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
2. R.DINESH
3. R.AJITH KUMAR

4. S.VISHAL
5.R.DAYANITHI
Under guidance of

Mr S.N.SUNDAR, M.E.
OCTOBER 2015
DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY).
A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE
CHENNAI 600123

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI- BANGALORE ROAD
SEMBARAMBAKKAM
CHENNAI 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

INTERNAL EXAMINER

PROJECT GUIDE

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 cosuccess of the project.

operation for the

CONTENTS

CONTENTS

CHAPTER NO.

TITLE
1. INTRODUCTION
2. SYNOPSIS
3. WORKING PRINCIPLE

ADVANTAGES

APPLICATIONS

CIRCUIT DETAILS (BLOCK DIAGRAM)

ELECTRICAL CIRCUIT DETAILS

COST ESTIMATION

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

KEYPAD

Power supply

TEMPERA
TURE
SENSOR

5V

MAIN PROCESSOR

Interface
Card

SOLENOID
VALVES

LCD DISPLAY

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,

MOTHER BOARD CIRCUIT DETAILS

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 ICs 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

TRANSFORMER

BRIDGE

POSITIVE

RECTIFIER

CHARGE
CAPACITOR

5V
REGULATOR

MOTHER
BOARD

DISPLAY
BOARD

12V
REGULATOR

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

TEMPERATURE SENSOR
CIRCUIT

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.

Keypad interface;
Here seven soft microswitches are soldered in the main board and
their connections are shown below.

PORT B (KEYPAD)INPUT & OUTPUT CIRCUIT

b) Display unit circuit:

Here two row &16 charactors LCD display is used to show the linear
dimension of the specimen. The LCD is mounted on the separate pcb board
and it is screwed on the novopan board. The LCD display is interface with
the microcontroller through PORTC 0-7.& PORTB 0,1.The LCD Pin
connections are shown below.

LCD WIRING DIAGRAM

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 channels (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
Cannot alter

Can be configured as

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

2. Power supply

-Rs.2200.00
-

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

PHOTO VIEW