Industrial Electronics: Applications for Programmable Controllers, Instrumentation & Process Control, and Electrical Machines & Motor Controls

by Kissell, Thomas E.

• ISBN13: 9780130126979
• ISBN10: 0130126977
• Edition: 2nd
• Format: Hardcover
• Copyright: 1999-07-01
• Publisher: Prentice Hall

Summary

For courses in Industrial Electronics and Electronic Controls, in two-year technical and community colleges and in four-year engineering and engineering technology programs. The role of today's technician has changed as industries compete in the global marketplaceand students need a comprehensive industrial electronics text that will prepare them to work on every aspect of an industrial system. The most expansive and in-depth treatment currently available, Industrial Electronics, Second Edition, provides detailed applications for each device and circuit discussed. Students will learn how devices operate and are tested, along with the real-life application where they will find them. All material has been fully updated to reflect recent developments and rapid changes in the industry. Drawing on more than 20 years of industry experience, the author incorporates course material that he also uses in consulting practicing technicians and engineers at corporations such as Ford Motor Company and General Mills.

Table of Contents

Solid-State Devices Used In Industrial Logic Circuits	1	(34)
Overview of Logic Used in Industrial Logic Circuits	2	(1)
Relay Logic	3	(3)
Terms for Relays	4	(1)
Types of Relays	5	(1)
Voltage Ratings for Coils and Contacts	5	(1)
Troubleshooting Relay Coils and Contacts	6	(1)
Typical Logic Circuits	6	(2)
Identifying Inputs and Logic in the Circuit	7	(1)
Relay Ladder Logic	7	(1)
Relay Logic Used to Control A Pneumatic Cylinder	8	(2)
Using Relay Logic to Determine Robot Program For Inserting Studs Into Taillights For Automobiles	10	(2)
Understanding the Relay Logic	11	(1)
Solid-State Devices Used for Logic	12	(2)
Transistor Equivalent to AND and OR Circuits	13	(1)
Solid-State Logic Blocks	14	(4)
Early Examples of Logic Gates	15	(1)
Programmable Logic Arrays	16	(2)
Programmable Array Logic (PAL)	18	(1)
Programmable Logic Controllers	18	(1)
Solid-State Logic Equivalent to the Cougar Taillight Assembly Circuit	18	(2)
Operation of the Solid-State Logic Circuit	19	(1)
Connecting Inputs to Solid-State Logic Devices	20	(2)
Outputs for Logic Circuits	22	(1)
Solid-State Relays	23	(2)
Features of SSRs	24	(1)
A Comparison of Solid-State Logic and Relay Logic	25	(2)
Strengths and Weaknesses of Solid-State Logic Devices	25	(2)
Strengths and Weaknesses of Relays	27	(1)
Solid-State and Relay Logic Circuits to Control Part Bins for Robotic Automatic Work Cells	27	(8)
Operation of the Relay Logic for Parts Bin Level Control	30	(5)
Advanced Solid-State Logic: Flip-Flops, Shift Registers, Counters, And Timers	35	(36)
Overview of The Need for Advanced Logic	36	(1)
Latches	37	(6)
RS Latch	38	(1)
Edge-Triggered Flip-Flops	38	(1)
The Edge-Triggered RS Flip-Flop	39	(1)
The Edge-Triggered JK Flip-Flop	39	(1)
The Edge-Triggered D Flip-Flop	40	(1)
Using Flip-Flops to Cycle Two Air Compressors	40	(1)
Using Flip-Flops to Control an Industrial Surface Grinder	41	(1)
Using Flip-Flops for Safety Circuits	42	(1)
Counters	43	(3)
Asynchronous and Synchronous Counters	43	(2)
Binary-Coded Decimal Counters	45	(1)
Up/Down Counters	46	(1)
Shift Registers	46	(5)
Operation of a Shift Register	47	(1)
Using Edge-Triggered JK Flip-Flops to Make a Shift Register	48	(1)
Using Shift Registers to Provide Time Delay	48	(2)
Word-Shift Registers	50	(1)
First-In, First-Out (FIFO) Shift Registers	51	(5)
The Johnson Counter	53	(1)
The Ring Counter	54	(1)
The Gray Code Counter	54	(2)
Timers	56	(2)
One-Shot Timers	56	(1)
The 555 Timer	57	(1)
Industrial Timers	58	(13)
On-Delay Timers	58	(1)
Off-Delay Timers	59	(1)
Normally Open and Normally Closed Time-Delay Contacts	60	(2)
