(IJCSIS) International Journal of Computer Science and Information Security, Vol. 9, No.

4, April 2011

TEMPERATURE MEASUREMENT OF DYNAMIC OBJECT

Varsha Khare
Shivajirao S. Jondhle Polytechnic, Asangaon Maharashtra India
geetaharshu@gmail.com

Mrs. Rodge M.P.

Shivajirao S. Jondhle College of Engg & Tech. Asangaon, Maharashtra India
vjtsscoe@rediffmail.com

Abstract: Temperature is one of the most commonly measured and controlled parameters in industry. Proper monitoring and control of process temperature improves product quality, reduces product scrap, and improves overall product yield and process speed. Every industry in todays competitive marketplace is putting in place programs and systems to lower production costs, through automated production and quality control systems. To measure temperature of dynamic object most of the industries are using telemetry technique for temperature measurement. This technique has certain limitations like; limited range of temperature, surface of dynamic objects, battery life and safety factor. In this paper an attempt is made to overcome this limitations using infrared thermometry. This system is tested on Zamak Mould Machine & Volkswagen Welding Machine in Tata Ficosa Company, Pune. It is nondestructive measurement method so no damage to product and no breakage due to contact with moving objects. Keywords: Infrared Sensor, Microcontroller, Zamak Mould Machine & Volkswagen Welding Machine

Most of the industries are using telemetry technique for temperature measurement. In this technique miniature battery with sensor and RF transmitter is situated on dynamic object & it transmits temperature data to stationary receiver located nearby where it is measured & indicated. This has certain limitations given as below. Surface of dynamic object may not be suitable. For example oil leakage on the surface i.e. high cleaning and maintenance required. Range of temperature. Battery life.

An attempt is made to overcome these difficulties by using infrared temperature system. This technique has no battery, no contact to surface of the dynamic object. Non-contact infrared temperature systems provide accurate reliable and cost effective temperature measurements at process critical control points. This technique comes under wireless infrared telemetry. This measuring technique uses the properties of infrared (IR) light waves to determine a targets temperature. By employing an infrared detector, the sensor detects the amount of thermal energy emitted from a target as IR light. There is known relationship between the amount of infrared relation emitted by an object and the object surface temperature. II. EXPLANATION:

I.

INTRODUCTION

In industry there are many cases when we want to measure the various parameters of dynamic objects like temperature, vibration etc.; it is the need in industry as it affects life, reliability of machine. Many a times safety factor is also involved. Temperature measurement is required for many applications such as engine shaft, machine shafts, pumps, generator etc. It improves product quality, reduces product scrap, and improves overall product yield and process speed.

The Block diagram of the system is given in fig.-1. Dynamic object may be linear or rotary moving object, such as products on conveyor belts of which

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(IJCSIS) International Journal of Computer Science and Information Security, Vol. 9, No. 4, April 2011

temperature is to be measured. Infrared sensor senses the rays transmitted by dynamic object and generates equivalent analog output. This sensor detects only specific IR wavelength. So, other sources of IR light, such as, the sun, will not interfere with the measurement. It calibrates the IR t/c (thermo couple) to provide a linear output signal similar to a specific thermocouple type over a specified temperature range. Thermopile sensor with lense system provides filtering and focusing and gives variable output in mV. Buffer is used for isolation and to avoid loading to the sensor. Power supply provides the necessary voltage to all circuits. Buzzer is provided to indicate the limit i.e. alarm signal when a temperature reaches a critical high or low point. Gain amplifier changes the output in the range of 0 to 5 volts with the resolution of 0.019 volt and adjusts gain to match ADC input to 89c51 microcontroller. The 89c51 is a low power, high performance CMOS 8 bit microcomputer with 4KB bytes of flash programmable and erasable read only memory (PEROM). The Flash memory allows the program to be reprogrammed insystem or by a nonvolatile memory programmer. By combining a versatile 8 bit CPU with on a monolithic chip, the Atmel AT89c51 is a powerful microcomputer which provides a highly flexible and cost effective solution to many embedded control applications. So it is used worldwide. Microcontroller output to LCD ASCII data for display and to RS232 converter to PC.

