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Direct Acting Solenoid – How it works? Applications

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What is Direct Acting ?

Direct Acting Solenoid Valve Components

 

Direct Acting Solenoid Valve Working - Animation


Direct acting means that valves uses a power supply to open and close.

Power is transformed into magnetic force,in a plunger type valve,forces a plunger to move and open or close the valve seats.

Other direct acting valve operate without a plunger but with same principle of direct power application to move.

Direct Acting Valves are for smaller flow rate.

Higher flow rates have stronger fluid pressure,with valves requiring more power to open or close. Direct acting valves are not feasible for high flow rates.

Many different direct acting valve materials,types,function and sizes exist.But all use direct application of power to open or close.

Construction of Direct Acting Valve  

Internal Architecture of Direct Acting Solenoid Valve


All solenoid valves are designed using tightly coiled copper wire to create a magnetic field.

The forces generated by this field pushes or pulls a piston up and down.

Direct acting solenoid valves are designed to fast switching,with direct application of power.

In this way the valves used applied power directly and is therefore called a direct acting valve.

Applications of Direct Acting Solenoid Valve 

Direct acting 3/2 valves are often used as a pilot valve for linear valve,Spring return rotary valve,pneumatic cylinders.

Ideal for controlling gases – 

DOL (Direct Online) Starter Working Animation

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ELECTRICAL MOTOR DOL STARTER WORKING – ANIMATION

DOL Starter Physical Structure



DOL Starter Working Animation - Electrical Motor Starting


Following States of DOL operation are shown in the animation

1.Starter at normal operation
2.Starting
3.Motor at overload condition
4.Normal Running
5.Stop

DOL is used to start electric motors.

Many types of electric motor starter is available.DOL is one of the simplest starter. It is composed of electrical circuit and electro-mechanical parts to start and stop an electric motor.

A DOL starter connects the motor terminals directly to the power supply. Hence the motor is subjected to the full voltage of power supply. Consequently,higher starting current flows through motor.

DOL starter is suitable for small motors below 5 hp.

The control circuit is typically run at 220v or 100v or 24 v with the aid transformer.




What is Thermocouple Gauge ?

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Thermocouple Gauge 

Thermocouple gauge is a device used to measure low vacuum.

Working of a Thermocouple Gauge

In Thermocouple Gauge a filament is heated by passing constant current through it.When gas molecule interact with filament heat is carried away.Therefor the temperature is directly depended on the pressure in the chamber.The higher the pressure the more molecule interact with the filament and more heat is taken from it.The temperature change in the system is monitored with the help of a thermocouple where the generated voltage is depend on the temperature of the filament. When the filament loses heat by interacting with gas molecules,the change of voltage in thermocouple is detected with the help of a volt meter. Therefor the measured voltage can be easily converted into pressure units.

Thermocouple Gauge Working – Animation 

How thermocouple gauge works - Animation


What is Pirani Gauge ? Advantages,Disadvantages and Application of Pirani Gauge

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Pirani Gauge

Pirani gauge is a device used to measure low vacuum in a pressure range from 0.5 Torr to 10?4 Torr.

Pirani Gauge Internal Structure


Working Principle and Construction of Pirani gauge 

Pirani Gauge Working Principle


Pirani gauge consist of two tungsten filaments,a power source and a volt meter or ammeter.One of the filaments is placed to gauge tube and is exposed to the environment where the pressure is measured.The other filament is placed in sealed reference tube filled with gas constant pressure.The filaments are heated up by passing current through them.As the gas molecules interact with the filament heat is carried away.The higher the pressure the more interaction with gas molecules and more heat is taken from the filament. The electrical resistance of the filament depends on the filaments temperature.Therefor the filaments electrical resistance depends on the pressure in the chamber.

The electrical resistance is measured by following the ohms law.It can be done in two ways.
Either keep the current constant and measure voltage or keep voltage constant and measure the current.

V=I/R – Ohms Law

How Pirani Gauge work – Animation

how pirani gauge works - animation


Application of Pirani Gauge

Low Vacuum Pressure measurement 

Advantages of Pirani Gauge 

Pirani gauge is often preferred over thermocouple gauge because it is 10 times faster and wider range of pressure can be measured.
Inexpensive
Rugged
Response to pressure change is good.
Pressure and resistance relation is linear for the range of use.
Reading can be taken remotely.

