7. OVER VIEW OF THE COURSE
7
Module Week Lectures
Text Book
Chapter
Topics Assessment
I
(Introduction to
Industrial Electronics)
1 1-2 Ch. 1, 3
Overview
- Semiconductor devices
-Introduction to Industrial and
Power semiconductors
II
(Electric Heating &
Welding)
2 3
Ch. 6
Electric Heating
- Principles of resistance/induction heating
- Industrial applications
-
2-3 4-6
Specialized Heating
- Dielectric heating mechanisms
- High-frequency welding systems
Quiz 1
Welding Control
- Spot welding timer circuits
- Transformer design considerations
-
III
(Industrial Motor
Drives)
4 7-8 Ch.9
DC Motor Drives
- Armature voltage control
- SCR-based drive systems
Assignment 1
5 9-10 Ch.10
AC Motor Control
- VFD operating principles
- Scalar/vector control methods
-
6 11-12 Ch.11
Servo Systems
- PID control theory
- Industrial servo applications
Quiz 2
IV
(Process
Instrumentation)
7 13-14 Ch.12
Process Control
- Open/closed-loop systems
- Block diagram analysis
-
8 15-16
Ch.4
Temperature Measurement
- RTD/thermocouple theory
- Calibration standards
-
9 17-18
Pressure/Displacement
- Piezoelectric/LVDT principles
- Signal conditioning
- Midterm Exam
10 19-20 Ch.5
Digital Instrumentation
- Smart sensor networks
- ADC/DAC selection
Quiz 3
8. 8
Module Week Lectures
Text Book
Chapter
Topics Assessment
V
(Ultrasonic /
Photoelectric System)
11 21-22 Ch.7
Ultrasonics
- Piezoelectric transducers
- Flow measurement theory
-
12 23-24 Ch.8
Photoelectric
- IR sensor physics
- Industrial counter designs
Assignment 2
VI
(PLC & Industrial
Control)
13 25-26 Ch.13
PLC Theory
- Ladder logic fundamentals
- Industrial I/O systems
-
14 27-28 Ch.14-15
DCS & SCADA
- Architecture comparison
- HMI design principles
Quiz 3
NA 15 29-30 -
Comprehensive Review
- Key concept integration
- Exam preparation
Final Exam
V
(Ultrasonic /
Photoelectric System)
11 21-22 Ch.7
Ultrasonics
- Piezoelectric transducers
- Flow measurement theory
-
12 23-24 Ch.8
Photoelectric
- IR sensor physics
- Industrial counter designs
Assignment 2
VI
(PLC & Industrial
Control)
13 25-26 Ch.13
PLC Theory
- Ladder logic fundamentals
- Industrial I/O systems
-
14 27-28 Ch.14-15
DCS & SCADA
- Architecture comparison
- HMI design principles
Quiz 3
NA 15 29-30 -
Comprehensive Review
- Key concept integration
- Exam preparation
Final Exam
OVER VIEW OF THE COURSE
9. OVER VIEW OF THE COURSE
9
References for the course
•Terry Bartelt, “Industrial Control Electronics,” 3rd Edition.
•Frank D. Petruzella, “Electric Motors and Control Systems”,
McGrawHill, Third Edition
•N. Mohan, T.M. Undeland, W. P. Robbins, Power Electronics:
Converters, Applications and Design, John Wiley& SonsInc.
•French College of Metrology, Industrial Metrology, ISTE
•Slides of the course
20. POWER TRANSISTORS
FOUR TYPES
Bipolar junction Transistor(BJT)
Metal Oxide Semiconductor Field Effect
Transistor(MOSFET)
Insulated Gate Bipolar Transistors(IGBT) and
Static Induction Transistor (SIT)
20
21. POWER BJT
• Three layer ,Two Junction npn or pnp type
• Bipolar means current flow in the device is
due to the movement of BOTH holes and
Electrons.
