Industrial Automation(PLC) and Electrical Motor Faults.

Assalamu Alaikum To All

_{I'am @mdpolasmia
From #bangladesh🇧🇩}

Hello Steemian Friends,
How are you all? I hope everyone is well. Today I am hosted by @mahadisalim sir. Want to participate in Industrial Automation (PLC) and Electrical Motor Faults engagement. Which I will post on Steem For Lifestyle Community. First I thank @mahadisalim sir for organizing such a beautiful engagement. Hope everyone likes it.

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A. What do you understand by industrial automation?

Industrial automation refers to the use of control system and technologies to operate machinery and processes in an industry level without people interfere. It involves many components like sensors, PLC, robots etc.

Industrial automation can do many types of work like:-

🔘An automation system can increase productivity.
🔘It is improve our products quality.
🔘Automation system can reduce maintanence cost because the machinery does not fail as often.
🔘An automation has reduced many human sufferings but has also increased unemployment for some.

Some components of industrial automation:-

🔘Programmable logic controllers or PLC.
🔘Robotics
🔘Sensor and actuators
🔘Human machine interfaces or HMI

Application of industrial automation:-

🔘Automation is widly used in manufacturing processes packaging and material handling.
🔘It is also used in oil or gas industry chemical and food processing.
🔘An automation system used in power plant and other energy plants.
🔘Automation is used in warehouse distribution centres such as picking, packing and sorting ultimately automation has improved out lives and led to the third industrial revolution in the world.

B. Write about the importance of industrial automation during the Industrial Revolution.

The importance of industrial automation during the industrial revolution:-

🔘Increase productivity and efficiency:- Earlier one or more manpower was required to operate a machine but after the advent of automation it is now being operated through PLC. As a result the production has increased manifold and the efficiency of the machine has increased.
🔘Reduced labor costs:- Before the advent of automation, a lot of labor was needed to make any production, but now a good amount can be produced with a very small number of people. As less labor is needed, the cost of labor has also decreased.
🔘Mass Production:- After the advent of automation, the production has increased much more than before. previously, there was not so much production by manual operation.
🔘Technological advantage:- The advent of automation was made humans much more innovative in terms of Technology.
🔘Improve quality:- After automation revolution our product quality is improve than before.
🔘Safety:- Automation can reduce risky operation. now we can do any risky operation by automation.
🔘Time:- An automation system saves time and very short of time it gives us huge production.

C. Write the names and operations of various parts of a PLC with a picture.

The names and operation of various parts of a PLC:-

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🔘Power supply:- Converts AC to DC voltage required by PLC internal components.
🔘CPU:- We know CPU is a brain of PLC. here we executing the program and controlling.
🔘Input module:- It receives signals from switch, sensor.
🔘Output module:- send singnal to the motor, valves.
🔘Mamory:- Mamory stores the program data. Two memory ROM:- Stores the ple's firmware and RAM:- Storage data in temporary.
🔘Communication parts:- Communication with other PLC, computer and networks. Here internet cable used for communication.

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D. Name five input and output electrical and electronics devices operated by PLC.

Five input and output electrical devices operated by PLC below:-

Five input	Five output
Limit switch	Solenoid valves
Proximity sensor	Motors
Photoelectric sensor	Relay
Pressure sensor	Signal tower
Temperature sensor	PID controllers

E. The power load for setting up an industry is assumed to be 10 MW. Five 5 kW and three 45 kW three-phase motors will be used in the production of the product. You are an electrician or electrical engineer in that company. Perform the following electrical works with responsibility:

E-01 The incoming electrical line in the industrial area is 11 KV. Prepare a transformer specification by first calculating the load.

So first i calculate the load:-

So the transformer specificeation:-

🔘Type of cooling = ONAN.
🔘Connection = Delta
🔘Rated KVA = 15000.
🔘HT voltage = 11KV.
🔘LT voltage = 415V.
🔘HT current = 788.229A.
🔘LT current = 20892.82A.
🔘No of phase = 03 Phase.

E-02 Draw the starter (power circuit) for running a 5 kW three-phase motor and write the required materials.

5KW motor power circuit diagram:-

This is a dol starter power circuit diagram. I use here Dol starter connection because we know that after 5KW we use star delta starter. So that is why i use here dol starter connection.

