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Author: Brian Ribeiro

  • Are there any downsides to using a regenerative blower?

    Are there any downsides to using a regenerative blower?

    Pros:

    • Greater production capacity in comparison to high pressure air: if sized properly, regenerative blowers can produce the volume pressure balance needed for the best possible product flow.
    • Regenerative blowers are generally quieter than continuous-duty blowers (PD blowers). It should be noted, though, that PD blowers can be mounted up to 100 feet away from the bagger outside of the building, up on a roof, or in any other place that won’t annoy operators. Regenerative blowers, on the other hand, usually have to be mounted at the bagger’s location.
    • The ability to mount on board the bagger means that all electrical and pneumatic connections can be pre-wired and plumbinged at the factory, saving money on installation costs. As a result, the plant site’s installation expenses were decreased.

    Cons:

    • Regenerative blowers must be installed on or very near to baggers in order to minimize noise pollution to operators and reduce blower dust and dirt. This will reduce the likelihood of unplanned, costly maintenance.
    • When comparing apples-to-apples air volume output, regenerative blowers usually need more horsepower to produce the same airflow as a smaller PD blower. This results in higher energy consumption and no significant cost savings at purchase (compared to a PD blower).
    • The upstart of a bag filled by a regenerative blower will take a little longer than that of a bag filled on the same machine using a PD blower because regenerative blowers do not build pressure as quickly as PD blowers.

     

     

  • What is the Rangeability and Turndown Ratio of Pressure Transmitters?

    What is the Rangeability and Turndown Ratio of Pressure Transmitters?

    Rangeability and turndown ratio are fundamental attributes of pressure transmitters. Simply put, rangeability refers to the ratio of maximum to minimum pressure that a pressure transmitter can accurately measure. Turndown ratio, often synonymous with rangeability, specifically denotes the maximum capacity a device has over its minimum measurable capability.

    Rangeability, commonly referred to as turndown ratio, is a critical parameter in control systems, especially when dealing with process pressure transmitters. Whether it’s the turndown ratio of a differential pressure transmitter, a gauge pressure transmitter or an absolute pressure transmitter, it’s a simple formula that compares the maximum measurable range of a device to its minimum measurable range.

    This ratio is often expressed as a number such as 3:1, 5:1, or even 100:1, indicating that the sensor is capable of accurately measuring pressures within that span. For example, in a transmitter with a 5:1 turndown ratio, if the maximum pressure (the high end) it can measure is 100 units, then it can accurately measure down to 20 units, which is its low end.

    Let’s dig a little deeper with a few definitions:

    • The Range is the measurement limit and covers from the minimum pressure to the maximum pressure that the pressure transmitter cell can measure, for example from 0 to 100 bar. The maximum measurement span is 100 bar.
    • Upper Range Limit (URL) refers to the highest pressure that the transmitter was designed to measure, respected the cell upper range limit.
    • The Lower Range Limit (LRL)refers to the lowest pressure that the transmitter was designed to measure, respected the cell lower range limit.
    • URV (Upper Range Value) is the maximum pressure at which the pressure transmitter is calibrated. It corresponds to the lowest point of the output scale, such as the 4mA point in a 4 to 20mA output signal.
    • LRV (Lower Range Value) is the minimum pressure at which the pressure transmitter is calibrated. Its corresponds to the lowest point of the output scale, such as the 4mA point in a 4 to 20mA output signal.
    • Span (Calibrated span) is the working range that is equal to URV – LRV. This is the equivalent of the 4 to 20mA output signal.
    • Turndown (TD) or Rangeabilityof a pressure transmitter is calculated by dividing the maximum pressure the device can measure (Upper Range Limit, or URL) by the minimum pressure it can measure accurately (minimum calibrated span).

    The understanding of rangeability and turndown ratio is crucial in various applications where pressure needs to be monitored and controlled. It’s especially important in fluid and gas control systems where accurately measuring and maintaining pressure levels is crucial to the operation’s success.

  • What is an RB-IGBT and how are they used in a UPS?

    What is an RB-IGBT and how are they used in a UPS?

    An RB-IGBT stands for Reverse Blocking Insulated Gate Bipolar Transistor. It is a type of power semiconductor device that combines the simple gate-drive characteristics of MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors) with the high-current and low-saturation-voltage capability of bipolar transistors. The “reverse blocking” capability means that the RB-IGBT can block current flow in both the forward and reverse directions when it is turned off, unlike standard IGBTs which can only block current in the forward direction.

