ELECTRIC FURNACE TEMPERATURE CONTROLLED THROUGH PLC

PROJECT REPORT

M. Raheel Afzal Beem-F15-001

Abdul Moeed Beem-F15-
Amir Shoail Beem-F15-
M.Ayoub Beem-F15-
M.Hamza Beem-F15
Moasin

Superior University
2 August
University Campus, Lahore

Supervisor: Engr. Shoaib Aslam

Electrical Engineering

Abstract

The electric induction furnace has been used in a massive range of applications from
heating, melting and welding to shrink-fitting, forming, soldering and even plasma
physics. Furnaces operate at frequencies between 10 Hz to 60 MHz, and as a result,
different power supplies - operating at different frequencies - have also been
developed. Induction steel heating furnaces (ISHF) have several advantages in
practical applications. However, when a material is heated within an ISHF, its
resistivity and magnetic permeability fluctuate, which proves detrimental to the
control of power within the furnace. One way to improve power control within an
ISHF is to use a programmable logic controller (PLC). Indeed, modern PLCs are
modular, affordable, have large memory capacities, and also have special functions
such as pulse wave modulation (PWM) and data communication. Using a PLC not
only eases position, temperature and pressure control within the ISHF, but also
provides overvoltage and overcurrent protection. A new PLC control system design
allows heating to take place at constant power.
Introduction

The modern sensing technology and control methods are undergoing continuous
innovation, where the real-time temperature control is demanding higher accuracy and
faster response more than ever. Temperature control is widely used in production and
industrial control processes in all aspects. For example, in the iron and steel smelting
process, iron and steel to be baked requires heat treatment in order to achieve their
performance indicators; plastic qualitative process also needs to maintain a certain
temperature range. The fact is that the temperature control system is a complex
process object involving large inertia and pure delay with multi-variable and
time-varying parameters. At present, the PID control methodology is adopted in most
cases . In this way, different PID parameters should be selected for different control
objects, for which some practical experience is needed. As a language controller, the
fuzzy PID control is to imitate the way of human thinking and experience to achieve
its control process that can more closely reflect the best control behavior of the
controller. With strong robustness and control stability, it can be applied to different
control objects. The combination of fuzzy control and PLC, which is widely used in
industrial control, is one of the hotspots in this research area. Therefore, this work
involved the use of the PLC-based fuzzy PID control technology, by which the system
temperature was set through the fan and the heating plate to control the box
temperature.

Project Industrial goal:

Developed Cost effective temperature controlled system for auto Industry,

Textile,Mills,lather industry,Casting Mills.

System design

In this design, the temperature control system consists of hardware and software
components.

In the hardware part of the system, the acquisition module uses the temperature sensor
to measure the measured object temperature, and the temperature signals are
converted into electrical signals which are then transmitted to the temperature
transmitter, where the electrical signal is converted into a 4 ~ 20mA current signal, so
that the module REX C400 in the PLC expansion module can be facilitated as to the
analog signal input. REX C400 receives data, which will be sent directly to the PLC
output control text display (display temperature) and the temperature control device
(heating &cooling device).
 PLC
Temperature
Controller

REX C400
Thermocouple Temperature

Heating Element

Figure 1:Block Diagram Electric furnace temperature controlled through Plc

1.1 Fabrication:
1.1.1 Sheet:
It is a hard steel sheet of 4 x 4 FT. Sheet matters a lot in making any design because it is always a
framework of any design. Some people use low quality sheet which can be easily bendable. So, while
making our framework quality assurance is our first priority. We used wooden sheet of lasani that is
high quality sheet in Pakistan.
1.1.2 Cable duct:
We have used 25x25mm cable duct for designing the cable path more convenient for
the users. We have made holes in the sheet with reference to the cable dust and used
screws for fixing it.
1.1.3 Channel strip:
Channel strip is made up of iron. It is used for mounting the components. Holes are also
being done in the sheet to fix the channel strip.

Temperature Controller

The THC 400c temperature controller provides temperature control to a single output
channel.The controller can be set to manual control where by for each channel a
single temperature can be selected.The controller will then raise the temperature of
the workpiece to the selected temperature and maintain it at the level.The unit display
both workpiece and set point temperatures.