Pneumatic Timer Operators	62	(1)
Motor-Driven Timers	63	(3)
Solid-State Time-Delay Devices	66	(1)
Programmable Timers	67	(4)
Programmable Controllers	71	(58)
Overview of Programmable Controllers	72	(4)
The Generic Programmable Logic Controller	73	(2)
Basic Parts of a Simple Programmable Controller	75	(1)
The Programming Panel	75	(1)
An Example Programmable Controller Application	76	(3)
Operation of a Conveyor Sorting System	77	(2)
Scanning a PLC Program When It is in the Run Mode	79	(3)
Image Registers	79	(2)
The Run Mode and the Program Mode	81	(1)
On-Line and Off-Line Programming	81	(1)
Equating The PLC With Traditional Solid-State Logic	82	(1)
Features of The Programmable Controller	82	(2)
Classifications of Programmable Controllers	84	(1)
Operation of Programmable Controllers	84	(2)
Immediate I/O Updates	84	(1)
The Need for High-Speed Inputs and Outputs	85	(1)
Addresses for Inputs and Outputs for the Micrologix 1000	86	(1)
Example Input and Output Instructions for the Micrologix 1000	87	(2)
Mnemonics: Abbreviations for Instructions	89	(1)
Using The Micrologix 1000 To Control The Batch-Mixing and Heat-Treating Process: Making Carbon Brushes	89	(1)
Inputs and Outputs for the Carbon Brush Process System	89	(1)
Operation of The Heat-Treating Part of the System	90	(3)
Using Latch and Unlatch Coils	92	(1)
Using Timers To Stage Electric Heat	93	(2)
TON and RTO Timers	93	(1)
Using the TON as an Automatic Resetting Timer for Lubrication	94	(1)
Counter Operation in a PLC	95	(2)
Using an Up/Down Counter to Count Good and Bad Parts	96	(1)
Using Counters in the Carbon Brush Application	96	(1)
Using a Resetting Counter Application	96	(1)
Timing And Counting Large Value	97	(2)
Sequences Used To Control The Batch Mixing For The Carbon Brush Application	99	(4)
Sequencer Application for the Carbon Brush--Mixing System	100	(1)
Programming the Sequencer into the MicroLogix 1000	101	(1)
Selecting a Mask for the Sequencer	101	(1)
Setting the Time for Each Step of the Sequencer	102	(1)
Other Sequencer Functions	103	(1)
Circuits for Input and Output Modules	103	(2)
Electronic Circuit for a 110 AC Output Module	103	(2)
Electronic Circuit for the Relay Output Module	105	(1)
Wiring Input Switches and Output Devices to The PLC	105	(1)
Analog Input Modules	106	(2)
Master Control Reset and Zone Control Last State	108	(1)
Using A Hand-Held Programmer	108	(8)
Force and Unforce Functions	111	(1)
Entering Programs with a Hand-Held Calculator	111	(1)
Programming Basic Circuits in the PLC	111	(2)
Wiring a Start-Stop Circuit to Input and Output Terminals on the PLC	113	(2)
Typical Problems a Technician Will Encounter with PLCs	115	(1)
Troubleshooting the PLC	115	(1)
Advanced Instructions Found In Larger PLCs	116	(1)
Addressing Other Allen Bradley PLCs	117	(7)
Allen Bradley PLC2 Addressing System	120	(1)
Allen Bradley SLC 500 and PLC5 Addressing System	120	(2)
Allen Bradley SLC 500 and PLC5 Hardware	122	(2)
Documenting a PLC Program With Software	124	(5)
Solid-State Devices Used to Control Power: SCRs, Triacs, and Power Transistors	129	(35)
Overview of SCRs, Triacs, And Transistors In Industrial Applications	130	(1)
Silicon-Controlled Rectifiers (SCRs)	131	(15)
Anode, Cathode, and Gate	132	(1)
Two-Transistor Model of an SCR	132	(1)
Static Characteristic Curve and Waveforms for the SCR	133	(1)
Waveforms of the SCR and the Load	134	(1)
Methods of Turning on an SCR	134	(2)
Turning on an SCR by Gate Triggering	136	(1)
Characteristics of the SCR Gate Signal	136	(2)
Basic Gate Circuit	138	(1)
Using Unijunction Transistors and Diacs to Trigger SCRs	139	(1)
Methods of Commutating SCRs	140	(1)
SCR Turn-Off Time and Reverse Recovery Time	141	(1)
Example Applications Using SCRs	142	(2)
Complementary SCRs, Silicon-Controlled Switches, Gate Turn-Off Devices, and Other Thyristors	144	(2)
Triacs	146	(6)
Operation of a Triac	148	(1)
Characteristics of Triacs	149	(1)
Switching On a Triac	149	(2)
