FABRICATION OF TEMPERATURE MEASUREMENT AND

CONTROL SYSTEM FOR ELECTRIC FURNACE

Submitted in the partial fulfillment of the requirement for the award

“DIPLOMA IN MECHANICAL ENGINEERING (FOUNDRY)”

SUBMITTED BY:

1. M.RAJ KUMAR 4. S.VISHAL 2. R.DINESH 5.R.DAYANITHI3. R.AJITH KUMAR

Under guidance of

Mr S.N.SUNDAR, M.E.

OCTOBER 2015

DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY).

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGECHENNAI 600123

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGECHENNAI- BANGALORE ROAD

SEMBARAMBAKKAMCHENNAI 600123

BONAFIDE CERTIFICATE

This is to certify that this Project work on

“FABRICATION OF TEMPERATURE MEASUREMENT AND

CONTROL SYSTEM FOR ELECTRIC FURNACE ”

submitted by …………………… ……………. Reg. No. ……………

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING (FOUNDRY)

This is the bonafide record of work carried out by him under our supervision during the

year 2015

Submitted for the Viva-voce exam held on ……………..

H.O.D PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the Principal

Mr.A.VIJAY KISHORE, M.TECH,for encouragement and valuable advice.

We thank our Esquired Head of Department Mr. S.N. SUNDAR, M..E. for presenting

his filiations on us.

We are grateful on our Entourages Mr. S.N.SUNDAR, M.E.

For guiding in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the Mechanical

Department and Foundry Department.

Ultimately, we extend our thanks to all who had rendered their co- operation for the

success of the project.

CONTENTS

CONTENTS

CHAPTER NO. TITLE

1 INTRODUCTION

2 SYNOPSIS

3 WORKING PRINCIPLE

4 ADVANTAGES

5 APPLICATIONS

6 CIRCUIT DETAILS (BLOCK DIAGRAM)

7 ELECTRICAL CIRCUIT DETAILS

8 COST ESTIMATION

9 CONCLUSION

10 BIBLIOGRAPHY

INTRODUCTION

INTRODUCTION

In our technical education the project work plays a major role. Every students is put in to

simulated life particularly where the student required to bring his knowledge, skill and

experience of the project work.

It helps how to evolve specifications under given constrains by systematic

approach to the problem a construct a work device. Project work thus integrates various

skills and knowledge attainment during study and gives orientation towards application.

As the students solve the various problems exposed by the project work, the

students get the confidence to overcome such problems in the future life. It helps in

expanding the thinking and alternatives for future applications.

SYNOPSIS

SYNOPSIS

In an IC Engine, water and lubricating oil temperature, fuel level, oil pressure,

vibration and noise are monitored continuously by the maintenance technician while the

engine is running. In order to reduce the maintenance cost of the IC engine, the above

parameters can be monitored automatically by the electronic control system .

In the project “ FABRICATION OF TEMPERATURE MEASUREMENT AND

CONTROL SYSTEM FOR ELECTRIC FURNACE” When the temperature of cooling

water in the engine exceeds beyond its limit, the micro controller gives alarm signal and

correspondingly cut off the fuel supply to the engine.

A Temperature sensor is fitted in the engine bodies and it sends the signal

continuously to the control system.

When the temperature exceeds, the control system switch on the alarm signal and

cut off the fuel supply to the engine.

WORKING PRINCIPLE

WORKING PRINCIPLE

This project monitors the temperature of an I C engine during running. The

temperature sensor is placed on the surface of the engine body and the supply is given

to the micro controller system.

When the micro controller start switch is pressed, the LCD display shows the

temperature reading. The temperature sensor converts the heat energy into electrical

signal. Here LM 335 is used as a temperature sensor.

The electrical signal are in the form of millivolts which is passed to the

microcontroller through the analoge port. The cooling water temperature to the engine

cylinder raises gradually during running condition and hence the temperature of engine

body surface also increased. The temperature sensor contact with the engine surface

sends the signal to the microcontroller .The microcontroller processes the input signal

and shows the temperature reading in LCD display. When the temperature increased

above the set limit, the microcontroller switch OFF the power supply to the fuel valve

and hence the avoids the seizing of engine .

