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Figure 11--1 (a) A solenoid valve that is in the de-energized position so that no fluid will flow through it. (b) A solenoid valve that is in the energized position so that fluid will flow through it. (Courtesy of Automatic Switch Co.)

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Figure 11--2 Cutaway view of coils for solenoid valves. (Courtesy of Automatic Switch Co.)

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Figure 11--3 A diagram of inrush and holding current for a solenoid coil.

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Figure 11--4 A diode is connected in reverse bias across a solenoid coil that is powered by dc voltage. The diode protects other electronic components in the circuit from inductive voltage that occurs when dc voltage to the coil is de-energized.

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Figure 11--5 Technical data sheet for a typical solenoid valve. (Courtesy of Automatic Switch Co.)

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Figure 11--6 Three-way, two-position solenoid valve.

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Figure 11--7 An air cylinder connected to a solenoid valve. The air cylinder is part of a robot arm that uses a vacuum cup to pick up parts.

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Figure 11--8 A three-position, four-way valve with all ports blocked when both solenoids are de-energized.

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Figure 11--9 AC-powered solenoid coils controlled by a triac in an optocoupler. The solenoids are on the left side of the terminal strip in this diagram.

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Figure 11--10 Electric diagram of selector switch and timer used to control a solenoid valve. The solenoid valve energizes a pneumatic cyclinder that extends an automotive dashboard into a curing oven for a shrinking and curing process.

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Figure 11--11 A control amplifier connected to a proportional valve. The amplifier is used to control the amount of voltage sent to a proportional valve. A potentiometer is used to control the input voltage to the amplifier. (Courtesy of Rexroth Corporation.)

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Figure 11--12 (a) A directional control valve and amplifier. (b) A pressure relief valve and amplifier. (c) A flow control valve and amplifier. (Courtesy of Rexroth Corporation.)

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Figure 11--13 Typical op amp circuit for a proportional valve. The potentiometer and capacitor provide a time constant that controls the slope of the ramp-up and ramp-down signal. (Courtesy of Rexroth Corporation.)

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Figure 11--14 Typical ramp-up and ramp-down signals. The slope of the ramp is controlled by the capacitor and potentiometer. The ramp provides smooth operation of a machine when hydraulic power is applied and turned off. (Courtesy of Rexroth Corporation.)

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Figure 11--15 Amplifier card for proportional valve. This card slides into a card cage and receives an input signal (0-9 volts DC) from a PLC (programmable logic controller) and sends an output signal (0-6 volts DC) to a proportional valve. (Courtesy of Rexroth Corporation.)

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Figure 11--16 Electronic diagram of a typical amplifier circuit. The amplifier receives its power supply and input signal on the left side of the circuit, and the proportional valve is connected to the right side of the circuit. (Courtesy of Rexroth Corporation.)

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Figure 11--17 Simplified diagram of a pneumatic-assisted valve with an electric-to-pneumatic signal converter.

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Figure 11--18 Cutaway diagram of a pneumatic-assisted control valve. (Courtesy of Masoneilan, Dresser Valve and Controls Division.)

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Figure 11--19 List to identify parts of the pneumatic-assisted control valve in Fig. 11-18. (Courtesy of Masoneilan, Dresser Valve and Controls Division.)

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Figure 11--20 Butterfly pneumatic-assisted control valve. (Courtesy of The Foxboro Company.)

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Figure 11--21 Current- to-pressure (I/P) converter. This device has an air pressure gauge to indicate the supply air, and another gauge to indicate the regulated pressure. (Courtesy of The Fox-boro Company.)

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Figure 11--22 A graph of the milliamp signal and air pressure signal for an I/P converter.

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Figure 11--23 Electric motor and dampers. (Cour-tesy of Johnson Controls Inc.)

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Figure 11--24 Types of industrial relays that include plug-in type relays, relays mounted in industrial panels and relays that are mounted in printed circuit boards. (Courtesy of Omron Electronics.)

