Automatic Temperature Control of Furnace

1
1,2

Mayank Singh, 2Mukesh Kumar Bharti

Electronics and Instrumentation, Galgotias College Of Engineering And Technology Greater Noida
1 2

mayanksingh880@gmail.com bhartimukesh4@gmail.com

Abstract The solution of this problem is Automatic Temperature Control of Furnace it is very useful to managing and controlling of the temperature of furnace. The main aim of this project is save the fuel which is feed to the Furnace. This is main done by the controlling the temperature of furnace. By analysing the temperature, our system controls the element system of the furnace. In this system, there is a sensor RTD which is placed in a furnace whose temperature is to be controlled. The RTD senses the temperature and supplied the signal to controller which decide or analysis the temperature and compare it with the reference temperature which is either maximum or minimum temperature. If the temperature of furnace increases the maximum limit, the feeding belt is automatically OFF by relay. If the temperature is less than the minimum limit then the feeding is automatically ON. Thus the fuel has been saved. Keywords RTD, MICROCONTROLLER 16F72, IC SENSOR, CRYSTAL OSCILLATOR, FND.

II.

AIM OF PROJECT

The main aim of this project is save the fuel which is fed to the furnace. This is main done by the controlling the temperature of furnace. By analysing the temperature, our system controls the feeding system. Here we use a temperature sensor which can sense the temperature of the furnace ,on sensing temperature it will forward the measured temperature to the microcontroller which control the entire operation of controlling temperature

III.

HARDWARE REQUIREMENTS:-

I.

Introduction

1) PIC Microcontroller 16F72 2) LM7805 Regulator 3) Power Supply 4) Resistors 5) Capacitors 6) Transistors 7) Connectors 8) Function numeric display(FND) 9) Light emitting diode(LED) 10) Temperature sensor 11) RELAY

In Industry & mills, the fuel which is fed to the furnace is controlled manually. So there is loss of fuel energy and the extra fuel generated is wasted. It may be controlled by controlling the feeder or belt. The solution to this problem is AUTOMATIC TEMPRATURE CONTROL OF FURNACE.. It is very useful to managing and controlling of the temperature of furnace. The main aim of this project is save the fuel which is fed to the Furnace. This is main done by the controlling the temperature of furnace. By analysing the temperature, our system controls the element system of the furnace. In this system, there is a sensor RTD which is placed in a furnace whose temperature is to be controlled. The RTD senses the temperature and supplied the signal to controller which decide or analysis the temperature and compare it with the reference temperature which is either maximum or minimum temperature. If the temperature of furnace increases the maximum limit, the feeding belt is automatically OFF by relay. If the temperature is less than the minimum limit then the feeding is automatically ON. Thus the fuel has been saved.

IV.

SOFTWARE REQUIREMENTS:-

MPLAB IDE v7.00: Source code Editor , Assembler

 V. BLOCK DIAGRAM

Capacitor Transistor LEDs Resistors FND Crystal Oscillator

VIII.

COMPONENT DESCRIPTION

SEVEN-SEGMENT DISPLAY: A seven-segment display (abbreviation: "7-seg(ment) display"), is a form of Display device that is an alternative to the more complex dot-matrix displays. Seven-segment displays are commonly used in electronics as a method of displaying decimal numeric feedback on the internal operations of devices. Contents: Here we have used a temperature sensor which will sense the temperature of the boiler, on sensing temperature it will forward the measured temperature to the microcontroller which control the entire operation of controlling temperature. Controller used here is a PIC controller which has inbuilt ADC using the ADC function the received signal is processed. The microcontroller compares the sensed temperature with the reference temperature which is either maximum or minimum temperature of the furnace and thus controls it. If the temperature of furnace increases the maximum limit, the furnace is automatically OFF by relay. If the temperature is less than the minimum limit then the furnace is automatically ON. Thus the fuel has been saved. 1. 2. 3. Concept and visual structure Implementations Alphabetic display

VI.

BLOCK DIAGRAM DESCRIPTION

VII.

