switeles All switching involves selection of any one out two basic states of wn electrical cireuit, such os ON or OFF, High or Low. In electronic circuits the: switching operations are carried out by following met | r Coit NO NC CHANGEOVER Fig.1-Blectro-mechanical Relays In relays a mechanical contact is activated by an electro-magnet when the coil of the electromagnet is energized by a suitable clectric current. ‘The mechanical contact can be of three types: ‘+ Normally Open (NO) ~ close in activated state Normally closed(NC)- Opens in activated state * Changeover (C/O) - A dual contact with both NO/NC feature. These contacts are called potential free contacts and are rated for a certain current rating (2A, SA) and can be inserted in any part ofa circuit for switching normally up to 240V AC/DC voltages. ‘Truth table for transistor switch operation Sensing PNP = NPN NO. NC NO NC Status | DST _V_| Status | Ds | V_| Status] DS]_V_] Status | DS | -V Un [0 Jo}vel o fijval 0 fo }val o |i ve sensed Sensed |" 1 1 |va| 1 [oe 1 1 [we[ 1 [0 [va VL ~ Lower Voltage Limit, Less than 1.5V typically ‘VH — Higher Voltage Limit, Near to Supply Voltage DS ~ Digital State ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 3ig Electronic Automation (3.0) TAACT 22 Interfacing Signals: Signals are required for carrying information. Information about the state of a process or the actual value of a process parameter has to exchange between different devic and parts of an automation system. In an electronic automation system all such signals are generally electrical voltages, currents or pulses. The type of signal depends upon the type of information, distances, environments and type of devices, common types of signals are given below. Binary Signals: These signals carry information only about the where only two states can exist such as, talus of process * A pump is ON or OFF + A value is closed or open + A tool in a machine has reached its position or not, + A temperature has exceeded a set limit or not Control voltages of different values like 24V,110V 240V, AC or DC can convey these type of information, Full voltage or NO voltage gives information about the i of process. ‘The voltages for such signals are derived from the control supply of an electrical system and need not be stabilized, Variation of even upto + 20% in the voltage would not affeet the correctness of information being carried. Such signal can be transmitted upto very long distances without risk of any distortion, Analog signals: For information regarding actual value of continuously varying type process parameters like temperature, pressure, flow, level, speed, current, power, continuously varying type electrical signals are needed, which can exactly convey the process parameter value. Different analog voltage and current signals are used for this Purpose. * Voltage signals: 0-5 V DC, 0-10 V DC, 2-10 V DC are the typical voltages. OV or 2V’ corresponds to the minimum value of the process parameter and 5 or 10 V to the max. value, A 0 Volt signal can also mean, that there is a break in transmission line, in which ease the information at the receiving device could be misleading, To overcome this more appropriate 2-10 V DC signal is selected where 2V corresponds to the minimum value of the parameter and a zero would indicate wire break. Since voltages drop when transmitted over long distances, voltage signal can be used effectively up to short distances only. Voltage signals are also susceptible to electrical noise. The signaling wites therefore need to be screened and laid at minimum specified distances from other high voltage or current carrying cables. ‘Teknocrat's Academy of Automation & Control Technology, Nashik 6ie Electronic Automation (3.0) TAACT these 23 23.1 signal voltages are generated inside the sensors, transmitters or controllers and are always highly stabilized to accurately reflect the parameter values. * Current signal ~ 0-10 mA, 0-20mA, 4-20mA are the typical cusrent signals, 4- 20 mA signals are a very common type. The reasoning of 4-20 mA is the same 4s that for 210V DC. Current values remain constant even over long transmission Tines and are therefore preferred over voltage signals for most applications, Current signals also need to be protected from noise and the signal cables should be screened and laid away from high voltage and current carrying signals, Current signals are also generated in the sensors transmitters and controllers Pulse Signals: Electrical pulses can be used to convey information about count values in numbers. A train of pulses is produced from devices like incremental encoders, where the no, of pulse corresponds to the no. of counts of the input Antenne Fig.2-Pulse signals Pulse signals are highly susceptible to noise and must be transmitted over well screened cables only. Pulsed signal also get distorted over long distances, Gray Code: A very special type of digital signal called ‘Gray Code’ is used generally in encoder's especially absolute encoders to carry information in digital format about the exact angular position and no, of turns. A simple binary code to convey internally thousand of unique analogue positions would require a very large no. of parallel bits and every small step change of position would require a n0. of bits to change. Introduction to Signal Conditioning & Isolation: Signal conditioning: Signal conditioning of low level signals generated by Sensors or field transmitters is necessary for error free processing of the sensor data by control systems such as PLC or DCS or even conventional Controllers & other Receiver instruments “The input signal is filtered, amplitied, converted & in some cases split into multiple outputs, thus enabling field devices to interface directly with indicators, controllers, recorders, DCS and PLC systems used extensively in manufacturing and Process industries. This eliminates malfunction of process measurement and control equipment caused by ground loops, surges due to inductive Joad switching, and other unpredictable electrical disturbance A ‘ariety of plant, process, and instrumentation engineers, along, with systems integrators, regularly face the difficult task of selecting the right signal conditioner, Their goal is to obtain the highest quality conditioner for a cost effective price, The problem is, the selection of the wrong signal conditioner can result in the purchase of Inadequate equipment, or equipment that will quickly become obsolete, Pre- procurement system planning that includes a clear definition of the system Tequirements is the first step in the sclcction process. As a minimum, you should determine sensor input, type of output, accuracy class, isolation level / type, power ‘Teknocrat's Academy of Automation & Control Technology, Nashik 7i TAACT 23.2 Electronic Automation (3.0) requirements, environmental tolerances, safety, physical dimensions, and acceptable performance criteria, Ifa sensor isnt part of the device, the accuracy specification probably won't include sensor error. Knowing the maximum combined errors of a device at reference test conditions allows you to test units against manufacturer specs, and helps estimate total system accuracy. The terms repeatability and hysteresis refer to the performance of @ conditioner output as the input is varied up and down. A conditioner output yields a different value for the same input depending on which direction it came from (due to component behaviors, transformer core losses, potentiometer shifts, and so on). An accuracy specification that includes the combined effects of these two characteristics (repeatability & hysteresis) implies that the output is always (repeatable) within the stated percentage from the ideal point ‘Terminal