The motor plays a vital role in any application where rotational or linear motion is involved. In earlier times, some mechanisms involved the use of pulley systems to meet such requirements but due to advancements in technology and the industrial revolution, motors were introduced for such purposes. There are many famed companies and industries which are thriving to be on the top in terms of motor manufacture and design and motor-based industrial, domestic, and automobile solutions. Every year, these companies introduce more efficient, economical, and robust designs. The motors can be AC or DC depending upon the use. All have their drives through which they are operated autonomously. The motors can be further classified as: Synchronous Motors Asynchronous Motors BLDC or Brushless DC motor AC induction motor Hydraulic based motor Stepper motor Servo motor Motors are widely used for automobiles and for domestic and industrial purposes that may include: Vehicles EV’s Drones Conveyer...
Programmable Logic Controllers (PLCs) are ruggedized computing devices used to control electro-mechanical processes, mainly in industrial settings. The PLC continuously monitors the state of connected input devices or sensors and collects the status information as input data. It then processes the input data and makes appropriate decisions based on pre-programmed parameters to control the state of the connected output devices. This way, PLCs can automate a specific industrial process, machine function, robotic device, or even an entire assembly/production line. Initially, PLCs were developed to replace complicated relay-logic control systems in automobile industries. Today, however, PLCs provide a comprehensive range of functions including controlling inputs and outputs, drives and motors, timing and counting functions, communications, as well as processing digital and analog signals in a variety of industrial and commercial applications. According to a PLC-industry analysis report by...
Automation involves using technology to perform tasks and processes without human involvement. This can include various systems, such as mechanical, hydraulic, pneumatic, electrical, electronic, and computer-based systems, which are often used in combination. Automation is becoming more common in various industries, including manufacturing, transportation, and energy, and can bring benefits such as labor savings, reduced waste, and improved quality and precision. Automation is also being implemented in the banking industry and can range from simple control systems to complex algorithms. In the manufacturing industry, automation has been implemented through robotics and automation equipment for tasks such as assembly, packaging, and material handling, leading to increased efficiency, productivity, and cost savings. The transportation industry has adopted automation through self-driving vehicles and drones, improving safety and reducing labor costs. The energy industry has implemented...
The term “Automation” describes a wide array of technologies, scientific techniques, and tools used to minimize human input in processes, making them more efficient, accurate, fast, and productive. Automation solutions are utilized in practically all areas of our everyday life, covering an extensive range of applications, from household appliances and consumer electronics to advanced and complex systems powering modern-day manufacturing facilities, transport vehicles including ships and aircraft, power plants, etc. Automated banking solutions are also available. One of the most widely adopted forms of automation is industrial automation, which involves the use of a combination of specialized control devices (such as logic controllers), information technologies, and computer-controlled equipment (e.g., robots) to enhance manufacturing/production processes. Essentially, industrial automation streamlines industrial systems by integrating computers and smart machine tools into multiple...
Automation is not a new concept and has been used for many years to help businesses improve efficiency, reduce human error, and increase production. Examples of early automation include the printing press, sewing machine, and assembly line for cars. Today, with advancements in technology, such as Robotic Process Automation, more tasks can be automated using digital bots within a company. As automation continues to evolve, it is becoming an increasingly important aspect of business operations. Understanding the basics of automation is crucial for companies looking to implement innovative solutions and enhance their workforce. Automation is the technology that enables tasks or processes to be completed without human involvement. To create an automated system, three main components are necessary: A source of power to drive the process and operate the system. A set of instructions that directs the process A control system that carries out the instructions. The control system is...
We’ve all heard of the promises of a potential fusion energy breakthrough and what it could mean for us in terms of clean, near-limitless power; however, concepts of how we can revolutionize and renew our current infrastructure aren’t too common at all. Recent developments in fusion research have left many engineers speculating about how far we can go with this technology and its possible ramifications – from revolutionizing robots and factories to opening up new frontiers in automated manufacturing. In this article, we’ll explore what scientists are currently working on regarding net positive breakthroughs for fusion energy production and discuss why these technological strides might just be the key to solving some major engineering challenges we face today, as well as any challenges that may arise along the way. “Nuclear fusion display at the Weiss Energy Hall. ” by kpfellows is licensed under CC BY-NC-SA 2.0 . Fusion energy has been an alluring concept for many years, with its...
Human-Machine Interfaces (HMIs) are used to improve industrial automation processes by providing a visual interface for operators to interact with and monitor the automated system. HMIs can be used to display real-time process data, control system parameters, and issue commands to the automated system. One of the main benefits of using an HMI in industrial automation processes is that it allows operators to easily monitor and control the system without having to understand the underlying control logic or programming. This makes it easier for operators to perform tasks such as troubleshooting, adjusting process parameters, and monitoring performance. In addition to providing a convenient interface for operators, HMIs can also improve the efficiency and reliability of industrial automation processes by enabling operators to identify and address potential issues in real time. For example, suppose an HMI is used to display real-time process data. In that case, operators can quickly...
In the world of industrial automation, control systems play a crucial role in ensuring the smooth operation of manufacturing processes and equipment. These systems are responsible for monitoring and controlling various aspects of the production process, including the movement of materials, the operation of machinery, and the quality of the final product. Traditionally, these control systems were implemented using programmable logic controllers (PLCs), which are specialized computers that are designed to handle the complex logic and control functions required in industrial automation. Programmable Automation Control (PAC) is a type of industrial controller that offers many of the same capabilities as PLCs but with greater flexibility and more powerful processing capabilities. An industrial control system is categorized as a PAC if it comprises five characteristics which include multi-domain functionality, flexible software tools, multi-discipline development platform, open modular...