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Figure 11--25 (a) Electrical diagram of a relay with two sets of NO and two sets of NC contacts. (b) Electrical diagram of a relay with two sets of NO and NC contacts. Each set of NO and NC contacts is connected to a common terminal. This configuration is called double-pole, double-throw (DPDT). (c) Electrical diagram of a relay with five sets of NO contacts. (d) Electrical diagram of a relay with five sets of NC contacts.

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Figure 11--26 Example of contacts that can be changed from NO to NC in the field. (Courtesy of Rockwell Automation.)

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Figure 11--27 Various types of relays available for industrial applications. (a) Add-on solid-state time-delay relay. (b) Add-on pneumatic time-delay relay. (c) AC latching relay. (d) AC standard relay. (e) AC standard relay. (f) Electrically held relay. (g) Magnetic latching relay with sealed contacts. (Courtesy of Rockwell Automation.)

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Figure 11--28 Examples of NEMA rated contactors. The size 00 is approximately 4 inches tall and the size 9 is approximately 4 feet tall. (Courtesy of Rockwell Automation.)

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Size 4

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Figure 11--29 National Electrical Manufacturers Association (NEMA) amperage and horsepower table for contactor and motor starter sizes. (Courtesy of Rockwell Automation.)

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Figure 11--30 Exploded view of a contactor showing all of the basic parts. A picture of a completely assembled contactor is also shown for comparison. (Courtesy of Rockwell Automation.)

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Figure 11--31 Inrush current, sealed currents and operating times for coils of NEMA rated contactors. (Courtesy of Rockwell Automation.)

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Figure 11--32 A typical motor starter. The motor starters are rated in size from 00-9 by NEMA. (Courtesy of Rockwell Automation.)

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Figure 11--33 Cutaway picture of a motor starter. (Courtesy of Rockwell Automation.)

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Figure 11--34 Stop push button and start push button connected to motor starter coil. Notice that the overload contacts are connected to series with the coil, and the auxiliary contacts are connected in parallel with the start push button.

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Figure 11--35 Electrical diagram of a motor starter. The coil and overload contacts are also shown. Incoming power is connected to terminals L1, L2, and L3, and the motor is connected to terminals T1, T2, and T3.

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Figure 11--36 Example of a Type W and Type J heating element. (Courtesy of Rockwell Automation.)

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Figure 11--37 Examples of overload mechanisms for motor starters. (a) shows a eutectic alloy overload relay. (b) shows a bimetal overload relay. (c) shows a phase-loss sensitivity overload relay. (Courtesy of Rockwell Automation.)

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Figure 11--38 Table for heating element selection for Allen-Bradley Type W heaters. (Courtesy of Rockwell Automation.)

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Figure 11--39 Solid-state motor starters that provides soft-starting functions for motors. (Courtesy of Rockwell Automation.)

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Figure 11--40 Picture of a variable- frequency drive. (Courtesy of Rockwell Automation.)

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Figure 11--41 The variable-frequency drive shown as three separate sections. The first section is the rectifier section, where AC is converted to DC. The second section is the DC intermediate circuit, which contains the capacitor and inductor for filtering. The third section is the DC-to-AC inverter, where DC is turned back to three-phase AC. (Courtesy of Rockwell Automation.)

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Figure 11--42 Block diagram of variable-frequency drive that also shows the components that are connected to the drive to provide additional control. (Courtesy of Rockwell Automation.)

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Figure 11--43 (a) Electronic diagram of an AC variable-frequency drive. The major parts of the drive include the rectifier, the filter, and the output transistors. (Courtesy of Rockwell Automation.)

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Figure 11--44 Output waveform of the PWM section of the variable-frequency drive. Notice all of the points where the transistor is switched on and off inside each half-wave. (Courtesy of Rockwell Automation.)

