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1 THE TRANSISTOR SWITCH AS A DECISION-MAKER1

Objectives1

1-1 Systems Containing Logic Circuits2

1-2 Logic Circuits Using Magnetic Relays2

1-3 Relay Logic Circuit for a Conveyor/Classifying System4

1-4 Logic Performed by Transistors8

1-5 Logic Gates——The Building Blocks of Solid-State Logic10

1-6 Solid-State Logic Circuit for the Conveyor/Classifying System11

1-7 Input Devices for Solid-State Logic14

1-8 Output Devices for Solid-State Logic19

1-9 Solid-State Logic Compared to Relay Logic21

1-10 A Solid-State Logic Circuit for a Machine Tool Routing Cycle22

1-11 Logic Circuit for a First Failure Annunciator25

1-12 Logic Circuit for a Machine Tool Drilling Cycle27

Expanding the Machine Tool Drilling System30

Summary30

Questions and Problems31

2 TRANSISTOR SWITCHES IN MEMORY AND COUNTING APPLICATIONS34

Objectives35

2-1 Welder Control Circuit Using RS Flip-Flops36

2-2 Oscillating Machining Table Using Clocked RS Flip-Flops37

2-3 JK Flip-Flops40

2-4 Shift Registers40

2-5 Counters45

2-6 Decoding46

2-7 Palletizing System Using Decade Counters and Decoders49

2-8 One-Shots51

2-9 Clocks53

2-10 Automatic Tank Filler Using a Clock and One-Shots54

2-11 Down-Counters and Encoders56

2-12 Timers59

2-13 Bin-Filling System Using a Down-Counter, an Encoder, and Timers66

Expanding the Oscillating Planning Circuit69

Summary70

Formula70

Questions and Problems70

3 PROGRAMMABLE LOGIC CONTROLLERS74

Objectives75

3-1 The Parts of a Programmable Logic Controller76

3-2 Programming a PLC to Control the Conveyor/Classifying System95

3-3 Programming Timing and Counting Functions102

3-4 A Machining Apparatus Utilizing Timing and Counting Functions108

3-5 Other PLC Relay-Type Functions114

3-6 Handling Analog Input Data122

3-7 Improving the Milling Machine System by Making it Temperature-Sensitive136

Summary141

Refining the Temperature-Response of the Milling Process141

Formula142

Questions and Problems142

4 SCRS148

Objectives149

4-1 Theory and Operation of SCRs150

4-2 SCR Waveforms150

4-3 SCR Gate Characteristics152

4-4 Typical Gate Control Circuits152

4-5 Other Gate Control Circuits155

4-6 Alternative Methods of Connecting SCRs to Loads158

4-7 SCRs in Dc Circuits160

MogLev Vehicles163

Summary168

Formula169

Questions and Problems169

Suggested Laboratory Projects170

5 UJTS174

Objectives175

5-1 Theory and Operation of UJTs176

5-2 UJT Relaxation Oscillators179

5-3 UJT Timing Circuits183

5-4 UJTs in SCR Trigger Circuits186

5-5 PUTs194

Triggering the SCRs in a MagLev Control Module198

Summary200

Formulas200

Questions and Problems200

Suggested Laboratory Projects201

6 TRIACS AND OTHER THYRISTORS206

Objectives207

6-1 Theory and Operation of Triacs208

6-2 Triac Waveforms209

6-3 Electrical Characteristics of Triacs210

6-4 Triggering Methods for Triacs211

6-5 Silicon Bilateral Switches214

6-6 Unilateral Breakover Devices219

6-7 Breakover Device(SUS)Used to Trigger a Triac220

6-8 Critical Rate of Rise of Off-State Voltage(dv/dt)222

6-9 UJTs as Trigger Devices for Triacs222

Removal of Ash Particulates from a Coal-Fired Electric Utility Stack230

Summary233

Formulas233

Questions and Problems233

Suggested Laboratory Projects235

7 AN INDUSTRIAL AUTOMATIC WELDING SYSTEM WITH DIGITAL CONTROL240

Objectives241

7-1 Physical Description of the Wheel-Welding System242

7-2 Sequence of Operations in Making a Weld243

7-3 Block Diagram of the Sequence Control Circuit246

7-4 Detailed Description of the Sequence Initiation Circuit and the Interval Triggering and Gating Circuit250