21
28. POWER MOSFET
• THREE TERMINALS – DRAIN,SOURCE AND GATE
• VOLTAGE CONTROLLED DEVICE
• GATE CIRCUIT IMPEDANCE IS HIGH (OF THE
ORDER OF MEGA OHM).HENCE GATE CAN BE
DRIVEN DIRECTLY FROM MICROELECTRONIC
CIRCUITS.
• USED IN LOW POWER HIGH FREQUENCY
CONVERTERS,SMPS AND INVERTERS
28
33. COMPARISON OF BJT AND MOSFET
S.No BJT MOSFET
1 BIPOLAR DEVICE UNIPOLAR DEVICE
2 LOW INPUT IMPEDANCE(KILO OHM) HIGH INPUT IMPEDANCE (MEGA
OHM)
3 HIGH SWITCHING LOSSES BUT LOWER
CONDUCTION LOSSES
LOWER SWITCHING LOSSES BUT
HIGH ON-RESISTANCE AND
CONDUCTION LOSSES
4 CURRENT CONTROLLED DEVICE VOLTAGE CONTROLLED DEVICE
5 NEGATIVE TEMPERATURE COEFFICIENT
OF RESISTANCE.PARALLEL OPERATION
IS DIFFICULT.CURRENT SHARING
RESISTORS SHOULD BE USED.
POSITIVE TEMPERATURE
COEFFICIENT OF RESISTANCE.
PARALLEL OPERATION IS EASY
6 SECONDARY BREAKDOWN OCCURS. SECONDARY BREAKDOWN DOES NOT
OCCUR.
7 AVAILABLE WITH RATINGS 1200V,800A AVAILABLE WITH RATINGS 33
34. INSULATED GATE BIPOLAR TRANSISTOR
(IGBT)
• COMBINES THE BEST QUALITIES OF BOTH BJT AND
MOSFET
• HAS HIGH INPUT IMPEDANCE AS MOSFET AND HAS
LOW ON-STATE POWER LOSS AS IN BJT
• OTHER NAMES
MOSIGT (METAL OXIDE INSULATED GATE TRANSISTOR),
COMFET (CONDUCTIVELY-MODULATED FIELD EFFECT
TRANSISTOR),
GEMFET (GAIN MODULATED FIELD EFFECT TRANSISTOR),
IGT (INSULATED GATE TRANSISTOR)
34
42. APPLICATIONS OF IGBT
• DC AND AC MOTOR DRIVES
• UPS SYSTEMS,POWER SUPPLIES
• DRIVES FOR SOLENOIDS,RELAYS AND
CONTACTORS
42
43. COMPARISON OF IGBT WITH MOSFET
S.No MOSFET IGBT
1. THREE TERMINALS ARE GATE,SOURCE AND
DRAIN
THREE TERMINALS ARE GATE,EMITTER
AND COLLECTOR
2. HIGH INPUT IMPEDANCE HIGH INPUT IMPEDANCE
3. VOLTAGE CONTROLLED DEVICE VOLTAGE CONTROLLED DEVICE
4. RATINGS AVAILABLE UPTO 500V,140A RATINGS AVAILABLE UPTO 1200V,500A
5. OPERATING FREQUENCY IS UPTO I MHz OPERATING FREQUENCY IS UPTO 50KHz
6. WITH RISE IN TEMPERATURE,THE INCREASE IN ON-STATE RESISTANCE IN MOSFET IS
MORE PRONOUNCED THAN IGBT.SO, ON-STATE VOLTAGE DROP AND LOSSES RISE
RAPIDLY IN MOSFET THAN IN IGBT ITH RISE IN TEMPERATURE.
7. WITH RISE IN VOLTAGE,THE INCREMENT IN ON-STATE VOLTAGE DROP IS MORE
DOMINANT IN MOSFET THAN IT IS IN IGBT.THIS MEANS IGBTs CAN BE DESIGNED FOR
HIGHER VOLTAGE RATINGS THAN MOSFETs.
