CHAPTER 13 : COMPUTER NUMERICAL CONTROL (CNC)

CNC (Computer Numerical Control) is a machine that controlled by a computer using a numerical language in process. In other explanation CNC is a flexible method automatically controlling machine through the use of numerical values. So, in CNC machine we didn't use manually operation for example in turning, drilling, and milling using manual or conventional machine. In CNC we can use a computer as an automatically controller for user.
For example below, the CNC machine type milling machine from HAAS :

CNC machine can be analogous as a printer machine. We must design in computer and the execute or print into CNC machine.

Actually, some industry using CNC machines to producing some product, there are two type of CNC machine in manufacturing industry :

1. CNC Machine Two Axis : This machine using two axis, X axis for perpendicular movement and Z Axis for parallel to rotary axis. For examples : Lathe Machine.
2. CNC Machine Three Axis : The machine using three axis, X Axis for horizontal direction movements, Y Axis for transverse direction movements, and Z axis for vertical direction movements. For Example : Milling Machine.

References :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill 

Nugraha, R. Andias (2014). Manufacturing Process Labwork Module.Bandung : Prosman Laboratory Telkom Universty

CHAPTER 12 : PROGRAMMABLE LOGIC CONTROL (PLC)

Programmable Logic Control (PLC) is a digitally operating electronic which uses a programming memory for internal storage of instructions for implementing specific functions such as logic, sequencing, timing, counting and arithmetic to control through digital or analog modules, various types of machines or process.

There are some components in PLC :

Power Supply : provides the voltage needed to run the primary PLC components.

I/O Modules : Provide signal conversion and isolation between the internal logic and also level signals inside the PLC and fields high level signal.

Processor : provide intelligence to command and govern the activities of the entire PLC systems.

Programming Device : used to enter the desired program that will determine the sequence of operation and control of process equipment or driven machine.

Memory : used to save the programming in PLC device. There are several memory like flash memory, EPROM, PROM, EEPROM.

There are 2 kind of PLC : fixed/compact PLC and modular PLC.

Advantages of PLC :

• Flexible
• A lot of contact.
• Low Cost
• Safe
• Sort time

Disadvantages of PLC :

• Training for users.
• Required a relay system for safety.

Reference :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill

CHAPTER 11 : TYPE OF PROCESSES

There are 3 type of processes in modern manufacturing industries :

• Continuous Process
• Batch Process
• Individual Products Production

1. Continuous Process 

Process which raw materials enter one end of the system and the finished product comes out the other end of the system and the process itself runs continuously. Continuous process using long period of time such as minutes, days or month. It's depending on process in manufacturing industry.

2. Batch Process

There is no flow of product material from one section of the process to another. Each batch of product may be different, many chemically company  based products are manufactured by using batch processes. Because as we known a lot of chemical company using a lot of material.

3. Individual Products Process

Process which is the most common of all processing systems, with this manufacturing process, a series of operation produces a useful output product. The item being produces may be required to be bent, drilled, welded, and so on. At different steps in process, the workpiece is normally a discrete part that must be handled on individual basis.

There are 3 type of processes and in modern automated industrial plant, the control of machines of processes can be divided into the following categories :

• Electromechanical Control
• Hardwired electronic control
• Programmable hardwired electronic control
• PLC (Programmable Logic Control)
• Computer Control (NC)

Reference :

Petruzella, D. Frank (1996). Industrial Electronics Page 304-305 . New York : McGraw-Hill

 

CHAPTER 10 :PRESSURE CONTROL

Pressure control is one type of control using pressure to control some equipment. Pressure controls can be control or maintenance the pressure of a gas and liquid or solid at some value. Another limit is sense that pressure has reached some preset limit or is moving out of some safe range.

Pressure is defined as a force per unit. Unit can be pounds per square inch (psi) or most popular is pascal/kilopascal (kPa). Pressure is one important industrial process variables.