Required materials:-

🔘01 pcs MCB = 16A.
🔘01 Magnetic contractor = 12A.
🔘01 thermal overload relay = 09-13A.
🔘01 push button for on(NO)
🔘01 push button for off(NC)
🔘01 control transformer if controlling in 110V or 24V etc.
🔘03×2.5 mm^2 cable need for power connection.
🔘Single phase controlling wire = 01×0.5mm^2.
🔘One encloser for protect the panel.

E-03 Draw the starter (power circuit) for running a 45 kW three-phase motor and write the necessary materials.

45KW motor power circuit diagram:-

Necessary materials:-

🔘01 pcs MCCB = 100A.
🔘02 Magnetic Contractor = 64A.
🔘01 Magnetic contractor = 50A.
🔘Thermal overload relay = 48-65A.
🔘Emergency push button = 01Pes.
🔘On push button(NO) = 01Pes.
🔘 Off push button(NC) = 01Pes.
🔘One transformer for controlling if need.
🔘03×25 mm^2 cable need for power connection.
🔘01×0.5 mm^2 cable for controlling connection.

E-04 A 15 kW motor will keep the product in a fixed location. The motor must run in both directions. Draw the motor's power circuit and write down the materials required for making the circuit.

15KW motor power circuit diagram:-

Required materials:-

🔘03 phase MCCB = 32A=1 pcs
🔘02 Magnetic contractor = 18A.
🔘Overload relay = 12-18A.
🔘On push button(NO) = 01Pes.
🔘Off push button(NC) = 01Pes.
🔘Control transformer if need.
🔘03×06 mm^2 cable for power connection.
🔘01×0.5 mm^2 cable for controlling connection.
🔘One encloser for protect the panel.

F. Review the pictures of the motor checked with a multimeter in my lesson and write your opinion in your own words.

I have seen the picture of the motor where you have checked by a multimeter. so firstly I am going to describe about your first lesson of star connection:-

This is a star connected three phase induction motor. To check the motor is ok you first open the incoming connection of the motor and then also open the star connection of the motor because to check the motor properly all the connections have to be opened. First you hold the multimeter knobs on W1 and W2 and the value comes -3.8 ohms. Then U1 also knobs on U2 and gets 3.9 and U1 and W2 knobs on 0 ohms. Finally a knob on the meter to check if the motor body is shorted. to the motor body and the other knob to U1 obtained a 0 ohms value (ie no short to the motor body). So here it means that the motor is fine because the ohms value is almost same and the body is not shorted.

Then i describe about your second lesson delta connection:-

First you take the multimeter knob w1 and w2 and the value is-3.7. Then you take v1 and v2, value is-5.6.At last you take u1 and u2 the value is-3.6.so there are v1 and v2 value is - 5.6 ohms.So i think the motor is not ok because the ohms value are not same. If the motor is ok then the ohms value must be same.

F-01 If the result of checking the motor seems good to you, then present your reasoning.

My reasoning is explain below:-

In your star connection lesson i see that the motor is ok.but how i know that?If the motor coil value between W1 and W2,U1 and U2 and V1 and V2 are almost same like-3.8;3.9 and 3.8 then the motor is ok.But at least check the motor is short or not.Then the multimeter one knob connect to the motor body and other knob connect to W1,U2,V3........ continuously connect every terminal.If the meter is not show any value then the motor is properly ok.So we check a motor by two step,first step is ohms check between the coils and last check is body short.

F-02 If you think the motor is bad, explain how you know it is bad.

Explain it in my own opinion :-

If the motor is bad then how i know it.In your delta lesson you checked a motor and the ohms value are not same, so the motor is not ok.Here V1 and V2 value is 5.6 but other ohms value is - around 3.7.So value are not same that is why this is not ok. At last i check the motor is short or not.Multimeter one know connect to motor body and other knob connect to V1,U1,W1...... continuously connect to V2,U2,W3 if any ohms value show then the motor body short.
So we can find out motor problem by this way.

SL NO.	My Invited Steemian Friend
1.	@sheikhtuhin
2.	@dove11
3.	@kouba01

Best Regards:- @mdpolasmia