43
46. WORKING OF SIT
• SIT IS A NORMALLY ON DEVICE
• IF VGS =0 AND VDS IS PRESENT ,ELECTRONS WOULD FLOW FROM
SOURCE TO n,P+
,n-
, n+
AND REACH DRAIN.DRAIN CURRENT FLOWS
FROM D TO S.
• IF VGS = NEGATIVE, P+
n-
JUNCTIONS GET REVERSE
BIASED.DEPLETION REGION IS FORMED AROUND P+ ELECTRODES
AND THIS REDUCES THE CURRENT FLOW FROM ITS VALUE WHEN
VGS =0.
• AT SOME HIGHER VALUE OF REVERSE BIAS VOLTAGE VGS ,THE
DEPLETION LAYER WOULD GROW TO SUCH AN EXTENT AS TO CUT
OFF THE CHANNEL COMPLETELY AND LOAD CURRENT WOULD BE
ZERO.
46
47. STATIC INDUCTION TRANSISTOR(SIT)
• IT IS A HIGH POWER,HIGH FREQUENCY DEVICE.
• LARGE DROP IN SIT MAKES IT UNSUITABLE FOR GENERAL
POWER ELECTRONIC APPLICATIONS.
• A 1500V,180A SIT HAS A CHANNEL RESISTANCE OF 0.5 Ω
GIVING 90V CONDUCTION DROP AT 180A.AN EQUIVALENT
THYRISTOR OR GTO DROP MAY BE AROUND 2V.
• TYPICAL TON AND TOFF TIMES ARE VERY LOW AROUND 0.35µs.
• HIGH CONDUCTION DROP WITH VERY LOW TURN-ON AND
TURN-OFF TIMES RESULT IN LOW ON-OFF ENERGY
LOSSES.THIS MAKES SIT SUITABLE FOR HIGH POWER,HIGH
FREQUENCY APPLICATIONS.
47
48. APPLICATIONS OF SIT
• AM/FM TRANSMITTERS
• INDUCTION HEATERS
• HIGH VOLTAGE LOW CURRENT POWER SUPPLIES
• ULTRASONIC GENERATORS
• TYPICAL RATINGS AVAILABLE -1200V,300AWITH
TURN ON AND TURN OFF TIMES AROUND 0.25 TO
0.35 µs AND 100KHz OPERATING FREQUENCY.
48
49. THYRISTORS
SILICON CONTROLLED RECTIFIER (SCR)
• Three terminal, four layers (P-N-P-N)
• Can handle high currents and high voltages,
with better switching speed and improved
breakdown voltage .
• Name ‘Thyristor’, is derived by a combination of
the capital letters from THYRatron and
transISTOR.
• Has characteristics similar to a thyratron tube
But from the construction view point belongs
to transistor (pnp or npn device) family.
49
50. THYRISTORS
• TYPICAL RATINGS AVAILABLE ARE 1.5KA &
10KV WHICH RESPONDS TO 15MW POWER
HANDLING CAPACITY.
• THIS POWER CAN BE CONTROLLED BY A GATE
CURRENT OF ABOUT 1A ONLY.
50
53. SCR / Thyristor
• Circuit Symbol and Terminal Identification
SCR
2N3668
ANODE
CATHODE
GATE
53
54. SCR / Thyristor
• Anode and Cathode
terminals as
conventional pn
junction diode
• Gate terminal for a
controlling input signal
SCR
2N3668
ANODE
CATHODE
GATE
54
55. SCR/ Thyristor
• An SCR (Thyristor) is a “controlled” rectifier
(diode)
• Control the conduction under forward bias by
applying a current into the Gate terminal
• Under reverse bias, looks like conventional pn
junction diode
55
56. SCR / Thyristor
• 4-layer (pnpn) device
• Anode, Cathode as for a
conventional pn
junction diode
• Cathode Gate brought
out for controlling input
P
N
P
N
Anode
Cathode
Gate
56
58. Apply Biasing
With the Gate terminal
OPEN, both transistors are
OFF. As the applied
voltage increases, there will
be a “breakdown” that
causes both transistors to
conduct (saturate) making
IF > 0 and VAK = 0.
