FINAL YEAR PROJECT

TESTING PROCESS

One of the methods for testing process is by checking the voltage and resistance value by using multi-meter. The sensor used in this project is controlled by the voltage output itself. The output voltage for temperature sensor is linearly porportional to the Celcius (centigrade) temperature. Hence the environment temperature can be analyzed by using multi-meter.

The prototype of temperature sensing using PID controller was able to detect, monitor and control the ambient temperature inside the prototype box and able to maintain safe operating temperature point of electric and electrical equipment. Only one sensor was used to detect temperature LM35 and the sensor was run properly. This project successfully programmed into the microcontroller, PIC16F887 can control LM35 as an input, control the output such as LCD 16x2 and buzzer. This project also successfully displayed the environment temperature.

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FINAL YEAR PROJECT

From the previous entry, a problem was occurs that in my project, fan2 was not working. It is because of the fan was burned. The fan was broken. So, when the output voltage go through the fan, it also not working.

SOLUTION:

I was trying with trial and error by replacing each component with new one, such as the motor driver, the rectifier, last but not least, the fan as well. After figure it out, I have changed the fan with new one. 

Here is the important of trouble shooting of every each components when it comes to failure. 

TROUBLESHOOTING

Troubleshooting is a form of problem solving, often applied to repair failure products or processes. It is a logical, systematic search for the source of a problem so that it can be solved. 

TRIAL AND ERROR

For trial and error is typically good for problems where you have multiple chances to get the correct solution. However, this is not a good technique for problems that don't give you multiple chances to find a solution.

FINAL YEAR PROJECT

PROBLEMS 

A problem was occur while trying to modified the circuit. I was just trying to make the push button with the longer wire so that i can put the wire at the wall for the prototype. I was just adjusting the push button from the PCB to a longer wire. I might burn some component on the PCB board that cause a failure to my circuit.

The figure above is the output voltage that present for output FAN1. The voltage shows 10V to operate the FAN1.

This figure is displayed the output voltage for FAN2. The voltage shows 0V. This prove that there was no voltage to operate the FAN2.  - FAILURE -

FINAL YEAR PROJECT

TEMPERATURE SENSING FLOWCHART 

      

      The flowchart above tells the flow of the temperature sensing process. The system starts when the operation system is ON. The set temperature value is sets after the operating system starts. The value of the set temperature is as the monitor values. While the systems operated, the temperature sensor as the input device starts their work by sensing the desired temperature and compared with the temperature value sets.

      When the system operation produce heat that are higher than the set temperature, the microcontroller will sent data signal to PID controller so controlling the fans that operate to controlling the heat so that the hot air can be suck out and replaced by the cool air from the outer side. The fan will operate until the temperature heat becomes natural as the set temperature values. Somehow, if the reading temperature is still in the range of the set temperature value the system will continue read the temperature.

      The last stage of the flow system is when it relates with the alarm system. The buzzer as the alarm system that activate when the extreme heat produce by the electric equipment more than  that is at the hazardous temperature. The buzzer will ON and allows the maintenance to check the failure system.

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FINAL YEAR PROJECT

PID CONTROLLER

      PID controllers are a family of controller. By using PID, a large number of options will provided. As the options is the number of possibilities for changing the dynamics of the systems. PID controller can gives a better performance that is better than using the proportional or integral alone. There are some tuning methods that available in tuning PID.

      The PID control algorithm is used for the control of almost all loops in the process industries, and is also the basis for many advanced control algorithms and strategies. In order for control loops to work properly, the PID loop must be properly tuned.

PID TUNING METHOD

A well tuned PID controller has parameters which are adapted to the dynamic properties to the process, so that the control system becomes fast and stable. If the process dynamic property varies without re-tuning the controller, the control system gets reduced stability, or becomes more sluggish.

The basic transfer functions of PID controller work as follows:

 The transfer functions of PID controller can also be written as:

STATEMENT OF PROJECT 

      

      In any kind of industries, the usage of an automation systems that doesn’t need many workers to control or supervise the machine eternally. All industries must have their own target of manufacturing their services or products. Due to accomplish their work on time or on the due date, they have to work on it and some equipment sometimes work non-stop. All workers and machines both must work consistently to each other to achieve the company’s target and also to maintain good reputations.

      One of the causes that will cause an accident is overheating on the equipment due to the industries that having an automation system works commonly nowadays. Why must monitoring the temperature? It is important to monitor or control the temperature heat carefully because the extreme temperature will cause a failure to the equipment and systems if the temperature is outside of the operating range. The damage can affect the company budget to the maintenance or replacing the damage or accident that happened. It also may affect the quality time for the company to produce the product and also affect the reputation of the company as well.