REQUIREMENT OF COMPONENTS

Following is the list of components that are necessary to build the assembly of the Digital Speedometer Cum Odometer: Micro Controller 16F72

IC Sensor Step Down Transformer

Concept and visual structure: 1. A typical 7-segment LED display component, with decimal point. 2. A seven segment display, as its name indicates, is composed of seven elements. Individually on or off, they can be combined to produce simplified representations of the Hindu-Arabic numerals. Each of the numbers 0, 6, 7and 9 may be represented by two or more different glyphs on seven-segment displays. The seven segments are arranged as a rectangle of two vertical segments on each side with one horizontal segment on the top and bottom. Additionally, the seventh segment bisects the rectangle horizontally. There are also fourteensegment displays and sixteen-segment displays (for full alphanumeric ); however, these have mostly been replaced by dot-matrix displays. Often the seven segments are arranged in an oblique, or italic, arrangement, which aids readability. The segments of a 7-segment display are referred to by the letters A to G, as follows: 3.

displays, though even in LCDs 7-segment displays are very common. Unlike LEDs, the shapes of elements in an LCD panel are arbitrary since they are formed on the display by a kind of printing process. In contrast, the shapes of LED segments tend to be simple rectangles ,reflecting the fact that they have to be physically moulded to shape, which makes it difficult to form more complex shapes than the segments of 7segment displays. However, the high common recognition factor of 7-segment displays, and the comparatively high visual contrast obtained by such displays relative to dot-matrix digits, makes seven-segment multiple-digit LCD screens very common on basic calculators. X. ALPHABETIC DISPLAY:

In addition to the ten numerals, seven segment displays can be used to show letters of the latin, cyrillic and greek alphabets including punctuation, but only few representations are unambiguous and intuitive at the same time: uppercase A, B, C, E, F, G, H, I, J, L, N, O, P, S, U, Y, Z, and lowercase a, b, c, d , e, g, h, i, n, , o, q, r, t, u. Detailed tables of alternative seven-segment symbols for letters and punctuation are given in the section Character representations, below.

Where the optional DP decimal point (an "eighth segment") is used for the display of non-integer numbers. IX. IMPLEMENTATIONS:

Most separate 7-segment displays use an array of lightemitting diodes (LEDs), though other types exist using alternative technologies such as cold cathode gas discharge, vacuum fluorescent, incandescent filament, liquid crystal display (LCD), etc. For gas price totems and other large signs, electromagnetically flipped light-reflecting segments (sometimes called "vanes") are still commonly used. An alternative to the 7-segment display in the 1950s through the 1970s was the vacuum tube-like nixie tube. For many applications, dot-matrix LCDs have largely superseded LED

HOW 7-SEGMENT DISPLAY WORKS? The 7 segment display is found in many displays such as microwaves or fancy toaster ovens and occasionally in noncooking devices. It is just 7 LEDs that have been combined into one case to make a convenient device for displaying numbers and some letters. The display is shown on the left. The pin out of the display is on the right. This version is a

common anode version. That means that the positive leg of each LED is connected to a common point which is pin 3 in this case. Each LED has a negative leg that is connected to one of the pins of the device. To make it work you need to connect pin 3 to 5 volts. Then to make each segment light up, connect the ground pin for that led to ground. A resistor is required to limit the current. Rather than using a resistor from each LED to ground, you can just use one resistor from Vcc to pin 3 to limit the current.

the semiconductor material, not by the colouring of the 'package' (the plastic body). LEDs of all colours are available in uncoloured packages which may be diffused (milky) or clear (often described as 'water clear'). The coloured packages are also available as diffused (the standard-type), ortransparent.

XI.

LIGHT EMITTING DIODEs (LEDs) COLOURS OF LEDS

Circuit Symbol:LEDs are available in red, orange, amber, yellow, green, blue and white. Blue and white LEDs are much more expensive than the other colours. The colour of an LED is determined by the semiconductor material, not by the colouring of the 'package' (the plastic body). LEDs of all colours are available in uncoloured packages which may be diffused (milky) or clear (often described as 'water clear'). The coloured packages are also available as diffused (the standardtype), or-transparent. BI-COLOUR LEDS A bi-colour LED has two LEDs wired in 'inverse parallel' (one forwards, one backwards) combined in one package with two leads. Only one of the LEDs can be lit at one time and they are less useful than the tri-colour LEDs described above.

FUNCTION LEDs emit light when an electric current passes through them. The LED is a PN junction device which emits distant when a current passes through in the forward direction. (i.e. when LED is forward bias). The charge carrier recombination occurs at a PN junction as electrons cross from N side and recombines with holes on the P side. When recombination takes place the charge carrier give up energy in the form of heat and light. If the semi conducting material is translucent, the light is emitted and junction becomes the source of light.

CALCULATING AN LED RESISTOR VALUE An LED must have a resistor connected in series to limit the current through the LED, otherwise it will burn out almost instantly. The resistor value, R is given by: R = (VS - VL) / I

CONNECTING AND SOLDERING LEDs must be connected the correct way round, the diagram may be labelled a or+ for anode and k or - for cathode (yes, it really is k, not c, for cathode!). The cathode is the short lead and there may be a slight flat on the body of round LEDs. If you can see inside the LED the cathode is the larger electrode (but this is not an official identification method).