Circuit Commutation for a Triac	151	(1)
Power Transistors	152	(5)
Power Transistor Applications	153	(2)
Darlington Transistors	155	(1)
The Need for Darlington Transistors	156	(1)
Insulated-Gate Bipolar Transistors	157	(1)
High-Voltage Bipolar Transistors	157	(2)
Junction Field-Effect Transistors (J-FETs)	159	(1)
Comparison Of Power Semiconductors	159	(5)
Solid-State Devices Used For Firing Circuits	164	(26)
Overview Of Firing Circuits	165	(1)
Unijunction Transistor (UJT)	166	(9)
Theory of Operation of a UJT	166	(1)
Firing Characteristics of a UJT	167	(1)
Voltage and Current Characteristics When a UJT Fires	168	(1)
Relaxation Oscillator	169	(1)
Voltage and Current in the Relaxation Oscillator	169	(3)
Synchronizing a UJT Pulse with AC Line Voltage	172	(2)
Isolating the UJT Firing Circuit from the SCR Load Circuit	174	(1)
Programmable Unijunction Transistors	175	(2)
Operation of a Programmable Unijunction Transistor	176	(1)
Using A Diac to Provide a Pulse for Thyristors	177	(2)
Theory of Operation of a Diac	178	(1)
Other Solid-State Devices Used as Triggers	179	(5)
Small SCRs and Complementary UJTs	179	(1)
Silicon-Controlled Switch (SCS)	180	(1)
Silicon Unilateral Switch (SUS)	180	(1)
Silicon Bilateral Switch (SBS)	180	(2)
SIDAC	182	(1)
Silicon Asymmetrical Switch (SAS)	183	(1)
Asymmetrical Silicon Bilateral Switch (ASBS)	183	(1)
Shockley Diode	184	(1)
Schottky Diode	184	(1)
Light-Activated Solid-State Devices	184	(6)
Photoelectronics, Lasers, and Fiber Optics	190	(44)
Analysis of Light	191	(2)
Photodiodes	193	(2)
Photovoltaic Cells	194	(1)
Theory of Operation of Photovoltaic Cells	194	(1)
Applications for Photoelectric Controls	194	(1)
Photoconductive Cells	195	(3)
Cadmium Selenide Cell	197	(1)
Modulated Light Source (MLS)	197	(1)
Industrial Photoelectric Devices	198	(7)
Through-Beam Photoelectric Devices	198	(2)
Retroflective Scan Photoelectric Devices	200	(3)
Diffuse Scan Photoelectric Switches	203	(1)
Electronic Circuits for Photoelectric Switches	203	(1)
Output Signals for Photoelectric Controls	204	(1)
Optoelectronic Devices	205	(3)
Phototransistors, Light-Activated SCRs, and Phototriacs	206	(1)
Light-Emitting Diodes (LEDs)	207	(1)
Optoisolators and Optointerrupters	208	(10)
Applications for Optocouplers	209	(1)
Theory of Operation of the Optoisolated Circuits	209	(1)
Optoisolation Relays (Solid-State Relays)	210	(2)
Optocouplers Used in Input and Output Module Circuits	212	(2)
Specialty Types of Optocouplers	214	(2)
Adding Bias to the Phototransistor of the Optocoupler	216	(1)
Using an Optocoupler to Convert a 4--20-mA Signal to a Variable-Voltage Signal	217	(1)
Photo IC Interrupter	218	(1)
Optodevices Used for Displays	218	(3)
Liquid Crystal Displays (LCD) and Plasma Display Screens	219	(2)
Lasers	221	(2)
Theory of Laser Operation	221	(1)
Types of Lasers	221	(1)
Diode Lasers	221	(1)
Industrial Laser Applications	222	(1)
Fiber Optics	223	(2)
Fiber Optic Transmitter and Receiver	223	(2)
Types of Fiberoptic Cables	225	(1)
Bar-Code Equipment	225	(9)
Bar-Code Scanner and Decoder	227	(1)
Types of Scanners	228	(1)
Typical Bar-Code Applications in Industry	228	(6)
Industrial Power Supplies, Inverters, and Converters	234	(38)
Overview	235	(1)
Industrial Rectifier Circuits: AC-To-DC Conversion	236	(14)
Single-Phase Rectifiers	236	(2)
Two-Diode Full-Wave Single-Phase Rectifiers	238	(1)
Four-Diode Full-Wave Bridge Rectifiers	239	(2)
Three-Phase Full-Wave Rectifiers	241	(1)
Other Types of Three-Phase Rectifiers	242	(2)
Six-Phase Full-Wave Bridge Circuits	244	(1)
A Comparison of the Different Types of Rectifier Circuits	245	(1)
Using Capacitors and Inductors as Filters for Power Supplies	246	(1)
Using a Zener Diode for Voltage Regulation	247	(1)
Surge Protection for Rectifier Circuits	248	(1)
Crowbar Protection Against Overvoltage	249	(1)
Applications For Industrial Power Supplies	250	(4)
Power Supply for a Variable-Frequency Motor Drive	251	(1)
Welding Power Supply	251	(2)
Uninterruptible Power Supplies	253	(1)
Inverters: Changing DC Voltage to AC Voltage	254	(7)
Single-Phase Inverters	255	(1)
Using Transistors for a Six-Step Inverter	255	(2)
Three-Phase Inverters	257	(1)
Variable-Voltage Inverters (VVI)	258	(1)
Pulse-Width Modulation Inverters	258	(2)
Current-Source Input (CSI) Inverters	260	(1)
Cycloconverters	260	(1)
Applications for Inverters	260	(1)
DC-To-DC Control (Converters and Choppers)	261	(7)
Overview of DC-to-DC Voltage Conversion	261	(1)
Linear Power Supplies	261	(1)
Switching Power Supplies	262	(1)
The Buck Converter	263	(1)
The Boost Regulator	264	(1)
The Buck-Roost Regulator	265	(1)
The Forward Converter	265	(1)
The Push-Pull Converter	266	(1)
The Half-Bridge Converter	267	(1)
The Full-Bridge Converter	267	(1)
What You May Find When You Work on A Power Supply	268	(4)
Operational Amplifiers	272	(24)
Overview of Operational Amplifiers	273	(1)
What Op Amps Do	274	(1)
Basic Op Amp Circuit	274	(2)
The Op Amp Power Supply	275	(1)
The Ideal Amplifier	276	(1)
The Comparator	276	(2)
The Voltage Follower	278	(1)
The Inverting Linear Amplifier	279	(1)
Operation of the Inverting Amplifier	280	(1)
The Noninverting Op Amp	280	(2)
Voltage-To-Current Converters	282	(1)
Applications for the Voltage-to-Current Converter	283	(1)
Current-To-Voltage Amplifiers	283	(1)
Summing Amplifiers	284	(1)
Op Amps Used as Integrators	285	(1)
Op Amps Used as Differentiators	286	(2)
The Op Amp Window Detector	288	(1)
Operation of the Window Detector (Comparator)	289	(1)
Adding Zero and Span to an Op Amp Circuit	289	(1)
Setting Zero and Span	290	(1)
The Differential Amplifier	290	(1)
Instrumentation Amplifiers	291	(5)
Open-Loop and Closed-Loop Feedback Systems	296	(42)
Overview of Open-Loop and Closed-Loop Systems	297	(1)
Parts of a Typical Control System	298	(1)
An Electric Heating Application	298	(1)
A Typical Open-Loop System	299	(5)
Manual Mode and Auto Mode	300	(1)
An Example of a Sump Pump Control	301	(1)
On-off Control	301	(1)
Adding Differential Gap (Dead Band) to the Sump Pump Application	302	(2)
Automating the Sump Pump Application	304	(1)
Single-Point Process Controller	304	(1)
Operating a Controller in Manual and Auto Modes	305	(1)
Bumpless Transfer	305	(1)
Valve Positioning System To Control Water Level In a Tank	306	(1)
How Fast Controllers Will Change the Output	307	(1)
Understanding Gain, Reset, and Rate	308	(4)
Using Gain for Control	309	(1)
Problems with Using Only Gain for Control	310	(1)
Using a Gain-Only Controller	311	(1)
Adding Offset (BIAS)	312	(1)
Problems with Adding Bias Manually	312	(1)
Example of an Industrial System That Uses Gain and Reset	313	(3)
Adding Integral (Reset) to the Formula to Change Bias Automatically	313	(1)
Using Values for Integral Action	314	(2)
Reset Action	316	(1)
Adding Derivative (Rate) to the Formula	316	(2)
Rate Action	317	(1)
Other Effects of Derivatives	317	(1)
Proportional and Derivative Control (PD)	318	(1)
Proportional Band	318	(2)
Ratio Control for On-Off Heating Contractor	320	(1)
Types of System Response	321	(1)
Tuning The Controller	322	(5)
Determining Gain, Reset, and Rate (PID) in Manual Mode	322	(3)
Determining PID Values from Process Gain, Dead Time, and Time Constant	325	(1)
Determining PID Values for a Slower Responding System	325	(1)
Determining PID Values in Automatic (Closed-Loop) Mode	326	(1)
Adjusting Gain, Reset, and Rate After A System has been Running	327	(1)
Process Alarms and Deviation Alarms	328	(2)
Inner and Outer Alarm Bands	329	(1)
Statistical Process Control (SPC)	329	(1)
Advanced Closed-Loop Systems	330	(1)
Cascaded Loops	330	(1)
Operation of the Cascade Controller	331	(1)
Example Servo Applications	331	(7)
A Simple Analog Servo Positioning System	332	(1)
Closed-Loop Velocity and Positioning Control of a Servomotor	332	(6)
Input Devices: Sensors, Transducers, and Transmitters for Measurement	338	(117)
