ME0035

TECHNICAL ELECTIVE 1
(MECHATRONICS)

SWITCHES
 CHAPTER 4

OBJECTIVES

■At the end of the chapter, the learner should be able to:
–Identify the different types and application of switches;
–Understand the working principle of switches; and
–Create gate diagrams using switches and Boolean Algebra.
Switch
A device used to interrupt/allow the flow
of electrons in a circuit.
Binary: completely ON (closed) or
completely OFF (open).
• Pole – defines how many separate circuits the switch can
control or number of switch contact sets.
• Throw – the number of positions each of the switch’s
poles can be connected to or the number of conducting
positions, single or double.
• Open – off position, non-conducting
• Closed – on position, conducting
• Pre Travel – movement of the actuator prior to closing the
circuit
• Over Travel – the distance an actuator travels after the
circuit is closed.
• Normally Closed (NC) – term given to a switch where
closed position is the normal state.
• Normally Open (NO) – term given to a switch where open
position is the normal state.
• Break-Before-Make (BBM) – A switch that is configured
to break (open) the first set of contacts before engaging
(closing) the new contacts.
• Make-Before-Break (MBB) – In a switching device, a
configuration in which the new connection path is
established before the previous contacts are opened.
• Actuation Force – the required force to change a circuit’s
electrical state
• Rocker switch
An ordinary light switch with two
positions – on or off
• Push switch
Needs to be pushed to activate
Can be either latching or
momentary (non-latching)
Usually a simple on-off switch
Toggle Switch
A handle is moves or swings to
make or break the circuit.

Slide switch
Switching movement is in linear
motion.
Rotary switch
Switching is via rotary movement
Used when number of circuits need to be
changed simultaneously exceeds the capacity
of a toggle/slide switch.

Limit switch
Used to limit something.
Switching is accomplished via lever actuation.
Maintained switch – stays in one state until actuated into a
new one.
e.g. toggle, on/off switches

Momentary switch – remains active as long as they are

actuated (pressed, held, magnetized, etc.)
e.g. keyboard
Single Pole Single Throw
(SPST)
• Simple on-off switch.
• There is only one circuit
through the switch and one
on position.
Single Pole Single Throw
(SPST)
Single Pole Double Throw
(SPDT)
• Used in switching between
devices
• Often called changeover
switch
• Only one of the loads can be
energized at a time.
Single Pole Double Throw
(SPDT)
SPDT Center Off (ON-OFF-
ON)
• A special version of standard
SPDT with a third switching
position in the center which
is off.
• Only one of the loads can be
energized at a time.
SPDT Center Off (ON-OFF-
ON)
Double Pole Single Throw
(DPST)
• There are two circuits through the
switch (pair of on-off swtich)
• Both load terminals can be
energized at the same time.
• They are independent of each
other and could be of different
voltages.
Double Pole Single Throw
(DPST)
Double Pole Double Throw
(DPDT)
• Pair of ON-ON switches which
operate together
• Functions like two spearate SPDT
switches operated by the same
actuator.
• Only two loads can be On at a time
Double Pole Double Throw
(DPDT)
Rotary (Multi-way) switch
• Have many conducting
positions.
• Available with a range of
contact arrangements from 1-
pole 12-way to 4-pole 3 way.
Relay
is an electromechanical switch, operated by passing
current through a coil of wire wound around a steel core,
which acts as an electromagnet, pulling the switch contact
down to make or break a circuit.
• The circuit that changes the relay state to on
and off is the Control circuit.

• The circuit that is activated/deactivated with

the switching of the relay is called the
Controlled circuit.
• A small current is passed though the coil which
generates a magnetic field and pulls the armature
down towards the coil. When the armature moves its
contact touches the contact of the controlled circuit.
This creates a closed circuit.
• Sample set-up of
relay
• Load side

• Control side
1. Electromagnet- consists of iron core wounded by coil
of wires. As electricity is passes through it becomes
magnetic therefore it is called as electromagnet.

2. Armature- a movable magnetic strip in which a

current flows through them, it energizes the coil and
produce magnetic field which is used to make or break
the normally open (N/O) or normally close (N/C) points.
3. Spring - When no current flow through coil
electromagnet, the spring pulls the armature away so
that circuit cannot be completed.

4. Set of electrical contacts- the contacts that makes or

breaks a circuit.

5. Molded frame- a covering of plastic or glass so that

we can observe the relay working without opening or
removing its cover.
• The Normally Closed set
of contacts are in contact
with the contact on the
armature when the relay is
not activated.

