AC/DC diagram and Operation Electrical

Motor and applications devices:

1. Introduction:
This report offers an in-depth analysis of electrical motor operations and applications. We
explore control devices and diagrams fundamental to industrial automation and safety.

This report provides an overview of different switches in the Electrical Diagram.

The purpose of this report is to analyze the operation and structure of Electrical
devices.
2. Background
Provide 31 chapters for users to broaden their knowledge of operation:
Chapter 3: Manual Starters
Manual starters require direct operator input. In single-phase setups, toggle switches combined with
overload heaters manage motor current, protecting against overload. For 240-volt systems, dual-load
contact starters control both current lines, enhancing control and safety during overloads or emergency
stops.

- Discuss the operation of manual starters:

Manual starters are characterized by the fact that the operator must go
the location of the starter to initiate any change of action.
Single-phase:
Fractional Horsepower single-phase starters:
Simple toggle with the addition of an overload heater, the toggle switch lever is
mounted on the front of the starter and is used to control the on and off the
operation of the motor.
When the current flows, the heater produces heat in proportion to the amount of
motor current. If the heater is sized correctly, it never get hot enough to open the
circuit under normal operating conditions.
If the motor should be overload, it causes a mechanical mechanism to trip and open
the switch contacts, disconnecting the motor from power line.
The starter shown in this example has only one line contact and is generally used to
protect single-phase motors intended to operate on 120 volts.
 - Starters operate on 240 volts contain two load contacts:
1. Enhance motor control:
- With two load contacts, the starter can control both the positive and
negative (or live and neutral) lines of the motor, allowing for more
comprehensive control over its operation. This setup enables the motor to
be stopped more effectively in the event of an overload or emergency
stop.
2. Improved current flow management:
- Controlling both load contacts and helps balance the current flow across
phases in 3-phase motors or improve the stability of single-phase by
disconnecting both conductors.
Manual starters of this type are intended to control fraction horsepower motors
only. Motor of 1 horsepower or less are considered fractional horsepower(động
cơ cỡ nhỏ).
Automatic Operation
Line-voltage thermostat is used to control the operation of a blower motor. When
the temperature rises or drop, the thermostat contact opens or turns off for
maintaining the temperature of diagram.

AC blower motor

Amber pilot light:

Pump operation: APL signal that a pump is running, helping operators confirm
active water circulation or pressure.
Warning or Fault Condition
Valve or Flow Status: Showing that valve is open => giving a clear visual
indicator for system flow status.
Automatic starters:
- Automation and High Efficiency
- Safety and Equipment Protection
- Wide Industrial Application:

-
Chapter 4: Overload Relays
Thermal overload relays protect motors using bimetallic strips to detect excessive current, commonly
found in simpler systems. Magnetic and electronic relays allow quick response, with digital compatibility
making them ideal for complex systems.

1. Thermal Overload Relay:

These are widely used for standard motor protection. They work by using a
bimetallic strip that bends when heated by excessive current, triggering the
relay to cut off the motor. They are effective for gradual overloads and
commonly found in smaller, less complex systems where thermal sensitivity is
needed.
2. Magnetic/Electronic Overload Relay:
Magnetic overload relays use electromagnetic coils or electric sensors to detect
overloads instantly.
Applications: Adjustable settings, compatibility with smart systems but are
generally replaced by electronic options due to their limited compatibility with
digital control systems.
Chapter 7, 8, 9: Timing Relays
Timing relays, used in industrial automation, provide precision with adjustable time settings. Common
applications include conveyor belt sequencing and robotic task coordination, ensuring smooth operation
across complex workflows.

- Timing relays: applying for various type in industrial automation

control.
- Features: Commonly reliability and precision, with adjustable time
ranges and multi-function options. Allowing them to handle of tasks in a
single device.
- Applications: Using in control systems to manage timed operations like
automated motor control, synchronized tasks in robotic movements.
General classifications:
o The on-delay relay:
Beginning time once an initial signal is applied, allowing the relay
to switch only after a preset delay has elapsed. Relays help regulate
the timing of conveyor belt operations, ensuring each section
activates sequentially to avoid system strain.
When power is connected to the coil of an on-relay timer, the
contacts delay changing position for some period of time. The
contacts remain in the open position for 10 second and then close.
o The off-delay relay:

Initiate their delay once the initial control signal is removed,

maintaining the relay's active until the set time has passed. Again
assume that the timer has been set for a delay of 10 seconds, and also
assume that the contact is normally open. When the power, or current
is applied to the coil of the off-delay timer, the contact changes
immediately from open to closed.
Applications: In robotics, off delay relays can maintain power to
actuators(a part of device helps it to achieve physical movements
by converting energy, often electrical, air, or hydraulic into
mechanical force ) and sensors after task completion, response time
that can be essential for system stability and user safety.
Pneumatic timers: by adjusting this valve or screw, the user can
increase or decrease the air passage, thus controlling the day time.
Allowing a slower airflow means the delay will be longer since it
takes more time for the air to fill the chamber. Otherwise, it can also
be affected by the inlet air pressure, and commonly to test and
calibrate the timing mechanism for accurating alignment of the delay
 setting with real-world performance.

Electric timers:
Using solid-state(Mạch ngắn)components to provide the time delay desired in
different various fields.

RC Oscillators are simpler

and suitable for applications with less strict accuracy requirements, while Crystal
Oscillators offer high precision and stability, making them for applications that
demand highly accurate timing.