Overview of Sensors, Transducers, and Transmitters	340	(9)
Signal Types	341	(1)
Analog and Digital Signals	341	(1)
Basic Sensor Circuits	342	(1)
Transmitters	343	(3)
Recorders	346	(1)
Alarm Systems	347	(1)
Applications for Explosion-Proof Sensors	347	(1)
Overview	348	(1)
Temperature Sensors	349	(24)
Temperature Conversions	349	(1)
Thermocouples	350	(3)
Types of Thermocouples	353	(6)
Resistance Temperature Detector (RTD)	359	(4)
Thermistors	363	(3)
Integrated Circuit (IC) Solid-State Temperature Sensors	366	(2)
Infrared Thermometry and Optical Pyrometers	368	(3)
Nonelectrical Temperature Sensors	371	(1)
Comparison of Temperature Sensors	371	(2)
Pressure Sensors	373	(18)
Parameters of Pressure	373	(1)
Vacuum: Pressure Readings Below Atmospheric Pressure	374	(2)
The Bourdon Tube as a Pressure Sensor	376	(1)
Diaphragm Pressure Sensor	377	(1)
Differential Pressure Sensor	377	(1)
Bellows Pressure Sensor	378	(1)
The Strain Gauge	378	(5)
Load Cells	383	(3)
Pressure Transducers and Transmitters	386	(1)
Industrial Scales and Weighing Systems	387	(2)
Piezoelectric Pressure Sensors	389	(1)
Capacitance Pressure Sensors	389	(1)
Variable Reluctance/Inductance Pressure Sensors	390	(1)
Differential Pressure Sensors (δP Sensors)	390	(1)
Ultralow-Pressure Sensors	390	(1)
Multiple Uses for Pressure Sensors	391	(1)
Flow Sensors	391	(14)
Flow Technology	392	(2)
Calculating Flow from a Pressure-Drop Measurement	394	(1)
Types of Flow Meters that Utilize a Pressure Drop	395	(3)
Velocity Flow Meters	398	(3)
Positive Displacement Flow Meters	401	(1)
Mass Flow Meters	402	(1)
Nonelectrical Flow Meters	403	(1)
Applications of Flow Meters	404	(1)
Density and Viscosity Sensors	405	(3)
Liquid Density Sensors	406	(2)
Viscosity Sensors	408	(1)
Level Sensors	408	(15)
Point-Contact Level Sensors	409	(6)
Continuous Level Sensors	415	(8)
Position Sensors	423	(19)
Linear Potentiometer	424	(1)
Rotary Potentiometer	425	(1)
Linear Variable Differential Transformers (LVDTs)	426	(2)
Magnetostrictive-Type Position Sensor	428	(3)
Proximity Switches	431	(2)
Hall-Effect Sensors	433	(2)
Linear and Rotary Encoders	435	(7)
Motion Sensors	442	(4)
Accelerometers	442	(2)
Tachometers	444	(1)
PH Sensors	445	(1)
Humidity Sensors	446	(1)
Gas Detectors	446	(9)
Output Devices: Amplifiers, Valves, Relays, Variable-Frequency Drives, Stepper Motors, and Servomotor Drives	455	(103)
Overview of Output Devices	457	(1)
Solenoid Valves	457	(8)
Typical Voltages and Wattages for Solenoid Valves	459	(2)
Types of Solenoids	461	(1)
Applications for Solenoids	462	(1)
Three-Position Solenoid Valves	463	(1)
Diagrams of Solenoids as Outputs	463	(2)
Proportional Valves	465	(7)
Types of Control from a Proportional Control Valve	466	(2)
Proportional Valve Amplifiers	468	(2)
Constant-Voltage Proportional Valves	470	(1)
Troubleshooting Proportional Amplifiers and Valves	471	(1)
Pneumatic-Assisted Control Valves	472	(7)
Simplified Pneumatic-Assisted Valve	473	(1)
Parts of a Pneumatic-Assisted Control Valve	474	(2)
Butterfly Pneumatic-Assisted Control Valves	476	(1)
Current-to-Pressure (I/P) Converters	476	(3)
Motor-Driven Valves	479	(2)
Using a Proportional Amplifier with a Motor-Driven Valve	480	(1)
Relays, Contactors, and Motor Starters	481	(17)
Types of Relays	481	(1)
Methods of Operation for Relays	481	(1)
Sets of NO and NC Contacts	481	(1)
Changing NO Contacts to NC Contacts in the Field	481	(1)
Pull-In and Hold-In Current	482	(2)
Types of Relays	484	(1)
Contactors	484	(3)
Basic Parts of a Contactor	487	(1)
Ratings for Coils	487	(2)
Motor Starters	489	(3)
Operation of the Overloads	492	(2)
Sizing Motor Starters	494	(1)
Sizing Heater Elements for Motor Starters	495	(2)
Solid-State Motor Starters	497	(1)
Variable-Frequency Drives	498	(16)
Block Diagram of a Variable-Frequency Drive	499	(1)
A Typical Drive Installation	500	(1)
External Control Switches and Contacts for the Drive	501	(2)
External Outputs for the Drive	503	(1)