point linearity and adjustment resolution imply that a device has endpoint calibration and can be adjusted at the endpoints to within the stated specification. Essentially, terminal point linearity allows calculation or error E (accuracy) as a function of output span using the following equation: E= (measured output value - ideal output value) x 100 / output span A typical accuracy rating is less than +0.1% of output span. ‘This means that a linear conditioner, calibrated with a 1-5V DC output (4V span), has an output within 44mV_ form the ideal point (4V span x 0.001). Moreover, because the accuracy specification should include repeatability and hysteresis, the output should always be within 4mV. of the ideal. If accuracy, lineatity, and repeatability ate specified separately, you mist combine the individual ratings to form a complete accuracy specification, Accuracy, Linearity, and Repeatability Overall system ascuracy is only as good as the least accurate device in the loop. This, typically, is the sensor or mechanical- to-electrical interface. If the sensor, for example, is only 1% to 5% accurate, you won't need extremely precise signal conditioning. Likewise, if your sensor is very accurate (say better than 0.5%), you will not want to hinder system integrity with low-cost, poor quality signals conditioners, Accuracy, linearity, and repeatability specifications are described in many different ways, Accuracy specifications should include the combined effects of repeatability, hysteresis, terminal point linearity, and adjustment resolution. They should also indicate worst case or peak error of the device at the reference conditions (cg. temperature, 25°C; power, 24V DC; and output load, 500 ohms). ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 8ie Electronic Automation (3.0) TAACT 23.3. Signal Isolation: un The term “Signal Isolation” means not having a direct electrical connection between two or more circuits .The Signal Isolation is achieved either by use of transformers or opto-couplers. Both devices transmit signals from one circuit to another (by way of ‘magnetic or optical signals), and both have very high impedance paths from input to ‘output. Signal isolation is required for the following reasons: (2) To isolate potential ground loops (2) To protect equipment from high voltage surges and spikes Following are the three most commonly used Signal Isolation types: 2 -Port Isolations: 2 Port eoator pt OF = Ls [b= 1G ior cara el! 26@ OM 4 Sopply Supply 2 Port Input side Isolation 2 Port Output side Isolation Fig.3-Port Isolation 2- ports Input side Isolation: The input is isolated from the output and power ‘supply, with no connection to earth ground. The output and power supply have a common ground. Such Signal Isolators can be connected to a grounded system, and is ‘ypically used for connecting signals from the field to a centrally grounded system like a PLC or DCS. 2-port Output side Isolation: The output is isolated from the input and power supply. The power supply & input have a common ground. This type of Signal Isolator is used for transmitting signals from a centrally grounded system like a PLC or DCS to the field 3-port Isolation: 3 Pert tolator +O 134, wT $> [Sir eh f ‘Sey Fig. ¢- Port Isoation ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 9ae Electronic Automation (3.0) TAACT All three sections viz. Input, output, and power supply sections are completely isolated from one another. Signal conditioners with 3 port isolation are therefore used in applications involving three separately grounded systems, This is the most safest & expensive type of isolation due to the isolation of the power circuitry from both the input & output sections. The 3 port Isolators are mostly used in Industrial Drive systems or Power system applications Adjustability (zero / span settings): Conditioners with adjustability can compensate for signal differences, and the ability to do so is usually worth the extra cost, Adjustability can be accomplished in hardware or software. Some applications have no software so it must be available in hardware. In other applications involving computers, such as data acquisition and control, it isnt possible or practical to perform all the adjustments in software, so hardware flexibility is a must. The capability to trim and calibrate hardware allows conditions to change without affecting other devices. In addition, system host processors don't get burdened, and system accuracy isn't compromised. Consider the following example. Let's say you are evaluating two signal conditioners. Both feature 1-5V DC outputs and are accurate to 40.1% of output span (4mV). One is non-adjustable and accepts a 0-100% input and has up to a 50% span adjusted capability. After defining your requirements, you decide that the input range you are interested in is 0-50% input. The second unit will have no problem calibrating and yielding a full range output while keeping the 40.1% accuracy rating. The first unit, however, is non-adjustable and will only yield 1-3V DC (2V DC span) for 0-50% input. Now, 4mV out of a 2V DC span is 0.3%. Hence, the first unit was not only inflexible, but tumed Out to be twice as inaccurate as the second. In the real world, sensors do not necessarily provide convenient endpoint signals (e.g., 0.00 mV through 50.0mV), but approximate values such as 6.37mV through 49.8mV. This gives adjustable signal conditioners two advantages: they can scale a signal with inconvenient endpoints, and optimize performance by calibrating out errors due to the sensors and/or the system (eg. voltage drops, other devices, and so on). Here are a few additional advantages of signal conditioner adjustability + As time goes on, components age and drift. The ability to calibrate and ‘maintain a conditioner increases its useful life. + An adjustable conditioner also saves a lot of CPU number crunching time if you expect to make all adjustments using a software program. It eliminates the need for additional end point calculations, Software programs are convenient for trimming and scaling. However, depending on the end points, scaling may introduce significant signal resolution and accuracy. + The ability to adjust zero and span on the conditioner allows conditions to change without affecting other devices, burdening host processors, and affecting system accuracy. + Signal conditioner adjustability also reduces device inventory; the more flexible the unit, the less need there is to stock unique modules. Teknocrat’s Academy of Automation & Control Technology, Nashik 10ie Electronic Automation (3.0) TAACT 234. Safety features * Short circuits in field cabling as well as Control pane! wiring is a commonly faced problem in most industries. The Signal conditioner / Isolator should have an internal fuse to protect the expensive electronics of the device. ‘The internal fuse can be of two types - A replaceable Glass cartridge fuse OR a Self resetting semiconductor fuse. The former is bulky & requires operator intervention for its replacement. The latter is compact & self resetting hence maintenance fee, As far as possible choose devices which have a semiconductor fase "Inthe worst case of a component failure within the device, itis desitable that this should not create a hazardous level of voltage for extemal devices NOR Should it esalt into a fire or explosion, This requirement is met in those Signal conditioners which are designed as per the European directive for device Safety .This directive is known as the Low voltage directive which requires that under no circumstances voltages above a certain safe level (32V) are generated by the device, * The handling of the Signal conditioner should not pose a risk of electric shock or injury to the