Industrial Automation is the use of digital control systems, robotics, and information technologies to control different processes and machinery in an industrial environment to replace human involvement in performing certain functions. These functions primarily focus on material handling, manufacturing, and quality control processes. Concisely, industrial automation makes use of logical programming commands and powerful computer-controlled machinery such as CNC machines to replace human workers on factory floors. At the core of industrial automation are three significant control techniques, namely: Distributed Control Systems (DCS), Programmable Logic Controllers (PLCs), and Supervisory Control and Data Acquisition (SCADA) systems. These control mechanisms consist of smart and interconnected field input and output devices, field instruments, distributed I/O controllers, supervisory control PCs, and Human-Machine Interfaces (HMIs). To provide flexible connectivity between the...
Solar farms, also sometimes referred to as solar parks, are large-scale, ground-mounted installations of massive arrays of Photovoltaic (PV) panels or other means of converting sunlight into solar energy, which is then routed to a utility’s power grid. They are simply solar power stations that operate just like other electricity-generating plants such as fossil-powered or natural gas power plants. But unlike traditional power plants, solar farms don’t produce any sort of pollution and they hardly use water in electricity generation. In general, the concept of a solar farm can be associated with both commercial solar projects and residential rooftop solar systems that have just a few solar panels. However, unlike these two solar systems, solar farms are decentralized and they normally consist of large arrays of ground-mounted solar panels. Also, rather than supplying power to a local household or business, solar farms are part of a utility’s energy mix and in most cases, they provide...
For many years, industrial networks were connected using RS232 serial communications, which was limited by only allowing devices in a network to communicate via direct serial connections. This means that if there are N devices per connection, then there would be (N-1) connections available for other communications within the industry. However, in the late 20th century, the Fieldbus International Standard was developed, which marked a significant turning point in connecting these networks, allowing for greater flexibility and scalability than previous technologies did allow for. Fieldbus is a network of computers embedded in various machines at work sites. They allow Input Devices (such as Ethernet Switches and Sensors) to communicate with Output Devices (Valves, Drives) without attaching them to an individual Controller. In summary, Fieldbus systems provide an efficient way to connect different devices to a single industrial network and make it easy to control them at every production...
Renewable and sustainable energy has been one of the hottest topics for the past decade. The most popular choices for the United States are all familiar to us: hydro, wind, and solar. While it seems that we have been seeing more progress with renewables every month, our current renewable energy production only supplies 20% of The United States’ total energy demands according to The Office of Energy Efficiency & Renewable Energy. While that figure does seem low, it has doubled in the last decade, proving that there is a considerable amount of innovation and production happening behind the scenes. Solar energy jobs and production have boomed since the last decade with an increase in jobs from about 100,000 workers to over 200,000 while decreasing the average cost of installation on residential homes by $22,000 (SEIA Comms Team). California has since become the first state to mandate all new homes be built with solar panels. If the tides are changing for our renewable energy production...
A motor is the main component of any machine that performs some valuable function. In industry, high-power and high-torque motors are used to carry out various operations. These motors are either single-phase or three-phase AC motors. Motor drivers or motor starters are used to control the motor’s direction, switching, and speed. Industrial electric motors require high electric current during the acceleration phase due to high inertia load till they reach their nominal speed of operation. There are different types of motor starting mechanisms, which include a direct online, auto transformer, and star delta. Other than these, solid-state devices are also used to start motors, including soft starters and variable frequency drives (VFDs). This guide will focus on the soft start, its advantages over other practices, and its applications in the industry. Eaton Culter-Hammer S801 Soft Starter S801T30N3S A three-phase soft starter is a circuit consisting of six TRIACs, which control the...
A PLC is an abbreviation of ‘Programmable Logic Controller.’ It is a programmable controller used in process control and manufacturing automation. PLCs replaced the relay logic control system, which was used in the industry for interlocks and sequential operations. The relay logic was a hard-wired system with many limitations, including difficulty tweaking logic control, upgradation, and troubleshooting. A PLC is an easy-to-use programmable device that can be programmed and reprogrammed to adapt to any control requirement. All the wiring, connections, and functions like timer, counter, and advanced math operations are accessible inside the software. PLCs can perform operations ranging from simple standalone tasks to complex machine control processes. PLCs can be divided into two types: compact and modular. Compact PLCs are small, low-cost, and easy to install. They house all necessary components in a single package, including a fixed number of input and output channels, power supply...
PowerFlex 700 and Powerflex 755 are part of Allen-Bradley’s product line of powerful AC drives that provide flexible control. The Powerflex 700 consists of low-power and high-power AC drives. These AC drives offer superior performance and are easy to use in operations. The PowerFlex AC drives control three-phase induction motors for numerous industrial applications. The applications range from simple speed control to demanding ones, including high torque control. In 2017, Rockwell Automation discontinued PowerFlex 700 AC high-power drives (250-700 Hp). The low-power AC drives are still available from the manufacturer. A new range of AC drives, PowerFlex 755, was introduced to replace the discontinued high-power PowerFlex 700 AC drives. The new AC drives have many features and enhanced performance to improve operations. This guide highlights the different features of PowerFlex 700 AC drives and PowerFlex 755 AC drives and provides an in-depth comparison. Allen Bradley PowerFlex 700...