Disadvantages of Pirani Gauge  

Frequent Calibration is required
Electric power is must for operation 



Basics of Conductivity Measurement

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Introduction to Conductivity Measurement 

The term Conductance refers to the readiness of materials to carry an electric current. Liquids which carry an electric current are generally referred to as electrolytic conductors. The flow of current through electrolytic conductors is accomplished by the movement of electric charges (positive and negative ions) when the liquid is under the influence of an electrical field. The conductance of a liquid can be defined by its electrical properties – the ratio of current to voltage between any two points within the liquid. As the two points move closer together or further apart, this value changes. To have useful meaning for analytical purposes, a dimension needs to be given to the measurement; i.e., the physical parameters of the measurement.


By defining the physical parameters of the measurement, a standard measure is created. This standard measure is referred to as specific conductance or conductivity.
It is defined as the reciprocal of the resistance in ohms, measured between the opposing faces of 1 cm cube of liquid at a specific temperature.
The units used to define conductance are:
1/ohm = 1 mho = 1000 mS = 1,000,000 uS.
S.I. units may be used in place of mhos;
1 mho = 1 Siemen (S).
Conductivity units are expressed as
µS/cm (1.0 dS/m = 1. 0 µS/cm) or mS/cm.

What is Conductivity ?

What is conductivity


Conductivity is the ability of a material to conduct electric current. The principle by which instruments measure conductivity is simple – two plates are placed in the sample, a potential is applied across the plates (normally a sine wave voltage), and the current is measured.  Conductivity (G), the inverse of resistivity (R) is determined from the voltage and current values according to Ohm’s law.

G = I/R = I (amps) / E (volts)


Principle of Measurement : 
Conductivity Measurement Principle


An electrolyte solution contains positive ions, each of which has a positive electrical charge, and negative ions, each of which have has a negative electrical charge. As illustrated in Fig. (A), a pair of metal plates placed at opposites sides in an electrolyte solution, and a battery is connected. The positive ions move toward the plate connected to the negative terminal of the battery, and the negative ions move toward the plate connected to the positive terminal of the battery, and thus electric current flows through the solution. When a voltage is applied, the ions move straight toward the respective oppositely charged metal plates, as illustrated in Fig. (B). Since conductivity is inversely proportional to resistance, the conductivity can be known if the resistance is measured as per the  Ohm’s law.

The voltage (E) of the battery being constant, the conductivity (k) and the current (I) are proportional; therefore, the conductivity can be obtained if  the current is measured. 

Therefore 
Conductivity K = 1 / Resistance(R) * Length(L) / Area(S)

As per the ohm’s law Resistance(R) = Voltage(E) / Current(I)
Substituting for R

We get 
Conductivity K = Current(I)  / Voltage(E) * Length(L) / Area(S)

Conductivity Measurement :

Conductivity measures the ability of a solution to conduct an electric current between two electrodes. In solution, the current flows by ion transport. Therefore, with an increasing amount of ions present in the liquid, the liquid will have a higher conductivity. If the number of ions in the liquid is very small, the solution will be “resistive” to current flow. AC current is used to prevent complete ion migration to the two electrodes.

The charge on ions in solution facilities the conductance of electrical current, the conductivity of a solution is proportional to its ion concentration. In some situations, however, conductivity may not correlate directly to concentration. The graphs above  illustrate the relationship between conductivity and ion concentration for two common solutions. Notice that the graph is linear for sodium chloride solution, but not for highly concentrated sulfuric acid. Ionic interactions can alter the linear relationship between conductivity and concentration in some highly concentrated solutions.

Conductivity Cell: 

A conductivity measuring cell is formed by two 1-cm square surfaces spaced 1-cm apart. Cells of different physical configuration are characterized by their cell constant, K. The flow of current through conductors is accomplished by the movement of electric charges (positive and negative ions) when the liquid is under the influence of an electrical field. 

This cell constant (K) is a function of the electrode areas, the distance between the electrodes and the electrical field pattern between the electrodes. 

