Introduction
Temperature controllers stabilize the temperature regime of the environment. The effectiveness of the temperature controller improves the productivity and performance of the machine. Industrial and manufacturing plants that utilize temperature controllers include food & beverage, plastics, packaging, healthcare, bakery, and molding plants. Thus, the capacity to regulate temperature conditions to suit operational performance improves electrical appliances’ shelf life.
A thermostat is a simple form of a temperature controller. For example, the temperature controller regulates the household heater to avoid damage. Consequently, ovens have temperature controllers that control heat conditions for the food and beverage industries. Healthcare organizations require specific temperatures to guarantee the effectiveness of drug formulations. As a result, the temperature controller stabilizes the working environment to improve drug efficacy. In summary, temperature controllers provide solutions to the effects of continuous working conditions of electrical appliances.
Project description
The project demonstrates the functions and capabilities of the digital temperature controller. The digital controller (Wh7016s) has three-relay units that modify hot and cold conditions. Consequently, the device activates an alarm system to signify temperature change. The digital temperature control relies on a separate power source for operations. As a result, the temperature controller is independent of the electrical appliance.
The three-relay design improves the operational use of the device. As a result, the operator can connect three bulbs, including the cooling, heating, and alarm components. Thus, the power source for the load compartment must be separated from the device input. The digital temperature controller members include the input measurand, the input sensor, the DAQ card, software configuration, and control element (Actuator circuits).
Implementation
Abstracting the problem
The development of the manufacturing industry depends on its production process. However, the operations of its production unit rely on durability and maintenance. As a result, the temperature control system improves performance and productivity. The optimal temperature of a manufacturing plan depends on its use. However, high temperature affects the working plan of the organization. As a result, managers rely on machine rest periods to sustain the production unit. The digital temperature controller can monitor and regulate heat conditions to sustain continuous work (Zhang, 2010).
As a result, the effects of long working hours can be mitigated with temperature control systems. Consequently, the cooling effect of the digital temperature controller can be used by pharmaceutical companies to stabilize the working environment.
Division of task
The components of a digital temperature controller include the input, output, and switch button. The controlled process of each input sensor depends on the host device. As a result, the signal and input sensor transmits temperature signals to the control unit. The optimal input sensors include a thermal device, linear input, and thermocouples. However, each input sensor varies with signal strength. For example, thermocouple sensors are categorized as T, K, B, S, and R (INSTRUMART, 2015). The temperature controllers can be organized using resistive thermal devices. However, faulty input sensors are detected by the break detect component.
The output unit activates heat, calm, and alarm mechanisms. Consequently, the output unit regulates the control process. The unit transmits signal messages to the system unit for implementation. The output unit’s components include relays, SSR drivers, DC voltage coil, SPDT, and linear digital unit. Other features of the digital temperature controller include setpoint, alarm value, and stabilizer. The switch control unit turns on the power source of the controller. The alarm system is activated when the temperature exceeds the setpoint. As a result, the signal unit transmits the alarm value to the implementation unit.
Problems faced
The challenges include setpoint configuration, system connection, sensor change, an alarm value. The cable connections have similar wire colors that required specific input. As a result, each unit must be connected with the exact color value. Consequently, the power source for the controllers must be differentiated from the load input. The setpoint adjustment requires careful practice. Sensor adjustment and alarm value challenges were encountered.
Sensor selection
Identification of the sensor type
Sensor selection is a vital process in the production phase. As a result, manufacturers select sensors based on their adaptive features. The electrical fields include the fan, heater, oven, molding machine, plastic plan, or milling systems. To avoid external involvement, the sensor selection process must be identified. The factors to consider include sensor type, output requirement, control algorithm, and a number of outputs.
Sensor sensitivity determines the effectiveness of the temperature controller. As a result, the thermistor is a suitable sensor that stabilises temperature values. Temperature value between two setpoint can be tested during the trial phase. Thus, slight changes in temperatures must be detected to avoid temperature error and system inefficiency. Manufacturers incorporate the thermistor in digital controller to improve temperature sensitivity. As a result, the capability of the input sensor enhances the temperature controller.
Performance test
The test was conducted to evaluate the sensor performance. The connection units include the cooling unit, heating unit, and alarm section. Consequently, the cooling, heating, and alarm unit is connected to a light indicator that reveals specific signal of the working environment. As a result, the power button activates the input switch on the controller. The sensor was placed in different working conditions to test its effectiveness. The sensor was placed in a water solution, body contact, and low temperature regime to test its sensitivity. However, the setpoint must be activated before the performance set.
For example, the setpoint for heat activation was adjusted to 78 degrees. As a result, the heat input was activated when the temperature reached 78 degrees. Consequently, the cooling input was adjusted to 82 degrees during the test phase. As a result, the cooling input was triggered when the temperature reached 82 degrees. However, the alarm input was triggered when the temperature reached the set value.
Measurement system implementation
Hardware configuration
The hardware configuration of the digital temperature controllers includes sensors, bulbs, power input, power output, connection cables, lighting bulbs, glass of water, and the electrical appliance. The complementary nature of the hardware component complements influences its performance. As a result, the software architecture upon activation reads the temperature of the working environment. An adjustment in temperature value is activated when the sensor unit signals the control unit. The temperature difference triggers the alarm unit when it exceeds the set value.
Software configuration
The software configurations of the digital temperature controller include setpoint value, reset ability, temperature variation, upper and lower limit. As a result, the temperature controller can be adjusted to suit specific ranges based on the working environment. For example, the alarm value can be adjusted to ranges between 1 and 5 degrees.
Conclusion
Digital temperature controllers stabilise the temperature value in electrical appliances. As a result, system units can ensure safety and efficiency. The three-relay controller mitigates the effect of long working hours of industrial appliances. As a result, external involvement can be reduced to improve performance.
References
INSTRUMART: Temperature controller basics handbook. (2015). Web.
OMEGA: Introduction to temperature control with PID controllers. (2015). Web.
Zhang, P. (2010). Advanced industrial control technology. Amsterdam: William Andrew/Elsevier.