operator. This requirement is met by devices which are designed as per IEC 61010 standards for Safety .You should confirm this with the manufacturer & crosscheck how these requirements are actually met, * The mounting arrangement for the device should be firm & should not be susceptible to vibrations. This is especially true for improperly designed DIN rail mounting clamps .The clamp should have a spring loaded mechanisin which can operate effortlessly & at the same time be firmly fixed on the DIN tail .DIN clamps with latch / screw operated fixing mechanism is prone to loosening up against slightest vibrations & the device can fall off the DIN rail during Control panel transportation, 23.8 Power consumption: If you have to use a large no. of Signal conditioners / Isolators in a single control Pane) it would make sense to check the power consumption of each Signal conditioner. As this will ultimately add to the heat dissipation within the panel resulting in elevated panel temperature & also load the incoming feeder. The power consumption of the signal conditioner is determined by the power supply design of the Signal conditioner & also choice of components used in the signal conditioning circuits. Signal conditioners with Hnear power supply circuits consume more power as they have poor efficiency, Whereas Signal conditioners with Switched mode power supplies consume very little power as they have a very high efficiency. The SMPS circuit also provides a much wider input voltage tolerance typically between 90 ~270 VAC thus providing flexibility in choice of mains OVAC of 230VAC. Another advantage of devices using a SMPS is that they have much less weight as compared to devices having linear power supplies. This facilitates easier handling while carrying out maintenance ‘Teknoctat's Academy of Automation & Control Technology, Nashik uRie Electron Automation (3.0) TAACT 23.6 237 238 Operating environmental tolerances Most of the industrial applications require the Control System hardware along with the Signal Conditioners / Isolators to be mounted in a Control panel. While selecting the hardware you must take into account the max. Ambient temperature outside the Control panel & also the elevated temp.due to the heat dissipation of the hardware mounted within the control panel. The heat dissipation within the pane! can be calculated based on the technical specs of each hardware module given by the ‘manufacturer. As a thumb rule,if the max, ambient temperature is expected to be say 50 deg C, then select hardware which can operate continuously at a temperature of 60 Deg C.. This should take care of the temp. Rise due to heat dissipation within the control panel Likewise the ambient relative humidity also should be taken into account. The higher the humidity the greater are the chances of hardware misbehavior due to moisture on the PCBs, components, wires & terminals. This is especially risky while handling low level signals (e.g. signals from RTD, Thermocouple, load cells etc).For tropical atmospheres select hardware which can operate continuously at 90%RH. If this is not possible you will have to make a provision for Space heaters within the panel. This ‘would mean extra cost of the heater & also the associated wiring, Physical dimensions: ‘The dimensions of the Signal conditioner play an extremely important role in PLC/ DCS Control panels where a large number of analog V/Os are usually wired up & a 24VDC bulk power supply is usually available, Here it is advisable to use 24VDC powered Signal conditioners. You should particularly look for Signal conditioners having the smallest pitch dimensions (< 25 mm width) so as to enhance the packing density per mounting rail. This will result in substantial control panel space saving & indirectly reduce panel costs. Electromagnetic compatibility: ‘The increasing miniaturization of electronic control systems such as Automation & Drives systems has made them susceptible to electromagnetic noise generated by external auxiliary devices like Signal conditioners & also other sources such as field instruments, panel cabling, power mains etc. As a result tough design measures are called for while designing Signal conditioners so as not to affect the safe operation of the electronic systems. The design guidelines are as given in the internationally renowned IEC 61000 — 4 standards. It is advisable to select Signal conditioners which are compliant to IEC 61000-4 standards Teknocrat’s Academy of Automation & Control Technology, Nashik 12ie Electronic Automation (3.0) TAACT 23.9 Applicatio Monitoring of Battery cell Voltage: The battery cell voltage is to be monitored through PLC analog inputs. There are 10 cells stacked in series in a given battery pack. And there are 12 nos. such battery packs. The voltage across each cell is to be ‘monitored on a continuous basis as the battery is getting discharged. Thus there are 120 nos. analog inputs (0 - SVDC) to be monitored. The PLC panel has limited ‘mounting space. Analysis of the application: The voltage output of each cell is floating and hence cannot be directly connected to the PLC analog input module which typically has input channels connected in groups of 4 or 8 or 16 with a common ground. For a error five measurement the PLC analog input GND has to be isolated from the floating GND of cach Cell Also the voltage outputs of the individual Cells have to be isolated from each other. Solution: Since +24VDC power is available & a large number of analog inputs are to be measured, a solution with SIM-Micro series Multichannel isolator modules can be realized, The application requirements can be fulfilled by using Signal isolator with 2 port input side isolation. This provides isolation between the input & output and also between the input & the supply. Signal Isolator PLC Analog inputs ——_| wp | loor] —————____, Battery Cell = i +24VDC Power supply +24VDC Power supply Fig.5-Signal Isolator Effectively, the voltage output of cach cell is measured by an independent input circuit .This input citeuit is completely isolated from the output stage & also the ‘24VDC power supply. The measured signal is filtered & applied to a chopper circuit which chops the signal & converts it into a frequency signal .This frequency signal is then transmitted across an optical isolator to the output side of the isolator. The output side then recreates the original signal & amplifies the same to 0-10VDC. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 13ae Electronic Automation (3.0) TAACT Multiple Output from Transmitter: A process transmitter output (4-20mA,2 wire ) is required to be connected to two different Instruments viz, PID controller & Multipoint Recorder. The measurement & control loop function is extremely critical & therefore itis desirable that a fault in one insirument should not affect the operation of the other instrument. Moreover the Recorder being used for multiple points should be connected in a way that if there is a fault in one channel, the other channels should not be affected. A bulk power supply of +24V DC is available for sourcing power. Analysis of the application: The PID controller being used for a critical application, there is a need for protecting the input & output sections from high voltage surges which may get induced on the input / output signal lines due to various electrical disturbances. So the Process transmitter signal output should be isolated from the PID controller input , and the PID controller output be isolated fiom the field output device. Likewise each input section of the Multichannel Recorder is also required to be protected from field disturbances by use of an Isolator, ‘The above two requirements can be fulfilled by using a Signal isolator