VBreakdown = VBR(F)
IF
IC2=IB1
IF
IC1 = IB2 Q2
BJT_NPN_VIRTUAL
Q1
BJT_PNP_VIRTUAL
ANODE (A)
CATHODE (K)
GATE (G)
Variable
50V
58
60. Apply a Gate Current
Q2
BJT_NPN_VIRTUAL
Q1
BJT_PNP_VIRTUAL
ANODE (A)
CATHODE (K)
GATE (G)
Variable
50V
IF
IF
IB2
VG
For 0 < VAK < VBR(F),
Turn Q2 ON by applying a
current into the Gate
This causes Q1 to turn ON, and
eventually both transistors
SATURATE
VAK = VCEsat + VBEsat
If the Gate pulse is removed, Q1
and Q2 still stay ON!
IC2 = IB1
60
61. How do you turn it OFF?
• Cause the forward current to fall below the
value if the “holding” current, IH
• Reverse bias the device
61
62. SCR Application – Power Control
When the voltage across
the capacitor reaches the
“trigger-point” voltage of
the device, the SCR turns
ON, current flows in the
Load for the remainder of
the positive half-cycle.
Current flow stops when
the applied voltage goes
negative.
Rload
15ohm
60%
25kOhm
Key = a
R
C
0.01uF
Vs
170V
120.21V_rms
60Hz
0Deg
A B
T
G
XSC1
D1
2N1776
62
64. SCR OPERATING MODES
FORWARD BLOCKING MODE: Anode is positive w.r.t cathode, but
the anode voltage is less than the break over voltage (VBO) .
only leakage current flows, so thyristor is not conducting .
FORWARD CONDUCTING MODE: When anode voltage becomes
greater than VBO, thyristor switches from forward blocking to
forward conduction state, a large forward current flows.
If the IG=IG1, thyristor can be turned ON even when anode
voltage is less than VBO.
– The current must be more than the latching current (IL).
– If the current reduced less than the holding current (IH),
thyristor switches back to forward blocking state.
REVERSE BLOCKING MODE: When cathode is more positive than
anode , small reverse leakage current flows. However if cathode
voltage is increased to reverse breakdown voltage , Avalanche
breakdown occurs and large current flows.
64
65. Thyristor- Operation Principle
• Thyristor has three p-n junctions (J1, J2, J3 from the anode).
• When anode is at a positive potential (VAK) w.r.t cathode with no
voltage applied at the gate, junctions J1 & J3 are forward biased,
while junction J2 is reverse biased.
– As J2 is reverse biased, no conduction takes place, so thyristor
is in forward blocking state (OFF state).
– Now if VAK (forward voltage) is increased w.r.t cathode,
forward leakage current will flow through the device.
– When this forward voltage reaches a value of breakdown
voltage (VBO) of the thyristor, forward leakage current will
reach saturation and reverse biased junction (J2) will have
avalanche breakdown and thyristor starts conducting (ON
state), known as forward conducting state .
• If Cathode is made more positive w.r.t anode, Junction J1 & J3 will
be reverse biased and junction J2 will be forward biased.
• A small reverse leakage current flows, this state is known as
reverse blocking state.
• As cathode is made more and more positive, stage is reached
when both junctions A & C will be breakdown, this voltage is
referd as reverse breakdown voltage (OFF state), and device is in
reverse blocking state 65
66. TRIGGERING METHODS
• THYRISTOR TURNING ON IS ALSO KNOWN AS
TRIGGERING.
• WITH ANODE POSITIVE WITH RESPECT TO CATHODE, A
THYRISTOR CAN BE TURNED ON BY ANY ONE OF THE
FOLLOWING TECHNIQUES :
FORWARD VOLTAGE TRIGGERING
GATE TRIGGERING
DV/DT TRIGGERING
TEMPERATURE TRIGGERING
LIGHT TRIGGERING
66
67. Forward Voltage Triggering
• When breakover voltage (VBO) across a thyristor is
exceeded than the rated maximum voltage of the device,
thyristor turns ON.