There are some term in pressure switch specification :

1. Adjustable operating range is range of pressures within which the pressure sensing element of the switch can be set to actuate the contact on the switch.
2. Adjustable differential range / deadband is range of pressure between higher pressure limit which change electrical contact and the lower pressure limit which returns electrical contacts to their normal conditions.
3. Set point repeatability is ability of the switch to operate repeatitively at its set point.
4. Enclosure type is rating of enclosure based on NEMA.
5. Electrical rating is current and voltage rating of electrical contacts.
6. Switch arrangement is type of switch supplied.

CHAPTER 9 : MOTOR STOPPING

Motor stopping used to stop or remove the supply voltage and motor will stop. Some application, motor must stop more quickly or held in position by some sort of braking device. Electric braking uses the windings of the motor to produce a retarding torque. There are two different means of electrical braking:

1. plugging stops a polyphase motor quickly, by momentarily connecting the motor for reverse rotation while the motor is still running in the forward direction.
2. A zero speed switch is coupled to a moving shaft on the machinery whose motor is to plugged.

Dynamic braking is a method of braking that uses the motor as a generator during the braking period immediately after the motor is turned OFF.

Electric braking can be achieved with three phase induction motor by removing the ac power supply from the motor and applying direct current to one of the stator phases,

Electromechanical friction brake refers to a device external to the motor that provides retarding torque.

Electric load brake / eddy current brake is simple, rugged device that consists of an iron rotor mounted inside  a stationery field assembly.

CHAPTER 8 : ARC SUPPRESSION

Arc suppression is the reduction of sparks formed when current carrying contacts are separated. The sparks is a luminous discharge of highly energized electrons and ions, and is an electrical arc. In other explanation arc suppression is required to keep contacts in the device from burning up.

In industrial, arc suppression used to devices such as electromechanical power switches, relays and contactors. 

There are two effectiveness using arc suppression :

1. Visual inspection of the arc.
2. Graphical representation of measurement obtained by an oscilloscope.

There are 5 benefits from arc suppression :

1. Minimizes contact damage from arcing and therefore reduced maintenance, repair, and replacement frequency.
2. Increased contact reliability
3. reduced heat generation resulting in less heat management measures such as venting and fans.
4. Reduce ozone and pollutant emissions.
5. Reduced Electromagnetic Interference (EMI) from arcs a common sources of radiated EMI.

From the figure above, we can analyze , contact A and contact B with and without arc suppression. 

References :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill

CHAPTER 7 : TIMING RELAYS

One kind of industrial control system is timing relays. Timing relays used to start of event must be delayed until another event has occurred.

Timing relays are conventional relays that equipped with an additional hardware mechanism or circuity to delay the opening or or closing of loads contacts.

There are two kind of timing relays :

1. Pneumatic (air) timing relay uses mechanical linkage and air bellows system to achieve its timing cycle. In pneumatic relay consists of two timed and two instantaneous contacts. when the coil is energized the timed contacts are prevented from opening or closing. When the coil is deenergized the contacts return immediately to their normal state.
   
2. Solid State Timing relay uses electronic circuitry to achieving its time cycle. Some of these timers use a resistor/capacitor (RC) time constant to obtain the time base, and others are quartz clocks as the time base. An RC oscillator networks generates  a highly stable and accurate pulse that it used to provide the different time delay increments and switch a contact output.
   

Time-delay relays can be classified into two basic :

• ON delay relay is often referred to as DOE (Delay On Energized) when power is connected to the coil of ON delay timer , the contacts delay changing position for some period of time.
• OFF delay relay is often referred to as DODE (Delay On Deenergize), the operation is opposite of the operation of the ON delay timer, when voltage is applied to the coil of the OFF delay timer, the contacts will change position immediately. when the coil is deenergized there is a time delay before the contacts change to their normal position.

