TEMPERATURE CONTROLLER FOR BABY INCUBATORS VIVI BINTI OSMAN This report is submitted in partial fulfillment of the requirements for the award of Bachelor of Electronic Engineering (Industrial Electronics) With Honours. Faculty of Electronic and Computer Engineering Universiti Teknikal Malaysia Melaka ‘Mei 2008vi ABSTRACT ‘Temperature plays an important part in our environment. Changes in temperature can effect the behavior of human beings, plants and even materials such as semiconductors. This project is to control the temperature of a given environment such as baby incubator. A baby mother’s womb, The system will function as stated in the programming code of a ‘ocontroller is used to control the temperature in a cubator where the temperature had to be kept constant at 36.9 °C as in PIC in order to keep the temperature stable. A simple temperature controller which has least complex circuitry has to be designed so that it saves space and be more reliable for an incubator. Present design which uses microprocessor as main controller in digital signal processing combined with complex combinational logic circuit are redundant and needs to be improved in the sense of functionality. Hence, replacement of microcontroller with a PIC microcontroller is prudent action due to its efficiency and reliability especially in an incubator where the life of an infant relies on it.vii ABSTRAK, Suhu memainkan peranan penting dalam kehidupan kita, Perubahan suhu boleh membawa kesan kepada kehidupan manusia, tumbuh-tumbuhan dan bahan lain seperti semikonduktor. Project ini bertujuan untuk mengawal suhu pada sesuatu persekitaran seperti inkubator bayi, Pengawalmikro di gunakan untuk mengawal suhu di dalam inkubator bagi memastikan suhu sentiasa tetap pada 36.9 °C seperti di dalam rahim ibu. Sistem ini akan berfungsi seperti yang di nyatakan dalam kod aturcara PIC untuk memastikan suhu stabil, Justeru itu, fitar pantauan dan kawalan suhu yang ringkas dan effisien perlu dirangkumkan dalam rekaan inkubator bayi Litar inkubator bayi masa kini menggunakan mikropemproses yang mempunyai sambungan komponen dan perkakasan yang kompleks. Rekaan sebegini menggunakan kuasa yang tinggi dan mempunyai kadar tindak balas yang lambat. Mikropengawal mempunyai tahap kecekapan tinggi dan rekaan dalaman yang ringkas bagi menggantikan mikropemproses dalam rekaan litar kawalan inkubator bayi. Langkah ini sangat penting kerana nyawa bayi tersebut bergantung pada kecekapan dan tindak balas sistem kawalan yang pantas.CHAPTER I INTRODUCTION 1.1 Overview This project is to design a temperature controller to be used to control the temperature of a small environment such as a baby incubator. A baby incubator is an infant-stimulating system used for intensive care of the newborn, premature or sick baby. It provides a safe and clean environment, which has fresh air, clean and sterile ambient conditions for the babies. In addition to these, the incubator environment provides a homogeneous and stable temperature, a relative humidity (RH) level and atmospheric gas concentration that is needed especially for intensive care of the premature baby. Usually the controller used in the baby incubator is a microprocessor. 1.2 Problem Statement Premature or tiny babies are unable to keep themselves sufficiently warm. They are also very weak and prone to infections. An incubator is a special type of a cot which ions as inside provides an ideal environment for the baby. It tries to stimulate the condithe mother’s womb. Current studies relate infant’s death in some cases while being cared in incubator due to suffocation and malfunction of the incubator. This happen when the temperature in the incubator increase and cause the level of CO3 to increase too. Beside, current incubator design uses combinational logic circuit which has more complicated connection involving the analog signal processing to the microprocessor and controlling system. This type of circuit will cause problems such + Space limitation [2] Lots of resistors, capacitors and other electrical components are being soldered onto one ci controller system. This circuit certainly consumes it plus large spaces in the interior part of the incubator. Thus, this type of is not very sufficient to be implemented in the incubator. + High power consumption [2] The big conventional combinational logic cireuit consume large amount of power to run the incubator due to its components characteristics. So, this circuit is not power efficient. + High heat dissipation (2] Consuming large amount of power certainly leaves effects to heat dissipation by the electrical components in the combinational logic circuit. This high heat dissipation would affect the performance of electronic components especially diodes in the forward- and reverse- bias regions according to the equation below: Ip = e-1) + Slow response for actuation [2] ‘The complex connections in the combinational logic circuit furthermore impose on the signal transmission due to lots of electronic components the signal must go through before it reaches the control system. This slow and long signal procedureeffectuate the suppose response and furthermore might bring fatality to the infant in the incubator. Therefore, it is highly recommended that the controller has reduced circuit ‘complexity and increase the control system action time response. PIC microcontroller is the solution to all the problems since PIC microcontroller offers more efficient, reliable and accurate control. 1.3 Objective ith temperature The main objective of this project is to design a baby incbator control using PIC microcontroller, while monitoring the incubator temperature. 1.4 Scope of Work The scopes are: i, Search for information related to required environment, for example the size of the baby incubator, function of the incubator and any information related to this project. ji, Search for the material and equipment required for this project. iii, Build an incubator that is suitable and functions almost the same as available incubator. This may require some research at the hospital. iv. Design the PIC microcontroller programming code according to the specification of temperature control in C language. Design the temperature control circuit using the Proteus ISIS 6 Professional. Program the microcontroller according to the specifications of the temperature control system.vii. Construct the circuit and build the model of incubator that suitable for this environment. 1.5 Project Workflow ‘The project workflow is shown in Figure 1.1 (starr) ? LTeraTuRE 5g. REVIEW | * PROGRAMMING CODE ANALYZE OATA a | HARDWARE | ca yest NO ves PROTOTYPE: ~ PROJECT —¥ Figure 1.1 Project workflowFor this project, one must have a very good understanding on the theory of the circuit, Before the project start, some studies and readings must be done in order to get th formation regarding to this project. Later, some literature review will take place to compare this project with the previous experiments and projects related to this title. The review will take journals, reports and books as its main reference. Furthermore, the PIC microcontroller programming must be write before going to the next step. If there no any problems occur, the hardware ready to be implement. The hardware implementation involves the design of the circuit in the software and constructs it on the breadboard and the built of the incubator model. The circuit for this project was designed by using the Proteus ISIS 6 Professional. Beside, it is very important, because it will help us in order to design the PCB of the circuit. If there any error occurs, the process will return to the programming code again. Next, the prototype is made and completes the project. 1.6 Thesis Outline This thesis will give the discussion on theories and temperature control system concepts of baby incubator. It also provides the temperature control system circuit specification. This thesis basically divides into five main chapters. The first chapter is mainly introduction of the whole project. It first gives a general overview of the baby incubator system and the needs of new system implementation. The first chapter also includes the objective and scopes of the project. In Chapter 2, the literature review regarding the current baby incubator system design, components and software of this project will be discussed. It will explain in detail about the structure of a baby incubator, the components and software that will beused in this project. Through this chapter, ideas on how to develop a baby incubator control system can be done. The methods used to develop the baby incubator control system in this project will be in Chapter 3. It will discuss about how to do the programming, simulation and realization of the temperature control system using various components and software. Chapter 4 will cover the discussion and results of the baby incubator temperature control system. Basically, this chapter is to prove the functionality of the temperature control system. Through this chapter, there will be no doubt of implementing the temperature control system in current baby incubator system design, Finally, the last chapter will explain the conclusion and recommendations of this project. A brief but thorough summary of this project was given. Lastly, it will discus on the possible enhancement and improvement to the project.CHAPTER IL LITERATURE REVIEW 2.1 Introduetion This chapter will review previous design of “Incubator Heating System” (United States Patent and Trademark Office, patent number: #5090617). This chapter will also present some description of the components and software used in this project. Through this chapter, ideas on how to develop a baby incubator control system can be done. This will help in explaining the perspective and methods that were used in the project.Figure 2.1: Baby incubator 2.2 Incubator Heating System. [1] For this system, an automatic incubator comprises a chamber surrounded by a water jacket and insulation and provided with temperature and gas level sensors, a gas injection solenoid valve and separate water jacket and air heaters together with microprocessor proportional-integral-derivative control for regulating temperature and gas concentration within the chamber. A fan is provided to circulate gas within the chamber and distribute heat. Manual set controls for selecting desired temperature and gas levels are provided as well as temperature and gas level displays, high and low temperature and gas