VL = LED voltage (usually 2V, but 4V for blue and white LEDs), I = LED current (e.g. 20mA), this must be less than the maximum permitted If the calculated value is not available choose the nearest standard resistor value which is greater, so that the current will be a little less than you chose. In fact you may wish to choose a greater resistor value to reduce the current (to increase battery life for example) but this will make the LED less bright. CONNECTING LEDS IN SERIES If you wish to have several LEDs on at the same time it may be possible to connect them in series. This prolongs battery

COLOURS OF LEDS LEDs are available in red, orange, amber, yellow, green, blue and white. Blue and white LEDs are much more expensive than the other colours. The colour of an LED is determined by

life by lighting several LEDs with the same current as just one LED. All the LEDs connected in series pass the same current so it is best if they are all the same type. The power supply must have sufficient voltage to provide about 2V for each LED (4V for blue and white) plus at least another 2V for the resistor. To work out a value for the resistor you must add up all the LED voltages and use this for VL. AVOID CONNECTING LEDS IN PARALLEL Connecting several LEDs in parallel with just one resistor shared between them is generally not a good idea. If the LEDs require slightly different voltages only the lowest voltage LED will light may be destroyed by the larger current flowing through it. identical LEDs can be successfully connected in parallel with one resistor this rarely offers any useful benefit because resistors are cheap current used is the same as connecting the LEDs individually. XII. TRANSISTOR

volts ON, less than five volts OF NPN is one of the two types of bipolar transistors, consisting of a layer of n-p-np transistor with the p- doped semiconductor the "base " between two N-doped layers. A small current entering the base is amplified to produce a large collector and emitter current. That is, when there is a positive potential difference measured from the emitter of an NPN transistor to its base (i.e., when the base is high relative to the emitter) as well as positive potential difference measured from the base to the collector, the transistor becomes active. In this "on" state, current flows between the collector and emitter of the transistor. Most of the current is carried by electrons moving from emitter to collector as minority carriers in the P-type base region. To allow for greater current and faster operation, most bipolar transistors used today are NPN because electron mobility is higher than hole mobility. OPERATION IN TRANSISTOR For proper working of a transistor, the voltage at the base region must be more positive than that of the emitter region. The voltage at the collector region, in turn, must be more positive than that of the base region (to put it vaguely collector>base>emitter). When voltage is applied to transistor, the emitter supplies electrons, which is pulled by the base from the emitter as it is more positive than the emitter This movement of electrons from emitter to collector creates a flow of electricity through the transistor. The current passes from the emitter to the collector through the base. Thus, adjustment of voltage in the base region modifies the flow of the current in the transistor by changing the number of electrons in the base region. In this way, small changes in the base voltage can cause large changes in the current flowing out of the collector. Let us compare transistor with valve to understand working of transistor. Emitter - analogous to the cathode of a valve The emitter only emits electrons in a NPN device. Base - the controlling terminal. A current at the base controls the current through the transistor. Collector - basically, collects the emitted electrons Somewhat analogous to the plate of a valve. Using working of pump, functioning of transistor can be explained easily. Let us consider working of pump on water current, which is similar to working of transistor on current. There are three openings in the pump, which have been labelled as follows 1. Opening "B", similar to Base of transistor. 2. Opening "C", similar to collector of transistor. 3. Opening "E", similar to emitter of transistor. Suppose, the main tank passes water into the opening "C"(same as source supplying voltage to collector) but the water cant flow ahead as there is a big plunger on the way, which is blocking the outlet to "E". Now, at this stage, if more water is passed out of main tank to opening "C", it will burst our pump (just the same way if we increase the voltage to a real transistor) opening "B" this water flows along the "Base" pipe and pushes plunger upwards allowing some water to

