Sensors such as limit switches are the only way
an electronic monitoring system has of knowing
what is going on in the world. If the sensors are
not wired properly, the rest of the system is
helpless. In an actual case of miswired limit
switches, a malfunction was missed that caused a
ship to be short by over one million pounds of
grain when it was loaded.
To verify that a set of limit switches is
properly wired, we can construct a "truth table"
as shown below. The first truth table is for a
basket valve. This valve has two limit switches,
and it can touch only one at a time. Therefore the
limit switches can see three possible positions:
(1) Ship Duct Closed, when the valve touches
the limit switch on the ship duct side;
(2) Return Duct Closed, when the valve touches
the limit switch on the return duct side;
(3) Both Ducts Open, when it does not touch
either limit switch.
The left side of the table (the input side) shows
all possible positions of the basket valve. The
right side of the table (the output side) shows
the states of the indicator lights for each input
position. A light which is supposed to be lit is
marked "ON", while a light which is supposed to be
off is marked with a "-".
Truth Table for
Basket Valve Indicators
Valve
Positions
Indicators
Ship
Closed
Return
Closed
Ship Duct
Closed
ON
-
Both Open
-
-
Return Duct
Closed
-
ON
To test the wiring, you put the valve in each
of its possible positions and verify that the
indicator lights are turned ON or OFF as specified
in the truth table. For a three-row truth table
with one valve and two indicators, this is simple.
The next truth table, which is much more
complicated, is for a pair of independent slide
gates. Again, the left side of the table (the
input side) shows all possible positions of the
gates, as seen by the limit switches. Since each
slide has two limit switches, it has three
possible positions:
Fully Closed (FC), touching the fully
closed limit switch;
Fully Open (FO), touching the fully open
limit switch;
Open (OP), when it does not touch either
limit switch.
Since there are two slides forming the diversion
point, there are 3X3=9 possible input positions.
The right side of the table (the output side)
again shows the states of the indicator lights for
each input position. A light which is supposed to
be lit is marked "ON", while a light which is
supposed to be off is marked with a "-". Clicking
on the left side of any row of the truth table
will display the positions of the gates and the
states of the indicator lights which correspond to
that row. Since this example is properly wired,
each indicator light is ON every time the table
says it should be.