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(IJCSIS) International Journal of Computer Science and Information Security,

Vol. 9, No. 4, April 2011

Varsha Khare Mrs. Rodge M.P.
Shivajirao S. Jondhle Polytechnic,
Shivajirao S. Jondhle College of Engg & Tech.
Asangaon Maharashtra India Asangaon, Maharashtra India

Abstract: Most of the industries are using telemetry technique for

temperature measurement. In this technique miniature
Temperature is one of the most commonly measured and
battery with sensor and RF transmitter is situated on
controlled parameters in industry. Proper monitoring and
control of process temperature improves product quality, dynamic object & it transmits temperature data to
reduces product scrap, and improves overall product stationary receiver located nearby where it is measured
yield and process speed. Every industry in today’s & indicated. This has certain limitations given as
competitive marketplace is putting in place programs and below.
systems to lower production costs, through automated
production and quality control systems. To measure • Surface of dynamic object may not be
temperature of dynamic object most of the industries are
suitable. For example oil leakage on the
using telemetry technique for temperature measurement.
surface i.e. high cleaning and maintenance
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 • Range of temperature.
overcome this limitations using infrared thermometry. • Battery life.
This system is tested on Zamak Mould Machine &
Volkswagen Welding Machine in Tata Ficosa Company, An attempt is made to overcome these difficulties by
Pune. It is nondestructive measurement method so no using infrared temperature system. This technique has
damage to product and no breakage due to contact with no battery, no contact to surface of the dynamic object.
moving objects.
Non-contact infrared temperature systems provide
accurate reliable and cost effective temperature
Keywords: Infrared Sensor, Microcontroller, Zamak
Mould Machine & Volkswagen Welding Machine
measurements at process critical control points. This
technique comes under wireless infrared telemetry.

I. INTRODUCTION This measuring technique uses the properties of infra-

red (IR) light waves to determine a target’s
In industry there are many cases when we want to temperature. By employing an infrared detector, the
measure the various parameters of dynamic objects like sensor detects the amount of thermal energy emitted
temperature, vibration etc.; it is the need in industry as from a target as IR light. There is known relationship
it affects life, reliability of machine. Many a time’s between the amount of infrared relation emitted by an
safety factor is also involved. Temperature object and the object surface temperature.
measurement is required for many applications such as
engine shaft, machine shafts, pumps, generator etc. It II. EXPLANATION:
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

ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 4, April 2011

temperature is to be measured. Infrared sensor senses The major features of IR t/c temperature sensors:
the rays transmitted by dynamic object and generates
equivalent analog output. This sensor detects only • Highly repeatable
specific IR wavelength. So, other sources of IR light, • Non-contact measurement method
such as, the sun, will not interfere with the • Self-powered no excitation needed
measurement. It calibrates the IR t/c (thermo couple) to • Emulates a t/c within a specific temperature
provide a linear output signal similar to a specific range with 2%
• Smart IRt/c’s linearize over wide temperature
thermocouple type over a specified temperature range.
ranges with superb accuracy.
Thermopile sensor with lense system provides filtering
• Multiple output options available
and focusing and gives variable output in mV. Buffer is • Factory calibrated to real world operation
used for isolation and to avoid loading to the sensor. conditions
Power supply provides the necessary voltage to all • Small size, simple, rugged and intrinsically
circuits. Buzzer is provided to indicate the limit i.e. safe
alarm signal when a temperature reaches a critical high • Easy installation - Fast response time
or low point. • Interchangeability ±1% cost effective

Gain amplifier changes the output in the range of 0 to 5 Advantages:

volts with the resolution of 0.019 volt and adjusts gain
to match ADC input to 89c51 microcontroller. The • Nondestructive method so no damage to the
89c51 is a low power, high performance CMOS 8 bit product.
microcomputer with 4KB bytes of flash programmable • less cleaning and maintenance required due to
and erasable read only memory (PEROM). The Flash non-contact method
• No breakage due to contact with moving
memory allows the program to be reprogrammed in-
system or by a nonvolatile memory programmer. By
• Fast thermal response time.
combining a versatile 8 bit CPU with on a monolithic • Wide temperature range
chip, the Atmel AT89c51 is a powerful microcomputer • Highly accurate data by measuring actual
which provides a highly flexible and cost effective product temperature, not the sensor’s
solution to many embedded control applications. So it Temperature
is used worldwide. Microcontroller output to LCD
ASCII data for display and to RS232 converter to PC.

ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 4, April 2011

heat transfer by liquid. Temperature of pump should

not increase otherwise it will burn itself.

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
DISABLE INTERRUPT & 5% of span which is required for present application.
INITIALISE STACK Graph 1 shows better accuracy between actual and
measured temperature which is given in table 1.








Fig. 3 Schematic Setup For Colling Zamak Mould Machine


Actual Temp Measured
30 32
40 41
45 47
Fig. 2 FLOW CHART 50 52
55 56
60 62
Flow chart is given in fig. 2. 65 66
70 71
Case - 1
75 77
The system is tested the temperature on Zamak Mould
Machine in Tata Ficosa Company, Pune whose basic
Table 1
set up is shown in above fig.3. The pump motor which
is circulating water should not burn due to dry run or

ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 4, April 2011

Actual Measured
70 Temp Temp
Series1 190 192
Series2 195 198
200 202
0 205 208
1 2 3 4 5 6 7 8 9 10
210 212
Graph 1
215 218
Case - 2.

The same system is tested temperature on Volkswagen Table 2

welding machine in Tata Ficosa Company, Pune. The
plastic part welding (fig.4) is done by using heaters 225
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 215
problem for attachment of sensor on such type of 210
surface. The time duration for welding is 30 seconds. If 205
temperature is higher than plastic will burn out, if it is 200 Series1
lower than plastic will not get welded & there will be
195 Series2
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 185
wastage of material is reduced. Graph 2 shows better 180
accuracy between actual and measured temperature 175
which is given in table 2. 1 2 3 4 5 6

Graph 2

The system has been tested the temperature on different

PLATE2 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,

ISSN 1947-5500
(IJCSIS) International Journal of Computer Science and Information Security,
Vol. 9, No. 4, April 2011

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


[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
[5]. Infrared thermometry Dwyer USA
[6]. IR manual Exergen UK

ISSN 1947-5500