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Wednesday, April 18, 2018

Ergonomics and Safety of the Workplace

Ergonomics and Manpower the Engine of Growth -  A Worker in One Firm is a Customer for another Firm. Healthy and Safe Workers implies a strengthening Consumer base.Just imagine what wonders it can do for the economy, when you broaden your view, think togetherness, as a Whole; not in isolated competitive groups, not in parts.

Ergonomics reduces Worker Stress. Helps in keeping good Mental and Physical Health. Safety is very important. His Limbs, Eyes and Ears are assets that a firm hires.

Ergonomics and Safety of the Workplace

A good Manager knows that Manpower is the Foremost Asset of any Company.

Thursday, April 05, 2018

Two Setpoint Temperature Controller

A Two Point Process Controller or Temperature Controller would look like this. When a High-Low Alarm Protection for uC based Controller was needed the same was modified and used.

Sometimes uC based instruments just forget and that can be costly, the watchdog timer has solved this problem. In Industrial Process Control we cannot take any chances, so a two tier or even three tier protection is required, especially so if the Job or Raw material being processed is expensive. So Real Time Analog Trip + uC Controller is safe. Then you can still have Electro Mechanical Devices for Extra protection against Fire or Meltdown.

Temperature is the most common process parameter, Pressure seems to be next. Flow, Level, RPM, Distance and many more follow.

Two Setpoint Temperature Controller

When a physical parameter let us say distance is measured, we first need a sensor that converts it into electrical values, digital or analog. The sensor used for length is a Linear encoder and it creates the electrical information for the DRO to Display.

Now many sensors like a strain gauge produce very low and weak signals and some are non-linear. So the signals undergo Amplifying, Temperature compensation and Linearizing together called Signal Conditioning. This stage outputs some standard values like 4-20mA, 0-10 V, 1-5V, or even directly digital or wireless in the new technologies. Even when a digital interfacing standard is used, amplification and some signal conditioning is required at sensor end. Compensation and Linearizing can be better done with a uC using Math or Look up Tables.

When you have many different parameters then it is better to use process controllers with a 4-20mA input standard. Then the inventory of controllers can be reused for any process.

It is always better to use sensor-end transmitters to get 4-20mA to your Controller, Recorder or SCADA System.Weak signals are corrupted by noise and dont travel long wire distance. Junction EMF at joints and terminal blocks add to errors. These are overcome by the 4-20mA signal that has the juice and punch to transmit the data over the shop floor to the control panel rooms.

Read more here Temperature Measurement and Control

Sunday, April 01, 2018

Safe and Sound - Product Safety

Caution is better than Risk, Prevention is better than cure. using the the right tools for a job alone is not sufficient; You have to get trained and informed about its proper use and safety precautions.

When we Design a Product or Develop further a design; we have to integrate Product Safety into the usage method and improve usability and safety. Product also has to be Engineered in such a way that manufacturing it does not pose hazard to the worker.

Safe and Sound - Product Safety

Product Safety
  • Product should not give even the lightest shock, Even metal parts on user side to be laminated.
  • High energy circuits never enters analog and digital circuit areas without Opto or other Isolation.
  • Gadgets, Furniture, Tools and Storage Units should not cause injury. Rounded Edges, Non Toxic.
  • LED and Lasers can damage Vision, welding too. Use Protective Filter Glasses. After a comment by John Bump