indicators, and a low water jacket level indicator. Beside, the circuit is mainly controlled by microprocessor which includes the variou: part of circuit. Each circuit has its own distinctive function which operates simultaneously to control the heating and CO, gas control system. It has control panel which provide temperature set point control allowing a user to select the desired9 concentration of temperature to be maintained within incubator chamber. The control panel also includes a temperature concentration display for indicating the actual level of temperature within chamber as measured by the temperature sensor. The panel provides information regarding high, normal or low temperature level conditions. The high and Jow temperatures levels are indicated by red coloured LED, while normal temperature level indicated by green coloured. The basic operation of the circuit is by monitoring the temperature within the incubator chamber. The temperature sensor will detect the temperature and send the signal to microprocessor for further action. If the temperature level is too high, then the microprocessor will send signal to the temperature injector to open the valve for as long, as the temperature level is being normalized. At the same time, microprocessor send signal to outlet fan which controls the outlet airflow in the incubator chamber will increase its speed to ventilate the excess temperature. If the temperature level is too low, then the microprocessor will send signals to inlet fan to stop, to make the temperature stabilized with the incubator chamber. During this high and low temperature level detection, the red colored LED indicator at the control panel will blink and the warning alarm will switch on until the temperature level is normalized.Soe ROL (KS EZ ee] es 007 vod Ae Figure 2.3 Controller circuit for incubator Using Microprocessorul The Figure 2.2 and 2.3 show the operation of the present control circuit. Refer to the number (92), it is the microprocessor which is the heart of the controller. It is an 80C451 microcontroller manufactured by Signetics. The microprocessor uses random memory (94) and erasable programmable read only memory for storing and operation of the controlling software. RAM (94) and EPROM (96) have data and address line connections (97) running between the microprocessor and the RAM and EPROM. ‘The temperature control switches (66) from figure 2.4 comprise the switches (306), (308), (310) while COs switches compromises switch (312), (314), (316). All of the switches are connected to a data line of multiplexer (98). The outputs of each switch being connected to display controller (100) via data lines (318), and to an input port of microprocessor (92) via data line (320). The selection lines 322 of multiplexer (98) are connected to an output port of microprocessor (92) and the output (323) of multiplexer (98) is returned to the ground, thus in operation, microprocessor (92) selects desired thumb wheel witeh (306) through (316) by selecting the appropriate multiplexer address line. With the appropriate line selected, the respective switch has its common lead connected to ground, allowing current to flow and provide the appropriate switch setting information and connected to display controller (100).The microprocessor (92) also connected to data lines (318) via data lines (320), allowing the processor to read the setting of each switch. The controller (100) is a 74C912 display controller chip, the address line (325) of the display controller being connected to the microprocessor (92). The display data output lines (222) of display controller are connected parallel to each display element of the temperature display (68) and CO> display (86). The transistors (226) are NPN types which are 2N4401 transistors. In operation, microprocessor selects the appropriate switch by asserting the corresponding lines of multiplexer (98). The setting of the selection switch will appear on data lines (318) allowing microprocessor to read it. Beside the microprocessor also uses data lines to supply current temperature and data CO; data, to display the display controller (100), where the processor will place data value on line (318) and an address12 on line (325). The others display enable lines (224) will have a low voltage applied on them. Thus the appropriate transistor (226), having a high voltage asserted on its base will switch on, allowing current flow from display element to display the asserted data fon lines (222). Microprocessor also access the various sensors of the incubator; temperature sensor (48), CO2 sensor (52), infrared CO> sensor (102), temperature calibration (104), safety calibration (106) and float switch (58) are all connected to multiplexer (108) as separate inputs. The signal output from multiplexer as in figure 2.3 is coupled to the input analog- to-digital- converter (110) is then fed via data lines (111) to the microprocessor ,where the microprocessor controls selection lines (109) to multiplexer (108) in order to read the desired sensor according to the control program ‘operating the microprocessor. CO2 sensor (52) is coupled to the control circuit of the incubator through CO» sense line (188) and CO> reference line (190). CO2 are connected through