N-P-N TRANSISTOR SYMBOL

P-N-P TRANSISTOR SYMBOL

PRINCIPLE OF TRANSISTOR Transistors are composed of three parts a base, a collector, and an emitter. The base is the gate controller device for the larger electrical supply. The collector is the larger electrical supply, and the emitter is the outlet for that supply. By sending varying levels of current from the base, the amount of current flowing through the gate from the collector may be regulated. In this way, a very small amount of current may be used to control a large amount of current, as in an amplifier. The same process is used to create the binary code for the digital processors but in this case a voltage threshold of five volts is needed to open the collector gate. In this way, the transistor is being used as a switch with a binary function: five

flow from opening "C" to opening "E". At this point of time, some water from "B" also gets added to the water running from "C to E". If more water is poured into "B", the plunger moves up further due to which a great amount of water current flows from "C" to "E". Thus, by controlling amount of water flowing into "B", flow of water from "C" to "E" can be controlled. Therefore, we can control a BIG flow of current with a SMALL flow of current. If we continually change the small amount of water flowing into "B" then we cause corresponding changes in the LARGE amount of water flowing from "C" to "E". So 1mA flowing into "B" would allow 100mA to flow from "C" to "E". The amount of current that flows from "C" to "E" is limited by the "pipe diameter". So, no matter to what extend plunger is pushed inside opening "C". Water flowing from "C to E" can`t exceed beyond a certain level. The transistor can be used to switch the current flow on and off. If we put sufficient current into "B" the transistor will allow the maximum amount of current to flow from "C" to "E". The transistor is switched fully "on". If the current into "B" is reduced to the point where it can no longer lift the black plunger thing, the transistor will be "off". Only the small "leakage" current from "B" will be flowing. To turn it fully off, we must stop all current flowing into "B". In a real transistor, any restriction to the current flow causes heat to be produced. To get rid of this heat, the transistor might be clamped to a metal plate, which draws the heat away and radiates it to the air. XIII. SYMBOL:CAPACITOR

outmost importance when connecting the capacitor into a circuit. Positive connector has to be connected to the node with a high voltage than the node for connecting the negative connector. If done otherwise, electrolytic capacitor could be permanently damaged due to electrolysis and eventually destroyed. Explosion may also occur if capacitor is connected to voltage that exceeds its working voltage. In order to prevent such instances, one of the capacitor's connectors is very clearly marked with a + or -, while working voltage is printed on capacitor body. Several models of electrolytic capacitors, as well as their symbols are shown on the picture below.

ELECTROLYTIC CAPACITORS Tantalum capacitors represent a special type of electrolytic capacitors. Their parasitic inductance is much lower than with standard aluminium electrolytic capacitors so that tantalum capacitor with significantly (even ten times) lower capacity can completely substitute an aluminium electrolytic capacitor.

XIV.

DIODES

A P-N junction is known as semiconductor diode or crystal diode. Circuit Symbol:-

PRINCIPLE OF CAPACITOR A small device used to store huge amount of electric charge in a small room is called capacitor. Take an insulated metal plate A. Charge the plate to its maximum potential. Now take another insulated plate B. Take the plate B nearer to plate A. You will observe that negative charge will be produce on the plate near to plate A and the same amount of positive charge will be produced on the other side of plate B.

The property of a crystal diode is to conduct to current in one direction only. A crystal diode can be represented by a symbol shown in figure. The arrow in the symbol indicates the direction of conventional current flow a crystal diode. It has two terminal anode and cathode. If anode of diode is positive with respect to cathode the diode is forward bias. If anode of diode is negative with respect to cathode diode is set to be under reverse bias condition.

XV.

POWER SUPPLY

ELECTROYSTIC CAPACITORS Electrolytic capacitors represent the special type of capacitors with fixed capacity value. Thanks to the special construction, they can have exceptionally high capacity, ranging from one to several thousand F. They are most frequently used in transformers for levelling the voltage, in various filters, etc. Electrolytic capacitors are polarized components, meaning that they have positive and negative connector, which is of

There are many types of power supply. Most are designed to convert high voltage AC mains electricity to a suitable low voltage supply for electronic circuits and other devices. A power supply can by broken down into a series of blocks, each of which performs a particular function. For example a 5V regulated supply:

Dual Supplies Some electronic circuits require a power supply with positive and negative outputs as well as zero volts (0V). This is called a 'dual supply' because it is like two ordinary supplies connected together as shown in the diagram. Dual supplies have three outputs, for example a 9V supply has +9V, 0V and -9V outputs. The low voltage AC output is suitable for lamps, heaters and special AC motors. It is not suitable for electronic circuits unless they include a rectifier and a smoothing capacitor. Transformer + Rectifier XVI. RELAYS

Most relays are designed for PCB mounting but you can solder wires directly to the pins providing you take care to avoid melting the plastic case of the relay. The supplier's catalogue should show you the relay's connections. The coil will be obvious and it may be connected either way round. Relay coils produce brief high voltage 'spikes' when they are switched off and this can destroy transistors and ICs in the circuit. To prevent damage you must connect a protection diode across the relay coil. The animated picture shows a working relay with its coil and switch contacts. You can see a lever on the left being attracted by magnetism when the coil is switched on. This lever moves the switch contacts. There is one set of contacts (SPDT) in the foreground and another behind them, making the relay DPDT. The relay's switch connections are usually labeled COM, NC and NO: COM = Common, always connect to this, it is the moving part of the switch. NC = Normally Closed, COM is connected to this when the relay coil is off. NO = Normally Open, COM is connected to this when the relay coil is on. Connect to COM and NO if you want the switched circuit to be on when the relay coil is on. Connect to COM and NC if you want the switched circuit to be on when the relay coil is off.

