"Industrial Automation(PLC) and Electrical Motor Faults."

If I talk about industrial automation then this is defined as usage of technology for controlling and monitoring industrial processes,for reducing human intervention and for increasing efficiency.It includes integrity of mechanical software and electrical systems for automation of different tasks including manufacturing,processing and handling of material.

If I talk about industrial automation then it use multiple technology's in which there are programmable logic controllers, robot, machine learning algorithms as well as sensors.Major purpose for these is improving quality, productivity and safety while reduction of expenses and environmental effect. So I can say that it is transforming industries in smaller factories with minimum intervention of human.

If I talk about importance of industrial automation during industrial Revolution then industrial automation is helpful in transformation of manufacturing processes. If I talk about automation then this is useful for enabling mass production, enhancement of efficiency and reduction of labour cost. There are also new machines and technologies including steam engines,textile machines as well as replaced manual labours which are permitting for fastest produced and increasing quality of products or goods.

Automation is also improving safety ,security of workers and also plays role in reducing fatigue.As final outcome we can say that industrial automation is driving the growth of economy,increasing production and is helpful in establishment of major industrial power.

Following are the names and operations of different parts of PLC;

• If I talk about first part then this is CPU which is a major component which central processing unit which is helpful in execution of programs and for controlling PLC.

• If I talk about second most important component then this is memory which is used for storage of information, data ,programs as well as configurations.

• If I talk about third most important component then this is input module which is used for receiving signals from sensors and devices.

• If I talk about another important component then these is output module which is used for sending signals to devices and then actuators.

• If I talk about programming terminal then this is another most important component useful in programming and configuration of PLC.

• If I talk about power supply then its another most important component which is useful for providing power to PLC.

• If I talk about communication module then these are useful for enabling communication with other systems and other devices and this is its purpose.

• Another most important component is relay modules which are used for controlling high current devices.

• Analogue modules are also important for processing analogue signals as these are indicating by name and this is also one of the most important component of PLC.

• Last but not least there are also digital modules which are purposeful and used for processing digital signals and these are also powerful component of PLC.

3-power motor

These are 5 input and 5 output electrical and electronics devices which are operated by PLC:

Input devices

• Limit switches
• Proximity sensors
• Photoelectric sensors
• Temperature sensors
• Pressure sensors

Output devices

• Motors
• Valves
• Relays
• Contactors
• Solenoids

For calculating load first there's a need of determining total power needed so;

5 x 5 kW motors = 25 kW
3 x 45 kW motors = 135 kW
Total load can be calculated as = 25 kW + 135 kW which is finally 160 kW

As according to task,incoming line is 11 kV so now I can consider a 3-phase, 4-wire system.For calculation of rating of transformer following steps will be followed;

Transformer rating = Total load / Efficiency(typically 0.95)

= 160 kW / 0.95

Here we are getting the following answer;

= 168.42 kVA

Transformer specification

• Rating: 200 kVA (standard rating above calculated value)
• Primary voltage: 11 kV
• Secondary voltage: 415 V (standard industrial voltage)
• Frequency: 50 Hz
• Efficiency: 95%
• Insulation class: F (155°C)
• Cooling: ONAN (Oil Natural Air Natural)

Materials needed

• Contactors (K1): 1 no.
• Overload relays (F1, F2): 2 nos.
• Thermal overload relay: 1 no.
• Circuit breaker: 1 no. (5 kW rated)
• Cables: suitable for 5 kW motor (size and type)
• Wire nuts for making connections
• Terminal blocks also used for connections

Materials needed

• Contactors (K1): 1 no.
• Overload relays (F1, F2): 2 nos.
• Thermal overload relay: 1 no.
• Circuit breaker: 1 no. (45 kW rated)
• Cables are suitable for 45 kW motor (size and type)
• Wire nuts are used for connections
• Terminal blocks are also used for connections

For controlling 15 kW motor for bidirectional operation materials which will be needed are following;

Electrical components

• Contactors: 2 nos from which 1 will be for forward and 1 will be for reverse direction
• Overload relays: 2 nos from which 1 will be for forward and 1 will be for reverse direction
• Push buttons:2 nos in which 1 will be for forward and 1 will be for reverse direction
• Reversing starter: 1 no.
• Circuit breaker: 1 no. (15 kW rated)
• Thermal overload relay: 1 no.
• Motor protection circuit breaker: 1 no.

Wiring and accessories

• Cables are important for 15 kW motor (size and type)
• Wire nuts are used for making connections
• Terminal blocks are used for connections
• Earthing materials are important for earthing motor as well as panel
• Panel board is important for housing of control components

If I have to evaluate result of checking motor that is it good or not then I need to check for efficiency, temperature,electrical readings,physical conditions as well as overall performance!

Exact requirement for this task is to explain about my perspective that motor is good or not by checking it with multimeter according to scenario so here I need to go with electrical readings in which I can check for resistance, current etc.

Result of checking motor seems bad to me

Above I have shared my personal perspective at this scenario because according to my understanding if I see in the picture then electrical reading for red to red wire is 13.30 kilo Ohm, yellow to yellow wire is 12.77 kilo Ohm and then Blue to blue wire is 30 kilo Ohm but in actual it would be more ideal if values exist in between 0-10 Ohm but here these are exceeding from limit so it's my personal reasoning behind my personal perspective about this task!

I want to invite @wilmer1988,@stef1,@sahar78,@suboohi