series resistors (282) and (284) to the inverting and noninverting inputs respectively of operational amplifier (286). The feedback resistor returns the output of operational amplifier to the inverting inputs, while a resistor (290) is disposed between the output of operational amplifier (286) and ground, Diode (292) is connected in series between the output of operational amplifier (286) and ground, with the anode diode connected at the operational output and the cathode retumed to analog ground. The operation of moveable resistor is to allow calibration of the output amplifier, where to provide a zero voltage output when CO; level within the chamber of the incubator, as measured by the COz sensor is zero. The moveable contact of resistor (296) is returned to analog ground through series capacitor (300). The output will allow microprocessor to read and display the voltage for servicing purposes. The parallel combination of capacitor (299) and resistor (297) is disposed between the multiplexer side of resistor (301) and analog ground. Infrared CO2 sensor (102) is a 2007-DHL -NAPCO manufactured by Valtronics of California is coupled through series resistor (302) to an input line of multiplexer (108), with the parallel combination of capacitor (305) and resistor (304) being disposed between the input line to multiplexer (108) and ground. Only one of the two sensorsB need be present and microprocessor will determines which CO. sensor is being used (sensor 52 or infrared sensor 102) based on the CO> sensor selector. In Figure 2.2, COp sensor comprises a selectable jumper which connects the input digital ground or the positive supply voltage through series resistor. The choice of sensor is typically based on the thermal conductance sensor reading fluctuate with variation in humidity, From figure 2.2, the control circuit comprises a heater relay control line (246) and a CO; solenoid control line (260) and alarm relay control line (274) and an audio alarm 120. All of them are coupled to output ports of microprocessor (92) through appropriate buffering circuitry. Heater relay buffer will comprise an operational amplifier connected in voltage follower configuration, has its noninverting input connected to a port on microprocessor while the output of buffer (240) is return to the inverting input. The output of amplifier is coupled through series resistor (242) to the base of switching transistor (244), the emitter of which is connected to ground while its collector is connected to relay control line (246) disposed in operational relationship to light operated triac (146) as in figure 2.4. Transistor (244) is suitably an NPN transistor When the microprocessor active the heater elements of the incubator, the microprocessor raises the output of the port connection to amplifier (240), causing the output of amplifier to go to high fro tuning transistor(244) on an allowing conduction through line (246). Triac (146) is activated whereby the heater elements are operated as in figure 2.4, Bes le that, the microprocessor also controls the operation of low temperature indicator (74), light emitting diode. It has anode connected to the positive supply voltage through series resistor (248) while cathode of the diode is connected to collector switching transistor (250), the emitter of which is return to digital ground while it base is couple with resistor to the output of the operational amplifier. Thus, when the microprocessor raises the output line and turns on the incubator heaters, the output line of amplifier goes high, switching the transistor on and allowing conduction through led (74) for lighting the diode, indi ite a low temperature condition. The controller also4 comprises operational amplifier (254) which is connected in a voltage follower configuration with the non inverting input coupled to an output port of microprocessor (92), the inverting input and output being connected together, and the output coupled through series resistor (256) to the base of switching transistor (258). The emitter of transistor is returned to ground while the collector is connected to CO> solenoid control line as in figure 2.4. When the microprocessor raises the output port connection to operational amplifier, the amplifier output goes high switching transistor (258) on, an allowing conduction on solenoid valve controlling line (260) for opening the solenoid. ‘The base switching transistor (262) is also connected to the output of operational (254) through series resistor (264), while emitter of transistor (262) is returned to digital ground and its collector to cathode of led (90).The anode of led (90) is empowered through series resistor (266) from positive voltage supply. When the microprocessor tums on the solenoid valve (260), the output of operational amplifier is high, forcing the base of transistor (262) high for causing the transistor conduct, where led emits light Light emitting diode (90) indicates low CO» condition within the incubator chamber. Operational amplifier (268) is connected in a voltage follower configuration with its non inverting input responding to an output port of microprocessor while the inverting input receives the amplifier output. The output of operational amplifier (268) is