• The Normally Open

contacts are not in contact
with the armature when the
relay is not activated.
1. Single Pole Single Throw (SPST)- these types of relay comprise
of 4 terminals. Two terminals are used as coil points and other two
can be used to connect or disconnect the circuit (A and B).
2. Single Pole Double Throw (SPDT)- these types of relay
comprise of 5 terminals two for coil one for common terminal(C) and
rest two can be connected to the common terminal.
3. Double Pole Single Throw (DPST)- these types of
relay comprise of 6 terminal two for coil and other four for
connecting and disconnecting two device. In other words it contains
two SPST relay in one package.
4.DoublePole Double Throw (DPDT)- these types of relay
comprise of 8 terminal two for coil and another two as common point
and rest for connecting and disconnecting devices. In another words
in this two SPDT relay are connected in one package
5 Pin Relay
4 Pin Relay
• Used to check open and closed connections for relays.
• Davim, J. Paulo (2011) Mechatronics Wiley c2011
• De Silva, Clarence W. (2010) Mechatronics CRC
Press c2010
• Preumont, A. (2010) Mechatronics Springer c2010
• Nagrath, I. J. (2008) Control Systems Engineering
Anshan c2008
• Alciatore, David G. (2004) Introduction to
Mechatronics and Measurement Systems: McGraw-
Hill
 ME0035
TECHNICAL ELECTIVE 1
(MECHATRONICS)

ELECTRIC
ACTUATION SYSTEM:
ELECTRIC MOTOR
 CHAPTER 5

OBJECTIVES

■At the end of the chapter, the learner should be able to:
–Identify the different classification and application of electric
motors;
–Understand the working principle of electric motors; and
–Understand the electric motor’s nameplate
Electric Motors
A device that converts electrical power to mechanical
power
• The first U.S. patent for a motor was issued to
Thomas Davenport in 1837.

• In 1888, Nikola Tesla patented the first AC

poly-phase motor.
Motors make things move
• Fans, Blowers
• Pumps, Compressors
• Grinders, Chippers
• Conveyors, Shredders
• Crushers, Mixers
• Cranes, Extruders
• Refiners, Chillers
Low power demand on start
Controlled acceleration
Adjustable operational speed
Controlled starting current
Adjustable torque limit
Reduced power line disturbances
Synchronous
Rotation of the rotor is synchronized with the frequency
of the supply current and the speed remains constant
under varying loads.
Ideal for driving equipment at a constant speed and are
Ideal
used in high precision positioning devices like robots,
instrumentation, machines and process control
Induction (Asynchronous)
Uses electromagnetic induction from the magnetic field
of the stator winding to produce an electric current in the
rotor and Torque.
These are the most common type of AC motor and
These
important in industry due to their load capacity.
Single-Phase induction motors used mainly for smaller
loads, like used in house hold appliances whereas
Three-Phase induction motors are used more in industrial
applications including like compressors, pumps, conveyor
systems and lifting gear.
Easy installation
Speed control over a wide range
Quick Starting, Stopping, Reversing and
Acceleration
High Starting Torque
Linear speed-torque curve
The brush DC motor is driven by directly applying a voltage
to the motor leads.
Current and speed of the motor depends on:
• Voltage applied
• Torque load
At maximum torque limit, the current into the
motor is maximum.

The maximum torque is limited by the current

rating of the motor
At maximum speed limit, the current into the
motor is minimum.

