Author: Ken Cheng

Understanding low, medium, and high voltage is considered to be crucial knowledge in industrial automation.  Not only does this knowledge facilitate a safer environment, but also promotes efficiency and functionality within the working systems.  Here is a breakdown that covers the differences in voltages, the safety aspect, and how knowing about them proves important in the field of industrial automation.

Read more: High Medium Low Voltage

What is Voltage?

Voltage refers to the force that moves electric charges through a conductor. It’s a fundamental aspect of electrical systems, crucial for powering devices and transmitting electricity across various distances. Industries categorize voltage levels into high, medium, and low. Industries base this on their magnitude and the applications they serve.

Low Voltage

Generally, low voltage refers to voltages below 1000 volts (V). Common examples include household outlets in many countries operating at 120V or 230V. Additionally, low-voltage systems might involve voltages as low as 12V or 24V used in electronics, small appliances, and LED lighting.  

Low-voltage systems are prevalent in everyday devices and smaller-scale electrical applications. They power household electronics, chargers, small motors, and many portable devices. Low voltage remains relatively safe for direct human contact. Furthermore, it remains widely used in residential, commercial, and industrial settings due to its lower risk of electrical hazards.

While low voltage is generally safer to handle, improper handling or faulty wiring can still pose risks of electrical shock or fire hazards, necessitating proper installation and adherence to safety standards.

Medium Voltage

Medium voltage typically ranges from 1000 volts to 35,000 volts. This level of voltage is commonly used in industrial settings, power distribution systems, and larger facilities.

It plays a crucial role in power distribution. They transport electricity from power stations to transformers, which then step down the voltage for use in commercial and residential areas. Medium voltage powers heavy machinery, large motors, and equipment in industries, hospitals, data centers, and universities.

Medium-voltage systems require specialized equipment and trained personnel for installation, maintenance, and operation due to increased risks of electrical accidents. Safety protocols, protective gear, and comprehensive training are essential for handling and working with medium-voltage systems.

High Voltage

High voltage refers to voltages exceeding 35,000 volts and can extend to extremely high levels used in power transmission lines, reaching hundreds of kilovolts (kV) or even megavolts (MV) in some cases.

High-voltage systems primarily serve the transmission of electricity over long distances. Power generated at plants is stepped up to very high voltages for efficient transmission across power lines. High-voltage systems are crucial for delivering electricity from power plants to substations, where it is then stepped down to medium or low voltage for distribution to end-users.

Working with high-voltage systems requires rigorous safety measures, specialized equipment, and highly trained personnel. The risks associated with high-voltage systems are significantly higher, including severe electrical shock, arc flashes, and other potentially fatal accidents.

Reasons to Know the Difference

Workplace Safety

In industrial or commercial settings, where medium or high voltage systems are common, employees must be well-versed in safety protocols specific to each voltage level. Proper training, understanding of safety procedures, and equipment usage reduce the risk of accidents, ensuring a safer work environment

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Efficiency and Integrity

Each voltage level serves specific purposes within an electrical system. Low voltage is suitable for smaller-scale applications, while medium voltage is crucial for efficient power distribution across larger areas. High voltage is indispensable for long-distance power transmission. Understanding these distinctions ensures that the right voltage is used for the intended application, optimizing efficiency.

Mismatching voltage levels or using incorrect equipment can compromise the integrity of electrical systems. Understanding the correct voltage requirements helps prevent equipment damage, system failures, and electrical fires, ensuring the longevity and reliability of the electrical infrastructure.

Compliance and Standards

Proficiency in handling different voltage levels is often a prerequisite for certifications and licensing in electrical work. Electricians, engineers, and technicians must demonstrate knowledge and competence in dealing with specific voltage levels to obtain the necessary credentials.

Emergencies

During emergencies such as electrical faults, fires, or accidents involving electrical systems, responders need to quickly identify and manage the voltage level involved. Knowledge about the voltage level enables them to take appropriate actions to mitigate risks and ensure a safe resolution of the situation.

Conclusion

In essence, knowledge of the differences between high, medium, and low voltage levels is foundational for maintaining safety, ensuring efficiency, complying with regulations, and responding to emergencies. It stands as the pinnacle standard for safe and efficient utilization of electrical power across various domains. This ranges from everyday household electronics to large-scale industrial infrastructure.

Over the decades the communication between operator and machine has been the driving force behind efficiency and safety. Without this crucial communication, manufacturers would come across a plethora of wasted cost as well as dangers situations. Giving precise commands and execute them instantaneously is crucial to making sure any automation facility operates at its best. PLC languages are very important, for their ability to allow the operator to communicate complex tasks to machines. Not only that, but their ability to automate tasks takes allows the operator to focus on other important tasks.
There exist a multitude of challenges that come with performing these tasks with a diverse scenario of situations. Because of this, there are multiple coding languages that become involved when discussing PLCs.

Read more: The Coding Languages of Industrial Automation

Traditional PLC Languages

Ladder Logic (LD)

The OG of programmable languages, Ladder Logic was created by Modicon Corporation in the 1970s for their PLCs. The industry needed a programming language that could effectively mimic the wiring diagrams used in relay-based control systems. These systems were prevalent in industrial settings for controlling machinery and processes.