coupled by series resistor (270) to the base of transistor (272), having its emitter retumed to digital ground and its collector connected to alarm relay line (274). Capacitor (276) in figure 2.2 is disposed in series between series alarm relay (274) and digital ground. When an alarm condition occurs, microprocessor will raise the appropriate output port for raising the input to the operational amplifier (268), where by the output of operational amplifier (268) goes high forcing the base of transistor (272) high and allowing conduction through alarm relay line (274) to ground. As a result, the alarm relay (158) as described in connection with figure 2.4 is operated. Audio alarm (120) is also coupled to an output port of microprocessor by driving transistor (228). The base of driving transistor is coupled through series resistor (230) to the output port of microprocessor and the emitter is return to ground, while the collector1s is connected to audio alarm (120). By pass capacitor (231) is disposed between base transistor (228) and ground. When the microprocessor raises the appropriate output port, the base of transistor goes high causing transistor (228) to conduct and allowing the alarm sound. Safety set point and alarm silence switch are each connected between digital ground, and through respective series resistors (278) and (280) to input of microprocessor. Temperature sensor (48) used in this system is LM35 which manufactured by National semiconductor and connected to the control circuit by temperature sensor line (340) as in figure 2.4. Temperature sensor gets power from the connection of positive supply and analog ground. Sensor line (340) is coupled to the non inverting input of operational amplifier (342), to the positive voltage through resistor (344) and to digital ground (113) by series capacitor (316).Operational amplifier (342) which amplifies the input signal from temperature sensor, is coupled in a non inverting configuration, with feedback resistor (352) to an input multiplexer (108) which allows microprocessor to read sensor information. Resistor (410) completes a voltages divider arrangement to analog ground together with resistor (352) while capacitor (412) returns the junction of the resistor to analog ground. The control circuit for the incubator also includes analog temperature safety circuit which is connected to temperature sensor and which provides an over ride in the event that microprocessor fails to disconnect the heater in response to a high temperature condition, The analog temperature safety circuit includes operational amplifier (360), with its non inverting inputs connected to the output of operational amplifier (342) through series resistor (362) and its output returned to the non inverting input by means of resistor (364). The inverting input of amplifier (360) is connected by resistor (366) and resistor (368) in series to one terminal of variable resistor (370) , the opposite terminal of which it retumed to analog ground by the way of resistor (372). The moveable contact resistor (370) is connected to an input of multiplexer (108)and to ground through the capacitor. The analog safety circuit comprises resistor which is16 connected to the positive supply voltage and in series with (378) and resistor (380) to analog ground. The moveable contact of resistor drives the non inverting input of operational amplifiers and its return through series capacitor (384) to digital ground .An operational amplifier disposed in a voltage follower configuration has its output connected to the inverting input as well as to the junction between resistor (366) and (368). Variable resistor (378) functions as the temperature safety set point control allowing the selection of a desired safety point at which the analog safety circuit will disconnect the incubator heaters, Variable resistor (370) provides a “factory” calibration for the temperature safety and is read by microprocessor through multiplexer (108) and ‘A/D converter. It comprises switching transistor having its base connected to the output of operational amplifier through series resistor (388). Capacitor (390) is interposed between the base of transistor and digital ground. The base of transistor also coupled to a multiplexer input which allows microprocessor to read the output of operational amplifier. Transistor (386) has its emitter returned to digital ground and its collector connected to temperature safety relay line. Operational amplifier operates as a comparator, with the reference voltage level set by the variable resistor (378), while its input voltage representation of temperature level, is provide by amplifier (342). If the output of temperature sensor amplified exceeds the temperature safety point, the output of amplifier (360) will be driven sufficiently high to place transistor (386) into a conductive state thereby allowing current flow through temperature safety relay (130) and for removing power from the heater elements of the incubator. A further safety is provided by the operational amplifier (394) which has its inverting input connected to the output of amplifier (342) through resistor (396). The output of operational amplifier is fed back to the non inverting input through resistor and the