The maximum speed is limited by the supply

voltage of the motor driver.
Series Wound – the field winding is connected in series with rotor
winding and speed control is by varying the supply voltage, however
this type offers poor speed control and as the torque to the motor
increase, then the speed falls. Applications include automotive,
hoists, lifts and cranes as it has a high starting torque.
Shunt Wound – This type has one voltage supply and the field
winding is connected in parallel with the rotor winding and can
deliver increased torque, without a reduction in speed by increasing
the motor current. It has medium level of starting torque with
constant speed, so suitable for applications include lathes, vacuum
cleaners, conveyors & grinders.
Compound Wound – a cumulative of Series and Shunt, where the
polarity of the shunt winding is such that it adds to the series fields.
This type has a high starting torque and run smoothly if the load
varies slightly. Typically for driving compressors, variable-head
centrifugal pumps, rotary presses, circular saws, shearing machines,
elevators and continuous conveyors
Permanent Magnet –rather than electromagnet a permanent
magnet is used and are used in applications where precise control
and low torque, such as in robotics, servo systems.
Mechanically much simpler in design (not having
brushes). The motor controller uses Hall Effect sensors
to detect the rotors position and using this the controller
can accurately control the motor via current in the rotor
coils) to regulate the speed.
The advantages of this technology is the long life,
little maintenance and high efficiency (85-90%)
These types of motors are generally used in speed and
positional control with applications such as fans,
pumps and compressors, where reliability and
ruggedness are required.
1. The rotation angle of the motor is proportional to the
input pulse.
2. The motor has full torque at standstill.
3. Precise positioning and repeatability of movement
since good stepper motors have an accuracy of 3 – 5%
of a step and this error is non cumulative from one step
to the next.
4. Excellent response to starting, stopping and reversing.
5. Very reliable since there are no contact brushes in the
motor. Therefore the life of the motor is simply dependant
on the life of the bearing.
6. The motors response to digital input pulses provides
open-loop control, making the motor simpler and less
costly to control.
7. It is possible to achieve very low speed synchronous
rotation with a load that is directly coupled to the shaft.
8. A wide range of rotational speeds can be realized as
the speed is proportional to the frequency of the input
pulses.
• The International Electrotechnical Commission is
the world’s leading organization that prepares and
publishes International Standards for all electrical,
electronic and related technologies
• National Electrical Manufacturers Association
• The National Electrical Manufacturers Association
(NEMA) represents nearly 350 electrical equipment
and medical imaging manufacturers that make safe,
reliable, and efficient products and systems.
• Nomenclature
• Composition
• Construction
• Dimensions
• Tolerances
• Safety
• Operating characteristics
• Performance
• Ratings
• Testing
• The service for which it is designed
  HP- Horsepower
 The horsepower
figure stamped on
the nameplate is the
horsepower the
motor is rated to
develop when
connected to a circuit
of the voltage,
frequency and
number of phases
specified on the
motor nameplate.
  RPM - Revolutions per
Minute
 The RPM value represents
the approximate speed at
which the motor will run
when properly connected
and delivering its rated
output
Poles Synchronous RPM Typical Nameplate RPM
2 3600 3450
4 1800 1725
6 1200 1140
8 900 850
  Voltage
 The rated voltage
figure on the motor
nameplate refers to
the voltage of the
supply circuit to
which the motor
should be connected,
to produce rated
horsepower and RPM.
  Hz-Frequency
 The frequency figure
on the motor
nameplate describes
the alternating
current system
frequency that must
be applied to the
motor to achieve
rated speed and
horsepower.
  Amps
 The amp figure on
the motor nameplate
represents the
approximate current
draw by the motor
when developing
rated horsepower on
a circuit of the
voltage and
frequency specified
on the nameplate.
  NEMA Design
 The NEMA Design
rating specifies the
speed torque curve
that will be produced
by the motor.
 NEMA - National Electrical
Manufacturers Association
 Insulation Class
 The insulation class
letter designates the
amount of allowable
temperature rise
based on the
insulation system
and the motor
service factor.
 Most common insulation classes are class B and F

Insulation Class Ambient Temp. Temp. Rise Total Temp.

A 40oC 65oC 105oC
B 40oC 90oC 130oC
F 40oC 115oC 155oC
H 40oC 140oC 180oC
  S.F. - Service Factor
 The number by which the
horsepower rating is multiplied
to determine the maximum
safe load that a motor may be
expected to carry continuously
 Example - a 10HP motor with
a
service factor of 1.15 will
deliver 11.5 horsepower
continuously without
exceeding
the allowable temperature rise
of its insulation class
  Frame
 The frame designation
refers to the physical
size of the motor as
well as certain
construction features
such as the shaft and
mounting dimensions.
Thermal Overload
• Process Caused (Excessive load)
• High Ambient Conditions (Hot, Blocked Ventilation)
• Power Supply Issues (Voltage/Current Unbalance, Harmonics)
Phase Fault
Ground Fault
Abnormal Operating Conditions
• Over & Under Voltage
• Underfrequency
• Below Voltage/Frequency Ratio (<7.0)
• Voltage and Current Unbalance
• Load Loss
• Jogging
• Davim, J. Paulo (2011) Mechatronics Wiley c2011
• De Silva, Clarence W. (2010) Mechatronics CRC
Press c2010
• Preumont, A. (2010) Mechatronics Springer c2010
• Nagrath, I. J. (2008) Control Systems Engineering
Anshan c2008
• Alciatore, David G. (2004) Introduction to
Mechatronics and Measurement Systems: McGraw-
Hill