By arranging this method , the minimum and maximum temperature is maintained by the

microcontroller.

BLOCK DIAGRM

5VPower supply

InterfaceCard

KEYPAD

MAIN PROCESSOR

SOLENOIDVALVES

LCD DISPLAY

TEMPERATURE SENSOR

ADVANTAGES

ADVANTAGES

1. We can measure the temperature continuously using the temperature sensor

with the help of microcontroller

2. We can monitor the temperature so we can prevent the piston from ceasing

3. temperaturae sensor can be easily replaced

4. cost of project is less

APPLICATIONS

APPLICATIONS

1. It can be used in IC engine for monitoring the temperature

2. we can also used as an instrument for monitoring by replacing the sensors

example pressure sensors, temperature sensors etc.,

CIRCUIT DETAILS

CIRCUIT DETAILS

The hardware circuit requirements details consists of

1. Micro controller system

2. Power supply (230V A.C. to 12 V and 5V DC)

3. LCD Display

4. 5 V TO 12 V Drive Card

5. Temperature Sensor

MICRO CONTROLLER SYSTEM:

This system monitors the engine condition by using PIC 16F870 (28

pin IC Package) micro controller. The pin details of micro controller are

shown in figure.

The circuit diagram for this micro controller board is shown below,

the reset switch is connected to PORTA (i.e)pin no 1,.the LCD DISPLAY is connected to

port C and portB 0,1The temperature sensor is connected to PORTA ,1.. The power

supply is connected to Pin 19 & 20.

POWER SUPPLY UNIT

INTRODUCTION:

All the electronic components starting from diode to Intel IC’s only work with a

DC supply ranging from +5V to +12V. We are utilizing for the same, the cheapest and

commonly available energy source of 230V-50Hz and stepping down, rectifying, filtering

and regulating the voltage.

STEP DOWN TRANSFORMER:

When AC is applied to the primary winding of the power transformer, it can either

be stepped down or stepped up depending on the value of DC needed. In our circuit the

transformer of 230V/15-0-15V is used to perform the step down operation where a 230V

AC appears as 15V AC across the secondary winding. Apart from stepping down

voltages, it gives isolation between the power source and power supply circuitries.

RECTIFIER UNIT:

In the power supply unit, rectification is normally achieved using a solid state

diode. Diode has the property that will let the electron flow easily in one direction at

proper biasing condition. As AC is applied to the diode, electrons only flow when the

anode and cathode is negative. Reversing the polarity of voltage will not permit electron

flow. A commonly used circuit for supplying large amounts of DCpower is the bridge

rectifier. A bridge rectifier of four diodes (4 x IN4007) are used to achieve full wave

rectification. Two diodes will conduct during the negative cycle and the other two will

conduct during the positive half cycle, and only one diode conducts. At the same time

one of the other two diodes conducts for the negative voltage that is applied from the

bottom winding due to the forward bias for that diode. In this circuit due to positive half

cycle D1 & D2 will conduct to give 0.8V pulsating DC. The DC output has a ripple

frequency of 100Hz. Since each alteration produces a resulting output pulse, frequency =

2 x 50 Hz. The output obtained is not a pure DC and therefore filtration has to be done.

The DC voltage appearing across the output terminals of the bridge rectifier will be

somewhat less than 90% of the applied rms value. Normally one alteration of the input

voltage will reverse the polarities. Opposite ends of the transformer will therefore always

be 180 degree out of phase with each other. For a positive cycle, two diodes are

connected to the positive voltage at the top winding.

FILTERING CIRCUIT:

Filter circuits which is usually capacitor acting as a surge arrester always follow

the rectifier unit. This capacitor is also called as a decoupling capacitor or a bypassing

capacitor, is used not only to ‘short’ the ripple with frequency of 120Hz to ground but

also to leave the frequency of the DC to appear at the output. A load resistor R1 is

connected so that a reference to the ground is maintained. C1, R1 is for bypassing

ripples. C2, R2 is used as a low pass filter, i.e. it passes only low frequency signals and

bypasses high frequency signals. The load resistor should be 1% to 2.5% of the load.

