Electrical Control for Machines

Diane Lobsiger is an electrical instructor at Delta College in University Center, Michigan. She instructs students in the Skilled Trades-Electrician program, Wind Turbine Technology program, and Pre-Engineering program. In her prior work as a senior manufacturing controls engineer for 24 years, she gained a wealth of knowledge and extensive experience in the design, troubleshooting, specification writing, and approval of machine controls systems. Her expertise includes relay control systems, programmable logic controllers, human-machine interfaces, servo systems, adjustable frequency drives, and fluid power systems. She earned a Bachelor of Science in electrical engineering from Auburn University and a Master of Science in electrical engineering from Michigan State University. She recently obtained her Secondary Teaching Certification in mathematics and physics from Saginaw Valley State University. In her free time, she can usually be found fishing at her cabin.

1. TRANSFORMERS AND POWER SUPPLIES.
Control Transformers. Transformer Regulation. Sizing a Transformer. Operating Transformers in Parallel. Temperature Rise in a Transformer. 60 Hz Versus 50 Hz Operation. Constant Voltage Regulators. Power Supplies for Control Voltage. Uninterruptible Power Systems. Circuit Diagram. Insulation Classifications. Conductor Ampacity. Conductor Color Code.
2. FUSES, DISCOUNNECT SWITCHES, AND CIRCUIT BREAKERS
Protective Factors. Fuse Construction and Operation. Fuse Types. Peak Let-Thru Current (IP) and Ampere Squared Seconds (I2t). Voltage and Frequency Surges. Circuit Breaker Types. Programmable Motor Protection. Electrical Metering and Voltage Protection. Selecting Protective Devices. Ground Fault Circuit Interrupter.
3. CONTROL UNITS FOR SWITCHING AND COMMUNICATION.
Oil-Tight Units. Push-Button Switches. Selector Switches. Heavy-Duty Switches. Indicating Lights. General Information on Oil-Tight Units. Circuit Applications. Annunciators. Light-Emitting Diodes. Membrane Switches.
4. RELAYS.
Control Relays and Their Uses. Timing Relays. Latching Relays. Plug-In Relays. Contactors.
5. SOLENOIDS.
Solenoid Action. Solenoid Force and Voltage. Low Voltage. Overvoltage. AC Solenoids on DC. DC Solenoids on AC. 50- and 60-Cycle Solenoids. Solenoid Temperature Rise. Valve Operation. Circuit Applications. Variable Solenoids. Proportional Valves. Servo Valves.
6. TYPES OF CONTROL.
Open-Loop Control. Closed-Loop Control. Proportional Control. Proportional-Integral. Proportional-Integral-Derivative.
7. MOTION CONTROL DEVICES.
Importance of Position Indication and Control. Limit Switches-Mechanical. Limit Switch Symbols. Circuit Applications. Proximity Limit Switches. LED Indicators. Solid-State Outputs. Detection Range. Hysteresis. Attenuation Range. Speed. Magnet-Operated Limit Switch. Vane Switches. Linear Position Displacement Transducers. Angular Position Displacement Transducers. Use of AC Synchronous and DC Stepping Motors. Servo Positioning Control. Sensing Theory. Flow Sensors.
8. PRESSURE CONTROL.
Importance of Pressure Indication and Control. Types of Pressure Switches. Circuit Applications.
9. TEMPERATURE CONTROL.
Importance of Temperature Indication and Control. Selection of Temperature Controllers. Electronic Temperature Controller (Pyrometer). Controller Outputs. Additional Terms. Temperature Switches (Thermostats). Temperature Sensors. Circuit Applications.
10. TIME CONTROL.
Selected Operations. Types of Timers. Synchronous Motor-Driven Timers. Solid-State Timers. Circuit Applications.
11. COUNT CONTROL.
Electromechanical Control Counter. Circuit Applications. Solid-State Counters.
12. CONTROL CIRCUITS.
Placement of Components in a Control Circuit. Control Circuit Examples.
13. MOTORS AND DRIVES.
DC Motors-Principles of Operation. DC Motors. AC Motors-Theory of Operation. Polyphase Squirrel-Cage Induction Motors. Variable Frequency Drives. Single-Phase Motors. Resistance Split-Phase Motors. Capacitor Start Motors. Permanent Split-Capacitor Motors. Shaded-Pole Motors. Brushless DC Motors.
14. MOTOR STARTERS.
Contacts and Overload Relays. Across-the-Line (Full-Voltage) Starters. Reversing Motor Starters. Multispeed Motor Starters. Additional Across-the-Line Starter Circuits. Reduced-Voltage Motor Starters. Solid-State Motor Starters. Starting Sequence.
15. INTRODUCTION TO PROGRAMMABLE CONTROL.
Primary Concepts of Relay Control. Introduction to Programmable Logic Controllers. Programmable Logic Controller Concepts. PLC Input/Output (I/O). Processor. Memory. Power Supplies. Programming. Examine On/Examine Off. Programming Devices. Data Communications. Converting from Relay Logic to PLC.
16.INDUSTRIAL DATA COMMUNICATIONS.
Overview. Industrial Information Technology Architecture. Data Communication Network Concepts. Data Transmission. Industrial Data Highway. Network Topologies. Industrial Networks. Data Transfer Rate. Ethernet and the Information Highway. Transmission Media. Troubleshooting Networks. Open Systems Versus Proprietary Systems. Network Layers. Typical Network Systems.
17. QUALITY CONTROL.
Defining Quality and Quality Control. Electrical and Electronic Circuits Used in Quality Control. Quality Achieved Through Machine and Process Monitoring. Process Tolerance (Standards). Information Systems. Maintaining Quality.
18. SAFETY.
Worker Safety. Machine Safety. Diagnostic Systems. Machine Safety Circuit. Programmable Controllers in Safety. Other Safety Conditions.
19. TROUBLESHOOTING.
Safety First. Analyzing the Problem. Major Trouble Spots. Equipment for Troubleshooting. Motors. Troubleshooting a Complete Control Circuit. Troubleshooting the Programmable Logic Controller. Electronic Troubleshooting Hints.
20. DESIGNING CONTROL SYSTEMS FOR EASY MAINTENANCE.
Design Considerations. Diagrams and Layouts. Locating, Assembling, and Installing Components.