Daniel P.

DeToma
State University of New York - Maritime College, Electrical Engineering Program

Saddle Winch Motor Controller Control

Circuit Redesign

Abstract The saddle winch motor and associated

motor controller are found on many classes of U.S.
Naval ships involved in underway replenishment
(UNREP). The goal is to redesign and modernize the
control circuit using off the shelf components. Using
modern components such as programmable logic
controllers (PLC) and solid state relays, the size of the
controller will be greatly reduced, while also reducing
the maintenance requirements with the existing control
circuit design. A simple test circuit will be used in
conjunction with the motor controller to verify the new
control circuit functions correctly. With shipboard
reliability of the utmost concern, the newly designed
controller with commercial off-the-shelf (COTS) circuit
components can be later replaced with a more rugged
design.
Index Terms COTS, modernization,
controller, PLC, solid state relays
I.

motor

INTRODUCTION

The saddle winch motor is a three phase AC induction

motor that uses a controller designed prior to the introduction
of programmable logic controllers (PLC) and modern power
electronics. As such, the current controller is bulky, and over
time could become inefficient and costly. By modernizing
the control circuitry using off the shelf components such as a
PLC and solid state relays, the overall controller size can be
reduced while minimizing cost. The existing motor controller
has both a power circuit and a control circuit. The redesign
will focus on the control circuit, leaving the power circuit
intact.
II.

COMPONENT REPLACEMENT

A. Programmable Logic Controller

Prior to choosing a programmable logic controller (PLC),
the application had to be considered. The PLC replaces a
minimum of ten control relays, while being controlled from a
control handle with six positions. Additionally, the PLC will
use the existing on and off buttons to activate the redesigned
control circuit.

To accomplish the task, the DirectLogic DL05-AA was

chosen. It has 8 AC-inputs as well as 6 AC-outputs. For the
modernization, 7 inputs are utilized. They are for On, Off,
Forward Slow, Forward Medium, Reverse Slow, Reverse
Medium, and Reverse Fast. The 6 outputs will be used to
activate the Forward Relay, Reverse Relay, Slow Relay,
Medium Relay, Fast Relay, and the Brake Relay.
While a PLC is limited by its memory size, the capacity
of most PLCs is more than sufficient to replace more than ten
control relays. Using an existing control circuit diagram, the
conversion to relay ladder logic (RLL) for the PLC was
performed.
By using RLL, every control relay was replaced,
including the time delay relays essential to the motors
correct operation. Additionally, if any changes are required
in the future, the control logic can be easily changed and
written to the PLCs memory. Advanced PLCs can even be
connected to computers for round-the-clock monitoring, as
well as remote software updates. [1]
Most Naval ships that have Saddle Winches have three to
fifteen per ship. Each has its own controller. Use of a PLC
would allow at least three winches to be controlled by a
single PLC, with enough inputs and outputs. This would
eliminate the space and power requirements of 30 or more
traditional and time delay relays. Additionally, the
maintenance requirements are lessened with a PLC because
any upgrades to the system are loaded via a RLL program
update, which does not require any rewiring.
One such PLC that would provide an expansion
capability would be the DirectLogic DL06-AR. This PLC
comes standard with 20 AC inputs and 16 relay outputs.
Additional inputs or outputs can be added as needed through
use of available expansion modules. The relay outputs
provide a greater flexibility for the types of solid state relays
that can be placed at the output. The disadvantage to the AC
output type PLC is that due to its solid state output stage,
there is a small amount of leakage current that exists even
when outputs are not energized (4mA for the DL05-AA).
This could accidently activate relays that require an input
current of 4mA or less.

B. Solid State Relays for Motor Operation

The existing controller uses a NEMA size 3
electromechanical relay. Aside from being large by modern
standards, the existing relays require approximately 0.8
Amps of current to remain activated. By replacing the size 3
relay with a solid state variety, the overall size will be
reduced, as well as the current required for activation. The
Teledyne E3P48A75, is a three phase, 75A solid state relay
that was chosen to replace the electromechanical relay. Due
to a backorder on the relays, they could not be obtained and
utilized; however, their datasheet provides the required
information to show they would work in this application. A
smaller single phase relay from AutomationDirect.com was
chosen for the test circuit.
With the addition of an adequate heat sink, the relay can
handle the current required by the Saddle Winch motor.
Additionally, the current required to activate the relay is
approximately 11mA/relay. [2] This is represents a reduction
in input current by a factor of approximately 72.
Another advantage of the solid state relay is that by
eliminating any moving parts, the pitting and corrosion that
occurs on the contactor surfaces due to the constant use of
the existing relays is eliminated. Additionally, on a naval
vessel, solid state relays are more suitable because they are
not subject to false relay operation that could be encountered
by extreme shock or vibration. [3] A disadvantage to these
relays is that they can be affected by electromagnetic
interferance and therefore must be shielded from such
effects.
III.

IMPLEMENTATION AND OPERATION

Firstly, the relay ladder logic program was created by

methodically examining the existing control circuit
operation with its associated circuit diagram. The program
was then loaded onto the PLC, and was successfully run
without errors.
The PLC was wired per figure 2, on the next page. After
wiring, a simple light bulb circuit was attached to the load
side of the solid state relays. The correct activation of the
relays was observed, including associated time delays
verifying that the PLC performed as required to replace the
many control relays inside the cabinet.
IV.

COST ANALYSIS

There are many advantages to redesigning the Saddle

Winch Motor Controller using modern, COTS components.
Aside from the lower power consumption and longer
operational lifetime of the components, the cost is another
advantage. The following cost analysis was performed on a
part for part replacement basis.
The current design, using 27 components costs
approximately $15,464. The cost breakdown comes from
component costs provided to me by the NAVSEA UNREP
division.

Table 1 Current Motor Controller Cost Estimate

Current Option
Part
Auxiliary Contactors
Time Delay Relays
Additional Control Relays
Size 3 Main Contactors
Grand Total

Quantity
11
5
5
6

Price
$
58.98
Various
Various
$ 1,557.11

Sub Total
$
648.78
$
3,584.78
$
1,887.97
$
9,342.66
$ 15,464.19

The cost of the replacement controller using the D005AA PLC and Teledyne Solid State Relays totals $991.24.
This represents a cost savings of $14,472.95 over the current
motor controller.
Table 2 Replacement using D0-05AA PLC
Replacement Option 1
Part
Automation Direct PLC D0-05AA
Teledyne E3P48A75

Quantity Price
Sub Total
1 $
139.00 $
139.00
6 $
142.04 $
852.24

Grand Total
Savings vs. Current Design

$
$

991.24
14,472.95

Finally, if future expansion is of concern, the option

using the D0-06AR PLC can be used while still maintaining
significant cost savings. The second option would require a
slightly more expensive Teledyne E3P48D75 solid state
relay. This relay has a DC input vice the AC input of the
E3P48A75 relay. This replacement option would cost
$1381.82. This represents a savings of $14,082.87 over the
current motor controller.
Table 3 Replacement using D0-06AR PLC
Replacement Option 2
Part
Automation Direct D0-06AR
Teledyne E3P48D75

Quantity Price
Sub Total
1 $
279.00 $
279.00
6 $
183.72 $
1,102.32

Grand Total
Savings vs. Current Design

$
$

1,381.32
14,082.87

This basic cost analysis shows the financial benefits of

updating the motor controller design. A savings of
approximately $14,000 per motor controller, equates to
approximately $42,000 per ship with 3 controllers or up to
$210,000 per ship with 15 controllers.
V.

HOUSE OF QUALITY

The house of quality (Figure 1 Below) was developed

with the interests of the Navy in mind. The size of the
controller is of importance, and the PLC based designs
allow three or more motors to be controlled from the same
amount of space that used to control a single motor.
Additionally, the lifecycle of the components is of the
utmost importance. These components must be able to last
years under harsh conditions. Ideally, they would last the
life of the ship. Additionally, the value or cost reduction
provided by upgrading this equipment must be immediately
seen.

