Automation in textile machinery : instrumentation and control system design principles

457 Pages·2018·16.042 MB·English

by  Kumar, L. Ashok, Kumar, Senthil T

Engineering - Industrial & Manufacturing S Automation in
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Automation in Textile Machinery i m
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k Textile Machinery
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Automation is the use of various control systems for operating equipment such as r
machinery and processes. In line, this book deals with comprehensive analysis of
Instrumentation and Control System Design Principles
the trends and technologies in automation and control systems used in textile en- A
gineering. The control systems descript in all chapters is to dissect the important u
components of an integrated control system in spinning, weaving, knitting, chemical
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processing and garment industries, and then to determine if and how the compo-
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nents are converging to provide manageable and reliable systems throughout the
chain from fiber to the ultimate customer.
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Key Features: i
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• Describes the design features of machinery for operating various textile n
machineries in product manufacturing
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• Covers the fundamentals of the instrumentation and control engineering

used in textile machineries T
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• Illustrates sensors and basic elements for textile automation x
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• Highlights the need of robotics in textile engineering
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• Reviews the overall idea and scope of research in designing textile

machineries M
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h
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n L. Ashok Kumar
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r M. Senthilkumar
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K30019
6000 Broken Sound Parkway, NW
Suite 300, Boca Raton, FL 33487 ISBN: 978-1-4987-8193-0
711 Third Avenue 90000
New York, NY 10017
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w w w. c rc p r e s s . c o m
K30019 cvr mech.indd All Pages 3/6/18 11:22 AM
Automation in Textile Machinery

Automation in Textile
Machinery

Instrumentation and Control System
Design Principles

L. Ashok Kumar
M.  Senthilkumar
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2018 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
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Contents
Organization of the Book ...........................................................................................................xxi
About This Book ........................................................................................................................xxiii
Preface ..........................................................................................................................................xxv
Acknowledgments ...................................................................................................................xxvii
Authors .......................................................................................................................................xxix
1. Control Systems Engineering ..............................................................................................1
1.1 Introduction ...................................................................................................................1
1.2 Electrical Terminology .................................................................................................1
1.2.1 Inductance .......................................................................................................2
1.2.2 Impedance .......................................................................................................3
1.2.3 Amplitude .......................................................................................................3
1.2.4 Phase ................................................................................................................3
1.2.5 Measurement of Voltage ................................................................................5
1.2.6 Measurement of Small Voltages ...................................................................5
1.2.7 Measurement of Current ...............................................................................6
1.2.8 Measurement of Small Currents ..................................................................6
1.2.9 Noise ................................................................................................................7
1.2.10 Interference Noise ..........................................................................................7
1.2.11 Screen Circuits ................................................................................................7
1.2.12 Avoid Signal or Ground Loops ....................................................................7
1.2.13 Electronic Noise ..............................................................................................8
1.2.14 Frequency Response and Filtering ..............................................................8
1.2.15 Potential Divider ............................................................................................9
1.2.16 Operational Amplifiers ...............................................................................10
1.2.17 The Non-Inverting Buffer ...........................................................................10
1.2.18 Operational Amplifier Properties ..............................................................11
1.2.19 Operational Amplifier Circuits—Unity-Gain Non-Inverting Buffer ...12
1.2.20 Non-Inverting Voltage Amplifier ...............................................................13
1.2.21 Differential Voltage Amplifier ....................................................................13
1.2.22 Instrumentation Amplifier .........................................................................13
1.2.23 Current Amplifier.........................................................................................14
1.2.24 Potentiostat ....................................................................................................14
1.2.25 Galvanostat....................................................................................................14
1.2.26 Active Filter ...................................................................................................15
1.3 Cell Design for Electrochemistry .............................................................................17
1.3.1 The Working Electrode ................................................................................17
1.3.2 The Counter Electrode (or Secondary or Auxiliary Electrode) .............18
1.3.3 The Reference Electrode ..............................................................................18
1.3.4 Composition ..................................................................................................19
1.3.5 Solution Flow ................................................................................................19
1.3.6 The Rotating Disk Electrode .......................................................................19
v
vi Contents
1.4 Principles of Control Systems ....................................................................................19
1.4.1 Open-Loop Control System ..........................................................................20
1.4.2 Closed-Loop Control System........................................................................21
1.4.3 Automatic Control System ............................................................................24
1.4.3.1 Functions of Automatic Control ...................................................24
1.4.3.2 Elements of Automatic Control ....................................................25
1.4.3.3 Feedback Control System Block Diagram...................................26
1.4.3.4 Stability of Automatic Control Systems ......................................28
1.4.3.5 Two Position Control Systems ......................................................29
1.4.3.6 Proportional Control Systems ......................................................29
1.4.3.7 Proportional-Integral-Derivative Control Systems ...................32
1.4.3.8 Controllers .......................................................................................32
1.5 Summary ......................................................................................................................34
References ...............................................................................................................................35
2. Instrumentation ....................................................................................................................37
2.1 Introduction .................................................................................................................37
2.1.1 Sensor and Transmitter .................................................................................37
2.1.2 Primary Measuring Element Selection and Characteristics....................38
2.1.2.1 Response Time ................................................................................39
2.1.2.2 Accuracy ..........................................................................................40
2.1.2.3 Precision ..........................................................................................40
2.1.2.4 Sensitivity ........................................................................................41
2.1.2.5 Dead Band .......................................................................................41
2.1.2.6 Installation Problems .....................................................................41
2.1.3 Signal Transmission ......................................................................................41
2.1.3.1 Signal Types ....................................................................................41
2.1.3.2 Standard Signal Ranges ................................................................41
2.1.3.3 Electronic Transmitter Adjusted ..................................................41
2.1.4 Transmission System Dynamics ..................................................................42
2.1.4.1 Transmission Lag ...........................................................................42
2.1.4.2 Transmitter Gain ............................................................................44
2.1.4.3 Smart Transmitters.........................................................................44
2.1.4.4 Smart Transmitter Microprocessor-Based Features ..................45
2.1.5 Characteristics of Instruments .....................................................................46
2.1.5.1 Static Characteristics ......................................................................46
2.2 Order of Control and Measurements Systems ........................................................47
2.2.1 Zero Order Control Systems ........................................................................47
2.2.2 First Order Control Systems .........................................................................47
2.2.3 Second Order Control Systems ....................................................................48
2.3 Temperature Measurement Systems ........................................................................49
2.3.1 Thermocouple Temperature Detectors .......................................................50
2.4 Instrumentation and Control: Pressure Detectors .................................................52
2.4.1 Bellows-Type Detectors .................................................................................52
2.4.2 Bourdon Tube-Type Detectors ......................................................................53
2.4.3 Resistance-Type Transducers .......................................................................53
2.4.4 Strain Gauge Pressure Transducer ..............................................................54
2.4.5 Strain Gauge Used in a Bridge Circuit ........................................................55
Contents vii
2.4.6 Resistance-Type Transducers ...................................................................55
2.4.7 Inductance-Type Transducers ..................................................................55
2.4.8 Differential Transformer ...........................................................................56
2.4.9 Capacitive-Type Transducers ...................................................................57
2.4.9.1 Detection Circuitry ..................................................................58
2.4.10 Pressure Detector Functions ....................................................................58
2.5 Angular Displacement .............................................................................................59
2.5.1 Potentiometers ............................................................................................59
2.6 Encoders .....................................................................................................................60
2.6.1 Tachometers ................................................................................................61
2.7 Linear Position ...........................................................................................................62
2.7.1 Potentiometers ............................................................................................62
2.8 Level Detectors ..........................................................................................................62
2.8.1 Gauge Glass ................................................................................................63
2.8.2 Reflex Gauge Glass ....................................................................................64
2.8.3 Ball Float ......................................................................................................64
2.8.4 Chain Float ..................................................................................................65
2.8.5 Magnetic Bond Method ............................................................................66
2.8.6 Conductivity Probe Method .....................................................................67
2.8.7 Differential Pressure Level Detectors .....................................................67
2.8.8 Closed Tank, Dry Reference Leg .............................................................67
2.8.9 Closed Tank, Wet Reference Leg .............................................................69