Chapter 10: Flow Switches and Sensors

Flow switches ensure proper fluid or air flow, essential for motor cooling and safety. In case of irregular
flow, they signal a shutdown to prevent motor damage. Transducers and sensors further monitor air or
liquid flow rates, optimizing system safety.

1. Flow Switches:

Used to detect the movement or absence of air, liquid flow. Maintaining the
operational safety and process control.
In motor cooling systems, flow switches confirm that coolant is flowing
correctly, and it flow is interrupted, they signal to shut down the motor to
prevent overheating.
Transducer: Detecting the amount of liquid, or airflow.

2.Sensors:

3.Air switches:
Typically using a vane, paddle, or pressure-sensing mechanism to detect the
presence or absence of air movement. When airflow falls below or exceeds a
set threshold, the switch either opens or closes, signaling the control of system
or triggering an action, like stopping equipment or sending an alert(báo nguy)
Chapter 15:Hall generator(Bộ xung phát hall)
Hall effect sensors:

Principles of Operation:
 A constant current of power supply is connected to opposite sides of a piece
of semi-conductor material with a sensitive voltmeter is connected to the other 2
sides.
If the current flows straight through the semiconductor material, no voltage
is produced across the voltmeter connection.

Voltage output: outputs a voltage proportional to the magnetic field strength and
the number of magnetic poles on the disk , allowing it to detect the proximity,
speed, or rotation of magnetic field (Motor speed Sensor).

Common Applications:
- Motor control
 - Automotive sensors: Hall Generators detect wheel speed, crankshaft
position (vị trí trục cơ)

- Camshaft position (trục cam).

- Current Sensing
- Proximity and Motion Detection
- Consumer Electronics: Allowing power-saving and safety features to
active.
Adv:
- Contactless Sensing: No mechanical wear, ensuring longevity
 - High precision: Sensitive to small changes in magnetic field, Precising
position and speed detection.
- Reliability in harsh environments: Aerospace Applications(aircraft
control systems), renewable energy(wind turbine is ensured and safe
operation of turbines in extreme weather conditions, including high
winds, rain, and snow.)
Chapter 11: Limit Switches
Limit switches control the position of moving parts in automated systems, enhancing safety and
precision. Micro and subminiature switches, suitable for compact setups, provide reliable control in
space-constrained applications such as robotics and portable devices.

Abstract:
- Limit switches are essential electromechanical devices in various
industrial applications to monitor, and control the position of moving
parts.
Introduction
- Limit switches serve a critical role in ensuring safety and precision in
automated systems. They are designed to monitor and control the
position of moving parts with bumper arms.

- Among the various types of limit switches, micro switches, and

subminiature switches are particularly noteworthy for their compact size
and sensitivity, making them suitable for space-constrained applications.
- Operational Principles
- Limit switches: operate based on a simple mechanism: when a moving
object, such as a platform, reaches a predetermined position, it activates
 the switch via a mechanical actuator. The actuator can take various
forms, including levers, rollers, or plungers, which physically interact
with the moving part. Upon activation, the limit switch sends an
electrical signal to the control system, indicating that the desired position
has been reached. This action typically leads to the stopping or reversing
of the platform's movement, thereby preventing over-travel or potential
mechanical damage.

Micro switches: Used in applications where space is limited, yet precise

control is required. It can switch electrical loads in response to minimal
actuator movement.

Subminiature micro switches: Providing similar functionalities in an

ultra-compact form factor. They’re particularly advantageous in
applications such as portable devices, robotics, and precision instruments.

Chapter 18: Basic Control Circuits

Two-Wire Circuits: Basic on/off control ideal for simple automated systems.
Three-Wire Circuits: Offers higher safety with both manual and automated stops, used in machinery
needing precise control, like robotics.

Two-wire control circuit:

 - A single input switch(float switch, pressure sensor, or basic off/on
switch)
- Direct control of the motor: When the switch is closed -> motor starts
Control the operation of three-phase motors by controlling the power applied to the
motor starter coil.

Three-wire control circuit:

- Start button
- Stop button
- Auxiliary relay or contactor

Advantages and Limitations

 Advantages:
o High safety: Offers both manual and automated stopping mechanisms.
o Reliability: Self-holding contactors provide stable operation without
continuous operator input.
 Limitations:
o More wiring complexity and space requirements than 2-wire circuits.
o Additional components (e.g., relays and holding contacts) increase
system cost.
Comparison in BOSCH and ABB Factories
3-Wire Circuits: Preferred for high-precision, safety-critical machinery, such as robotics.
2-Wire Circuits: Used in automated workflows like feeders and lighting, where simplicity is an
advantage.

 3-Wire Circuits are preferred for safety-critical machinery and high-

precision operations requiring controlled stops. These include large
automated systems, robotics, and processing machinery where manual
intervention may be needed at times.
 2-Wire Circuits are widely used in automated workflows where simple
start/stop functionality is sufficient. For example, automated feeders and
lighting systems benefit from their simplicity, where continuous human
monitoring is unnecessary.

Applications in Water Systems

3-Wire Circuits: Used for critical water pumps requiring manual stop for
emergencies.
2-Wire Circuits: Common in float-activated pumps, enabling automatic
control based on water levels, ideal for unattended operation.

In water system control, such as in treatment plants, irrigation, or cooling systems,

both types of control circuits are applied according to specific operational needs:

 3-Wire Circuits: Ideal for critical water pump control where the pump’s
operation must be manually stopped in emergencies to prevent flooding or
contamination.
 2-Wire Circuits: Common in float or pressure-activated pumps that need
automatic operation based on water level changes. These circuits simplify
the setup and allow unattended operation.

Chapter 16: