Engineering Institute of Technology

 

 

Unit Name

POWER AND DRIVE CONTROLS

Unit Code

BIA 304S

 

Unit Duration

Term

Award

Bachelor of Science (Industrial Automation Engineering)

 

Duration 3 years

Year Level

Three

Unit Creator/Reviewer

D M Macdonald/ S P Maj

Core/Sub-discipline

Sub-discipline

Pre/Co-requisites

 

BSC102C, BIA209S

Credit Points

3

 

Total Program Credit Points 81 (27 x 3)

Mode of Delivery

Online or On-campus

Unit Workload

(Total student workload including “contact hours” = 10 hours per week)

Pre-recordings / Lecture – 1.5 hours Tutorial – 1.5 hours

Guided labs / Group work / Assessments – 2 hours

Personal Study recommended - 5 hours

Unit Description and General Aims

The objective in presenting this unit is to impart to students a comprehensive knowledge of controls meant to regulate the power flow to electrical machinery used in typical industrial operations. The subject matter covered in this unit will include: the different production processes used in industry and the control requirements for machinery used in these processes; speed control of different types of motors used in manufacturing activities such as metal forming, rolling, manufacturing of paper, and etc.; the control of heaters used in machinery such as moulding and extrusion presses; and, the control of heating furnaces and welding controllers. The scope of the unit will also include a study of power electronic devices, their basic control strategies and characteristics, the equipment configurations in which these devices find applications, and the control functions used in power electronic equipment to achieve precise operational control.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

  1. Describe the different types of manufacturing processes and their control requirements with an emphasis on lowering the power consumption.

  2. Detail power electronic device types used for controlling the output of electrical equipment industrial applications.

  3. Describe the circuits for rectification and inversion and their application in motor controls.

  4. Specify the use of DC motors in different industry segments and the control strategies adopted.

  5. Specify the use of AC motors in different industry segments and the control strategies adopted.

  6. Evaluate the principles of industrial heating and welding and their control requirements.

    Professional Development

    Completing this unit may add to students professional development/competencies by:

    1. Fostering personal and professional skills and attributes in order to:

      1. Conduct work in a professionally diligent, accountable and ethical manner.

      2. Effectively use oral and written communication in personal and professional domains.

      3. Foster applicable creative thinking, critical thinking and problem solving skills.

      4. Develop initiative and engagement in lifelong learning and professional development.

      5. Enhance collaboration outcomes and performance in dynamic team roles.

      6. Effectively plan, organise, self-manage and manage others.

      7. Professionally utilise and manage information.

      8. Enhance technologist literacy and apply contextualised technologist skills.

    2. Enhance investigatory and research capabilities in order to:

      1. Develop an understanding of systematic, fundamental scientific, mathematic principles, numerical analysis techniques and statistics applicable to technologists.

      2. Access, evaluate and analyse information on technologist processes, procedures, investigations and the discernment of technologist knowledge development.

      3. Foster an in-depth understanding of specialist bodies of knowledge, computer science, engineering design practice and contextual factors applicable to technologists.

      4. Solve basic and open-ended engineering technologist problems.

      5. Understand the scope, principles, norms, accountabilities and bounds associated with sustainable engineering practice.

    3. Develop engineering application abilities in order to:

      1. Apply established engineering methods to broadly-defined technologist problem solving.

      2. Apply engineering technologist techniques, tool and resources.

      3. Apply systematic technologist synthesis and design processes.

      4. Systematically conduct and manage technologist projects, work assignments, testing and experimentation.

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for Engineering Technologists, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

 

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Systematic, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the technology domain.

1.2

Conceptual understanding of the, mathematics, numerical analysis, statistics, and computer and information sciences which underpin the technology domain.

1.3

In-depth understanding of specialist bodies of knowledge within the technology domain.

1.4

Discernment of knowledge development within the technology domain.

1.5

Knowledge of engineering design practice and contextual factors impacting the technology domain.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the technology domain.

2.

Engineering Application Ability

2.1

Application of established engineering methods to broadly-defined problem solving within the technology domain.

2.2

Application of engineering techniques, tools and resources within the technology domain.

2.3

Application of systematic synthesis and design processes within the technology domain.

2.4

Application of systematic approaches to the conduct and management of projects within the technology domain.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self and professional conduct.

3.6

Effective team membership and team leadership.