    How RB-IGBTs are Used in UPS Systems

    RB-IGBTs are particularly useful in Uninterruptible Power Supply (UPS) systems for several reasons:

    1. Efficiency and Performance: The efficiency of a UPS is crucial, especially for systems designed to support critical loads over extended periods. RB-IGBTs offer high efficiency and fast switching speeds, which are essential for minimizing energy losses and improving UPS performance. This results in a UPS that can provide clean and stable power with lower operational costs.
    2. Bidirectional Power Flow: The reverse blocking capability of RB-IGBTs allows for more efficient management of bidirectional power flow. This is particularly beneficial in UPS systems that feature energy storage or are integrated with renewable energy sources. For instance, in applications where a UPS is connected to a battery storage system or solar panels, RB-IGBTs can efficiently manage the charging and discharging processes, ensuring optimal power flow from and to the grid.
    3. Size and Weight Reduction: The use of RB-IGBTs can contribute to reducing the size and weight of UPS systems. Their high efficiency and fast switching capabilities allow for the use of smaller cooling systems and transformers, which in turn can lead to a more compact and lightweight UPS design. This is especially advantageous for applications where space is at a premium.
    4. Enhanced Protection: In UPS systems, protecting sensitive loads from power quality issues such as voltage sags, surges, and interruptions is paramount. RB-IGBTs enhance the UPS’s ability to quickly respond to and mitigate these issues, providing superior protection for connected equipment.
    5. Scalability and Flexibility: The incorporation of RB-IGBT technology in UPS systems allows for greater scalability and flexibility. This means that the UPS can be easily scaled up to meet growing power demands without compromising on efficiency or performance.

    In summary, RB-IGBTs play a critical role in modern UPS systems by enhancing efficiency, performance, and reliability. Their unique properties make them ideal for applications requiring high-quality power delivery and protection, contributing to the development of more advanced, efficient, and compact UPS solutions.

  • What is an AC drive?

    What is an AC drive?

    A Variable Frequency Drive (VFD), also known as a Variable Speed Drive (VSD) or Adjustable Frequency Drive (AFD), is an electrical device used to control the speed and torque of an electric motor. It does this by varying the frequency and voltage supplied to the motor, which in turn adjusts the motor’s rotational speed. VFDs are commonly used in industrial and commercial applications where precise control of motor speed is required. Here’s how they work and some of their key features:

    1. Frequency and Voltage Control: VFDs control the frequency and voltage supplied to an AC (Alternating Current) motor. By varying these parameters, they can increase or decrease the motor’s speed and torque. This allows for precise control of the motor’s performance.
    2. Energy Efficiency: One of the primary benefits of using VFDs is energy savings. They can significantly reduce energy consumption by matching the motor’s speed to the actual requirements of the load. When a motor operates at full speed all the time, it often uses more energy than necessary. VFDs enable motors to run at lower speeds when the load is light, saving electricity.
    3. Soft Start and Stop: VFDs can provide a soft start and stop for motors. This gradual acceleration and deceleration help reduce mechanical stress on equipment and improve the lifespan of the motor and connected machinery.
    4. Precise Control: VFDs offer precise control over motor speed. This is crucial in applications where speed and torque must be adjusted for specific processes, such as conveyor systems, pumps, fans, and compressors.
    5. Dynamic Braking: Some VFDs can perform dynamic braking, which converts excess kinetic energy into electrical energy, dissipated as heat. This feature can help stop a motor quickly and safely.
    6. Motor Protection: VFDs often include built-in protection features, such as overload protection, overvoltage protection, and under-voltage protection, which help prevent damage to the motor and connected equipment.
    7. Reduced Wear and Tear: By avoiding sudden starts and stops, VFDs reduce the mechanical wear and tear on motors and associated machinery. This extends the lifespan of these components and reduces maintenance costs.

    Remote Control and Monitoring: Many VFDs can be controlled remotely and integrated into automation systems, allowing for centralized monitoring and control of multiple motors and processes. VFDs are widely used in various industries, including manufacturing, HVAC (Heating, Ventilation, and Air Conditioning), water and wastewater treatment, and transportation, among others. They offer a cost-effective way to improve energy efficiency, process control, and equipment reliability. 

     

  • What is the difference between an IGBT and a MOSFET? 

    What is the difference between an IGBT and a MOSFET? 