at the input side & the output side, However the 4-20mA output of a single Signal isolator connected to both the instruments in series, does not guarantee measurement loop integrity of individual instruments. Therefore the input signal is required to be conditioned, isolated & split into two independent signals for connecting separately to the PID controller & Recorder. Solution: Since +24VDC power is available, a solution with SIM-Micro_ series ‘modules can be realized. All the requirements of the application can be fulfilled by tng * 1 no, SIM-Micro series DC Current Signal splitter ( 2 port output side isolation ) = 1 no, SIM-Micro series DC Current Signal Isolator ( 2 port input side isolation ) [rows i yp | Co {n>} 2? Trawmive: |f |” | Copa 7 Ps Fie The SIM-Micro series DC current Signal splitter isolates the Process transmitter ‘output from inputs of the Controller & the Recorder. The two output sections of the Signal splitter are isolated from each other & also the power supply by means of in- ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 4ie Electronic Automation (3.0) TAACT built DC/DC converters .This ensures complete measurement loop integrity as irrespective of the fault in one loop the other loop shall continue to operate without loss ofits functionality. At the output side of the Controller, no. SIM-Micto series DC Current Signal Jsolator (with 2 port input side isolation) isolates the Controller output from the field devi. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 15sronie Automation (3.0) TAACT ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 16ie Electronic Automation (3.0) TAACT 34 3.0 Sensors for position, velocity, and displacement Introduction: Imagine yourself without eyes & cars walking on a road full of traffic. You will feel like walking towards end of life! Why? Because your brain,the controller of your body won't receive any feedback about any Obstacles coming in your way. The process will be uncontrolled without any feedback & you will end into trouble. So you know how important is the job of your eyes & ears, your sensors for lot of processes, which are controlled by your brain, the intelligent area of your controller. The main purpose of any sensor is to continuously update the controller about the status of the machine or process, In context of automation system a sensor converts an event or value of process parameter into an electrical signal, [ Transducer MP | Processing | => U — ‘Alay Power Suply ae/be Internal block diagram of sensor Sensors consist of three main parts... + Transducer * Processing circuit "Driver circuit Transducer converts the physical parameter into an electrical signal. It converts the Parameter to be measured into proportional electrical quantity. The signal from transducer is generally not strong enough to drive the output. It needs to be processed and driven by an electronic circuit, to generate a standard electrical signal such as 0 — 1OV DC o 4 to 20 ma or NPN/ PNP output. An electronic circuit is used to process the transducer output to required standard electrical signal. A sensor is a device, which covers all the above functions, Classification of Sensors: Sensors are generally classified as; + Active sensors + Passive sensors ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 733 ie Bectronie Automation (3.0) TAACT Active sensors: Active sensors operate under energy conversion principles, also called self-generating type. They develop their own voltage or current. The energy required for producing this signal is obtained from the process parameter being sensed. They generate an equivalent electrical signal without any external power supply. Examples: = Temperature to ¢.m.f (mY) in case of Thermocouple * Pressure to e.m.f (mV) in case of Piezo-clectric transducers * Photovoltaic cell Passive sensors: The passive sensors operate under energy controlling principle. In this case the process parameter is converted into another passive parameter such as resistance, capacitance or inductance, which would need an auxiliary supply to produce an electrical signal. Examples: + Proximity sensors * RTD + Strain gauge ‘The auxiliary power supply for their functioning may be AC & DC like 230V AC or 10-30V DC. Limit switch: Basic principle: It is a mechanical device to sense the presence of an object by physical contact. Limit switch activates an electrical contact (NO to FC Or NC to FO) ‘on making a mechanical contact with an outside objec. Construction and Working operation: The mechanical motion of a cam, machine component or an object moving towards a predetermined position engages the limit switches roller lever over plunger which actuates an electrical contact inside the switch, Teknocrat’s Academy of Automat n & Control Technology, Nashik 8te Electronic Automation (0) TAACT Applications: Limit switches are normally used where ruggedness and reliability are important. These switches are very sturdy and can work in ditty oily and hazardous gnvironments. Major application are in machine tools, packing, wrapping, sealing ‘machines, botling plants, conveyers, lifts, hoist, cranes ete Actuation, CAM button 42) Fig.2 a-Limit Switch working principle Fig.2b-Limit Switch Selection criteria: * Mounting: Horizontal /Vertical/ at Angle + Enclosure: Standard/Weather proof/flame proof Contact rating:1A /5A/10A, * Switch Form: INOHINC or 2NO+2NC + Max. Temperature = Max Pressure * Cable entry 3.4 Proximity sensor Proximity sensors provide better alternative to the conventional clectromechanical limit switches. They find wide application in M/c tools, Automobile, ‘Textiles, Pharmaceuticals and all automation systems. These sensors are epoxy potted and are available in various shapes such as cylindrical, rectangular, slot ete. Advantages: Non-contact sensing * Bounce free operation * Works in rugged industrial environment * Compact size * Visual LED indication for presence of object Proximity Sensors include Inductive, Capacitive, and Photoelectric sensors. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 19ae Electronic Automation (3.0) TAACT 3.4.1 Inductive proximity sensors: Basie Principle: Inductive proximity sensors can sense the presence of Ferrous metal object from a small distance. These are useful for position sensing and slow speed counting, Induetive proximity sensors operate under the electrical principle of inductance. The sensors work on damping of oscillator principle. An inductive proximity sensor consists of a coil, a ferrite core, an oscillator, a detector circuit, and a solid-state output. The oscillator creates a high frequency field radiating from the coil in front of the sensor, centered on the axis of the coil. The ferrite core bundles and directs the electro-magnetic field to the front. When a metal object target enters the high-frequency field, eddy currents are induced on the surface of the target. This results in loss of energy in the oscillator circuit and, consequently, reduced amplitude of oscillation, The detector circuit senses the change in amplitude and generates a signal, which turns the solid-state output “ON” or “OFF”. When the metal object leaves the sensing area, the oscillator regenerates, allowing the sensor to retum to its normal state, There are four components inside the sensor: - the goil, oscillator, detection circuit and output circuit, wl Ik]. wane | camo | oumuT f Ec af i r . ovata ft dives Metal za) (Let ey AY Oseitator [ouput ‘date | switchi + Oscillations damped due to presence of object, Fig.3-working of inductive proximity switeh Construction: These sensors are generally available in cylindrical shaped enclosures with diameters from 4 mm to 80 mm. Sensors with other shapes such as Rectangalar, Slot, Block, Button