Engineering & Innovation Hub

Control loop

What may cause the neutral and the earth voltage on consumer supply connection to increase to high volts but not on the electrical grid line? How can this problem be resolved?

It is indication that there is a problem with the electrical grounding (grounded) system (or) a fault in the consumer’s electrical installation if the neutral & earth voltage increases to high voltage on the consumer end connection but not on the grid powerline.

1). Grounding problem
PROBLEM: Voltage imbalances can be caused by poor or insufficient grounding.
SOLUTION: Verify the grounding (earthing) connection at the customer’s location to make sure it is installed and connected correctly. Check to see if the grounding electrode (earth plate) is firmly connected to the planet.
2). Neutral-to-ground fault
PROBLEM: The voltage on the neutral & ground conductors may rise as a result of a fault between the neutral & ground wires.
SOLUTION: Check the electrical system of the customer for any wiring errors, loose connections, or frayed wires. To find any unusual connections, check the neutral & ground wires for continuity.
3). Unbalanced shared neutral load
PROBLEM: Voltage alterations on the neutral could result from an imbalance in loads across the circuits if the consumer’s electrical installation has shared neutral circuits.
SOLUTION: Make that the loads attached to the common neutral circuits are evenly distributed.
4). Transformer problem
PROBLEM: Even though the voltage increase does not happen on the grid’s powerline, it is still important to take a defective transformer into consideration.
SOLUTION: To report the problem and require for a complete equipment testing, get in communication with the electricity

Street Lighting Automation
BT136 (triac)

Shift registers SHL/SHR are friends we needed when tracking empty bottles on the conveyor

Calibration of pressure transmitter with fluke 718 300G/719 300G

Calibration is the assurance of reliability and availability of plant instrumentation. Every instrument installed should be calibrated at regular intervals and during maintenance activities to ensure their proper functioning.

All modern transmitters transmit a signal of 4-20mA.
This is to enhance the "live zero" effect where a difference between a "0" reading and an error in the circuit can be clearly seen.

Proximity sensor is an electronic device that is used to detect an object without any physical contact.
It operates an internal electronic switch

Proximity sensors are being used in industry today to replace device such as mechanical limit switches.

Is it possible to use a proximity sensor to measure speed?
It is not intended for this purpose but perhaps at low speeds
Each time a gear tooth passes the sensors, a voltage pulse is created.
The speed or RPM of the geared wheel is determined by converting the pulse train frequency

A proximity sensor has a switching frequency specification which limits it's use to measure speed.

There are sensors designed for speed measurement that operate exactly as proximity sensors
An important specification is the "Rated Operating Speed" or "Norminal Sensing Speed"

Industrial networking is an essential component of industrial automation. It is the use of computer networks to manage and control industrial processes and machinery. There are several industrial networking technologies used in industrial automation, including Ethernet/IP, Modbus, and Profibus.

1. Ethernet/IP: Ethernet/IP is a protocol used to connect industrial devices over Ethernet networks. It is an open standard that allows for the integration of industrial equipment, such as programmable logic controllers (PLCs), human-machine interfaces (HMIs), and sensors, into a single network. Ethernet/IP is widely used in many industries, including manufacturing, energy, and transportation.

2. Modbus: Modbus is a serial communication protocol used to connect industrial devices to a control system. It is a simple, robust, and widely supported protocol that can be used over many communication channels, such as RS-232, RS-485, and Ethernet. Modbus is commonly used in industrial applications such as building automation, process control, and energy management.

3. Profibus: Profibus is a digital communication protocol used to connect industrial devices in process automation and manufacturing. It provides a high-speed, deterministic network that allows for the control and monitoring of industrial processes in real-time. Profibus is commonly used in industries such as automotive, pharmaceutical, and food and beverage.

In addition to these technologies, other industrial networking technologies include DeviceNet, ControlNet, and CANopen. These protocols are designed for specific applications and provide different features and benefits, such as increased speed, reliability, and flexibility.

Overall, the use of industrial networking technologies is critical for the success of industrial automation. It allows for the efficient communication between industrial devices and systems, improves productivity, and enhances the safety of industrial processes.

PLCProgrammning, PLCTraining

Imagine being able to check and control the temperature of your house with just a few taps on your air-conditioning system. Now imagine being able to do the same thing for an industrial water tank or a facility pump. This is where Human Machine Interfaces (HMIs) come in - they enable plant-floor operators to keep a close eye on critical processes, and make quick decisions based on real-time data.