Solid-State Circuits for Variable-Frequency Drives	503	(2)
Pulse-Width Modulation Waveforms for Variable-Frequency Drives	505	(1)
Insulated Gate Bipolar Transistor Drives	506	(1)
Variable-Frequency Drive Parameters	506	(3)
Typical Applications for Variable-Frequency Drives	509	(3)
Operating the Variable-Frequency Drive	512	(1)
Scalar Drives and Vector Drives	512	(1)
Variable-Voltage Input Drives	513	(1)
Current-Source Input Drives	514	(1)
DC Drives	514	(4)
Modern Programmable DC Drives	517	(1)
Stepper Motors	518	(12)
Types of Stepper Motors	519	(1)
Stepper Motor Theory of Operation	519	(3)
Switching Sequence for Full-and Half-Step Motors	522	(2)
Microstep Mode	524	(1)
Stepper Motor Amplifier Circuits	524	(3)
Stepper Motor Applications	527	(1)
Selecting the Proper Size Stepper Motor	527	(3)
Linear Stepper Motors	530	(3)
Operation of the Linear Stepper Motor	531	(1)
Linear Motor Applications	531	(2)
Servomotors	533	(25)
Simple Servo Amplifiers	535	(3)
Amplifiers for DC Servomotors	538	(1)
AC Servo Amplifiers	539	(1)
Digital Servo Drives	540	(1)
Servomotors	541	(2)
Servomotor Controllers	543	(3)
PWM Servo Amplifier	546	(1)
Applications for Servo Amplifiers and Motors	546	(5)
Selecting a Servomotor for an Application	551	(7)
AC And DC Motors And Generators, Transformers, and Three-Phase Electricity	558	(103)
Introduction	559	(1)
Magnetic Theory	560	(1)
DC Motor Theory	561	(3)
DC Motor Components	564	(5)
Armature	565	(1)
Motor Frame	566	(2)
End Plates	568	(1)
Brushes and Brush Rigging	568	(1)
DC Motor Operation	569	(1)
Types of DC Motors	570	(5)
DC Series Motors	570	(1)
Series Motor Operation	571	(1)
Producing Back EMF	571	(1)
Reversing the Rotation of a Motor	572	(2)
Installing and Troubleshooting a Series Motor	574	(1)
DC Series Motor Used as a Universal Motor	575	(1)
DC Shunt Motors	575	(6)
Shunt Motor Operation	576	(1)
Controlling the Speed of the Motor	576	(1)
Torque Characteristics	577	(1)
Reversing the Rotation of the Motor	578	(1)
Installing a Shunt Motor	578	(1)
Troubleshooting the Shunt Motor	579	(2)
DC Compound Motors	581	(3)
Cumulative Compound Motors	581	(1)
Differential Compound Motors	582	(1)
Compound Interpole Motors	582	(1)
Reversing the Rotation of the DC Compound Motor	582	(1)
Controlling the Speed of the Motor	583	(1)
AC Motors	584	(1)
Characteristics of Three-Phase Voltage	585	(1)
Three-Phase Motor Components	586	(3)
Stator	586	(2)
Rotor	588	(1)
Motor End Plates	589	(1)
Operation of an AC Induction Motor	589	(2)
Induced Current in the Rotor	590	(1)
Connecting Motors for Torque Speed and Horsepower Conditions	591	(2)
Wye-Connected Motors	592	(1)
Delta-Connected Motors	592	(1)
Reversing The Rotation of a Three-Phase Induction Motor	593	(1)
Connecting Motors for A Change of Voltage	594	(3)
Connecting Three-Phase Motors for a Change of Speed	597	(2)
Interpreting the Wiring Diagrams and Tables	597	(2)
Motor Data Plates	599	(4)
Identification Number (ID)	599	(1)
Frame Type	599	(1)
Motor Type	600	(1)
Phase	600	(1)
Horsepower Rating (hp)	600	(1)
rpm (Speed)	600	(1)
Volts	601	(1)
Amps	601	(1)
Frequency	601	(1)
Service Factor (SF)	601	(1)
Duty Cycle	601	(1)
Insulation Class	602	(1)
Ambient Temperature Rise	602	(1)
NEMA Design	602	(1)
NEMA Code Letters	603	(1)
Three-Phase Synchronous Motors	603	(2)
AC Single-Phase Motors	605	(1)
Single-Phase Motor Components	605	(5)
Stator	605	(2)
Terminal Identification	607	(1)
Rotor and End Plates	608	(1)
Centrifugal Switch for the Start Winding	609	(1)
Thermal Overload Protector	610	(1)
Changing Voltage and Speeds of Single-Phase Motors	610	(1)
Increasing the Starting Torque of a Single-Phase Motor	611	(1)
Split-Phase Motors	611	(2)
Counter EMF	612	(1)
Applications for Split-Phase Motors	613	(1)
Capacitor Start, Induction Run Motors	613	(4)
Electrical Diagram for a CSIR Motor	613	(1)
Connecting the CSIR Motor for Dual-Voltage or Dual-Speed Applications	614	(1)