• At the breakover voltage the value of the thyristor anode
current is called the latching current (IL) .
• Breakover voltage triggering is not normally used as a
triggering method, and most circuit designs attempt to avoid
its occurrence.
• When a thyristor is triggered by exceeding VBO, the fall time
of the forward voltage is quite low (about 1/20th of the time
taken when the thyristor is gate-triggered).
• However, a thyristor switches faster with VBO turn-ON than
with gate turn-ON, so permitted di/dt for breakover voltage
turn-on is lower.
67
68. dv/dt triggering
• With forward voltage across anode & cathode of a thyristor, two
outer junctions (A & C) are forward biased but the inner junction (J2)
is reverse biased.
• The reversed biased junction J2 behaves like a capacitor because of
the space-charge present there.
• As p-n junction has capacitance, so larger the junction area the larger
the capacitance.
• If a voltage ramp is applied across the anode-to-cathode, a current
will flow in the device to charge the device capacitance according to
the relation:
• If the charging current becomes large enough, density of moving
current carriers in the device induces switch-on.
• This method of triggering is not desirable because high charging
current (Ic) may damage the thyristor. 68
69. Temperature Triggering
• During forward blocking, most of the applied voltage
appears across reverse biased junction J2.
• This voltage across junction J2 associated with leakage
current may raise the temperature of this junction.
• With increase in temperature, leakage current through
junction J2 further increases.
• This cumulative process may turn on the SCR at some high
temperature.
• High temperature triggering may cause Thermal runaway
and is generally avoided.
69
70. Light Triggering
• In this method light particles (photons) are made to
strike the reverse biased junction, which causes an
increase in the number of electron hole pairs and
triggering of the thyristor.
• For light-triggered SCRs, a slot (niche) is made in the
inner p-layer.
• When it is irradiated, free charge carriers are
generated just like when gate signal is applied b/w
gate and cathode.
• Pulse light of appropriate wavelength is guided by
optical fibers for irradiation.
• If the intensity of this light thrown on the recess
exceeds a certain value, forward-biased SCR is turned
on. Such a thyristor is known as light-activated SCR
(LASCR).
• Light-triggered thyristors is mostly used in high-
voltage direct current (HVDC) transmission systems.
70
71. Thyristor Gate Control Methods
• An easy method to switch ON a SCR into conduction is to
apply a proper positive signal to the gate.
• This signal should be applied when the thyristor is forward
biased and should be removed after the device has been
switched ON.
• Thyristor turn ON time should be in range of 1-4 micro
seconds, while turn-OFF time must be between 8-50
micro seconds.
• Thyristor gate signal can be of three varieties.
– D.C Gate signal
– A.c Gate Signal
– Pulse
71
72. Thyristor Gate Control Methods
D.C Gate signal: Application of a d.c gate signal causes the flow of gate
current which triggers the SCR.
– Disadvantage is that the gate signal has to be continuously applied,
resulting in power loss.
– Gate control circuit is also not isolated from the main power circuit.
A.C Gate Signal: In this method a phase - shifted a.c voltage derived from
the mains supplies the gate signal.
– Instant of firing can be controlled by phase angle control of the gate
signal.
Pulse: Here the SCR is triggered by the application of a positive pulse of
correct magnitude.
– For Thyristors it is important to switched ON at proper instants in a
certain sequence.
– This can be done by train of the high frequency pulses at proper
instants through a logic circuit.
– A pulse transformer is used for circuit isolation.
– Here, the gate looses are very low because the drive is discontinuous.
72
73. Thyristor Commutation
• Commutation: Process of turning off a conducting thyristor
– Current Commutation
– Voltage Commutation
• A thyristor can be turned ON by applying a positive voltage
of about a volt or a current of a few tens of milliamps at the
gate-cathode terminals.
• But SCR cannot be turned OFF via the gate terminal.
