BENE 3113 INDUSTRIAL CONTROL

TUTORIAL 1: INRODUCTION TO INDUSTRIAL CONTROL & DISCRETE

CONTROL COMPONENTS

Question
1. Define the meaning of manually and automatically in control system.
Control is considered to be manually operated when someone must initiate an action for the
circuit to operate. Automatically is self-driven action for the system to operate.

2. What does normally closed and normally open switches mean? Draw both symbols.
Normally closed switch mean it allows currents until its switch is closed (ON) and
normally open switch does not pass current until it is closed (ON)

3.

What are the basic component of relay and explain how it works?
The basic component of relay is a coil and a contact. When the current flow through the coil,
an electromagnetic will be produce and pulled the armature.

4.

Design a ladder diagram to start a DC motor using push button and stop button. An
indicator light will be used to show the motor is running. An emergency button is design
to stop the motor if an accident occurred.

5. An automatic storeroom light system lights up a small storeroom. A switch (s1) is

installed at the door such that if the door is open, the switch is on and the light inside the
storeroom is on. A detector (switch s2) is installed to detect human inside the room and
keep the light on. Design this system in ladder diagram.

6. A dc relay is connected as in figure 1. The relay is an Omron MY4 24Vdc with

specifications as below:
S1
CR
Rated voltage, E = 24 Vdc
2
Coil resistance, r = 636
E
Arm. off inductance, Loff = 3.20 H
24V
6
Arm. on inductance, Lon = 5.72 H
Find:
(a) relays time constant,
Figure 1
(b) relays rated current, Irated
(c) current through relay at 7 msec after switch is pressed
(d) if the pull-in current, Ip, is specified at 80% of rated current, will the relays
armature be fully pulled in after 7 msec?
(e) relays drop-off current, Id, if it is specified at 30% of Irated.

Answer:

L Loff

r
r
= 5.03 msec
E
24
relays rated current: I rated
r 636
= 37.74 mA
current through relay at 7 msec:
t

E
i(t ) (1 e )
for figure 1,
r
0.007

24

(1 e 0.00503 )
636
= 28.35 mA
pull-in current: Ip = 0.80Irated = (0.80)( 37.74 mA)
= 30.19 mA
Since at 7 msec, i(7msec) = 28.35 mA < Ip = 30.19 mA, then the relays armature has
not been pulled in yet.
relays drop-off current: Id = 0.30Irated = (0.30)( 37.74 mA)
= 11.32 mA

(a) relays time constant:

(b)
(c)

(d)

(e)

7.
A ac relay is connected as in figure 2. The relay is an Omron MY4 12Vac with
specifications as below:
S1
CR
Rated voltage, Vac = 12 Vac
2
Coil resistance, r = 46
Arm. off inductance, Loff = 0.17 H
Vac
6
Arm. on inductance, Lon = 0.33 H
12V 50Hz 0Deg
Find:
(a) relays rated current, Ip
Figure 2
(b) relays in-rush current, Id

Answer:
(a) relays pull-in current, Ip
Vac
I
For figure 2,
r jL

Ip

12
46 j (2 )(50)(0.17)

I p 170.25 mA

(b) relays drop-out current, Id

12
46 j (2 )(50)(0.33)
I d 105.80 mA

Id

8.

The circuit of figure 1 and figure 2 are controlled by the switch in a configuration called
2-wire control because 2 wires are needed to connect the controlling switch to the rest of
the circuit. Figure 3 is an example of a 2-wire control for a dc motor.
A common somewhat automated configuration to control motor is a 3-wire control as in
figure 4. The term 3-wire derives from the 3 wires needed to connect to the 2 switches
and 1 relay NO contact.
What are the advantages of the 3-wire control?

Stop

Start

S1
CR

S1

DC_MOTOR_ARMATURE

DC_MOTOR_ARMATURE

Figure 3

Figure 4

Answer:
Advantages of 3-wire control:
1. Safety in case of power trips. When the dc voltages to the circuits of figure 3
and figure 4 are cut off, the respective dc motors turn off. Note that in the 3wire circuit, the relay contacts are now opened.
When the dc voltages are restored to figure 3 and figure 4, the motor in figure
3 immediately turns on, whereas in figure 4, the start push button has to
pressed first to turn on relay CR in order to close the contact to the dc motor.
The necessity of re-pressing of start button prevents inadvertent starting of a
hazardous process.
2. 3-wire control makes it possible to shut down the dc motor automatically.
3. 3-wire control provides isolation between user interface panel and high-current
carrying cables (cables to the dc motor).
4. The user-interface connecting wires cost less due to the lower current it has to
carry.

9.

Give three advantages of Reed relay compare to mechanical relay.

Reeds are generally smaller, allowing for greater density on a board. The lower mass of the
reeds compared to larger armatures means they can actuate faster than electromechanical
relays. Reed relay cycle speeds are as much as 10 times faster than electromechanical relays.

10 Design a ladder diagram from a logic diagram below.

a)
b)

c)

11. Design a ladder diagram and the wiring layout of the process below.
a)

Start Pb1 pressed

M1 (DC motor) ON

M1 OFF and M2 (DC motor) ON

Sw1 & Sw2 pressed

Both M1 and M2 OFF

Stop PB1 pressed

(Both M1 and M2 using separate 4 Pole - Relay)

b)

Start Pb1 pressed

L1 (Light) ON

Timer 1 (After 5 sec)

Stop PB1 pressed

4 Pole Numbering

Coil
Common
NO contact
NC contact

13
9 10 11
5 6 7
1 2 3

L1 OFF

System OFF

4 Pole Relay Base

14
12
8
4

12 11

4
11 a)

Line Numbering

10

14

13

Pb 1
1

Pb 2

14

13

R
9

10

9 R1

M1
1

11

14

13

R1

10

R1

M2
P (+) N (-)
24 Vdc

Pb1

Pb2

Sw1

Sw2

2 1

2 1

M1
Relay R

12 11 10

Relay R1
12 11 10

M2

4 14 13

4 14 13

b)
Pb1

Pb2
1

14

13

R
9
R
10

T1
6

L1

14

T1

13

L2

R
11

T1
10

P (+) N (-)
24 Vdc

Pb2

Pb1

2 1

2 1

L1

Relay R
8

12 11 10

Timer T1
12 11 10

L2

4 14 13

4 14 13

12.

What is a difference in control system between linear and non-linear?

Linear: Can be described with a simple linear differential equation. This is the preferred
starting point for simplicity, and a common approximation for real world problems.

13.

What happen if one system which is stable and self-regulating using closed loop
system?
wasting time and money, may cost the system toward unstable condition , Feedback
may support the system to operate much better.

14.

Explain the meaning of discrete-state control and its division.

Discrete-State control is concerned with controlling a sequence of events rather than motion
or process of individual variables. Each operation in the sequence is performed either for a
certain amount of time (time-driven) or until the task is finished (event-driven).