Reference :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill 

CHAPTER 6 : DIRECT CURRENT MOTORS

Direct Current motor is is one kind of electric motor, as we known an electric motors are used in some industry. so, electric motor using electrical and magnetic energy to produce mechanical energy. The mechanical energy depends on the interaction between two magnetic field. In DC motor there are two magnetic area which are north and south area.

From the picture above shows that the red part represent about north magnetic and the green part represent about south magnetic. Another, there are commutator, brushes, and single coil.

Basic principle of DC motors is two magnetic fields can be made to interact to produce motion and the purpose of a motor is to produce a rotating force known as torque.

DC motors are used where a wide range of torque and speed control is required to match the needs of the application. A current carrying conductor, placed in an rights angles to magnetic field, tends to move at right angles to the field. The amount of exerted to move it varies directly with the strength of the magnetic field, the amount of current flowing through the conductor, and the length of the conductor.

So, how determine the direction of movement of conductor carrying current in magnetic field ?

Right Hand motor rule !!

The thumb and the first two fingers of the right hand are arranged so that they are at right angles to each other, with the force finger pointing in the direction of magnetic lines of force of the field and the middle finger pointing in the direction of current flow using plus (+) and minus (-) in the conductor. The thumb will be pointing in the direction of movement of the conductor. From the figure above illustrate how motor torque is produced by a current carrying coil or loop of wire placed in a magnetic field. The interaction between two magnetic field causes a bending of the line force. when the line tends to straighten out, they cause the loop to undergo a rotating movement. The left conductor is forced doneward, and the right conductor is forced upward, cause a counter clockwise rotation of armature, So the torque can be produced by this principles.

References :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill 

CHAPTER 5 : INTEGRATED CIRCUIT

Integrated Circuit (IC) electronic circuit with contained within single chip of silicon. In other explanation IC semiconductors wafer on which thousands or millions of tiny resistors, capacitors, and transistors fabricated.

There are two kind of Integrated Circuit (IC) :

1. Linear/analog IC have continuously variable output (theoretically capable of attaining an infinite number of states) that depends on the input signal level. As the term implies, the output signal level is a linear function of the input signal level. Ideally, when the instantaneous output is graphed against the instantaneous input, the plot appears as a straight line. Linear ICs are used as audio freqiuency (AF) and radio-frequency (RF) amplifiers. The operational amplifier (op amp) is a common device in these applications.
   
2. Digital IC operate at only a few defined levels or states, rather than over a continuous range of signal amplitudes. These devices are used in computers, computer networks, modems, and frequency counters. The fundamental building blocks of digital ICs are logic gates, which work with binary data, that is, signals that have only two different states, called low (logic 0) and high (logic 1).
   

References :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill

http://whatis.techtarget.com/definition/integrated-circuit-IC

CHAPTER 4 : RELAY

Actuator is any devices that converts an electrical signal into mechanical motion. So, actuator like as output. One type of relay is relays. Relay is simple electromechanical switch made up of an electromagnet and a set of contacts. Another explanation is an electrically operated device that mechanically switches electric circuit.

1. There are four components in relay: electromagnetic, armature, spring, set of electrical contacts. Relay has control over several variables:The voltage and current that is needed to activate the armature
2. The maximum voltage and current that can run through the armature and the armature contacts
3. The number of armatures (generally one or two)
4. The number of contacts for the armature (generally one or two -- the relay shown here has two, one of which is unused)
5. Whether the contact (if only one contact is provided) is normally open (NO) or normally closed (NC)

From the figure above, we can analyze that if button we push number 87a is known as Normally Closed (NC) because it isNormally closed.That means it lets current flow through it in its normal statea and number 87 is known as Normally Open (NO) because (you guessed it) it's Normally open. That means it wont let current through in its normal state.

References :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill

http://electronics.howstuffworks.com/relay1.htm

http://www.allcorsa.co.uk/forums/showthread.php/relays-work-42660.html

CHAPTER 3 : THE PRINCIPLE OF TRANSFORMER

In this article, I want to share you about transformer! what is transformer?