• It will turn-off only after the anode current is negated either
naturally or using forced commutation techniques.
• These methods of turn-off do not refer to those cases where
the anode current is gradually reduced below Holding
Current level manually or through a slow process.
• Once the SCR is turned ON, it remains ON even after removal
of the gate signal, as long as a minimum current, the Holding
Current (IH), is maintained in the main or rectifier circuit.
73
74. Thyristor Turn-off Mechanism
• In all practical cases, a negative current flows through the device.
• This current returns to zero only after the reverse recovery time (trr) ,
when the SCR is said to have regained its reverse blocking capability.
• The device can block a forward voltage only after a further tfr, the
forward recovery time has elapsed.
• Consequently, the SCR must continue to be reverse-biased for a
minimum of tfr + trr = tq, the rated turn-off time of the device.
• The external circuit must therefore reverse bias the SCR for a time toff >
tq.
• Subsequently, the reapplied forward biasing voltage must rise at a dv/dt
< dv/dt (reapplied) rated. This dv/dt is less than the static counterpart.
74
76. MOS CONTROLLED THYRISTOR (MCT)
• IT IS BASICALLY A THYRISTOR WITH TWO MOSFETS
BUILT INTO THE GATE STRUCTURE
• ONE MOSFET IS USED TO TURN ON THE MCT AND THE
OTHER FOR TURNING OFF OF MCT.
• IT IS A HIGH FREQUENCY,HIGH POWER,LOW
CONDUCTION DROP SWITCHING DEVICE.
• IN A MCT, THE ANODE IS THE REFERENCE W.R.TO
WHICH ALL THE GATE SIGNALS ARE APPLIED. IN A
SCR,CATHODE IS THE REFERENCE SIGNAL TO THE
GATE SIGNAL.
76
79. MERITS OF MCT
• LOW FORWARD CONDUCTION DROP
• FAST TURN AND TURN OFF TIMES
• LOW SWITCHING LOSSES
• HIGH GATE INPUT IMPEDANCE
• LOW REVERSE VOLTAGE BLOCKING
CAPABILITY IS THE MAIN DISADVANTAGE OF
MCT
79
82. TRIAC
(TRIODE FOR ALTERNATING CURRENT)
• TRIAC is five layer device that is able to
pass current bidirectionally and
therefore behaves as an a.c. power
control device.
• The main connections are simply named
main terminal 1 (MT1) and main terminal
2 (MT2).
• The gate designation still applies, and is
still used as it was with the SCR.
82
83. TRIAC (CONTD….)
• it not only carries current in either direction, but the gate
trigger pulse can be either polarity regardless of the polarity of
the main applied voltage.
• The gate can inject either free electrons or holes into the body
of the triac to trigger conduction either way.
– So triac is referred to as a "four-quadrant" device.
• Triac is used in an ac environment, so it will always turn off
when the applied voltage reaches zero at the end of the
current half-cycle.
• If a turn-on pulse is applied at some controllable point after
the start of each half cycle, we can directly control what
percentage of that half-cycle gets applied to the load, which is
typically connected in series with MT2.
• USED for light dimmer controls and motor speed controls.
83
85. TRIAC OPERATION
• TRIAC can be considered as two thyristors
connected in antiparallel .The single gate terminal is
common to both thyristors.
• The main terminals MT1 and MT2 are connected to
both p and n regions of the device and the current
path through the layers of the device depends upon
the polarity of the applied voltage between the main
terminals.
• Device polarity is usually described with reference to
MT1, where the term MT2+ denotes that terminal
MT2 is positive with respect to terminal MT1.
85
Editor's Notes
#46:WOULD FLOW FROM SOURCE TO n,P+,n-, n+ AND REACH DRAIN.DRAIN CURRENT FLOWS FROM D TO S.
IF VGS = NEGATIVE, P+n- JUNCTIONS GET REVERSE BIASED.DEPLETION REGION IS FORMED AROUND P+ ELECTRODES AND THIS REDUCES THE