Graduate Attributes

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 7 criteria, Engineers Australia Stage 1 Competency Standards for Engineering Technologists and the Sydney Accord:

 

Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Learning Outcomes

A. Knowledge of Science and Engineering Fundamentals

A1. Breadth of knowledge of engineering and systematic, theory-based understanding of underlying principles, and depth of knowledge across one or more engineering sub- disciplines

 

1.1, 1.3

 

1, 2, 3, 4, 5, 6

A2. Knowledge of mathematical, statistical and computer sciences appropriate for engineering technology

 

1.2

 

A3. Discernment of knowledge development within the technology domain

1.4

4, 5, 6

A4. Knowledge of engineering design practice and contextual factors impacting the technology domain

 

1.5

 

B. Problem Solving, Critical Analysis and Judgement

B1. Ability to research, synthesise, evaluate and innovatively apply theoretical concepts, knowledge and approaches across diverse engineering technology contexts to effectively solve engineering problems

 

1.4, 2.1, 2.3

 

6

B2. Technical and project management skills to design complex systems and solutions in line with developments in engineering technology professional practice

 

2.1, 2.2, 2.3, 3.2

 

C. Effective Communication

C1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience

 

3.2

 

C2. Ability to engage effectively and appropriately across a diverse range of cultures

3.2

 

D. Design and Project Management

D1. Apply systematic synthesis and design processes within the technology domain

2.1, 2.2, 2.3

 

D2. Apply systematic approaches to the conduct and management of projects within the technology domain

 

2.4

 

E. Accountability, Professional and Ethical Conduct

E1. Innovation in applying engineering technology, having regard to ethics and impacts including economic; social; environmental and sustainability

 

1.6, 3.1, 3.4

 

E2. Professional conduct, understanding and accountability in professional practice across diverse circumstances including team work, leadership and independent work

 

3.3, 3.4, 3.5, 3.6

 

4, 5

Unit Competency and Learning Outcome Map

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Engineering Technologist.

 

 

 

Graduate Attributes

A1

A2

A3

A4

B1

B2

C1

C2

D1

D2

E1

E2

 

Engineers Australia Stage 1 Competency Standards for Engineering Technologist

1.1

 

 

 

 

 

 

 

 

 

 

 

1.2

 

 

 

 

 

 

 

 

 

 

 

1.3

 

 

 

 

 

 

 

 

 

 

 

1.4

 

 

 

 

 

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

1.6

 

 

 

 

 

 

 

 

 

 

 

2.1

 

 

 

 

 

 

 

 

 

2.2

 

 

 

 

 

 

 

 

 

 

2.3

 

 

 

 

 

 

 

 

 

2.4

 

 

 

 

 

 

 

 

 

 

 

3.1

 

 

 

 

 

 

 

 

 

 

 

3.2

 

 

 

 

 

 

 

 

 

3.3

 

 

 

 

 

 

 

 

 

 

 

3.4

 

 

 

 

 

 

 

 

 

 

3.5

 

 

 

 

 

 

 

 

 

 

 

3.6

 

 

 

 

 

 

 

 

 

 

 

 

Unit Learning Outcomes

LO1

 

 

 

 

 

 

 

 

 

 

 

LO2

 

 

 

 

 

 

 

 

 

 

 

LO3

 

 

 

 

 

 

 

 

 

 

 

LO4

 

 

 

 

 

 

 

 

 

LO5

 

 

 

 

 

 

 

 

 

LO6

 

 

 

 

 

 

 

 

 

Student assessment

Assessment Type

When assessed

Weighting (% of total unit marks)

Learning Outcomes Assessed

 

Assessment 1

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: Manufacturing processes and control requirements.

Students may complete a quiz with MCQ type answers and solve some simple equations to demonstrate a good understanding of the fundamental concepts

 

Week 3

 

15%

 

1

 

Assessment 2

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: : Power electronic devices and circuit applications.

Students may provide solutions to simple problems on the listed topics

 

Week 6

 

20%

 

2, 3

 

Assessment 3

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project

/ Report

Example Topic: Motor speed control and Welding applications. Simulation on Motor speed control.

Students may complete a quiz with MCQ type answers or solve some simple problems or using software to complete a practical.

 

Week 9

 

20%

 

4, 5

 

Assessment 4

Type: Examination Example Topic: All topics

An examination with a mix of detailed report type questions and/or simple numerical problems to be completed in 3 hours

 

Final Week

 

40%

 

1 to 6

 

Attendance / Tutorial Participation

Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.