Ladder Logic’s graphical representation consists of horizontal lines (rungs) with vertical lines (rung rails) that represent control circuits. This is much like the rungs on a ladder. The visual resemblance to electrical wiring diagrams made it intuitive for personnel accustomed to working with relay logic. This eased the transition from hard-wired systems to programmable control.

Today, Ladder Logic’s simplicity and visual nature makes it a fundamental programming language in industrial automation.

Structured Text (ST)

For intricate algorithms and mathematical operations within industrial automation, Structured Text emerges as a prevalent choice. Resembling high-level languages like Pascal or C, ST allows engineers to articulate complex control strategies with ease. Its readability and versatility make it an ideal choice for implementing algorithms in industrial settings.

Function Block Diagram (FBD)

Employing a graphical approach, Function Block Diagrams break down complex systems into interconnected blocks. This visual representation simplifies the design and maintenance of systems, facilitating easy comprehension and troubleshooting in industrial environments.

Sequential Function Chart (SFC)

In scenarios requiring a structured approach to depict sequential operations, Sequential Function Charts come into play. This graphical language represents a sequence of operations in a state-based manner. It offers a clear depiction of complex processes and control flow.

Instruction List (IL)

Instruction List, akin to assembly language, operates at a low level using mnemonic codes. Ideal for detailed control in PLCs, IL enables engineers to create precise instructions for control systems, making it indispensable for fine-tuning operations.

C/C++

C++ became integrated into industrial automation and PLC during the late 90s and early 00’s. However, C++ was slow to be integrated due to lack of optimization to work in a real time setting. Another factor for its slow adoptions, was compatibility. At the time languages like Ladder Logic and Function Block Diagram were more widely used in industry. However, C++ made up for this early setback with its ability to compute complex tasks.

Future Languages

Python and Java

The advent of Python and Java in industrial automation signifies a shift toward versatility and broader system integration. Python’s ease of use, coupled with its capabilities in data analysis, scripting, and interfacing with various systems, has positioned it as an increasingly popular choice. Java, with its platform independence and object-oriented approach, finds a place in larger-scale industrial applications.

The choice of programming language in industrial automation hinges on a multitude of factors, including system requirements, hardware compatibility, existing infrastructure, and the expertise of the programming team. Each language brings its own strengths to the table, catering to different facets of control and automation.

Conclusion

As industries evolve and technology advances, the landscape of programming languages in industrial automation continues to expand. Understanding and leveraging these languages empower engineers to build robust, efficient, and adaptive systems that drive the future of manufacturing and industrial processes.

In the realm of industrial automation, the choice between single pole (SP) and double pole (DP) switches plays a crucial role in designing reliable and efficient control systems. Single pole and double pole switches serve as fundamental components determining how electrical circuits open and close. In this article, we will explore the characteristics of single pole and double pole switches, their applications in industrial automation, and the considerations involved in making the right choice.

Single Pole vs Double Pole

Single pole switches (SP) and double pole switches (DP) are fundamental electrical components that control the flow of electricity in circuits, yet they differ significantly in their functionality and applications.

In terms of installation and physical appearance, both single pole and double pole switches share similarities. They are often available in similar sizes and designs, making them interchangeable in certain situations. However, the difference lies in their internal structure and functionality, impacting their capacity to manage electrical circuits.

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Industrial automation systems have revolutionized manufacturing and processing industries, improving efficiency and productivity. However, with the increasing complexity of machinery, ensuring worker safety has become a significant challenge. Safe Torque Off (STO) is an essential safety feature in industrial automation system. Its key design is to mitigate risks and protect personnel and machinery.

What is Safe Torque Off

Safe Torque Off (STO) is a critical part of the overall functional safety framework compliant with international standards such as IEC 61508 and ISO 13849. The primary purpose of STO is to ensure the controlled and safe deactivation of the torque produced by electric motors. This stops the motion of machinery in a controlled and secure manner. It allows for the decoupling of the motor from the load, ensuring that it cannot generate any motion or torque.

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Introduction

The under evaluating of surge protectors is not something that is exclusive to the world of industrial automation.  People tend to buy them for their multiple outlet utility overlooking their actual value.  However, surge protectors play a very pivotal role in the function and protection of our devices.  Often their importance goes unrecognized until of course disaster strikes.  In the world of industrial automation, the importance of surge protectors is just as important yet overlooked as ever.

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In today’s world of automation and robotics, precise control of machinery is critical. The ability to control the position, velocity, and acceleration of moving parts with pinpoint accuracy is essential. This is regardless of whether it’s in manufacturing, robotics, or aerospace. This is where AC servo motors come into play. These advanced electric motors have revolutionized the way we control and automate complex mechanical systems. In this article, we will delve into what AC servo motors are, how they work, and their applications.

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In today’s technologically advanced world, electrical equipment plays a pivotal role in our daily lives. From industrial machinery to household appliances, these devices power our world. However, the safety and functionality of electrical equipment is not just about proper installation and maintenance. It also involves understanding and implementing the appropriate protection standards. One essential aspect of this is NEMA ratings.

NEMA, or the National Electrical Manufacturers Association, is a trade association based in the United States that represents manufacturers of electrical equipment. NEMA ratings are a standardized system used to classify and define the level of protection an electrical enclosure or housing provides against environmental elements, such as dust, water, and corrosive substances. These ratings are essential for selecting the right equipment for specific applications, ensuring durability, and maintaining safety standards.

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