With those criteria in mind, the House of Quality

was developed to address the two different PLC based
options, as well as the current design. The two PLC based
designs show a large improvement over the current design.
Additionally, the expansion capabilities of the D0-06AR
give a slight edge in the size, as the expansion modules,
which can be added for additional motors, are smaller than
using an entirely new PLC for each controller. Additionally,
the expansion modules provide a better value as they are
cheaper. Due to its relay outputs, however, the D0-06AR
has a slightly lower lifecycle than the D0-05AA which has
solid state outputs.
VI.

like to thank Mr. Ron Sullivan, Mr. John Mondragon, and

Mr. Matthew Poloniak from the NAVSEA UNREP Division
for providing the original motor controller to be redesigned,
as well as continued support in the effort to modernize the
controller. Additional thanks go to AutomationDirect.com
for providing SUNY Maritimes Electrical Engineering
Department with a DirectSOFT license to program the PLC.
Prices for components were obtained on 4/12/12 from the
following sites: AutomationDirect.com, Mouser.com, and
OnlineComponenets.com.
REFERENCES
[1] "Programmable Logic Controllers: LADDER LOGIC,"
All About Circuits, [Online]. Available:
http://www.allaboutcircuits.com/vol_4/chpt_6/6.html.
[Accessed 12 April 2012]

CONCLUSION

The saddle winch motor controller control circuit

redesign was successfully completed using a PLC and a
group of solid state relays. These commercial off-the-shelf
components proved to be much less expensive, while having
other advantages such faster switching speed, lower power
consumption, and less maintenance. Future testing of this
design could be accomplished by implementing the DL06AR PLC as well as using the redesigned control circuit
for actual motor operation.

[2] Series E3P Three-Phase Output to 75A 600Vac DC and

AC Control Solid-State Relay, Teledyne, [Online].
Available:
http://www.teledynerelays.com/pdf/industrial/e3p.pdf.
[Accessed 16 April 2012]
[3] A. Tasker, "Solid State Relays Increase System
Reliability," Design News, pp. 83-86, 24 October 2005.

ACKNOWLEDGMENT
Daniel DeToma would like to thank Dr. Jean-Claude
Thomassian for advising him on this project. He would also

House of Quality for Motor Controller Redesign

Strong +
Positive

X Negative
# Strong -

#
X

PLC D0-06AR

Current Design

Life Cycle

Value

Technical Priorities
Percentage of Total

60

72

29

MILSPEC

PLC D0-05AA

Utilize Same Control Switch

Off The Shelf Components

Solid State Relays

PLC Control Circuit

= 9 High

Size

Customer
Requirements
(What)

Improve

Planning matrix

Importance (1-5)

Direction of Improvement
Design
Requirements
(How)

45

29% 34% 14% 1% 22%

PLC D0-05AA

Technical

PLC D0-06AR

Evaluation

Current Design

Design Targets

Figure 1 House of Quality

=3
= 1 Low

Input Common Bus

C0

C1

X4

35

X5

23

X7

X6

35

43

19

23

25

22

Microswitches
On Switch
Off Switch

C2

Y2

Y3

Y4

Y5

20

Ground

Fuse 1.0A

L
G
N

PLC Power Terminals

Line (Hot)

Neutral

Y1

C3

18
26

120 VAC

Y0

Master Controller

35
27

Winch #1 Master
Control Switch

43

Fuse 1.5A

Saddle Winch #1
Motor Controller

X3

25

PLC Outputs

X2

Solid State
Relays
(Input Side)

X1

X0

Output Common Bus

PLC Inputs

16

Figure 2 PLC Wiring Diagram

Figure 4 Redesigned Motor Controller

shown with Original Control Switch
Note: Figure 3 shows the original motor controller, approximately
36 wide and 50 high. Figure 4 shows the PLC at left, as well as
six AC input solid state relays. At the bottom of figure 4 is a set of
light bulbs used as a test load. This entire replacement controller
could fit in a space of 30 wide by approximately 10 high.
Figure 3 Original Motor Controller