    IGBTs (Insulated Gate Bipolar Transistors) and MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors) are both types of semiconductor devices, but they have different characteristics and are suitable for different applications.

    Here are some key differences between IGBTs and MOSFETs:

    1. Type of Device:
      • IGBT: Combines features of both MOSFET and bipolar transistor. It has a voltage-controlled gate like a MOSFET and a bipolar-like current-carrying capability.
      • MOSFET: A voltage-controlled transistor that relies on the voltage applied to the gate to control the flow of current between the source and drain terminals.
    2. Voltage Rating:
      • IGBT: Generally suitable for higher voltage applications (hundreds to thousands of volts).
      • MOSFET: Typically used in lower to medium voltage applications (tens to hundreds of volts).
    3. Current Handling:
      • IGBT: Well-suited for high current applications. It combines the voltage control of a MOSFET with the current-carrying capability of a bipolar transistor.
      • MOSFET: Generally used for lower to moderate current applications.
    4. Switching Speed:
      • IGBT: Slower switching speed compared to MOSFETs. Suitable for applications where switching speed is not the primary concern.
      • MOSFET: Faster switching speed, making them suitable for applications that require high-frequency operation.
    5. Efficiency:
      • IGBT: Lower conduction losses compared to a MOSFET at high voltages and currents. Suitable for high-power applications like motor drives and power inverters.
      • MOSFET: More efficient at low voltages and currents. Often used in applications where efficiency and fast switching are critical, such as power supplies and certain amplifiers.
    6. Applications:
      • IGBT: Commonly used in high-power applications such as motor drives, power inverters, and induction heating systems.
      • MOSFET: Widely used in applications where fast switching and efficiency at lower power levels are crucial, such as voltage regulators and electronic switching circuits.
    7. Gate Drive Requirements:
      • IGBT: Requires a positive voltage on the gate relative to the emitter for turn-on, but the turn-off can be controlled by reducing the gate voltage.
      • MOSFET: Requires a positive voltage on the gate relative to the source for both turn-on and turn-off.

    The choice between IGBTs and MOSFETs depends on the specific requirements of the application, including voltage and current levels, switching frequency, and efficiency considerations. Each device has its advantages and is better suited to different types of electronic circuits and systems.

  • What are manual motor starters?

    What are manual motor starters?

    Manual motor starters are devices used to control the operation of electric motors in industrial settings. They serve several key functions:

    1. Starting and Stopping: As the name suggests, manual motor starters allow for the manual starting and stopping of motors. This is typically done through a switch or a button that an operator can engage or disengage.
    2. Overload Protection: They often incorporate overload protection, which helps to safeguard the motor against potential damage caused by overcurrents. This is usually achieved through thermal or magnetic means. The thermal protection works by detecting excessive current over a period, indicative of an overload condition, while magnetic protection responds to short-circuit conditions.
    3. Short-Circuit Protection: Some manual motor starters may also offer short-circuit protection, although this is often handled by separate devices like fuses or circuit breakers in many installations.
    4. Disconnecting Means: They provide a means of disconnecting the motor from the power source for maintenance or emergency purposes. This feature is crucial for ensuring safety during repairs or when resolving issues with the motor or associated equipment.
    5. Local Control: Manual motor starters allow for local control of a motor, meaning that the start and stop functions can be performed at the motor’s location. This is particularly useful in smaller or simpler systems where centralized control is not necessary or practical.
    6. Adjustable Settings: Many industrial manual motor starters have adjustable settings that allow operators to set overload protection thresholds according to the specific requirements of the motor and the application.
    7. Robust Design: Designed for industrial environments, these starters are typically built to withstand harsh conditions, including dust, moisture, and mechanical vibrations.
    8. Simplicity and Cost-Effectiveness: Manual motor starters are generally simpler and more cost-effective compared to automatic starters or those with more advanced control features. They are well-suited for applications where automatic control is not necessary, or where manual operation provides sufficient control.

    In summary, manual motor starters are fundamental components in motor control, offering basic functionalities such as start/stop control, overload protection, and a means of disconnection for maintenance and safety purposes. They are widely used in various industrial applications due to their simplicity, reliability, and cost-effectiveness.