Connecting the CSIR Motor for a Change of Rotation	614	(1)
Applications for CSIR Motors	615	(1)
Current Relay Operation	616	(1)
Capacitor Start, Capacitor Run Motors	617	(2)
Using a Potential Relay to Start a CSCR Motor	618	(1)
Permanent Split-Capacitor Motors	619	(2)
Connecting a PSC Motor for a Change of Speed	620	(1)
Changing Voltage or Direction of Rotation	620	(1)
Shaded-Pole Motors	621	(1)
Repulsion Start Motors	622	(1)
Troubleshooting Three-Phase and Single-Phase Motors	622	(1)
Motor Will Not Turn When Power Is Applied	622	(1)
Motor Hums But Will Not Turn When Power Is Applied	623	(1)
DC Generators	623	(7)
Basic Parts and Basic Operation of a DC Shunt Generator	623	(2)
Separately Excited Shunt Generator	625	(1)
Self-Excited Shunt Generator	626	(1)
Compound Generator	627	(1)
Series Generator	627	(1)
Controlling the Amount of Voltage and Its Polarity in a DC Generator	627	(2)
Troubleshooting a DC Generator	629	(1)
AC Alternators	630	(4)
Theory of Operation of the Alternator	630	(1)
AC Voltage in the Strator	631	(1)
Producing Three-Phase Voltage	632	(1)
Using an Alternator to Produce DC Voltage	632	(1)
Troubleshooting an Alternator	633	(1)
Overview of Transformers	634	(1)
Operation of a Transformer and Basic Magnetic Theory	635	(2)
Connecting a Transformer to a Disconnect for Testing	637	(1)
Transformer Rated for 230 Volts and 208 Volts	638	(1)
Transformer Voltage, Current, and Turns Ratios	638	(2)
Step-Up and Step-Down Transformers	640	(1)
VA Ratings for Transformers	640	(1)
The 120-Volt AC Transformer	641	(1)
Wiring the Control Transformer for 480 Volts AC Primary Volts	642	(1)
Wiring the Control Transformer for 240 Volts AC Primary Volts	643	(1)
Troubleshooting a Transformer	644	(1)
Nature of Three-Phase Voltage	644	(1)
Why Three-Phase Voltage is Generated	645	(1)
Three-Phase Transformers	645	(2)
The Wye-Connected Three-Phase Transformer	647	(1)
The Delta-Connected Three-Phase Transformer	647	(1)
Delta-and Wye-Connected Transformers With a Neutral Terminal	648	(2)
The High Leg Delta System	650	(1)
Three-Phase Voltage on Site	651	(1)
Installing Wiring in a Three-Phase Disconnect	652	(1)
Testing for a Bad Fuse in a Disconnect	653	(1)
Single-Phase Voltage from a Three-Phase Supply	654	(1)
Bus Duct and Bus Disconnect Boxes	654	(1)
Wiring a Duplex Receptacle as a Utility Outlet	655	(6)
Case Studies of Four Industrial Applications	661	(27)
Application 1: No Can/No Fill Sensing for Beverage Fillers	663	(7)
Overview of the System	663	(1)
Typical Operation	663	(2)
Using a Shift Register to Control Signal Timing	665	(2)
Electrical Diagram of Sensors and Valves Connected to the Controller	667	(1)
Troubleshooting the System	667	(3)
Application 2: Aluminum Rolling Mill	670	(7)
Overview of the System	670	(2)
Controls for the Cold-Roll Mill	672	(1)
Typical Operation of the Mill	672	(1)
Butt-Weld Section	673	(1)
Accumulator Section	673
The Three-Stand Tandem Mill	672	(2)
Speed Control for the Rollers	674	(1)
Mainframe Computers, PLCs, and Motor Drives	675	(2)
Application 3: Microprocessor-Controlled Plastic Resin Dryer	677	(6)
Overview of the System	677	(1)
Basic Parts of the System	678	(1)
Control Parameters for the Dryer	678	(1)
Normal Operation of the Dryer	679	(1)
Control Loops for the Dryer	680	(1)
Wiring Diagram for the Dryer	681	(2)
Application 4: Finishing and Balancing Brake Rotors	683	(5)
Overview	683	(1)
Electronics Used	683	(1)
Sensors for Balancing	683	(5)
Robots and Other Motion Control Systems	688	(46)
Overview of Robots	689	(1)
Types of Robots	690	(8)
Cylindrical Robots	692	(1)
Rectilinear Robots	693	(2)
Spherical Robots	695	(1)
Jointed Spherical (Articulated Arm) Robots	696	(2)
Types of Robot Control	698	(4)
Point-to-Point Robot Control	698	(1)
Continuous-Path Control	699	(1)
XYZ Control	700	(1)
Positive-Stop Control	701	(1)
Types Of Robot Programs	702	(3)
Point-to-Point and XYZ Programs	703	(1)
Continuous-Path Programs	703	(1)