1000f/25V : for the reduction of ripples from the pulsating

10f/25V : for maintaining the stability of the voltage at the load side.

0.1f : for bypassing the high frequency disturbances

BLOCK DIAGRAM FOR

POWER SUPPLY

STEP DOWN BRIDGE POSITIVETRANSFORMER RECTIFIER CHARGE

CAPACITOR

5V 12V REGULATOR REGULATOR

MOTHER DISPLAY BOARD BOARD RELAY

VOLTAGE REGULATOR:

The voltage regulators play an important role in any power supply unit. The

primary purpose of a regulator is to aid the rectifier and filter circuit in providing a

constant DC voltage to the device. Power supplies without regulators have an inherent

problem of changing DC voltage values due to variations in the load or due to

fluctuations in the AC linear voltage. With a regulator connected to the DC output, the

voltage can be maintained within a close tolerant region of the desired output. IC7812

and 7912 is used in this project for providing +12V and 12V DC supply.

SPECIFICATION:

Resistors R1 and R2 maintain line load regulation.

At the secondary side of the transformer, applied voltage = 15V

Conducting drop across the diodes = 2 * 0.6 = 1.2V

Without capacitor:

Vavg = (15-1.2)V = 13.8c pulsating DC

Frequency = 100Hz

With capacitor:

V = Vavg * 1.414 (form factor) = 19.51V

Frequency = 0 Hz

with 7812 voltage regulator:

V0 = +12V

with 7912 voltage regulator: V0 = -12V

POWER SUPPLY 5V DC AND 12V DC;

A 12 –0 v step down transformer is used to stepdown 230V AC to 12V AC .This

12V AC supply is converted to 12V DC using four rectifier diodes. The voltage from the

rectifier section is regulated to 12V DC using 7812 IC .This voltage is used for supply

for the stepper motor. From 12V DC the 7805 IC is used for regulating 5V DC for the

power supply of microcontroller.the power supply circuit is shown in fig.

TEMPERATURE CONTROL UNIT:

In this system, the temperature of the engine body can be measured by

using LM 335 sensor unit. When the temperature of the sensor rises, the

sensor continuously sends the variable voltage signal to the micro controller

unit. The temperature sensor unit is shown in figure. The LCD display

shows the temperature reading

5 VDC TO 24V DC DRIVE CARD

Here we have to drive the 24V DC load. The 5V signal from the PIC

16F870 micro-controller is fed into the input of interface circuit. SL100

transistor is used here for high speed switching purpose and IRF 540N

MOSFET is connected to the motor to handle the larger current drawn by the

Valve.

INTRODUCTION TO MICROCONTROLLER

INTRODUCTION TO MICROCONTROLLER

PIC WITH RS-232

INTRODUCTION:

The PIC Microcontrollers are supported with a full range of Hardware and

software development tools. The used PIC16F870 device comes in 28 pin package. To

communicate with the PIC we are using RS-232 standard port of computer. In personal

computer, data transfer takes place serially. RS-232 standard is used for serial

communication. PIC Microcontroller is linked to PC through the RS-232 port. The PC

displays the menu for selecting the calibrating equipment and all the calibration results

graphically and in tabular form. The user can access the calibration reports, comparison

graphs etc at any time using the menu offered in the PC.

PIC MICROCONTROLLER:

The PIC Microcontrollers are supported with a full range of hardware and software

development tools. The used PIC16F870 device comes in 28 pin package. To

communicate with the PIC we are using RS-232 port of the computer. So we have to

initialize the port before using it. To initialize and to communicate with the PIC, the file

COM.C defines and uses several functions. The functions and their definitions are given

below.

ADC RELATED FUNCTIONS:

void Set Reference (int ref);

This function is used to set the INTERNAL or EXTERNAL reference for the ADC.

The parameter ref can accept any one of the two values. They are,

Internal_ref

External_ref

Set Reference (INTERNAL_REF);

Float GetAdcCh(int Chno);

This function is used to get the specified channel’s (Chno) digital value from ADC. The

parameter Chno can accept a range of values from 0 to 9, which is the channel number.