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Figure 11--45 Insulated gate bipolar transistors (IGBTs) connected to the output stage of the variable-frequency drive. The IGBTs are used instead of traditional bipolar transistors in newer drives. (Courtesy of Philips Semiconductors.)

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Figure 11--46 List of parameters for a variable-frequency drive. (Courtesy of Rockwell Automation.)

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Figure 11--46 (Continued)

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Figure 11--47 (a) Diagram of TB2 for a 1336 Allen Bradley drive. (b) Diagram of TB3 for a 1336 Allen Bradley drive. (c) Diagram of TB1 that shows the power connections to the drive and the terminal connections for the motor. (Courtesy of Rockwell Automation.)

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Figure 11--47 (Continued)

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Figure 11--48 Block diagram and waveform for a variable-voltage input drive. This is one of the earliest types of variable-frequency drives. (Courtesy of Rockwell Automation.)

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Figure 11--49 Block diagram with waveform of a current-source input drive. (Courtesy of Rockwell Automation.)

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Figure 11--50 Typical DC drive shown as a stand-alone drive and mounted in a panel. (Courtesy of Rockwell Automation.)

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Figure 11--51 Block diagram of a DC drive. Three-phase voltage is supplied at the top of the diagram, and the DC motor is shown as a shunt field and armature. (Courtesy of Rockwell Automation.)

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Figure 11--52 Block diagram of microprocessor controlled DC drive. This drive provides PID control of the DC motor speed. (Courtesy of Rockwell Automation.)

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Figure 11--53 Two sizes of typical stepper motors with their controllers. The larger motor is approximately 8 inches in diameter, and the smaller motor is approximately 3 inches in diameter. (Courtesy of Parker Compumotor Division.)

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Figure 11--54 Cutaway diagram of a permanent magnet stepper motor. (Courtesy of Parker Compumotor Division.)

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Figure 11--55 Canstack rotor that is used in permanent magnet stepper motors. (Courtesy of Parker Compumotor Division.)

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Figure 11--56 Hybrid stepper motor combines features of the permanent magnet stepper and the variable reluctance stepper motors. (Courtesy of Pacific Scientific.)

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Figure 11--57 Diagram that shows the position of the six-pole rotor and four-pole stator of a typical stepper motor. (Courtesy of Parker Compumotor Division.)

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Figure 11--58 Movement of the stepper motor rotor as current is pulsed to the stator. (a) Current is applied to the top and bottom windings, so the top winding is north. (b) Current is applied to left and right windings, so the left winding is north. (c) Current is applied to the top and bottom windings, so the bottom winding is north. (d) Current is applied to the left and right windings so the right winding is north. (Courtesy of Parker Compumotor Division.)

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Figure 11--59 (a) Diagram of switching circuits for stepper motor. (b) The switching sequence for a fourstep (full-step) switching mode. (Courtesy of Superior Electric, Warner Electric.)

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Figure 11--60 The diagrams that show the position of each pole while the motor is in full-step mode. The diagrams a, b, c, and d show the movement of the rotor in sequence. (Courtesy of Parker Compumotor Division.)

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Figure 11--61 (a) The stepper motor with its switches. (b) The switching sequence for the eight-step input (half-step mode). (Courtesy of Superior Electric, Warner Electric.)

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Figure 11--62 Phase-current diagram for a stepper motor controller in microstep mode. (Courtesy of Parker Compumotor Division.)

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Figure 11--63 (a) A diagram of a translator and stepper motor. (b) Example of stepper signal and direction signal. (Courtesy of Parker Compumotor Division.)

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Figure 11--64 A unipolar drive amplifier circuit. The transistors act as the switches to provide the power drive current waveforms for the motor. (Courtesy of Parker Compumotor Division.)

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Figure 11--65 A chopper amplifier circuit for a stepper motor. This type of circuit is also called a recirculating chopper amplifier. (Courtesy of Parker Compumotor Division.)