etc in Flush type and non-flush type are also available. The sensing distance of the sensor depends upon the diameter. The larger the diameter higher is the sensing distance. ‘Teknocrat's Academy of Automation & Control Technology, Nashik 20Re Electronic Automation (3.0) TAACT Applications: Inductive proximity sensors provide a better altemative to the conventional electromechanical limit switches for position sensing and a good solution for many linear and rotary counting applications in the Automobile, Textile, Pharmaceutical and many other automation systems : Inductive Proximity Sensor used to detect presence of ‘metallic cans, Selection criteria: * Flush Mounting (shield type): By adding a shield (a metal jacket around the sides of the coil) the magnetic field becomes smaller, but also more directed. Shields are often available for inductive sensors to improve their directionality and accuracy. This type is used where other metallic objects may be present close to the object to be sensed. * Non-flush mounting (unshielded type): ‘The magnetic field of the unshielded sensor covers a larger Volume around the head of the coil. These types of sensors are susceptible to the influence of surrounding metals, but have sensing distance more than the flush type. When two or more sensors are to >be mounted side to side the spacing between them should be 3 times the diameter of sensors. These types of sensors should be mounted with their sensing zone in metal free areas. Fig.5-Non-flush Mounting * Sensing zone: The sensor has a dome shape electromagnetic field present in front of the sensing area, The sensor senses any object entering into this area. = Sensing distance: This is the maximum sensing distance between the target and the sensing face at which sensor operates. This is usually specified considering M.S material as object. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik aHe Electronic Automation (3.0) TAACT + Usable sensing distance: This is the distance, which is guaranteed within the permitted temperature and voltage range. * Correction factor: Gylinsieal Site tadedy 380 | Fig.6-Flush type inductive switch ‘Targets other than M.S. actuate the inductive sensor at relatively less distance with correction factor as given below. Metals MS [SS Brass Aluminum | Copper Correction factor [1 [os 05 0.45 o4 = Repeat Accuracy: This is the accuracy with which the switch operates repetitively at given stable ‘operating conditions. For inductive switches the accuracy is better than 0.02 mm. + Response Time: Is the period in which a switch changes its output state after target enters the sensing zone and determines the max. frequency operation of the switch. For DC Switches the ‘operating frequency can be as high as 3 KHz but for AC Switches this is limited to few 100Hz due to extemal load parameters. This response time decides the max. Counting speed of the sensor when itis used for counting applications. * Supply Voltage: For DC Switches a filtered / regulated power supply should be used and for AC Switches the supply should be EMI free as far as possible. * Switching Hysteresis: The difference between the Operate and the Release points is called Hysteresis or differential travel. The amount of target travel required for release after operation must be accounted for while selecting target and sensor locations. 1g (tuning on and off rapidly) when the sensor is subjected to shock and vibration or when the target is stationary at the nominal sensing distance. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 2aye Electronic Automaton (3.0) TAACT It is the difference between “Switch ON” and “Switch OFF” point of the switch. It is adjusted within limits of 5% to 15% of nominal sensing distance Motion Direction ‘Target ‘Switch point when leaving ape Switch point when approaching — sp oa SY Hysteresis divine Proximity sensor} Fig. 7-Hysterisis + Load Current 1s the maximum sinking or sourcing current that the transistors switch or output contacts can sustain. The external load connected to sensor output decides this current, = Types of output connections: ‘) 2 wire DC ii) 3/4 wire DC ifi) 2-wire AC iv) 2-wire NAMUR The NAMUR type sensors are intrinsically safe sensors & designed to work in the hazardous areas. The working voltage and current levels of these sensors are restricted to safe values as per some recommended standard, * Color code of sensor wires: ‘Sensor wires are normally color coded in two ways as shown below Types Positive Negative | Load iD ‘Brown Blue Black | 2 Red Black Green ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 23cl TAACT Electronic Automation (3.0) New trends in the technology: [1] Inductive proximity switches with analog output are nowadays available. ‘They can be used for length measuring. Applications upto approx. 10mm distance. [2] High Temp.Ind. Prox.: switches are now available which can withstand ‘upto 350°C ambient temp. Ordering specification: Sensing distance: in mm, ‘Type of the output required. e.g. PNP NO / NPNNO/ AC-NO / AC-NC ete. Flush/non-flush, other types Load current ‘Type of mounting flush /Now flush ohm ‘Output voltage Ambient temp Type of housing Length of wire / connector / non connector type. ° Flush + Cylindric—» Non-Flush Block Fie.8-Tvves of enclosures of Inductive vroximity ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 24ie Electronic Automation (3.0) TAACT 34.2 Capacitive Proximity Sensor: Capacitive Proximity sensors are designed for sensing wide range of metallic and non-metallic materials. These sensors can also be used for detection of non-metallic objects, which inductive type sensors cannot. —— Bleetric field ee Object beef + —(enas Lest 82 see |__| Detector oe Lat J Filg.9-Probe oscillator Rectifier Output Basic principle: Capacitive proximity sensors operate by generating an electrostatic field, The field strength changes are caused in this field when a target approaches the sensing face. The sensor's internal circuit consists of a capacitive probe, an oscillator, a signal rectifier, a filter circuit and an output circuit In the absence of a target, the oscillator is inactive. As target approaches, it raises the capacitance of the probe system, When the capacitance reaches a specified threshold, the oscillator is activated which triggers the output circuit to change between “on” and “ott” The capacitance of the probe system is determined by the target’s size, dielectric constant and distance from the probe. The larger the size and dielectric constant of a target, the larger is the capacitance. The shorter the distance between target and probe, the more is the capacitance. Construction- same as for inductive proximity switches. Applications: ‘The major applications of capacitive proximity sensors include sensing of liquid level in Food / Pharmaceutical Industry ‘These sensors are recommended for: * Detection of conductive materials at distances + Detection of conductive materials through insulated partitions * Detection of non-conductive materials on or in front of metal parts ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 25ae Electronic Automaton (3.0) TAACT Selection criteria: + Shielded vs, Unshielded Capacitive Sensors g” Flush +~ Cylindrical Non-Flush Block type Fig.10-Types of enclosures of capacitive switches Shielded capacitive proximity sensors are best suited for sensing low dielectric constant (difficult to sense) materials due to their highly concentrated electrostatic fields, This allows them to detect targets, which unshielded sensors cannot. However, this also makes them more susceptible to false triggers in case of accumulation of dirt or moisture on the sensor face. The electrostatic field of an unshielded sensor is less concentrated than that