But HMIs are not just limited to temperature control. They can visually display important production data, track trends and tags, oversee Key Performance Indicators (KPIs), and monitor machine inputs and outputs, among other things. Essentially, they serve as the eyes and ears of operators, system integrators, and engineers in industrial settings.

Control system engineers in particular rely heavily on HMIs to review and monitor processes, diagnose problems, and visualise data. Without these essential resources, it would be difficult to keep up with the pace of industrial automation and maintain a competitive edge.

So if you're interested in PLC programming and industrial automation, understanding the role of HMIs is essential. With their user-friendly interfaces and powerful capabilities, HMIs are the ultimate tool for professionals who want to stay on top of industrial processes and achieve optimal performance.

plctraining, plcprogramming, hmi, control system

Preventative maintenance is the process of regularly inspecting and servicing equipment to identify and address potential issues before they become major problems. By having a solid preventative maintenance plan in place, you can reduce downtime, increase equipment lifespan, improve safety, save money, and enhance productivity and quality ⚡

Regular maintenance can help you avoid unexpected breakdowns, which means less downtime and fewer costly repairs. It can also extend the lifespan of your equipment, saving you money in the long run. When equipment is well-maintained, it operates more efficiently, which can improve productivity and output, and increase the quality of your products.

Preventative maintenance can also improve safety in the workplace. Regular maintenance ensures that equipment is operating safely, reducing the risk of accidents and injuries! This is especially important in industries with strict regulations regarding equipment maintenance and safety!

In short, having an efficient preventative maintenance plan is essential for any organisation that wants to minimise downtime, extend equipment lifespan, improve safety and quality, and save money in the long run.

Sequence of a Traffic light (PLC program)
GREEN
AMBER
RED

A delay time of 20 seconds was used

We've simulated our program to see if there were no errors

Get to watch this real industrial Automation video of a traffic

SITOP PSU, Logo PLC, SIMATIC PANEL(HMI)
Wiring done
We'll publish the Eplan for this panel

Industrial Electricians should know how to read the Eplan, wire the panel & do fault finding

This panel is very useful for process control
If you're an electrician and you don't have the skill to work Automation systems then you need to upskill, learn basic programming

We're going to program a traffic light system & we'll share the video of a working program

Basics

In solar systems technicians talk about KVA and Wattage when sizing the system
3kva
5kva
10kva

Today we'll take you through this power concept

How many KVA makes 3300 watts?
We can easily calculate it by using our Power Triangle Formula. It is the most authentic method of calculating the Watts from KVA or vice versa.

Where;

S = Apparent Power = KVA
P = Actual Power or Real Power = KW
Q = Reactive Power = KVAR

If we have Power factor known, then it is very easy to determine the other values. If p.f is not known, we assume the power factor to be 0.8 or 0.9 for an equipment or a system.

Let’s say we have a generator of 10 KVA, with a p.f of 0.8 lagging, then we can easily calculate the KW in this way.

p.f = KW/KVA
Just plug in the values.
0.8 = KW/10
KW = 10*0.8
KW =8
SO WE GET A POWER OF 8000 WATTS

In your case, lets assume,we have p.f of 0.8 and 3300 watts, so calculate KVA’s in this way;

p.f = KW/KVA
0.8 = 3.3/KVA
OR
KVA = 3.3/0.8
KVA = 4.125

Or

4.125 kVA MAKES 3300 WATTS.

HMI is the term used for Human Machine Interface, generally used in the field of industrial automation.

HMI is a device that can connect with the PLC on a network and gives all the information of process parameters as well as stats of inputs and outputs without losing the integrity of PLC security.
HMI may be the general-purpose computer screens or maybe the special purpose screen that is mounted on the sheet of a metal frame with the machine.
Most of the industrial HMI comes with touch-capacitive screens that help to operate it in a better way.

Electrical personnel can program the HMI in a way that can be easy to understand the operator about machines and sensor status.

Industrial computers & their communication protocols
Be ready
We'll be sharing great information
This might be your chance to a great career

Automation is the use of machines, control systems, and information technologies to optimize productivity in the manufacturing processes with little human involvement

Over-current vs Overload