Often, for considerations having to do with sample volume or space, a cell’s physical configuration is designed differently. Cells with constants of 1.0 cm-1 or greater normally have small, widely spaced electrodes. Cells with constants of K = 0. 1 or less normally have large closely spaced electrodes. Since K (cell constant) is a “factor”which reflects a particular cell’s physical configuration, it must be multiplied by the observed conductance to obtain the actual conductivity reading. 

For example, for an observed conductance reading of 200 µS using a cell with K = 0. 1, the conductivity value is 200 x 0. 1 = 20 µS/cm. 

The cell constant is defined as the ratio of the distance between the electrodes, d, to the electrode area, A. This however neglects the existence of a fringe-field effect, which affects the electrode area by the amount AR. Therefore K = d/(A + AR). Because it is normally impossible to measure the fringe-field effect and the amount of AR to calculate the cell constant, K, the actual K of a specific cell is determined by a comparison measurement of a standard solution of known electrolytic conductivity. 
The most commonly used standard solution for calibration is 0.01 M KCl. This solution has a conductivity of 1412 µS/cm at 25oC 

The Effect of Temperature   

The conductivity of a solution with a specific electrolyte concentration will change with a change in temperature. The temperature compensated conductivity of a solution is the conductivity which that solution exhibits at the reference temperature. This temperature is chosen to be either 25oC or 20oC. A measurement made at reference temperature, therefore, needs no compensation. Generally for most aqueous samples, a coefficient of 2.1 % per degree Celcius is used in temperature compensation, with the apparent value being 2.1 % high for each degree C above 25oC or conversely the apparent value being 2.1 % low for each temperature for measurement is 25oC. A useful algorithm for temperature correction is: 

CT = C25 [1 + 0.021 (T – 25)]   

Where CT = the measured conductivity of a solution at sample temperature; C25 = the conductivity of the solution at 25oC and T = the sample temperature(oC).  
Many conductivity meters today automatically compensates for temperature if the conductivity probe includes a Thermistor. However, as will be explained later, this can be a major source of error in analysis if the Thermistor is not accurate or if the instrument is improperly calibrated.  
Note the two following examples to explain the effect and compensation of the fringe-field effect and temperature. 

Basics of Load Cell

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What is a Load Cell?

Load cell is a device that converts force in to an electrical signal.A load sensor is a sensor or a transducer that converts a load or force acting on it into an electronic signal.This electronic signal can be a voltage change,current change or frequency change depending on the type of load cell and circuitry used.

Load cells or Load sensors as they are commonly commonly called can be made using resistive,capacitive,inductive or other techniques.Most commonly available load cells are based on the principle of change of resistance in response to an applied load.  

Load cell is designed to measure tension,compression or both.

No moving parts are present in load cells.Because of that no wear and tear between main components.

Types of Load Cells

Load Cell Types


S-Type
Button
Canister
Shear
Beam

Working of Load Cells

Working Principle of Load Cell - Wheatstone Bridge


Load cells work on the principle of Wheatstone bridge.Usually at least four strain gauge are configured in a Wheatstone bridge configuration with four separate resistor connected as shown below in what is called Wheatstone bridge .

How Wheatstone bridge work?
An excitation voltage usually 10v is applied to one set of corners and the voltage difference is measured between the other two corners.At equilibrium with no applied load,the voltage output is zero or very close to zero when the four resistor are closely matched in value.

Components of Load cell

Components of Load Cell


Connector
Hub
Strain Gauge
Interconnecting Wires
Base
Diaphragm

What is Strain Gauge ? 

How Pressure Switch Works ?

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What is a Pressure Switch ?

A pressure switch turns an electric circuit on or off at a preset pressure.This pressure is referred to as the setpoint of the switch. A bourdon tube,a diaphragm, or a bellows can actuate the switch.

How Pressure Switch Works?

Working of a Pressure Switch


The contacts in a pressure switch may be normally open or normally closed if the pressure is below the setpoint. 

The contacts in a normally open (N.O) switch remain open until the pressure increases above the setpoint.Then the sensing element makes the contact snap to the closed position.The contacts open again when the pressure decreases below the setpoint. 

The contacts in a normally closed (N.C) switch remain closed until the pressure increases above the setpoint.Then the contact snap open and remain open until the pressure decreases below the setpoint position.

Most pressure switches contains two sets of contacts.One normally open and the other normally closed.Thus the switch will work regardless of which kind of contact is needed in a particular installation.  

Internal Architecture of Pressure Switch


Deadband is the difference between the value at which a control action occurs and the value at which at which the control action is cancelled. All pressure instruments have some inherent deadband due to moving parts and free play.Pressure control instrument usually have some provision for deadband adjustment.

Application of Pressure Switch 

One important application of pressure switch is limiting pressure.

How to calibrate a Pressure Switch?

Pressure Switch Calibration

Basics of Electric Motors for Beginners

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Electric Motors 

There are many types of Electric Motors used for a variety of purposes in commercial industry.

Physical Structure of Electric Motor


Motor Direction

One critical task must performed prior to installing a motor is  determining the motors rotational direction.If a motor is required to rotate in a specific direction,it will have a direction arrow prominently displayed on the frame.But with few exception most three phase motors are made with symmetrical parts so the motor can rotate in either direction.Since these multi-directional motors are equally efficient in either direction there is no standard direction of rotation.Therefor when a three phase motor is first connected it may run in either direction and technicians must be careful to install it properly.While the motor itself can run in either direction without harm the components that the motor drives maybe uni directional.For instance running a pump in the wrong direction may cause damage due to caviatation or expulsion of the shaft seal.

If the motors rotation is incorrect for the required application it can be reversed by simply changing their connection to any two of the three power wires.

Electric Motors Direction Changed by reversing wire


While many motors are three phase and easily reversible others are not,for non reversible motors you must be very careful to check and double check that the correct rotation is specified.

Frequency Current Relation

In addition rotation technicians must pay close attention to the frequency and current requirements for a given motor application. Frequency and current is inversely proportional. As the frequency decreases current will increase.Motors are frequency sensitive which means that frequency change can cause speed changes within the motor.If frequency decreases significantly the motor may experience a large increase in current which can cause motor components to overheat.

Electric Motor Frequency Current Relation


Pressure Relief Valve – Working Principle

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Pressure Relief Valve Working Principle

Pressure relief Valve is one of the most important type of safety valve.

This type of valves sets a limit on the rise of pressure within a hydraulic line.In normal operation the valve is closed and no fluid passes through.But if the pressure in the line exceeds the limit the valve opens to relieve the pressure.This protects expensive machinery such as motors,pumps and actuators from becoming damaged from high pressure.

Without a relief valve the pressure can continue to grow until another component fails and pressure is released.

Two Types of Pressure Relief Valves are there.

1.Direct Acting
2.Pilot Operated 

Basics of Differential Flow Meter

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How Differential Flow Meter Works?

The differential flow meter is the most common device for measuring fluid flow through pipes.

Flow rate and pressure differential of fluids such as gases,vapors and liquids are explored using the orifice plate flow meter.

Types of Differential Flow Meter


The differential flow meter venuri tube,flow nozzle or orifice plate is an inline instrument,that is installed between two flanges .

Orifice Flow Meter


The orifice plate is a flow meter which is comprised of a circular metal disk with a specific hole diameter that reduces the fluid flow in the pipe. Pressure taps are added on each side of the orifice plate to measure the pressure to differential. 

According to the loss of conservation of energy the fluid entering to the pipe must equal the mass leaving the pipe during the same period of time.The velocity of fluid leaving the orifice is greater than the velocity of the fluid entering the orifice.

Working Principle of Differential Flow meter


Applying Bernoulli principle the increase fluid velocity results in a decrease in pressure.As the fluid flow rate increases through the pipe,back pressure on the incoming side increases due to the restriction of the flow created by the orifice plate.The pressure of the fluid at the downstream side of the orifice plate is less than the incoming side due to the accelerated flow.With a known differential pressure and velocity of the fluid the volumetric flow rate can be determined. 

The flow rate “Q” of a fluid through an orifice plate increase in proportion to the square root of the pressure difference on each side multiplied by the K factor.Â