  • How to communicate through HMI Systems

    How to communicate through HMI Systems

    Human Machine Interfaces (HMIs) play a critical role in efficiently monitoring and controlling control systems, whether they are on a small scale or span multiple geographic locations. Regardless of the system’s scope, effective communication is essential as it ensures transparency, rapid responsiveness, and allows decision-makers to free themselves from a specific physical location. These goals can be achieved through three main approaches:

    Direct Access:
    Modern PCs are equipped with hardware that, when combined with well-designed HMI software, facilitates communication. The simplest and most established method is through an HMI’s web server. The procedure involves connecting the HMI to the internet via an Ethernet connection. The company’s data and functions become accessible through web pages and technologies like the cloud, allowing other mobile devices to access them via simple addresses. While security is a growing concern in open communication, web server technologies such as Apache HTTP and Microsoft IIS adhere to the latest security standards, including SSL and HTTPS security, ensuring user data integrity. User rights can be established to enhance security and reduce misuse of authority. Over-reliance on the internet can, however, lead to operational interruptions in the event of network breakdowns.

    Onsite IT:
    A more expensive but reliable approach involves using onsite IT hardware and software. This option provides more power and flexibility for distributing data across multiple devices but requires specialized hardware and software, along with ongoing maintenance. Multiple HMIs within a plant are connected through Ethernet ports, forming an intranet with all the functionalities of the internet, but on a local level. Information can be accessed in the same way as before through various devices, but with greater security and control. Setting up an internal IT network that extends to all corners of the plant and associated offices is necessary. The intranet should ideally be location-independent and connect all company assets, both enterprise and manufacturing. Security is less of a concern, but the network requires high maintenance and constant service to operate without interruptions.

    The Cloud:
    Cloud technologies can revolutionize the way information flows, allowing devices to interact in a more stable, reliable, and resourceful manner. Multiple redundant connections enable each device to connect to the cloud and access HMI functions through smartphone apps. These apps reflect changes across databases and spreadsheets stored in the cloud, which are subsequently reflected in the industrial hardware in place. Cloud systems offer flexibility, affordability, and high security. Examples include Amazon Web Services and Microsoft Cloud, which employ a high level of virtual and physical security and a range of backup mechanisms to ensure uninterrupted operations even in adverse scenarios. The cloud-based system represents the latest and most viable solution for HMI communications with remote devices. The widespread availability of the internet, including 4G cellular networks, and powerful mobile devices have transformed it into an industrial technology poised to establish itself over the coming decades.

  • Why is fluid flow management becoming increasingly important in the manufacturing industry?

    Why is fluid flow management becoming increasingly important in the manufacturing industry?

    The need for accurate measurement and control of fluids is ubiquitous in manufacturing processes, in research laboratories, during the transformation of raw materials into finished products and during packaging. Continuous measurement, control, and analysis of fluid flow using appropriate measurement technologies improve the reliability, performance, and uptime of industrial processes, as well as environmental sustainability and compliance with standards and regulations.

    Industrial fluid flow measurement and control technologies are well established for applications involving large pipes, but accelerating market trends present a distinct and pressing challenge: measuring flow in small pipes. The move towards faster, smaller, more compact and less expensive machines has increased the need to measure fluid flow in small diameter, densely spaced pipes. Examples include semiconductors, pharmaceuticals, biopharmaceuticals and life sciences, food processing, heating, ventilation and air conditioning, and any high-purity water application. Applications in small pipes and confined spaces require a new method of measuring and metering, and not just in terms of size. Manufacturers are looking for accurate, efficient and cost-effective technology that offers ease of use, low or no installation costs, reliable data and low energy consumption.

  • What is the difference between single-phase and three-phase drives?

    What is the difference between single-phase and three-phase drives?

    A Variable Frequency Drive (VFD), also known as a Variable Speed Drive (VSD) or Adjustable Frequency Drive (AFD), is an electrical device used to control the speed and torque of an electric motor. It does this by varying the frequency and voltage supplied to the motor, which in turn adjusts the motor’s rotational speed. VFDs are commonly used in industrial and commercial applications where precise control of motor speed is required. Here’s how they work and some of their key features:

    1. Frequency and Voltage Control: VFDs control the frequency and voltage supplied to an AC (Alternating Current) motor. By varying these parameters, they can increase or decrease the motor’s speed and torque. This allows for precise control of the motor’s performance.
    2. Energy Efficiency: One of the primary benefits of using VFDs is energy savings. They can significantly reduce energy consumption by matching the motor’s speed to the actual requirements of the load. When a motor operates at full speed all the time, it often uses more energy than necessary. VFDs enable motors to run at lower speeds when the load is light, saving electricity.
    3. Soft Start and Stop: VFDs can provide a soft start and stop for motors. This gradual acceleration and deceleration help reduce mechanical stress on equipment and improve the lifespan of the motor and connected machinery.
    4. Precise Control: VFDs offer precise control over motor speed. This is crucial in applications where speed and torque must be adjusted for specific processes, such as conveyor systems, pumps, fans, and compressors.
    5. Dynamic Braking: Some VFDs can perform dynamic braking, which converts excess kinetic energy into electrical energy, dissipated as heat. This feature can help stop a motor quickly and safely.
    6. Motor Protection: VFDs often include built-in protection features, such as overload protection, overvoltage protection, and under-voltage protection, which help prevent damage to the motor and connected equipment.
    7. Reduced Wear and Tear: By avoiding sudden starts and stops, VFDs reduce the mechanical wear and tear on motors and associated machinery. This extends the lifespan of these components and reduces maintenance costs.

    Remote Control and Monitoring: Many VFDs can be controlled remotely and integrated into automation systems, allowing for centralized monitoring and control of multiple motors and processes. VFDs are widely used in various industries, including manufacturing, HVAC (Heating, Ventilation, and Air Conditioning), water and wastewater treatment, and transportation, among others. They offer a cost-effective way to improve energy efficiency, process control, and equipment reliability.

    Single-phase and three-phase AC drives are electrical systems used to control the speed and torque of AC (alternating current) motors. The primary difference between the two lies in the number of phases of the AC power supply they use and the motors they can drive.

    Single-Phase AC Drives:

    • Single-phase AC drives are designed to operate with a single-phase AC power supply, typically 120V or 230V in residential and light commercial applications.
    • They are commonly used for smaller loads, such as household appliances (e.g., fans, pumps, and some small machinery).
    • Single-phase motors have only one winding in the stator, which makes them less efficient for some applications and generally not suitable for high-power or industrial use.
    • Single-phase AC drives are less complex and generally more cost-effective for lower-power applications.

    Three-Phase AC Drives:

    • Three-phase AC drives are designed to work with a three-phase AC power supply, which is the standard in industrial and commercial settings.
    • They are used for a wide range of applications, from small motors to very high-power industrial machines.
    • Three-phase motors have three windings in the stator, which provides smoother operation and better performance, making them more efficient and suitable for high-torque and high-power applications.
    • Three-phase AC drives can provide more precise control over motor speed, torque, and direction and are commonly used in industrial automation and manufacturing.

    In summary, the main difference between single-phase and three-phase AC drives is the number of phases in the AC power supply they are designed for and the types of motors they can drive. Single-phase drives are typically used for smaller, low-power applications, while three-phase drives are used in a wide range of industrial and high-power settings.

     

  • The Evolution of HMI Systems

    The Evolution of HMI Systems

    The evolution of Human Machine Interfaces (HMIs) has unfolded over decades, influenced and propelled by emerging technologies in electronics, telecommunication, and power engineering. Over the past 30 years, HMIs have served communication and control purposes, adapting to evolving technology.

    1980’s
    In the 1980s, process flow diagrams dominated monitoring processes, with large walls dedicated to such diagrams, adorned with gauges, indicators, and switches for a realistic representation of industrial processes.

    1990’s
    In the mid-1990s, PLC manufacturers gained ground, utilizing proprietary Operator Interface Terminals for control. The mid-1990s saw the introduction of PCs to manufacturing, necessitating a real-time Operating System. With the advent of Windows OS, Distributed Control Systems migrated to PCs. Platform-independent software was introduced, shifting HMI towards a software-centric technology. Simultaneously, ethernet revolutionized connectivity, transcending previous boundaries.

    2000’s
    In the early 2000s, HMIs capable of operating in hazardous areas were developed. Distributed control systems focused on HMI software and PC hardware. Touchscreens became prevalent in industrial technology, offering ease of use and reducing reliance on keyboards and mice.

    2010-Present
    The continual rise of new technologies ensures ongoing evolution in HMIs. Regardless of their future form, these devices will remain vital on the plant floor. The entry of multitouch video technologies, like tablets and smartphones, has once again transformed the role and scope of HMIs. Manufacturers now explore HMIs dependent on cross-platform technologies, such as HTML5, with Cloud Computing Servers at the backend, enabling access, monitoring, and control from any global location.