of.a shielded model. This makes them well suited for detecting high dielectric constant (easy to sense) materials or for differentiating between ‘materials with high and low constants. For the right target materials, unshielded capacitive proximity sensors have longer sensing distances than shielded versions, Unshielded models are equipped with a compensation probe that allows the sensor to ignore mist, dust, and small amounts of dirt and fine droplets of oil or water accumulating on the sensor. The compensation probe also makes the sensor resistant to variations in ambient humidity. Unshielded models are therefore a better choice for dusty and/or humid environments. Unshielded capacitive sensors are also more suitable than shielded types for use with Plastic sensor wells, an accessory designed for liquid level applications. The well is ‘mounted through a hole in a tank and the sensor is slipped into the well's receptacle ‘The sensor detects the liquid in the tank through the wall of the well. This allows the well to serve both as a plug for the hole and a mount for the sensor. * Nominal sensing distance (Sn): Similar to that defined for inductive proximity sensors, the nominal sensing distance is calculated using a standard mild steel square target of, 1 mm thickness. The outside dimensions of the square plate are equal to that of the sensor sensing face. + Sensitivity of sensors: Sensors incorporate a 20-turn sensitivity adjustment potentiometer. This enables the sensitivity of the sensor to be adjusted to suit the type of object to be detected. The sensors are factory preset for nominal sensitivity. Depending on the application, adjustment of the sensitivity could. be necessary as follows: ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 26ie Electronic Automation (3.0) TAACT Increasing the sensitivity for objects which have a weak influence (Low dielectric constant, for example: paper, cardboard, glass, plastic) Decreasing the sensitivity for objects which have a strong influence (High dielectric constant, for example: metals, liquids) However, in the event of severe variations in the ambient conditions, do not increase the sensitivity of the sensor such that it is set near to its maximum operating limits, An increase in sensitivity causes an increase in the switching Hysteresis, Fig. -sensitivity adjustment in a proximity switch Target Correction Factors for Capacitive Proximity Sensors For a given target size, dielectric constant of target decides the correction factors for capacitive sensors. Materials with higher dielectric constant values are easier to sense than those with lower values. Ordering informatio, * Type of output: NPN or PNP, NO/NC, AC, DC, Namur Type Sensing Distance Supply Voltage Load Current Switching frequency Indication Ambient Temperature Housing Type Connectet/ Non connecter 343° Ultrasonic Proximity Sensors: ‘he ultrasonic sensors are designed for use in industrial applications involving Presence detection of objects. Ultrasonic sensors enable detection, without contact, of any object irrespective of its characteristics like... ‘Material (metal, plastic, wood, cardboard, etc.), Nature (Solid, Liquid, Powder, ete.), Color, Degree of transparency Teknocrat’s Academy of Automation & Control Technology, Nashik ahe Electronic Automation (3.0) TAACT Principles of Operation: The principle of ultrasonic detection is based on measuring, the time taken between transmission of an ultrasonic wave and reception of its echo (return of transmitted wave), Ultrasonic sensors operate in diffused mode. An ultrasonic transducer transmits and receives the ultrasonic signals. Within a stipulated distance range, the incoming echo | Dead bani /orking distance - ‘Transmitted pulse Ny ‘Target Fig.12-Ultra-sonie sensing ‘The time taken for the sound to travel the distance is determined and a corresponding ‘output signal is emitted. If the distance between sensor and object is too small, the echo arrives before the ultrasonic transducer has reached a steady state and is ready to receive. Objects in the dead band cannot be detected reliably. Ultrasonic sensors are generally of cylindrical type shape. They comprise of = High voltage generator *» Piezoelectric transducer (transmitter and receiver) = Signal processing stage * Output stage Excited by the high voltage generator, the transducer (transmitter-receiver) generates a pulsed ultrasonic wave (200 to 500 kHz depending on the product), which travels through the ambient air at the speed of sound. When the wave strikes an object, it reflects (echo) and travels back towards the transducer. ‘A micro controller based circuit analyses the signal received and measures the time interval between the transmitted signal and the echo. By comparison with the preset oF learnt times, it determines and conirols the output states. The output stage controls a solid-state double switch (PNP and NPN transistor) corresponding to a NO contact (detection of object). Analog models provide an output voltage proportional to the distance from the sensor face to the target, while digital / discrete output models change output state when this distance crosses a pre-set threshold ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 28ie Blecronie Automation (0) TAACT 5 en _¥ 3 y Bo) gat Housings Fig.13-Howsing ype of ultrasonic sensors Applications: One special aspect of the ultrasonic technique is the capability of deflecting sound with smooth reflectors. This allows the level of an aggressive fluid to be measured for instance. By contrast, measuring errors occur if the sound is to be beamed deflected with smooth tubes for instance th Fig. 14-Ultrasonic detection with defected sound Ultrasonic proximity sensors are ideally suited for level monitoring application, The sensing range is available from 0.5M to 20M. They are used in industrial applications for detecting: + The position of machine parts, * The presence of the windscreen during automobile assembly * The flow of objects on a conveyor system like glass bottles, cardboard packages, cakes, etc. * The level of different color paints in pots, level of plastic pellets in injection molding machine feeders etc * Detection of moving objects + Level of solids, liquids in large bins. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 29Sg Eleetonic Automation (3.0) TAACT Selection criteria: These sensors are useful for sensing targets that Blind zone Operating sensing distance are beyond the very short ry operating range of inductive and Overall Stundasd capacitive type of sensors, Beam angel They sense dense target material such as metals and liquid best. They don’t work well with soft y4inimum sensing material such as cloth, foam distance rubber ete distance They operate poorly with liquids Fig.15-sensing range of ulirasonic sensor that have surface ripples or waves. These sensors don’t operate in vacuum. However because of their relatively Jong sensing range designer must take care when using more than one sensor in a system because of potential for cross talk between sensors. + Nominal sensing distance (Sn): It does not take into account manufacturing tolerances nor variations caused by external conditions such as voltage and temperature. + Sensing range (Sd): Zone in which the sensor is sensitive to objects + Minimum sensing distance: Lower limit of the specified sensing range ‘Maximum sensing distance: Upper limit of the specified sensing range * Assured operating distance (Sa): This corresponds to the operating zone of the sensor (activation of outputs), and is included in the sensing range. Its limits are fixed ~ At the factory for fixed sensing distance sensors, - When setting-up within the application for sensors with teach mode. "Blind zone: Zone between the sensing face of the sensor and the minimum sensing distance in which no object can be reliably detected. Avoid any passing of objects in this blind zone during operation of the sensor. This could lead to instability of the output states. * Differential travel: ‘The differential travel (H) or Hysteresis is the distance between the pick-up point as the standard metal target moves towards the sensor and the drop-out point as it moves away from the sensor. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 30ae Etectronic Automation (3.0) TAACT 344 Standard target: The standard TEC defines the standard target as a square metal plate, | mm thick with rolled finish, placed perpendicularly to the reference axis Its side dimension depends on the sensing range: Sensing range (mm <300 300 oprica we can ‘The mark sensors are a version of a diffused beam Sensor. The amount of infrared Gens energy reflected from two different shades of colors varies, whichis sensed through a cao oti’ sensitive electronic circuit and an out put signal is generated. Ne gine? . ‘These sensors are used where application requires differentiating between two colors. Working principles: Color sensors function using a three-color method. Red, green and blue light is sent by high quality, maintenance-free and long-lived semiconductor light sources on the test objects. From the reflected radiation the color sensor determines the proportional values and compares it with the stored values. If the values agree, an exit is activated. Up to 4 different colors can be Jearnt by the sensor. For each channel the tolerance is individually selectable. This makes it possible to recognize rough and fine differences in color. Beam color can be important. A red color LED does not see red mark on the white but sees blue and yreen. A blue LED sees green and red, but not blue. A green LED sees red and blue but not green. Visible white LED solves a wide variety of sensing Applications: ‘When the proper light source color is selected for an application, even very small color difference can be detected. ‘These are mostly used in packaging industry e.g. soap packaging Sensing the progmmmed colour . Teknocrat’s Academy of Automation & Control Technology, Nashik 36Electronic Automation (3.0) Some new sensors can be programmed easily to differentiate slight levels of color contrast for demanding applications using TEACH mode setup. The sensor can be taught to look ‘ {or window of acceptable conditions, or set point threshold { (the light condition on one side of the threshold, and the dark condition on the other) i TEACH is a step-by-step sequence in which two sensing ’ a y reference points (light and dark) are taught to the sensor, coflen using a push bution. The sensor circuitry automatically sels its sensitivity to an out put level. Fig.29-Expert Sensor Applications: These are especially used in package industries for soap Packaging, Pharmaceutical, Food ete where color reorganization is required 34.46 Laser Sensor: Laser sensors are used in the SPM industry as well as in other production fields, High precision detecting and positioning is of great importance. With inductive proximity switches, which have to be very close to the detected: object, or with conventional photo switches or through beam sensors such applications are often very difficult to solve. solution for this type of application is optical sensors with Laser diodes as light source. Because of the precise focused laser beam, often switching accuracies better 0.1 mm ean be achieved 344.7 Optic Fiber sensors: There are applications where objects to be sensed are located in sich consrGied pce inside a poche are complete sensor cannot be fixed any ‘here near the object, Fiber optic sensors are used for such application, Fie.30-Laser sensor Plastic fiber optic photoclectri il XW Fig31.-Fiber optic photoelectric Fig.32-Plastc fiber optics Photoelectric sensors for glass fibers sensor sensor ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 37ae Senses @ Magnet Electronic Automation (3.0) - Sensing qaacr POSkHan SASK In Frettmedhie 3.4.5. Magnetic Proximity switches: These switches sense the presence or absence of magnetic fields. They are based on Reed switches. Working principle: A teed switch consists of springy metal reeds having plated long life contact at the tips and encapsulated in a sealed glass tube. A two reed type has Normally open contacts (NO) which closes when activated or Normally closed (NC) contacts which ‘opens when activated. A three reed type is a changeover, ie, it has a pair of normally ‘open (NO) and a normally closed (NC) contact, When the switch is operated both these pair change to the opposite state ees Glass Seal Glass Tube =e t—— Thick Wire Normally Contact Closed wa — ‘Normally Open(NO) ‘Fig.33- Two reed and three reed Reed switches are activated from an external permanent magnet or electromagnet in close proximity. The field causes the reed to become magnetic, the ends are attracted and the contact either closes or opens. Its important to note that: ‘The strength of the magnetic field decreases drastically as the distance from the magnet increases. At twice the distance the field strength reduces to one fourth. The activating magnet should therefore move very close to the switch. (less than 10mm) "The reed switches only have a momentary action, - : There ore hermifieuly sealed sense Ne Necessary gw The object Shouts wagner ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 38Electronic Automation (3.0) TAACT Applications: Reed switches are used for position sensing in pneumatic and hydraulic cylinders, rotameters and level sensing of liquids. Magnetic switch Reed switch OFF ON L Magnetic switch Magnetic switch ON” OFF aN Magnetic fitted on piston Fig.34-Application of Reed switch Selection Criteria: These devices are very tolerant to misalignment and are Particularly suited to environments that are contaminated by dust, liquid and where non-contact interlocking or hygiene is a consideration. ‘The magnetic switches available in the market can be classified in two different groups. One group switches are with contacts, called mechanically operated or reed ‘witches, The other groups of switches, without contacts, are called solid-state type. 3.4.6 Magnetic float switches: ‘These are reed switch based sensors for point level sensing of liquid. Working principle: A float switch is a point level sensor. A float with a magnet inside moves with the liquid surface. A hermetically sealed reed switch on the fixed part of the float switch gels activated by magne! in the float. The reed switch may be of NO, NC or changeover type depending upon the application. \geover type depending upon the applicati a Magnatie Flvcd level I] Bring Obovemes Pagned ~ seasny wd R= Reed Suodtey ‘Teknosrai's Academy of Automation & Technology, Nashik 39Horizontal Float Sawltchg~ mounted Prom side of he tank Norizontally Me Electronic Automation (3.0) TAACT — Enclosure l ms —__—Condui conn, Adapter Process conn, Se Stopper Float Garde fedee oF 0m Ferrous aud Fig.35- Magnetic loat switches Application: Magnetic float switches are used in water tanks and storage tanks, for sensing the level of liquids, Selection criteria: swith Rabe — Selenena tf BoveS fom pe tI Ne oF * Contact Type: SPST-NO, SPST- NC Ane tae Length of Standard Wire lead E.G. 1.5 Mtr. long MAR Tomy * Switching Capacity: Watts/VA_ MVE Pre ram, * Switching Voltage Cavic eater + Switching Current ‘+ Max. current carrying capacity:05A,1A,1.5A ete. + Lead Wire: E.G 2 Core, 2mtr.Fla/Round Ete + Body / Float Material: PE, stainless steel, 30% Gf nylon Float Level suites suit Float ‘Teknocrat’s Academy of Automation & Contro} Technology, Nashik ~_4o Meta Potentiometersfice