non inverting input is return to analog ground through series resistors (400) and (402). Both resistors form a voltage divider for placing a predetermined voltage on the non inverting input of amplifier (394). The output of operational amplifier (394) is17 coupled by series resistor (406) to the base of switching transistor (408), the emitter of which is connected to digital ground while the collector is attached to temperature safety line. Amplifier (394) operates as a comparator and functions as a temperature sensor malfunction detector. If the output of operational amplifier is too low as a result of too Jow a temperature reading from temperature sensor, sensor presumed to have failed and the output of operational amplifier (394) will go high and driving the base of transistor (408) high and thereby allowing conduction through transistor (408). Thus, current will flow through safety relay (130) as in the figure 2.4, where open the voltage supply to the incubator heater, It can prevent from incubator overheating in the event that temperature sensor malfunction. Figure 2.4 Power circuit of incubator Using Microprocessor18 Figure 2.4 shows the power circuit includes a power entry connector for coupling to ‘AC power mains .A varistor (128) is shunted across leg one and leg two of the power input lines to provide suppression of voltage spikes from AC power source. Leg two of the power input is connected to the common contact lead of safety relay (130), while a diode (164) is line are connected to the primary of power transformer (132), the secondary of which connected to the +5V side of the relay coil. Legs one and two of the AC provides a 9.5volt AC output. The center tap of transformer secondary (132s) is connected to analog ground (189) as well as to digital ground (113) and both this ground are supplied to the cireuit in figure 2.2 and 2.3. The transformer (132) has a number of primary taps allowing the incubator to be used with various AC voltage configurations, where to provide corresponding to input voltages of 100 volts, 120 volts, 220 volts and 240 volts .A selector (220) has a common point coupled to leg of two of the incoming voltage line with the selection being made of connect the input to the appropriate transformer primary tap. Connected series with the output terminals of transformer secondary (132s) are rectifying diodes (134) and (136) where in the anodes of the diodes ydes are connected are connected to the transformer secondary and the cathodes of the to unregulated direct current line (138). Capacitor (172) is disposed between ground and line (138) to provide filtering. Voltage regulators (140) and (142) are each connected to line (138) and operate to maintain DC voltage levels .Regulator (140) is adjusted to provide 7.35 volts and this voltage is supplied to thermal conductance carbon dioxide sensor (52) as shown in figure (2). Voltage regulator is adjusted to provide and output 5.1 volt DC and this voltage is then supplied to Vee to the circuit controlling the operat of the incubator. Beside that, power circuit also compromises triac (144) which has anode two connected to the normally closed contact of temperature safety relay (130) and anode ‘one connected to the electrical resistance heater elements (62,42,34,35). Relay is activated when the temperature within the incubator chamber exceeds a safety point or when the temperature sensor malfunction is detected. If either of this occur, transistor (408) or (386) of figure 2.3 will flow through the relay and passing the safety lines to19 ground, The gate of triac (144) is coupled to anode one of optically isolated triac (146) while anode two of triac (144) is further connected through series resistor (148) to anode two triac (146),The anode of the input lighting emitting diode of isolated triac (146) is coupled through series resistor (152). When the microprocessor (92) asserts a signal of optically isolated triac(146), causing power to be applied to the various heating elements of the incubator. Furthermore, the power circuitry comprises operational amplifier (154) which is connected in a voltage follower configurati with the noninverting input. The output of operational amplifier is provided to output jack (156) and represents the temperature of the incubator chamber. Beside that, in this power circuit there have relay (158), which having one leg of the relay coil connected to output alarm relay line (274) as in figure 2.2. When the microprocessor asserts an alarm condition, current will flow on the alarm relay line through the coil of relay (158) causing the contact of the switch. The output of relay coil (158) is connected to alarm jack (160) for connection with an external alarm response for sensing device. Diode (162) is disposed across the operating coil of relay (158) with the cathode of diode (162) connected to + SV of the relay coil Power circuit also includes solenoid valve connector (166) disposed in series between +5 volt line and solenoid valve control in signal line (260) from microprocessor (02).Diode (168) is connected in series between +Svolt line and solenoid valve connector. ‘When the microprocessor (92) provides an input on line (260), current will flow through the solenoid valve, to allow