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Figure 11--66 The dump circuit is shown connected across the + V and ground in parallel with the power supply capacitor. This circuit recirculates the excess current that is generated when the motor decelerates. The regeneration circuit makes the stepper motor more efficient. (Courtesy of Parker Compumotor Division.)

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Figure 11--67 The detailed electrical diagram of the dumping circuit for the stepper motor chopper amplifier shown in the previous figure. (Courtesy of Parker Compumotor Division.)

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Figure 11--68 Applications that use stepper motors. (Courtesy of Parker Compumotor Division.)

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Figure 11--69 A linear motor and its amplifier. (Courtesy of Parker Compumotor Division.)

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Figure 11--70 The forcer is shown on top of the platen of a linear motor. The electromagnets are identified on the forcer. (Courtesy of Parker Compumotor Division.)

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Figure 11--71 A block diagram of a linear motor controller. (Courtesy of Parker Compumotor Division.)

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Figure 11--72 A linear stepper motor used in a coil winding application. The linear motor is used to control the position of the coil winder. (Courtesy of Parker Compumotor Division.)

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Figure 11--73 A linear stepper motor used to transport a silicon semiconductor wafer through a laser inspection station. (Courtesy of Parker Compumotor Division.)

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Figure 11--74 Block diagram of a typical servo control system. (Courtesy of Parker Compumotor Division.)

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Figure 11--75 A servo system with velocity and position loops. This system uses analog and digital components. (Courtesy of Rockwell Automation.)

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Figure 11--76 A typical linear amplifier for a servo system. (Courtesy of Parker Compumotor Division.)

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Figure 11--77 Push-pull amplifier for an AC servomotor. This diagram shows the power stages of the amplifier.

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Figure 11--78 Output stages of a chopper amplifier for an AC servomotor.

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Figure 11--79 Two-transistor amplifier for a DC servomotor.

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Figure 11--80 Four-transistor amplifier for a DC servomotor.

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Figure 11--81 An AC servo drive amplifier specifically designed to operate with an AC trapezoidal brushless servomotor. (Courtesy of Parker Compumotor Division.)

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Figure 11--82 Microprocessor controlled servo drive amplifier. This diagram is for a two-phase AC brushless servomotor. (Courtesy of Parker Compumotor Division.)

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Figure 11--83 Typical PM servomotors. (Courtesy of Pacific Scientific.)

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Figure 11--84 Cutaway picture of a permanent magnet servomotor. (Cour-tesy of Pacific Scientific.)

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Figure 11--85 (a) Trapezoidal input voltage and square wave current wave-forms. (b) Sinusoidal input voltage and sinusoidal voltage and square wave output voltage wave-forms. (c) Sinusoidal input voltage and sinusoidal current waveforms. This has become the most popular type of brushless servomotor control. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--86 (a) Transistors connected to the three windings of the brushless servomotor. (b) Waveforms of the three separate voltages that are used to power the three motor windings. (c) Waveforms of the signals used to control the transistor sequence that provides the waveforms for the previous diagram. (d) Waveform of the overall back EMF. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--87 Example servomotors and amplifiers. (Courtesy of Pacific Scientific.)

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Figure 11--88 Diagram of a servo controller. This diagram shows the digital (on-off) signals and the analog signals that are sent to the controller, and the signals the controller sends back to the host controller or PLC. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--89 Diagram of a pulse-width modulator (PWM) amplifier with a brush-type DC servomotor. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--90 Application of a servomotor controlling the speed of material as it enters a press for cutting pieces to size. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--91 Application of a beverage-filling station controlled by a servomotor. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--92 Application of a precision auger filling station controlled by a servomotor. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--93 Example of a labeling application controlled by a servomotor. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--94 Example of a packaging system with random timing functions controlled by a servomotor. (Courtesy of Electro-Craft, A Rockwell Automation Business.)

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Figure 11--95 Technical data table for selecting servomotors. The motors are listed across the top of the table and the data are listed down the side. (Courtesy of Parker Compumotor Division.)

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