The major features of IR t/c temperature sensors: Highly repeatable Non-contact measurement method Self-powered no excitation needed Emulates a t/c within a specific temperature range with 2% Smart IRt/cs linearize over wide temperature ranges with superb accuracy. Multiple output options available Factory calibrated to real world operation conditions Small size, simple, rugged and intrinsically safe Easy installation - Fast response time Interchangeability 1% cost effective

Advantages:
Nondestructive method so no damage to the product. less cleaning and maintenance required due to non-contact method No breakage due to contact with moving object Fast thermal response time. Wide temperature range Highly accurate data by measuring actual product temperature, not the sensors Temperature

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heat transfer by liquid. Temperature of pump should not increase otherwise it will burn itself.

START

DISABLE INTERRUPT & INITIALISE STACK

Our sensor senses the shaft temperature directly. Sensor reading is noted as indicated temperature and it is seen that present readings are on +2 more range than the actual one which is acceptable as it is below 5% of span which is required for present application. Graph 1 shows better accuracy between actual and measured temperature which is given in table 1.

SET DELAY & INITIALISED LCD

TANK
SET CHANNEL ADDRESS FOR ADC & START CONVERSION

PUMP

JOB
CONVERSI ON END?

MOTOR

Fig. 3 Schematic Setup For Colling Zamak Mould Machine

READ DATA & CONVERT IT INTO DECIMAL Actual Temp 30 35 40 45 50 55 60 65 70 75 Measured Temp 32 36 41 47 52 56 62 66 71 77

DISPLAY DECIMAL DATA

Fig. 2 FLOW CHART

EXPERIMENTATION Flow chart is given in fig. 2. Case - 1 The system is tested the temperature on Zamak Mould Machine in Tata Ficosa Company, Pune whose basic set up is shown in above fig.3. The pump motor which is circulating water should not burn due to dry run or

Table 1

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(IJCSIS) International Journal of Computer Science and Information Security, Vol. 9, No. 4, April 2011

90

80 70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10
Series1

Actual Temp 190 195 200 205 210 215

Measured Temp 192 198 202 208 212 218

Table 2

Series2

Graph 1

Case - 2. The same system is tested temperature on Volkswagen welding machine in Tata Ficosa Company, Pune. The plastic part welding (fig.4) is done by using heaters where it is not possible to attach normal sensor on the heater surface which is used for welding is having movable part (Axial) along with it. Also wiring is problem for attachment of sensor on such type of surface. The time duration for welding is 30 seconds. If temperature is higher than plastic will burn out, if it is lower than plastic will not get welded & there will be leakage and it may also damaged circuit. Sensor shows readings on higher value by 3 degree than actual one. Due to correct temperature & focusing of sensor wastage of material is reduced. Graph 2 shows better accuracy between actual and measured temperature which is given in table 2.

225 220 215 210 205 200 195 190 185 180 175 1 2 3 4
Graph 2

Series1
Series2

PLATE1

RESULT & CONCLUSION The system has been tested the temperature on different machines which were operating at very high temperatures ranges from 200 to 550. We have observed in all cases that the temperature variation ranges from 2 to 6 degree. Infra-red temperature technology improves the process control and throughput also increases production speed and reduces scrap through regulation of process critical procedures. It improves quality with a low cost, direct monitoring solution, decrease safety risks due to out of control processes. This technique can be used to measure the temperature of moving or dirty samples,

PLATE2

HEATER

Fig. 4. PLASTIC WELDING MACHINE

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too difficult or labor intensive for a contact measurement technique. The same system can work for higher temperature upto 1000 degree range by lineraising the sensor input using lookup table. The system can be connected to P.C for continuous monitoring by providing serial communication. REFERENCES [1]. The 8051 micro controller and embedded system, Muhammad Ali Mazidi [2]. Vanice Gillispi Mazdi, Persow Prentice Hall. [3]. Atmel data book for microcontroller [4]. National semiconductor manual analog electronics [5]. Infrared thermometry Dwyer USA [6]. IR manual Exergen UK [7]. www.atmel.com [8]. www.microcontroller.com

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