Much as I’d like an apprentice again I’m now too ill to work. BUT I will help you where I can.
I had to accept change from the simple control of 40 years back to take on board the changes in legislation. You are now constrained by that legislation from the outset.
Modifying a basic starter becomes embroiled in red tape. The stupid thing is, nothing in the basics has changed, its just more complicated.
I spent time in R&D with a totally lunatic production engineer. I had a notice above my desk, “I’m looking for ways to stop it!” He wanted everything speeding up.
Stopping a plant safely is the prime directive.
Some plant designs I’ve done where massive centrifuges were used, part of the program would short out all the safety interlocks. Overloads, thermisters, et al all bridged out by the program. It didn’t matter if the motor was on fire, it had to keep running! If someone was wrapped up in it, their dead long before anything can be done about it.*
For it to start its cycle everything had to be in place.
It would be too dangerous to stop the machine without it going in to a controlled emergency shutdown mode. Shut down took time but it stopped as quick as I could get it to do so safely without endangering the other workers.
The original design had an E-Stop, it just cut the power and it drifted to a stop. My set up the centrifuge went in to regenerative braking but only if the temperature in the centrifuge made it safe to do so. The first thing that would happen is three X 150HP water pumps would kick in to cool the centrifuge shell. The temperature in the centrifuge could be 1300°C
*HV work, one question you get asked is “what do you do if someone receives a HV shock?”
The answer is callous, “assume they are dead!”
The safety of the living is more important!
Have sent you a PM.