For example,

Var = GetAdcCh(5);

Void Initialize Port (char * str);

This function must be called before performing any digital input/output operation.

Register D:

Register D:

Register C:

Register A:

Reserved Bits Can be configured asCannot alter

Configurable bits can be either zero or one according to the initialization. If the

particular bit is to be used as a input port then write ‘1’ to it else ‘0’ for output.

For Example,

Initialize Port (“[1ffffffff]”);

Above statement mention all registers bits are act as input port.

MICROCONTROLLER CORE FEATURES:

High-performance RISC CPU

Only 35 single word instructions to learn

All single cycle instructions except for program branches which are two cycles

Operating speed: DC-20 MHz clock input DC – 200 ns instruction cycle

4K x 14 words of Program Memory, 256 x 8 bytes of Data Memory (RAM)

Interruput capability (upto 14 Internal / External interrupt sources)

Eight level deep hardware stack

Direct, indirect, and relative addressing modes

Power-on Reset (POR)

Power-up Timer (PWRT) and Oscillator Start-up Timer (OST)

Watchdog timer (WDT) with its own on-chip RC oscillator for reliable operation

Programmable code-protection

Power saving SLEEP mode

Selectable oscillator options

Low-power, high-speed CMOS EPROM technology

Fully static design

In-circuit Serial Programming (ISC)

Wide operating voltage range: 2.5V to 5.5V

High Sink / Source current 25/25 mA

Commercial and Industrial temperature ranges

Low power consumption

<2 mA at 5V, 4 MHz

22.5 mA typical at 3V, 32 KHz

<1 mA typical standby current

PERIPHERAL FEATURES:

Timer 0: 8-bit timer / counter with 8-bit prescaler

Timer 1: 16 bit timer / counter with prescaler, can be incremented during sleep via

external crystal/clock

Timer 2: 8 bit timer / counter with 8 bit period register, prescaler and postscaler

Two capture, compare, PWM modules

Caputure is 16 bit, max. resolution is 12.5 ns

Compare is 16 bit, max. resolution is 200 ns,

PWM max. resolution is 10 bit

12 bit multi channel Analog-to Digital converter

On-chip absolute band gap voltage reference generator

Synchronous Serial Port (SSP) with SPI (Master Mode) and I 2 C

Universal Synchronous Asynchronous Receiver Transmitter, supports high / low

speeds and 9 bit address mode (USART/SCI)

Parallel Slave Port (PSP) 8 bits wide, with external RD, WR and CS controls

Programmable Brown out detection circuitry for Brownout Reset (BOR)

Programmable Low-voltage detection circuitry

COST ESTIMATION

COST ESTIMATION

1. Micro controller System -Rs.2200.00

2. Power supply - Rs. 300.00

3. Temperature sensor -Rs. 800.00

4. LCD Display unit -Rs. 800.00

5. 5 to 12 V DC interface card Rs.300.00

6. Novapan Board - Rs. 100.00

7. Project Report - Rs. 700.00

---------------Rs. 5200.00---------------

CONCLUSION

CONCLUSION

We have successfully completed the project work at our institute.

In executing this project work, we were exposed to many practical problems and

difficulties, Facing such situation and solving the problems has given us a confidence and

courage, which are very essential for a successful engineer.

By doing this project work, we understood the working principle and uses of

various sensors, switches, relays and motors. As more and more industries are

automating their manufacturing process, it will be of no doubt that micro controller will

be an integral part of any process in industry in the near future and we have utilized the

micro controller for the completion of this project.

Once again we express our sincere thanks to our staff members.

BIBLOGRAPHY

BIBLIOGRAPHY

1. Design with Micron roller – John Peatman

2. Customizing and programming PIC Micro controller – Myke Predko

3. Electronics for you Projects – Volume 1 to 15

4. Sensors – Keyence Manual

5. Micro controller and its application – Kenneth Ayala

6. www.microchip.com

7. www.google.com

8. www.8051.com

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