XVII.

CRYSTAL OSCILLATOR

A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field, which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have two switch positions and they are double throw (changeover) switches. Relays allow one circuit to switch a second circuit that can be completely separate from the first. For example a low voltage battery circuit can use a relay to switch a 230V AC mains circuit. There is no electrical connection inside the relay between the two circuits, the link is magnetic and mechanical. The coil of a relay passes a relatively large current, typically 30mA for a 12V relay, but it can be as much as 100mA for relays designed to operate from lower voltages. Most ICs (chips) cannot provide this current and a transistor is usually used to amplify the small IC current to the larger value required for the relay coil. The maximum output current for the popular 555 timer IC is 200mA so these devices can supply relay coils directly without amplification. Relays are usually SPDT or DPDT but they can have many more sets of switch contacts, for example relays with 4 sets of changeover contacts are readily available. For further information about switch contacts and the terms used to describe them please see the page on switches.

It is often required to produce a signal whose frequency or pulse rate is very stable and exactly known. This is important in any application where anything to do with time or exact measurement is crucial. It is relatively simple to make an oscillator that produces some sort of a signal, but another matter to produce one of relatively precise frequency and stability. AM radio stations must have a carrier frequency accurate within 10Hz of its assigned frequency, which may be from 530 to 1710 kHz. SSB radio systems used in the HF range (2-30 MHz) must be within 50 Hz of channel frequency for acceptable voice quality, and within 10 Hz for best results. Some digital modes used in weak signal communication may require frequency stability of less than 1 Hz within a period of several minutes. The carrier frequency must be known to fractions of a hertz in some cases. An ordinary quartz watch must have an oscillator accurate to better than a few parts per million. One part per million will result in an error of slightly less than one half second a day, which would be about 3 minutes a year.

XVIII.

MICROCONTROLLER (PIC16F72)

CRITERIA FOR CHOOSING A MICROCONTROLLER

The basic criteria for choosing a microcontroller suitable for the application are: 1) The first and foremost criterion is that it must meet the task at hand efficiently and cost effectively. In analyzing the needs of a microcontroller-based project, it is seen whether an 8- bit, 16-bit or 32-bit microcontroller can best handle the computing needs of the task most effectively. Among the other considerations in this category are: (a) Speed: The highest speed that the microcontroller supports. (b) Packaging: It may be a 28-pin DIP (dual inline package) or a QFP (quad flat package), or some other packaging format. This is important in terms of space, assembling, and prototyping the end product. (c) Power consumption: This is especially critical for batterypowered products. (d) The number of I/O pins and the timer on the chip. (f) How easy it is to upgrade to higher performance or lower consumption versions. (g) Cost per unit: This is important in terms of the final cost of the product in which a microcontroller is used. 2) The second criterion in choosing a microcontroller is how easy it is to develop products around it. Key considerations include the availability of an assembler, debugger, compiler, technical support 3) The third criterion in choosing a microcontroller is its ready availability in needed quantities both now and in the future.

Through this Project We Conclude that the Temperature Of The furnace Can Control Automatically Using Temperature Sensor And Microcontroller. Microcontroller Successfully Control the Feeding of Fuel For furnace And Thus Save Fuel As Well As Control Its Temperature. ACKNOWLEDGMENT I/We hereby certify that the work which is being presented in the review paper entitled Automatic Temperature Control of Furnace by me/us in partial fulfillment of requirements for the award of degree of B.Tech. (Electronics & Instrumentation Engineering) submitted in the Department of Electronics and Instrumentation Engineering at Galgotias College of Engineering & Technology has been carried out by me/us under the supervision of Gavendra Singh.

REFERENCES
Mazedi, The Microcontroller and Embedded Systems, Prentice Hall, 1ST Edition Kenneth J. Ayala, The Microcontroller, Penram International Publishing,1996, 2nd Edition Some references : www.alldatasheets.com www.datasheetcatalog.com www.electronicscircuits.com www.scielectronics.com www.parallax.com

XIX.

PIN DIAGRAM OF PIC16F72

XX.

CONCLUSIONS