      

      In terms of education, nowadays many of higher institutions were built and somehow, the idea of producing the low cost of prototype is to help any higher institutions to get the prototype as additional learning references other than books. So, students can get more knowledge and extra information by getting closer to the real applications before they finished their studies and apply the terms on the real world. 

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FINAL YEAR PROJECT

GANNT CHART

     This gannt chart is the flow of my work that i will follow from week 1 until week the last week of semester week 15. The proposal writing already start on the first week as well. The hardest part is when the stage of idea generate. It is the toughest when on that duration, I have to search all the methods that compared to my project.

CIRCUIT RESEARCH

     From this circuit, I will construct or modified to be a new circuit that I can use for the project itself. I'm about to use the variable resistor to control the brightness of bulb so that it will make an easiest way to demonstrate the product as well. To control the value that will display on the LCD screen, I will choose to use the push button and yet. I'm thinking about the safety part of pushing the button. I'll figure it out again someday. Also, at the above circuit as well, it does not include the circuit of the motor that to drive the fan, so that the function of reducing the heat is operated. So, I will add the circuit on the modified circuit as well.

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FINAL YEAR PROJECT

WORK PLAN PROCESS

Some steps must be followed to achieved the proposed project. So, there are some steps that included to completing the task. 

ESTIMATING PROPOSED PROJECT BUDGET

To build something or to produce something or product, there should be some budget to proposed to buy some components, devices, or others to make it happen. Here included some estimating budget to be proposed.

i. HARDWARE BUDGET

ii. STATIONARY BUDGET

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FINAL YEAR PROJECT

PID CONTROLLER

PID is "proportional", "integral" and "derivative" controller. I've choose PID controller is because the simple structure of PID itself, easy to understand and possible to do the manual tunning as well as a PID calculates an "error" value as the difference between a measured process variable and a desired set point. The controller attempts to minimize the error by adjusting the process control inputs. The PID controller is mostly approach to the industrial field.

WHY USED IT? 

1. It helps get your output temperature where you want it, in a short time, with minimal overshoot, and with little error.  
2. PID is the main popular method of control in industry since it is probably the most extensively used method in industrial process control applications. 

PID controller structured is basis on three most important controller structures which there are proportional, integral and derivative controller which include in single packages of controller. The PID controller also have some disadvantages that be a factor which lead to be unsatisfactory in tuning PID controller.

PIC16F887

PIC stands for "Peripheral Interface Controller". This powerful 200 nanosecond instruction execution yet easy to program that only 35 single word instruction CMOS FLASH based 8-bit microcontroller packs Microchip's powerful PIC architecture into a 28 pin package. It's also low cost and high clock speed. It's code is extremely efficient, allowing the PIC to run with typically less program memory than its lager competitors. A simple instruction set and seamless migration between product families make this PIC the logical choice for design requiring flexibility and performance. One of the advantages is that yet easy to program that only 35 single word instructions CMOS FLASH based 8 bit microcontroller packs Microchip's powerful PIC architecture into a 28 pin package. 

SPECIAL MICROCONTROLLER FEATURES:

• Precision Internal Oscillator:
• factory calibrate to 1%
• software selectable frequency range of 8 MHz to 32 MHz
• software tunable
• two-speed start up mode
• fail-safe clock monitoring for critical applications
• clock mode switching during operation for low power operation
• power saving sleep mode
• power on reset (POR)
• selectable brown out reset (BOR) voltage
• extended watchdog timer (WDT) with its own on-chip RC oscillator for reliable operation
• self-reprogrammable under software control
• programmable code protection
• capture/compare/PWM (CCP) module

DATASHEET: http://www.engr.usask.ca/classes/EE/391/notes/PIC16F886.pdf

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FINAL YEAR PROJECT

On this project title, temperature sensor as the input to sense the whole temperature during the working process. Temperature sensors are needed to sense the temperature heat that will occur during the temperature system is activated and to beware about the high temperature. This is because the high temperature will effect the system.

Why Monitor Temperature? 

"COMPONENTS MAY BE DAMAGED IF THE TEMPERATURE FALLS OUTSIDE THE OPERATING RANGE AND THEN THE OPERATION WILL BE FAILURE"

At first I have to search and comparing a certain temperature sensors that available in the market that suit the characteristic of the project function before deciding to choose either one.

