89S52
Based Petrochemical Level Indicator and Controller with Temperature Monitoring For
Spinning / Cotton Process Industries
Title of the project : Petrochemical Level Indicator and Controller
With Safety Measurements for Spinning /
Cotton process Industries
Domain : Embedded Systems Design
Software : Embedded C, Keil, Proload
Microcontroller : AT89S52
Power Supply : +5V,
500mA Regulated Power Supply
Display : a)
LCD
b)
LED
LCD : HD44780 16-character, 2-line (16X2)
LED : 5mm
Sensor : Reed Switch / Magnetic sensors
Applications : Spinning
Mills, Cotton Process Industries
89S52
Based Petrochemical Level Indicator and Controller with Temperature Monitoring For
Spinning / Cotton Process Industries
ABSTRACT
BACKGROUND OF THE PROJECT
In spinning mills Petrochemical based cleaning solutions are used for
cleaning of raw cotton. This petrochemical liquid is pumped from tank to the
process container by using an AC motor. The process container is the capacity
of 2000 liters. The motor takes more than one hour to fill the process
container. An operator has to pay attention to the container to switch off the
motor to avoid overflow of petrochemical. During the process 390C
temperature has to be maintained.
AUTOMATION:
If a system is developed for automation of pump for filling the
container, no operator is required for supervising the system. Automatic water
level controllers are already available in the market. But these controllers
are not suitable for this application, as the electrodes are having direct
contact with the content. As it is petrochemical based liquid, direct contact
with electrodes is not acceptable.
Wine Yard implemented a unique system for this application by using
magnetic sensors. The sensors are fixed at specified locations on the
container. A floating magnet floats on the liquid and triggers the magnetic
sensors one-by-one based on the liquid level. Microcontroller monitors the
liquid level and the level displayed on LCD. If the maximum level is reached,
the microcontroller switches off the motor. If the liquid reaches the lower
level, the controller drives the driver circuit and switches on the motor. A
thermistor is used as temperature sensor.
The microcontroller compares the temperature with a ref constant and if
the temperature increases beyond 390C, the controller drives the
siren circuit to alert the operator.
This project is
specially designed for spinning / cotton process Industries. Direct contact of
level probes with the content / liquid is completely avoided in this project.
Magnetic sensors / Reed switches are used as level sensors. Thermistor is used
as temperature sensor. The level of the content and its temperature is
monitored by the microcontroller and displayed on LCD.
Relay driver
circuit can be activated by sensing “Level Full” and “Low Level” indicators and
operates the motor automatically. Siren driver circuit would be activated by
thermistor sensor.
As magnetic
sensors / reed switches are used, the problem of oxidization of level probes is
completely eliminated. This is an advanced, trouble-free, fit and forget system
for industrial applications.
This project
uses regulated 5V, 500mA power supply. 7805 three terminal voltage regulator is
used for voltage regulation. Bridge type full wave rectifier is used to rectify
the ac out put of secondary of 230/12V step down transformer.
Advantages:
- Fit and forget system
- Digital Level Display on 16X2 LCD
- Temperature Monitoring
- Magnetic Sensors
- Free from floride and oxidization
- Buzzer indication on abnormal temperature
Scopes for Advancements:
- Reliability of liquid level can be increased by increasing number of sensors.
- Auto temperature control can be set up in case of abnormal temperature condition
Applications:
Spinning mills
Cotton process
industries
Petrochemical
industries
Liquid level
sensing units
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