2.8.10 Density Compensation ..............................................................................69
2.8.10.1 Specific Volume ........................................................................69
2.8.10.2 Reference Leg Temperature Considerations ........................70
2.8.11 Level Detection Circuitry .........................................................................71
2.8.11.1 Remote Indication ....................................................................71
2.8.11.2 Environmental Concerns ........................................................72
2.9 Instrumentation and Control Module on Flow Detectors ..................................73
2.9.1 Head Flow Meters ......................................................................................73
2.9.1.1 Orifice Plate ...............................................................................74
2.9.1.2 Venturi Tube ..............................................................................75
2.9.1.3 Pitot Tube ...................................................................................75
2.9.2 Hot-Wire Anemometer ..............................................................................76
2.9.3 Electromagnetic Flowmeter .....................................................................76
2.9.4 Ultrasonic Flow Equipment .....................................................................76
2.9.5 Steam Flow Detection ...............................................................................77
2.9.6 Simple Mass Flow Detection System ......................................................77
2.9.6.1 Flow Circuitry ...........................................................................79
2.9.6.2 Use of Flow Indication .............................................................79
2.9.6.3 Environmental Concerns ........................................................80
2.10 Instrumentation and Control Module on Position Indicators ............................80
2.11 Switches ......................................................................................................................82
2.11.1 Limit Switches ............................................................................................82
2.11.2 Reed Switches .............................................................................................82
2.12 Variable Output Devices ..........................................................................................83
2.12.1 Potentiometer..............................................................................................83
viii Contents
2.12.2 Linear Variable Differential Transformers .............................................83
2.12.3 Position Indication Circuitry ....................................................................85
2.13 Summary ....................................................................................................................86
References ...............................................................................................................................86
3. Programmable Logic Control Systems ............................................................................89
3.1 Introduction ...............................................................................................................89
3.1.1 Ladder Logic ...............................................................................................89
3.1.2 Programming .............................................................................................91
3.1.3 PLC Connections .......................................................................................92
3.1.4 Ladder Logic Inputs ..................................................................................93
3.1.5 Ladder Logic Outputs ...............................................................................93
3.2 Programmable Logic Controller Hardware ..........................................................94
3.2.1 Inputs and Outputs ...................................................................................95
3.2.1.1 Inputs ...........................................................................................96
3.2.1.2 Output Modules .........................................................................98
3.2.2 Relays .........................................................................................................100
3.2.3 Electrical Wiring Diagrams ....................................................................101
3.2.3.1 Joint International Committee Wiring Symbols ..................101
3.3 Logical Sensors ........................................................................................................103
3.3.1 Sensor Wiring ...........................................................................................103
3.3.1.1 Switches .....................................................................................103
3.3.1.2 Transistor–Transistor Logic ....................................................103
3.3.1.3 Sinking/Sourcing .....................................................................104
3.3.1.4 Solid-State Relays .....................................................................108
3.3.2 Presence Detection ...................................................................................108
3.3.2.1 Contact Switches.......................................................................108
3.3.2.2 Reed Switches ...........................................................................108
3.3.2.3 Optical (Photoelectric) Sensors ..............................................108
3.3.2.4 Capacitive Sensors....................................................................110
3.3.2.5 Inductive Sensors .....................................................................112
3.3.2.6 Ultrasonic ..................................................................................112
3.3.2.7 Hall Effect ..................................................................................112
3.4 Logical Actuators ....................................................................................................113
3.4.1 Solenoids ...................................................................................................113
3.4.2 Valves .........................................................................................................113
3.4.3 Cylinders ...................................................................................................115
3.4.4 Hydraulics .................................................................................................116
3.4.5 Pneumatics ................................................................................................116
3.4.6 Motors ........................................................................................................117
3.5 Boolean Logic Design .............................................................................................118
3.5.1 Boolean Algebra .......................................................................................118
3.5.2 Logic Design .............................................................................................119
3.5.2.1 Process Description ..................................................................120
3.5.2.2 Control Description .................................................................120
3.5.2.3 Define Inputs and Outputs .....................................................120
3.5.2.4 Boolean Equation .....................................................................120
Contents ix
3.5.3 Common Logic Forms .............................................................................121
3.5.3.1 Complex Gate Forms .............................................................121
3.5.3.2 Multiplexers ............................................................................122
3.6 Programmable Logic Controller Operation ........................................................123
3.6.1 Operation Sequence .................................................................................124
3.6.1.1 The Input and Output Scans ................................................125
3.6.1.2 The Logic Scan ........................................................................126
3.6.2 Programmable Logic Controller Status ................................................127
3.6.3 Memory Types ..........................................................................................127
3.6.4 Software-Based Programmable Logic Controllers .............................128
3.7 Latches, Timers, Counters, and More ...................................................................128
3.7.1 Latches .......................................................................................................129
3.7.2 Timers ........................................................................................................130
3.7.3 Counters ....................................................................................................132
3.7.4 Master Control Relays (MCRs) ...............................................................134
3.8 Structured Logic Design ........................................................................................134
3.8.1 Process Sequence Bits ..............................................................................135
3.8.2 Timing Diagrams .....................................................................................136
3.9 Flowchart-Based Design ........................................................................................137
3.10 Programmable Logic Controller Memory ...........................................................141
3.10.1 Memory Addresses ..................................................................................141
3.10.2 Program Files ............................................................................................142
3.10.3 Data Files ...................................................................................................143
3.10.4 Ladder Logic Functions ..........................................................................144
3.11 Analog Inputs and Outputs ..................................................................................145
3.11.1 Analog Inputs ...........................................................................................146
3.11.1.1 Analog Inputs with a PLC ....................................................148
3.11.2 Analog Outputs........................................................................................148
3.11.2.1 Pulse Width Modulation Outputs .......................................148
3.12 Continuous Actuators ............................................................................................149
3.12.1 Electric Motors .........................................................................................149
3.12.1.1 Basic Brushed DC Motors .....................................................150
3.12.1.2 AC Motors ...............................................................................151
3.12.1.3 Brushless DC Motors .............................................................153
3.12.1.4 Stepper Motors ........................................................................153
3.12.1.5 Wound Field Motors ..............................................................155
3.12.2 Hydraulics .................................................................................................156
3.13 Continuous Control ................................................................................................156
3.13.1 Control of Logical Actuator Systems ....................................................157
3.13.2 Control of Continuous Actuator Systems .............................................158
3.13.2.1 Block Diagrams.......................................................................158
3.13.2.2 Proportional Controllers .......................................................159
3.13.3 PID Control Systems ................................................................................159
3.13.3.1 Water Tank Level Control .....................................................160
3.14 Summary ..................................................................................................................161
References .............................................................................................................................161