 

Continuous

 

5%

 

1 to 6

Prescribed and recommended readings

Textbook

Bralla, JG 2007, Handbook of Manufacturing Processes - How Products, Components and Materials are Made, Industrial Press, ISBN 978-1-60119-933-1. Online version available at: http://app.knovel.com/hotlink/toc/id:kpHMPHPCM1/handbook-manufacturing/handbook- manufacturing

Phipps, CA 1999, Variable Speed Drive Fundamentals, 3rd edn, Fairmont Press Inc., ISBN 978-1-61583-295. Online version available at: http://app.knovel.com/hotlink/toc/id:kpVSDFE001/variable-speed-drive/variable-speed-drive

Rashid, MH 2011. Power Electronics Handbook - Devices, Circuits, and Applications. 3rd edn. Elsevier. Online version available at: http://app.knovel.com/hotlink/toc/id:kpPEHDCAE1/power-electronics-handbook/power- electronics-handbook

 

 

Reference

Erickson, CJ 1994, Handbook of Electrical Heating for Industry, IEEE, ISBN 13: 9780780304208.

 

Notes and Reference texts

Knovel library: http://app.knovel.com

IDC notes and Reference texts as advised. Other material advised during the lectures

 

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

 

Topics 1 and 2

 

Industrial manufacturing processes and control methods

  1. Basics of industrial manufacturing (batch processes and assembly lines)

  2. Metal forming (hot and cold)

  3. Metal cutting/stamping

  4. Forging and casting

  5. Machine tools (Turning, shaping/planning, drilling, boring, grinding, and milling)

  6. Die casting and moulding operations

  7. Heat treatment

  8. Welding

  9. Heating furnaces

  10. Melting furnaces

  11. Plating and coating

  12. Interlocks and controls in different machines

  13. Automation in manufacturing

 

Topic 3

Power electronic devices used in industrial equipment

  1. Principle of operation and characteristics of semiconductor diodes

  2. Principle of operation and characteristics of power transistors

  3. Principle of operation and characteristics of thyristors and triacs

  4. Principle of operation and characteristics of GTO devices

  5. Principle of operation and characteristics of IGBTs and IGCTs

  6. Important specifications of semi-conductor devices and their relevance in selection.

 

Topic 4

Rectifiers and their control

  1. Half wave, full wave and bridge rectifiers with diodes and their waveform (single and 3 phase)

  2. Half-controlled and fully-controlled 3 phase rectifiers and waveform

  3. Pulse circuit for thyristor control

  4. Snubber circuits and their design

  5. Protection of devices using semi-conductor fuses

  6. Power factor and harmonic problems in the supply circuit due to rectifier operation

 

Topic 5

Inverters and their control

  1. Inversion by switching and inversion by voltage synthesis

  2. GTO thyristors as invertors

  3. Transistors and IGBTs as inverters

  4. Voltage and current source inverters

  5. Pulse-width modulation type voltage source invertors

  6. Line commutated inverters for high power motors

 

Topic 6

DC motors and their control

  1. DC motor operating principle

  2. DC motor types based on field supply (shunt, series, compound)

  3. Speed/torque characteristics

  4. DC motor control and constant torque/constant power mode of control

  5. Armature voltage control using thyristor rectifiers

  6. Field voltage control

  7. 4-quadrant operation

Topics 7 and 8

AC motors and control

  1. Single phase AC motors-operating principle

  2. 3 phase motors-types

  3. 3 phase motor operating principle (rotating magnetic field)

  4. Starting of cage motors-controls (direct and assisted starting)

  5. Soft-starters using power thyristors

  6. Slip ring motors construction

  7. Starting using rotor resistance control

  8. Synchronous motors and their starting

  9. Speed control of AC motors VVVF type

  10. 4-quadrant AC drives

  11. Braking using resistance and regenerative braking

  12. Slip power recovery type of drives for wound rotor motors

 

Topic 9

Welding control

  1. Basics of electric welding

  2. Resistance welding (spot, seam) and controls

  3. Current control for DC arc welding using rectifiers

  4. AC Arc welding and control of welding machines

  5. Welding in automobile manufacture

  6. Overview of robotic control of welders in production lines

 

Topics 10 and 11

Heaters, furnaces, and control methods

  1. Resistance heating

  2. Control of resistance heaters (on/off and voltage control methods)

  3. Radiant heating and its control

  4. Induction furnace and its application in melting

  5. High frequency induction heating and control

  6. Dielectric heating

  7. Power source for induction/dielectric heaters

  8. Heating furnaces and temperature control (heat treatment operations)

  9. Arc furnace for melting and control of arc current/length

  10. Voltage problems due to arc furnaces

  11. Voltage compensation using Static VAR compensators (SVC)

  12. SVC for voltage correction and load balancing

Topic 12

Unit Review

In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

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