Positive-Stop Programs and PLC Programs	704	(1)
BASIC Programs and C Programs	704	(1)
Computer Numerical Control (CNC) Machines	705	(1)
Basic Parts of a Robot System	706	(12)
Power Supply	707	(3)
Controllers and Teach Pendants	710	(3)
Axis-Control Module	713	(1)
Amplifiers, Motors, and Feedback Sensors	714	(3)
Positional Feedback Loop and Velocity Feedback Loop	717	(1)
Other Types of Robot Actuators	718	(2)
Hydraulic Actuators	718	(1)
Pneumatic Actuators	718	(1)
Comparison of Robot Actuator	719	(1)
Input and Output Signals for Robots	720	(2)
Input Circuits for Robot Signals	722	(2)
Output Circuits for Robot Signals	724	(1)
Input and Output Modules	725	(1)
Robots Used in Typical Work Cells and Manufacturing Cells	726	(8)
Automotive Welding Line	727	(1)
Loading and Unloading Bonding Machines	728	(1)
Robotic Painting Cells	729	(5)
Motor-Control Devices and Circuits	734	(47)
Introduction	735	(1)
Pilot Devices	736	(5)
Limit Switches and Other Pilot Switches	737	(1)
Symbols for Limit Switches and Other Motor-Control Devices	738	(1)
Electrical Symbols for Other Pilot Devices	739	(2)
Control Circuits and Load, Circuits	741	(13)
Two-Wire Control Circuits	742	(2)
The Three-Wire Control Circuit	744	(1)
A Three-Wire Start/Stop Circuit with Multiple Start/Stop Push Buttons	745	(1)
Three-Wire Control Circuit with Indicator Lamp	746	(1)
Reverse Motor Starters	747	(2)
Reversing Motors with a Drum Switch	749	(2)
Jogging Control Circuits	751	(2)
Sequence Controls for Motor Starters	753	(1)
Other Types of Pilot Devices	754	(3)
Timers	757	(1)
Fuses and Circuit Breakers	757	(5)
Slow Overcurrents	757	(1)
Protecting Against Slow Overcurrent	758	(1)
Short-Circuit Currents	758	(2)
Single-Element Fuses	760	(1)
Dual-Element Fuses	761	(1)
Interruption Capacity	762	(1)
Types of Fuses	762	(1)
Enclosures	762	(5)
Conductors	767	(2)
Overview of Lockout, Tag-out Safety	769	(12)
A Typical Lockout, Tag-out Policy	770	(1)
Determining the Lockout, Tag-out Policy and Procedure	770	(1)
Identifying the Sources of Kinetic Energy and Potential Energy	770	(1)
Designing Safety into the Machine	771	(1)
OSHA Inspections	772	(1)
What Is Lockout?	772	(1)
What Is Tag-out?	773	(1)
Designing a Lockout, Tag-out Procedure	774	(1)
Removing the Lockout, Tag-out Devices and Returning Power to the Machine	774	(1)
Review of Lockout, Tag-out Procedures	775	(6)
Data Communications for Industrial Electronics	781	(32)
Overview of Data Communications Used in Industry	782	(2)
Network Architectures	784	(5)
The Physical Layer	785	(1)
The Data Link Layer	785	(1)
The Network Layer	786	(1)
The Transport Layer	786	(1)
The Session Layer	787	(1)
The Presentation Layer	787	(1)
The Application Layer	788	(1)
Review of the ISO Model	788	(1)
Data Formats	789	(1)
The ASCII Code	789	(1)
The EBCDIC Code	789	(1)
Protocols and Standards	790	(6)
Ethernet and IEEE 802 Standards	791	(1)
MAP Protocol	792	(1)
The Technical Office Protocol (TOP)	792	(1)
Transmission Control Protocol and Internet Protocol (TCP/IP)	793	(1)
Systems Network Architecture (SNA)	793	(1)
Manufacturing Message Specification (MMS)	793	(1)
European Standards: The Fieldbus	793	(1)
Profibus	794	(1)
Device Net	795	(1)
Comparing Standards and Protocols	795	(1)
Parts and Media of the Physical Layer	796	(8)
Transmission Media	796	(2)
Physical Cable Connections: The RS232 Interface	798	(3)
The Nine-Pin Connector for the RS232 Interface	801	(1)
The RS422 Interface	802	(1)
Other Common Connectors Used in Industrial Data Communications	802	(1)
De Facto Standards for DB25 Connectors for Modern Personal Computers	802	(2)
Typical Network Topologies	804	(1)
Types of Network Topologies	804	(1)
Typical Factory Automation Networks	805	(2)
Strengths of the Ethernet	807	(1)
The Broadband Network	807	(1)
Troubleshooting Networks	807	(6)
Test Equipment	808	(5)
Appendix a Shop safety and Shop Practices	813	(11)
Appendix B Technical Data	824	(25)
Acronyms	849	(2)
Glossary	851	(10)
Index	861