Desired Sensor Characteristics

 

 i.  RESISTANCE TEMPERATURE DETECTOR (RTD)

ii. IC SENSORS

 

iii. THERMOCOUPLE SENSORS

 

 iv. THERMISTOR

From all the temperature sensor above, temperature sensor LM35 is one of the most accurate and economical integrated circuit temperature sensors that available in market. The LM35 series are precision integrated circuit temperature sensors, whose output voltage is linearly proportional to the Celsius temperature. The LM35 thus has an advantage over linear temperature sensors calibrated in ° Kelvin, as the user is not required to subtract a large constant voltage from its output to obtain convenient Centigrade scaling. The LM35 also does not require any external calibration or trimming to provide typical accuracies of ±¼°C at room temperature and ±¾°C over a full -55 to +150°C temperature range.  

APPENDIX : DATA SHEET : http://www.ti.com/lit/ds/symlink/lm35.pdf  

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FINAL YEAR PROJECT

This week is an Eid-ul-Fitr holidays for all student in UniKL BMI. I will take this time to search more information relate to my project title.

PREVIOUS PROJECT 

1. THE DESIGN OF TEMPERATURE CONTROL SYSTEM USING PIC 18F4620

    Large scales of application are dedicated to control the temperature in a realistic environment suitable to various needs. In order to obtain the optimum performance it would be advantageous to provide a temperature control structure by providing a safer cooling or heating system with better performances in terms of energy efficiency, flexibility and portability. Extensively research has been made on heating control because of the necessity in practical applications. In this paper the idea focuses on a simple process that could be suitable to educational application in order to illustrate different control design aspects. Moreover, the designed plant is a low cost application with components ease of access. The plant consists in a cooler, a resistance, a sensor and a microcontroller that are encapsulated in a small testing room. The analog temperature sensor LM335 will offer information of the current state of degrees at every sampling time. To relieve the performance of the proposed cooling system it is necessary to increase the test room temperature with an electrical heat resistor made of nickel. The heat discharge in the small test room will be fixed by limiting the value of the current with a variable voltage actuator for alternative current. The function of the cooler will be to decrease the air temperature from the test room. The control architecture allows for the users to implement their knowledge of control engineering in an easy way due to process access by a friendly design. The implemented PID controller on PIC18F4620 can offer zero steady state error even if a load disturbance is introduced in the test room. In the cases where the plant response is slow, it may be possible to decrease the processor speed and save power. 

 

2.  AUTOMATIC ROOM TEMPERATURE CONTROL 

 

    The proposed system would use heated water to control the temperature of the room. Heated water would be circulated in a room by motorized pump. The motor would be controlled by a microcontroller. A thermistor would provide the temperature input to the microcontroller. The microcontroller will process the raw input, and then turn the motor on/off by comparing the current temperature with the required temperature set by the user. The proposed has been designed to control the temperature of a medium sized room. This is achieved by using a conventional water pump to circulate the water through pipes. The water is passed through an instant geyser which heats it up. Instant geysers fire-up when water is passed through them, otherwise they are dormant. This system controls the circulation of water by controlling the motor, which in turn controls the geyser. Therefore, efficiency and economy of both gas and electricity is achieved through this method of heating. Another application by some modification is the incubator. Incubator requires a constant temperature to be maintained. And this system provides an efficient mechanism for controlling the temperature in an incubator.

SYSTEM OVERVIEW

Features to make an improvement

      From all the above previous project, it usually used PIC16F876A Microcontroller and microcontroller 8051 to control the NPN transistor (BD 135). To make an improvement from others, I'm planning to change a little bit for the controller. The idea came when doing the research of the project title, the idea is to implementing PID controller to maintain the temperature by controlling the flow of air system inside the control panel. The project will includes identifying on how PID controller can be implemented in the low cost system in maintaining the safe operation temperature controller to share the product to the purpose of studies in the educational field. For all work that wanted to be done, there must be a process to implement the task. So, I've decided to separate the process of work into three main part. 

PROCESS OF WORK

In order to achieve the objective of these project, all work must be arranged neat and smooth.  

MICROCONTROLLER

A microcontroller is a small computer on a single integrated circuit containing a processor core, memory, and programmable input or output peripheral. Microcontrollers are design for embedded applications. Microcontroller is one of the microchip that emphasizes self-sufficiency and cost effectiveness, in contras to a general purpose microcontroller usually used in personal computer. 

WHY CHOOSE MICROCONTROLLER?

"IT CAN REDUCE THE SIZE AND COST."

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