Controlling, Monitoring and Faults detection of Industrial Motor using PLC

Project Supervisor: Madam Nida Kashif Group Members: Khurum Sharif Ata-ur-Rehman Khalid Nadeem Asghar

Block Diagram

Induction Motor
An induction motor or asynchronous motor is

a type of alternating current motor where power is supplied to the rotor by means of electromagnetic induction.

Types of Induction Motor

Two types of induction motor which are commonly used 1. Single phase induction motor 2. Three phase induction motor

Three Phase Induction Motor

A 3-phase induction motor has a stator and a rotor. The stator carries a 3-phase winding (called stator winding) while

the rotor carries a short-circuited winding (called rotor winding). Only the stator winding is fed from 3-phase supply. The rotor winding derives its voltage and power from the externally energized stator winding through electromagnetic induction and hence the name. The induction motor may be considered to be a transformer with a rotating secondary and it can, therefore, be described as a transformer type AC machine in which electrical energy is converted into mechanical energy.

Equivalent Circuit of 3-Phase Induction Motor at Any Slip

Fig. shows the equivalent circuit (though not the only one) per phase for an induction motor.

V1 = applied voltage per phase to the stator

R1= stator resistance X1=stator leakage reactance per phase E1= self induced e.m.f in the stator winding E'2 =mutually induced e.m.f (E'2= s E2 = s K E1 where K transformation ratio) is induced in the rotor winding. The flow of stator current I1 causes voltage drops in R1and X1. V1 = -E1 + I1(R1 + j X1) ...phasor sum R2= rotor resistance X2= rotor leakage reactance per phase The induced voltage/phase in the rotor is E'2 = s E2 = s K E1. Since the rotor winding is short-circuited, the whole of e.m.f E'2 is used up in circulating the rotor current I'2. E'2 = I'2 (R2 + j s X2 ) The rotor current I'2 is reflected as I"2 (= K I'2) in the stator. The phasor sum of I"2 and I0 gives the stator current I1.

Circuit breaker:
A circuit breaker is an automatically

operated designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and interrupt current flow. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation.

 There are different types of circuit breaker

including bimetallic, thermal magnetic and magnetic circuit breakers. A typical three phase circuit breaker is given below

Contactors:
Contactors typically have multiple contacts, and

those contacts are usually (but not always) normally-open, so that power to the load is shut off when the coil is de-energized Most common industrial use for contactors is the control of electric motors.

Working of contactors:
Typical contactor working diagra is given below

The top three contacts switch the respective

phases of the incoming 3-phase AC power, typically at least 480 Volts for motors 1 horsepower or greater.

 The lowest contact is an "auxiliary" contact which has

a current rating much lower than that of the large motor power contacts, but is actuated by the same armature as the power contacts . The auxiliary contact is often used in a relay logic circuit, or for some other part of the motor control scheme, typically switching 120 Volt AC power instead of the motor voltage. One contactor may have several auxiliary contacts, either normally-open or normally-closed, if required.

Phase failure relay

A phase failure relay monitors the incoming three

phase service lines. If the lines become reversed or loss of one phase causing single phasing, the relay's internal contacts change status. In control panels the control voltage usually is connected through the phase failure relay's auxiliary contacts. If any line anomalies occur the control voltage is cut off and the panel becomes inoperable. Once the line fault is corrected the fault relay senses that everything is alright and then allows the control voltage to power the control panel again.

Thermal overload relay:

It operates when

current increases from certain specific limits. It normal close contacts closes when current increases from certain limits

 There are different types of phase failure relay,

zahra RST-25 is such type of relay which can sense phase failure, phase sequence and over , under voltage.

Current sensor:
The device consists of a precise, low-offset, linear

Hall circuit with a copper conduction path located near the surface of the die. Applied current flowing through this copper conduction path generates a magnetic field which the Hall IC converts into a proportional voltage.

 The output of the

device has a positive slope when an increasing current flows through the primary copper conduction path (from pins 1 and 2, to pins 3 and 4), which is the path used for current sampling.

Proximity sensor:
Inductive Proximity Sensors detect the presence of metal

objects which come within range of their oscillating field and provide target detection to zero speed. Internally, an oscillator creates a high frequency electromagnetic field (RF) which is radiated from the coil and out from the sensor face . When a metal object enters this field, eddy currents are induced into the object.

 As the metal moves closer to the sensor, these

eddy currents increase and result in an absorption of energy from the coil which dampens the oscillator amplitude until it finally stops.

Potential Transformer
Transformer:

A transformer is a device that transfers electrical

energy from one circuit to another through inductively coupled conductorsthe transformer's coils.

Programmable Logic Controllers

A programmable logic controller (PLC) is a

specialized computer used to control machines and process. It uses a programmable memory to store instructions and execute specific functions that include On/Off control, timing, counting, sequencing, arithmetic, and data handling.

Relays:
Relays:

A relay is an electrically

operated switch. Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have two switch positions and most

PLC programming

LADDER DIAGRAM:

SCADA
The term SCADA usually refers to centralized

systems which monitor and control entire sites, or complexes of systems spread out over large areas (anything from an industrial plant to a nation). Most control actions are performed automatically by PLCs. Host control functions are usually restricted to basic overriding or supervisory level intervention.

SCADA DEVELOPEMENT