7-5 Detailed Description of the Interval Stepping Circuit and Decoder255

7-6 Interval Time Counter and Interval Time Counter Preset Circuit259

7-7 Heat-Cool Stepping and Gating Circuit264

7-8 Heat-Cool Counter and Heat-Cool Counter Preset Circuit266

7-9 The Weld Power Circuit268

Summary278

Re-creating the Schematic Diagram of the Weld Power Circuit with Alternating-Polarity Heat Subintervals278

Questions and Problems279

8 OP AMPS282

Objectives283

8-1 Op Amp Ideas284

8-2 Closed-Loop Characteristics-Inverting Amplifier286

8-3 Noninverting Amplifier291

8-4 The Output Offset Problem293

8-5 Op Amp Summing Circuit294

8-6 Voltage Comparator296

8-7 Operation from a Single-Polarity Power Supply298

8-8 Op Amp Differential Amplifier299

8-9 Op Amp Voltage-to-Current Converter300

8-10 Op Amp Integrators and Differentiators301

Troubleshooting the MagLev Sidewall-Position-Signal Processing Circuit303

Summary310

Formulas310

Questions and Problems311

Suggested Laboratory Projects313

9 FEEDBACK SYSTEMS AND SERVOMECHANISMS314

Objectives315

9-1 Open-Loop Versus Closed-Loop Systems316

9-2 Closed-Loop System Diagrams and Nomenclature319

9-3 Examples of Closed-Loop Control Systems321

9-4 Modes of Control in Industrial Closed-Loop Systems325

9-5 On-Off Control326

9-6 Proportional Control329

9-7 Proportional Plus Integral Control339

9-8 Proportional Plus Integral Derivative Control342

9-9 Process Response346

9-10 Relationship Between Process Characteristics and Proper Mode of Control352

9-11 PID Process Control with a Programmable Logic Controller355

Using a PLC for Automated Variation of Process Conditions and Data Gathering360

Summary362

Questions and Problems362

10 INPUT TRANSDUCERS-MEASURING DEVICES368

Objectives369

10-1 Potentiometers370

10-2 Linear Variable Differential Transformers(LVDTs)375

10-3 Pressure Transducers376

10-4 Thermocouples378

10-5 Thermistors and Resistive Temperature Detectors(RTDs)382

10-6 Other Temperature Transducers385

10-7 Photocells and Photoelectric Devices386

10-8 Optical Fibers403

10-9 Ultrasonics405

10-10 Strain Gages406

10-11 Accelerometers409

10-12 Tachometers410

10-13 Hall-Effect Transducers413

10-14 Other Flowmeters417

10-15 Resolvers424

10-16 Humidity Transducers434

Troubleshooting with a Multichannel Digital Storage Scope438

Summary441

Questions and Problems442

Formulas442

11 FINAL CORRECTING DEVICES AND AMPLIFIERS448

Objectives450

11-1 Solenoid Valves450

11-2 Two-Position Electric Motor-Driven Valves451

11-3 Proportional-Position Electric Motor-Driven Valves453

11-4 Electropneumatic Valves454

11-5 Electrohydraulic Valves457

11-6 Valve Flow Characteristics459

11-7 Relays and Contactors461

11-8 Thyristors465

11-9 Split-Phase Ac Motors466

11-10 Ac Servo Motors471

11-11 Solid-State Ac Servo Amplifiers478

11-12 Dc Servo Motors488

11-13 Amplifiers for Dc Servo Motors490

Troubleshooting an Electropneumatic Valve Operator493

Summary494

Questions and Problems494

12 WOUND-ROTOR DC MOTORS498

Objectives499

12-1 Motor Types500

12-2 Wound-Rotor Dynamo Principles501

12-3 Wound-Rotor Dc Motor Performance519

12-4 Characteristic Graphs of Shunt-Configured Dc Motors535

12-5 Characteristics of Series-Configured Dc Motors538

12-6 Compound Configuration546

12-7 Interpoles547

12-8 Starting,Stopping,and Reversing548

Removal of Sulfur from a Coal-Fired Electric Utility Stack556

Summary561

Formulas561

Questions and Problems562

13 NONTRADITIONAL DC MOTORS566

Objectives567

13-1 Conventional Permanent-Magnet Motors568

13-2 Coreless Permanent-Magnet Motors569

13-3 Stepper Motors572