tered sgikhr Gye ae Electronic Automation (3.0) 3.5 Tachogenerators: Tachogencrators are used for sensing speed of any rotating covpreet snag oughly proportional to the shaft speed. With precise construction and design, generators can be made to produce very precise voltages for certain range of shaft speeds thus making them suited as a measurement device for shaft speed of ‘mechanical equipment. A generator specially designed and constructed for the Purpose is called a Tachogenerator. Voltmeter with scale calibrated in (v RPM Filg.36-Tachogenerator By measuring the voltage produced by the tachogenerator, you can determine the rotational speed of the equipment, itis coupled to. ‘The output voltages of the tachogenerator can also indicate the direction of rotation by its polarity. ‘The tachogencrators are like small fractional horsepower motors in looks and are either flange mounting or foot mounting type. The shaft of the {achogenerator is coupled to the rotating equipment through a coupling and should be accurately aligned with the shaft of the rotating equipment. A misalignment of the shaft would give inaccurate voltage readings besides causing damage to the tachogenerator. Application: Speed control of DC motors "Speed control of engines, conveyors, machine tool, fans, mixers ete Selection criteria: = Qutput voltage: Tachogenerators are available for different output voltages like 0-10V, 0-200V, et Output voltage of tachogenerators should be compatible with the control equipment. Teknocrat’s Academy of Automation & Control Technology, Nashik 4aite Electronie Automation (3.0) TAACT + Speed range: ‘The technogenerator are generally designed for a particular speed range like 0-100 rpm or 0- 4000 rpm.etc. The speed range should match the speed of the rotating equipment to which the tacho is to be connected, * Mounting: Flange or foot mounted type depending upon the site condition, * Temperature compensated type technogencrators The output voltage of the normal tachogenerator varies slightly with the ambient temperatorure and the heating of the gennator widings. For applications which require extremely precise speed control, the output voltage integrity required is also very high. For such applications temperature compensated tachogenarators are available which have a builtin temperature compensation circuit to offset the effect of temperature on output voltage. Fectures ‘Typical Technical specification: — Generares eicetricad 1, Output load voltage = 200V at 400mm Srna vn vespease 12 2. Ripple Max = 3.5% +10% Wary movement 3. Max Speed = 4000 rpm Hoy Signal acqurany 4, Max linearity error +1% J SIMA acer] 5, Max output current -SmA Appi - Perkin sensyiey 6. Weight - 200 gms + 10gm Siena "meugainy 7 Operation periods ~ continuous — Lengra x) 3.6 Encoders: While designing an automation system for Length measurement in rotating machines), it is necessary to know the position of machine in particular angular position, speed of the machine or how many revolutions the machine has completed. This can be done with Rotary encoder, which is fitted on motor shaft; output of which can be given to counters or PLCs for further operations. Rotary Encoder is a device that senses a physical parameter and converts it into a digital code. A rotary encoder, in basic terms, is a device that translates shaft angular position into an electronic signal, Optical rotary encoders dominate industrial applications-for reasons of reliability, ruggedness, and accuracy. With varying degrees of environmental protection, they suit a wide range of applications In many motion systems, rotary optical encoders provide the most versatile and economical means to obtain feedback signals for position and speed control. Features Generates Acomeal Signal Optical encoders are of two types. "Incremental Encoder In vesponr® to ryt "Absolute Encoder Hah Kymed — accure'y provement By Mehr eens Lengh, Pease si ‘Teknocrat’s Academy of Automation & Control Technology, Nashik —~ 42ie Electronic Automation (3.0) TAACT 3.6.1 Incremental Encoder: Incremental Encoders a clear glass disk with black regions is etched into glass surface separated by a particular distance which is decided by required PPR(pulse per ‘otations).As shown in figure Light from one side (LED) passes through the disk on to photo-detectors, which produces encoders outputs, TepL1C. hactaomny fy angaivesdoey Sasjeay , Robots Wensiboy Working prineiples: A stationary light source (usually an LED) illuminates the‘ <.4)ment rotating code disk, which has a number of light transmitting slits, Light passing through the code disk then falls upon the phase plates, which consists of a similar but stationary set of slits. Finally, the detector photodiode converts the transmitted light to an electronic signal. This signal is then amplified and “squared up” to provide a standard +24/+5 volt digital signal, which can be input to a counter circuit oe PIL Veco LS fee aa [an PAST eapecior | UL Channel B Fig.37-Quadrature Output The phase plate consists of two sets of slits, with the second set offset by 1/4 of the inter slit spacing. This generates two electrical signals, called Channel A and Channel B, which are 90 degrees out of phase (also referred to as being “in Quadrature”), All incremental encoders provide single channel’ Quadrature output codes. Incremental encoders often have a third channel with a single segment slot or reference, which is used to zero or home the device. Adding a second channel and offsetting it by 1/4 eyele from the first channel provides two advantages. * Direction information is indicated by the sequence between the two channels (A leads B or B leads A). * The encoder resolution is effectively increased since there are now 4 transitions for each line pair, instead of 2. The phase lag or lead between channels A and B in electrical degrees is nominally 90°.Quadrature code is, easily converted to step and direction or up-clock and down-clock. To OL I eS 8 l jy J Fie,38-Channel leads B Channel Teknocrat’s Academy of Automation & Control Technology, Nashik BTAACT ‘The Quadrature code produced by incremental encoders has 4 state changes (edges) per Quadrature cycle (one per % cycle), ‘A 500 CPR encoder has 500 cyeles, (2000 codes) per revolution, ‘X1 decoding - means that the external electronics counts only once per full cycle. X2 counts two states per cycle X4 counts every Quadrature state. Logic circuits can now easily determine direction, since channel A will switch before channel B for one rotation direction, and afterwards when rotating in the opposite direction. An added bonus is a four-fold increase in resolution in the counting circuit, ‘The number of pulses per rotation that are produced by either the phase A or phase B outputs specifies incremental encoders. By dividing the number of pulses per rotations into 360’, we get number of degrees per pulses called the resolution. ‘This is the smallest change in shaft angle that can be detected by the encoder. For example 360- pulse incremental encoder has a resolution of 360°/360=1° resolution. Incremental encoders are available up to 72,000 PPR. Fig.39 - Length measurement with measuring edge Applications: Incremental encoders are used! in * Textile machinery * Conveyor systems * Robotics handling equipment In the event of a power failure Incremental encoder will lose positional information, and a reset or homing cycle must be performed to synchronize the encoder with the control devices og Eheader © swale ox hattocd shaht @ we euse dis ® whe ght source @_ ee grat dvaphrage @ Me protosione/ deceding circushy @ Conner Teknocrt's Academy of Automation & Control Technology, Nashik “4 Speci f cede “ Sayply von O) Out leet O map genre Srey By veel Belem Chen os .