CO> to be injected into the incubator chamber. Fan motor (208) is connected across legs one and two of the AC input from power entry point (126). Heater elements (42) & (62) are disposed between leg one of the AC input and anode triac (144). Selectors 220b and 220c operate in conjunction with the selector (220) to alternatively place the water jacket heater (34) in parallel across the AC power legs for 100 to 120 volt inputs. Fuse (216) is connected in series between the leg two of the AC power input and transformer (132).20 ET POINT 37.0 SET POINT Figure 2.5 Display And Control Panel Of The Incubator Using Microprocessor as a Controller Refer to the figure 2.5, the control panel comprises a temperature set control which allow the incubator operator to select the desired temperature at which chamber should be maintained. Control panel also comprises a temperature display for indicating the current temperature of the incubator chamber as measured by temperature sensor, the temperature display being a three digit LED display in a preferred embodiment. The temperature set point control and display are suitably calibrated to degrees Centigrade as shown, The control panel also comprises three indicators (70), (72), (74) for indicating whether the chamber temperature is high, normal or low. The connection of switches (66) and (82) to display controller (100), which is connected to displays (66), (68), (70), (72), (86), (84), and (88) allows for displaying a digital read-out of temperature, high temperature warning, normal temperature indication,2 RESET PSITIALIZE HAROVARE] AND SOFTWARE, Figure 2.6 Flow Chart Shows the Sequence of Operations Performs By the Control Software Programmed In Microprocessor. On initial power-up of the incubator, a controller reset is executed which reset the processor. Initialization of the hardware is then performed, resetting software variables, setting up a 250 microsecond clock for system operation, enabling system interrupts and | conversion, After that the software enter the main loop , thumb wheel switches (66) and (82) are read, and beginning analog to di comprising the following steps, firs converted to decimal values to determine the temperature and CO) set points. Second the22 analog inputs are read and converted to decimal values. The processor then executes proportional control block as discussed in figure 2.4. Next check safety- emperature is carried out by comparing the safety temperature setting with the current thumb wheel temperature setting and warning the user if the safety set point is too low in comparison with the thumb wheel temperature set point. The processor then enter checks for key pressed, displaying the safety temperature set point if the safety key (78) is depressed an! or tuning off the audio alarm (120) in the figure 2.2. After that the control digital output tums the heater relay and CO; solenoid on or off. Next the control LEDs and 8 segment LED is entered which causes the temperature of the chamber to be displayed. Beside, it also indicates the light for high, low and normal temperature and CO, as appropriate. Microprocessor will not control the low water indicator. The float sensor (58) is directly connected to low water indicator and a low water level will light indicator directly. However microprocessor is able to check the status of float switch through multiplexer. The control software will now return to the beginning of the loop and begin to execute again.fenccuLATe ANO LAT) INTEGRAL BAS; | BIAS » BIAS (kes SPAR” ety 20 8KS 4 1000 CALCULATE OUTPUT FROM BIAS, PROPCRTIONAL AND DERWATIVE TERMS, OUTPUT «BIAS - OUTPUT s 103 Figure 2.7; Flow Chart Shows the Proportional Control in the Programme. HEATER FLAG + AG THERT VARIABLE 00224 The PID control process comprises the step of determining the current error where E=SP-PV SP represent the current set point as determined by thumb wheel switches (68) or (84) and PV represent the value of process variables as measured by CO sensor (52) or temperature (48). The process variable (PV) as currently measured, is subtract from the set point (SP) as determined by the thumb wheel of the control panel. The value of, BIAS which represents the integral term of PID control is calculated as: BIAS = BIASp+ (Ke/ SPAN)* (T,/ T; )*E. The value Ke, a proportional constant, is determined empirically from each incubator chamber size and heater element wattages. This constant has the value between 0.00 and 100.0 and divided by SPAN and then multiplies by the value of T, and divided by Ti, where it is a sample of time how often PID process control loop is executed. Both T, and T; are determined experimentally. The quantity is then multiply by the ERROR (E) -Afier that, the value of output was determined by using below formula; OUTPUT =BIAS + (K, /SPAN)* [E- (Tp/Ts)*(PV —-PVx) OUTPUT is calculated from the ERROR quantity minus the quantity Tp divide by the T, multiplied by the different of the current process variable during the previous loop PVx. The value is multiplied by K. divided by SPAN and the result is added the value of BIAS from previous step to produce the output. The process variable is increasingly rapidly, output is thereby reduced, to reduce overshoot, Next, the output is compare to