13-4 Brushless Dc Motors589

13-5 Comparing Electronically Commutated to Brush-Equipped Dc Motors592

Learning a Complex Stepper Motor Test Circuit596

Summary598

Formulas598

Questions and Problems598

14 AC MOTORS602

Objectives603

14-1 The Rotating Field604

14-2 The Squirrel-Cage Rotor610

14-3 Getting the Phase-Shift614

14-4 Operating Characteristics of Squirrel-Cage Motors619

14-5 Three-Phase Ac Power Systems624

14-6 Three-Phase Squirrel-Cage Induction Motors635

14-7 Characteristics of Three-Phase Motors639

14-8 Starting,Reversing, and Two-Voltage Operation643

Troubleshooting a Motor Overload649

Summary650

Questions and Problems651

Formulas651

15 NINE EXAMPLES OF CLOSED-LOOP INDUSTRIAL SYSTEMS656

Objectives657

15-1 Thermistor Control of Quench Oil Temperature658

15-2 Proportional Mode Pressure Control System661

15-3 Proportional Plus Reset Temperature Controller with Thermocouple Input667

15-4 Strip Tension Controller674

15-5 Edge Guide Control for a Strip Reciler679

15-6 Automatic Weighing System682

15-7 Carbon Dioxide Controller for a Carburizing Furnace691

15-8 Control of Relative Humidity in a Textile Moistening Process700

15-9 Warehouse Humidity Controller703

Troubleshooting an Op-Amp Proportional Control Circuit707

Summary707

Questions and Problems707

16 MOTOR SPEED-CONTROL SYSTEMS710

Objectives711

16-1 Dc Motors-Operation and Characteristics712

16-2 Thyristor Control of Armature Voltage and Current714

16-3 Single-Phase Half-Wave Speed-Control System for a Dc Shunt Motor715

16-4 Another Single-Phase Speed-Control System717

16-5 Reversible Speed Control718

16-6 Three-Phase Drive Systems for Dc Motors720

16-7 An Example of a Three-Phase Drive System721

16-8 Pulse-Width-Modulated Control723

16-9 The Type 555 Timer-Oscillator727

16-10 Variable-Frequency Inverters740

16-11 Varying the Voltage Along with Frequency747

16-12 Cycloconverters752

Troubleshooting a High-Power SCR-Based Dc Motor Drive765

Summary766

Formulas767

Questions and Problems767

17 TELEMETRY772

Objectives773

17-1 Telemetry by Pulse-Width Modulation774

17-2 Telemetry by Pulse-Frequency Modulation778

17-3 Multiplexed Telemetry788

17-5 Digital Telemetry792

17-4 Radio Telemetry792

Testing a Pulse-Frequency-Modulated Telemetry System809

Summary811

Formulas812

Questions and Problems812

18 CLOSED-LOOP CONTROL WITH AN ON-LINE MICROCOMPUTER816

Objectives817

18-1 A Coal-Slurry Transport System Controlled by a Microcomputer818

18-2 The System Control Scheme818

18-3 Programming a Microcomputer820

18-4 The Program Flowchart821

18-5 The Microcomputer s Architecture823

18-6 Executing a Program831

18-7 The Coal-Slurry Control Program834

Using a Logic Analyzer for Debugging850

Summary852

Questions and Problems853

19 INDUSTRIAL ROBOTS856

Objectives857

19-1 The Robot Concept858

19-2 Mechanical Configurations of Industrial Robots860

19-3 Categories of Software for Industrial Robots864

19-4 Positive-Stop Programs866

19-5 Point-to-Point Programs873

19-6 Continuous-Path Programs883

19-7 Mechanical Grippers886

19-8 Vacuum Holders888

19-9 Pneumatic Grippers891

19-10 Proximity Sensors894

Understanding Robotic Malfunctions899

Summary900

Questions and Problems900

20 SAFETY904

Objectives905

20-1 Electric Shock906

20-2 Grounding Wires908

20-3 Ground-Fault Interrupters911

20-5 Burns913

20-4 Administering Aid to a Victim of Electric Shock913

20-6 Eye and Head Protection914

20-7 Fire915

20-8 OSHA Color Codes915

Summary916

Questions and Problems917

APPENDIX A:Universal Time-Constant Curves919

GLOSSARY921

INDEX933