Transformer is a static device used to transfer energy from one to another circuit without any direct electrical connection and with the help of mutual induction between two windings. It transforms power from one circuit to another without changing its frequency but may be in different voltage level. There are two kind of transformer :

1. step up transformer 

2. step down transformer

The differences between step-up and step down transformer is depend on the transfer energy of the voltage. When the transformation take place with an increase in voltage it's called step up transformer but if the voltage is decreased, it's called a step down transformer.

The figure above shows the part of transformer, there are primary and secondary winding or coils, and also primary coils. Primary winding used to the power from supply and from primary come to secondary winding which is used to delivers the power to the load.

So, How the transformer works?

The principle of transformer is depends on Faraday's Law about electromagnetic induction. mutual induction is one of principle of transformer. mutual induction occurs when the magnetic field surrounding one conductor cuts across another conductor inducing a voltage in it.

one of application of transformer :

References  :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill 
http://www.electrical4u.com/what-is-transformer-definition-working-principle-of-transformer/

CHAPTER 2 : ELECTRICAL SYMBOLS

Talking about the symbol of course everyone knows will symbol, each object must have a symbol to present the objects, as well as in the world of electronic components each industry must have a symbol, it is becoming important as to make it easy for us considering the various types of electronic components and also to enable us to make electronic circuit that serves as a driving force or programs from an electronic goods.

So as industrial engineering, the use of the symbol is important because in many companies use the symbol to indicate a command or instruction. The creation of symbol must match the standard that has been set as to facilitate readers because if different standard then the reader will feel the confusion with the meaning of the symbol.

         “Symbols sometimes look nothing like the real thing, so we have to learn what the symbols mean”

In this article discusses the symbol used in the electronics components industry. These are some examples of electrical symbols.

References :

Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill 

http://www.rapidtables.com/electric/electrical_symbols.htm (Retrieved on May 3rd 2014)

CHAPTER 1 : SAFETY IN THE WORKPLACE

Industrial safety is a tool or instructions that can make workers comfortable and also feel secure with his work. Security in industry is very important especially in the workplace. Actually, so many accidents in a work environment where can be avoided. Companies should give a policy that can make workers safe and also people can contribute reduce the number of accidents on workers. There are 2 the main causes of accidents at work environment among others:

1.   Human error: accidents caused by human error in industry. For example: operators oil platforms of smoking at the time of refueling in the car so as to cause of the fire.
2. Material failure: accidents caused by goods production with quality bad, so that doesn’t accord standard and causing the accident in industry or example: an additional ingredient chemically so that workers poisoning.

Factors cause of the accident such work can be avoided by giving a clue security for operators and people. Standard safety become very important for all companies in the world, because resources is very important for all industry in the world.

Occupational Safety and Health Administration Administration (OSHA) has been established colors to design caution and dangers:

1.  Red: Fire protection equipment and apparatus portable containers or flammable liquids. Emergency stop buttons and switches.
2.  Yellow: caution and physical hazardous.
3. Orange : dangerous part of machines and also safety start buttons.
4. Purple: Radiation hazardous.
5. Green : safety.

Personal Safety Attire

Clothing should fit snugly to avoid danger of becoming entangled in moving machinery or creating a tripping or stumbling hazard. Recommended safe work clothes include:

1. Thick-soled work shoes for protection against sharp objects such as nails. Wear work shoes with safety toes if the job requires. Make sure the soles are oil resistant if the shoes are subject to oils and grease
2. Rubber boots for damp locations
3. A hat or cap. Wear an approved safety helmet (hard hat) if the job requires.

Confine long hair or keep hair trimmed and avoid placing the head in close proximity to rotating machinery. Do not wear jewelry. Gold and silver are excellent conductors of electricity.

So, that all equipment which can using in industry to make operator and worker feel safe and comfortable in workplace.

Reference : Petruzella, D. Frank (1996). Industrial Electronics. New York : McGraw-Hill 

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