Presented by NABANITA CHATTERJEE Dept.

Electrical and Electronics Engineering NATIONAL INSTITUTE OF SCIENCE AND TECHNOLOGY BERHAMPUR

Introduction
The aim of the project is to develop a microcontroller

based Air Heater System.

The entire work can be divided into four parts

Hardware development 2. Hardware interface with PC 3. Parameter Identification 4. Control of process parameter
1.

Design and Implementation

The air is drawn from the atmosphere by a blowing fan.
The air is then heated as it is passed through an electric

heater. The temperature of air should be at a desired level. The entire setup mainly consists of 1. One heater 2. Three temperature sensors 3. Blowing fan 4. PIC microcontroller

Functional Blocks of the system

Air inflow fan

Sensor input
PCB

PC
Controller and display unit

An electric heater is placed within a blowing tube A four pin blowing fan is fitted at that end near the electric heater Three LM35 temperature sensors are placed at equal distance to sense the temperature of the air

LM35 TEMPERATURE SENSOR

Why LM35 ?
Precision integrated circuit temperature sensor Output voltage is linearly proportional to the celsius temperature It does not require any external calibration to provide typical accuracies

It is rated to operate over -55 degree C to +150 degree C

Electric Heater
One heater is used for heating the air flowing through the

blowing duct The supplied power is controlled by a PWM control arrangement

4 PIN CPU FAN

The fan is placed at that end of the blowing pipe where the heater is

placed
The fan is required for the cooling purpose PWM control arrangement is used for the fan speed control

PIC18F2550 (28 PIN DIP)

PIC is referred to as Peripheral Interface Controller
PIC is Harvard Architecture Microcontroller where instructions and

data come from separate sources

USB Features
USB V2.0 compliant On chip USB transceiver with on chip voltage regulator

Support up to 32 endpoints(16 bidirectional)

Wide operating voltage range(2.0 v to 5.5 v)

COMPLETE CIRCUIT DIAGRAM

Pictorial View of Real Time System

BLOWING DUCT SYSTEM

Printed Circuit Board

System Modeling
for heat balance

Q=q + qi - qo qt
where
q : rate of heat supplied by the heater qi : rate at which heat is carried into the volume V qo : rate at which heat is carried out of the volume V qt : heat lost from the volume V to the surroundings by radiation and conduction

System parameter Identification

The entire thermal system is approximated as a first order system
The sensors are physically located at certain distance and introduce a

pure time delay into the system

H(s)=Vo(S)/Vi(S) = (Ke-ds)/(s+1)
Using Visual Basic 6 at the PC end the heater input and the fan speed

can be adjusted manually and so system behaves as an open loop system

Process reaction curve method is used to calculate the time constant

and the time delay

Visual Basic 6 Window

Time Constant Calculation

Time constant =260 ms

Temperature profile of sensor

Time Delay Calculation (due to sensor 2 )

Time delay =31 ms

Time Delay Calculation (due to sensor 3 )

Time delay =62ms

Controller Design
. Proportional controller is designed to control speed of the

fan and the temperature of the air

One Integral action has been introduced parallel to

proportional controller to improve the performance.

Proportional (P) Controller

The controller output at the nth instant is given by mn = Kpen + bn Kp = proportional gain Bn = fixed bias Block Diagram of P-Controller

controller o/p
where

mn = Kpen + bn

Kp = proportional gain Bn = fixed bias

P Controller Response

Sensor1 response

P Controller Response

Sensor2 response

P Controller Response

Sensor3 response

PI Controller

m = Kp e(t) + 1/Ti0t e(t).dt + b

PI Controller Response

Sensor1 response

PI Controller Response

Sensor2 response

PI Controller Response

Sensor3 response

PC End Interfacing
USB 2.0 Port is connected to pin 15 and pin 16 of the

microcontroller for interfacing.

The particular PIC microcontroller incorporate fully featured

USB Communication module

So USB compatible data acquisition , monitoring and control is

possible

Conclusion
A microcontroller based air heater system is developed
The temperature of air and speed of the blowing fan can be monitored

and controlled both manually and automatically

The temperature sensors sense the temperature of the air throughout

the length of the blowing duct and monitoring and control of the control parameters are done at the PC end.
The system designed is simple, easy to operate and can be used as a

model for training and research purpose.

Application and Future Scope

The process air heater is used in a number of different types of industrial plant like food processing industry , chemical process plants , manufacturing plants etc.
The range of the temperature that is monitored and controlled here can also be improved

The high level language offers sufficient flexibility for developing control algorithms using fuzzy logic , neural networks or genetic algorithms

THANK YOU