Figure 2:Temperature Controller

Thermocouple:
Feature:
Thermocouple Type:K Type (ungrounded)
Operating Temperature: 0 – 1200 °C
Probe Material:Stainless Steel
Probe Diameter :5mm
Probe Length (L):85mm
Threads Size:1/8” NPT
Threads Lock:Adjustable Compression Lock (Adjustable Length)
Cable Length:2m
Cable External Shielding:Stainless Steel Braiding
Cable Internal Insulation:Fiberglass
Fits all our temperature controllers.
Allows forming and bending of the thermocouple without the risk of cracking

Included:
1 x K Type Thermocouple

Figure 3: Thermocouple

1.2 Relays:
A relay is an electromagnetic switch that is used to turn on and turn off a circuit by a low power signal,
or where several circuits must be controlled by one signal. We know that most of the high end
industrial application devices have relays for their effective working.
 Figure 4-1: Relay

Relays are simple switches which are operated both electrically and mechanically. Relays consist of an
electromagnet and also a set of contacts. The switching mechanism is carried out with the help of the
electromagnet. There are also other operating principles for its working. But they differ according to
their applications. Most of the devices have the application of relays. The main operation of a
relay comes in places where only a low-power signal can be used to control a circuit. It is
also used in places where only one signal can be used to control a lot of circuits.

1.2.1 Specification:
 Coil Voltage: 24V dc
 Minimum Operating Temperature: -40°C
 Maximum Operating Temperature: +60°C
 Length: 34.5mm
 Maximum Switching Power DC: 300 W
 Operating Temperature Range: -40 → +60°C
 Dimensions: 34.5 x 34.5 x 53.3mm
 Coil Resistance: 430 Ω
 Application: General Purpose
 Terminal Type: Plug InHeight: 53.3mm
 Number of Poles: 3
 Contact Material: Silver Alloy
 Switching Current: 10 A
 Maximum Switching Power AC: 2.5kVA
 Depth: 34.5mm
 Maximum Switching Voltage AC: 250V ac
 Maximum Switching Voltage DC: 250V dc

1.3 PLC
A Programmable Logic Controller, or PLC, is a ruggedized computer used for industrial automation.
These controllers can automate a specific process, machine function, or even an entire production
line.
The PLC receives information from connected sensors or input devices, processes the data, and
triggers outputs based on pre-programmed parameters. Depending on the inputs and outputs, a PLC
can monitor and record run-time data such as machine productivity or operating temperature,
automatically start and stop processes, generate alarms if a machine malfunctions, and more.
Programmable Logic Controllers are a flexible and robust control solution, adaptable to almost any
application.

Siemens makes several PLC product lines in the SIMATIC S7 family. They are: S7-200, S7-300, and
S7-400. Siemens Step 7 is a powerful integrated software solution for automation, and includes the
programming environment for Siemens programmable logic controllers.

Figure 4-2: PLC

1.3.1 Specification:
 Dc input: 12/24v
 Output: 10A
 Weight: 0.3 kg
 Brand : SIEMENS
 Model: 6ED1052-1FB00-0BA6
 PLC out put 8
 PLC input 9

1.4 Power supply:

A power supply is an electrical device that supplies electric power to an electrical load. The primary
function of a power supply is to convert electric current from a source to the correct voltage, current,
and frequency to power the load. As a result, power supplies are sometimes referred to as electric
power converters. Some power supplies are separate standalone pieces of equipment, while others
are built into the load appliances that they power. Examples of the latter include power supplies
found in desktop computers and consumer electronics devices.
 Figure 4-3: Power Supply

1.4.1 Specification:
 Output Power: 101 - 200W
 Output Type: Single
 Input Voltage: 100-240V
 Output Voltage: 24V
 Output Frequency: 50/60Hz
 Output Current: 8A
 Type: Driver Led
 Load regulation: ±0.5%
 Overload: 120%~160%of rate output power
 Title: 24v dc input led driver
 Dimension: 200*98*42
 Weight: 723g

Cable Numbering:
A cable number is a unique identification label generally used on every control wire in a control
switchboard.The configuration of the actual number used can be in many different formats. A
common format (and the one that Metroid uses) generally uses 5 digits as follows:

Figure 4-4: Cable Numbering

 1st & 2nd digits: the drawing page number.

 3rd & 4th digits: the line number on the drawing.
 5th digit: the connection number on the line.
Dc Fan

24 volt dc motor used in dc fan for the purpose of high speed of air for exhaust
purpose.7 wings are used.

Electric Furnace heater

Nicrome element used in electric furnac.

Nicrome element provide effective temperature to the electric furnace ,However

heating temperature also depend on power supply wehther

Its single phase 220 or three phase 440volts.

Project hardware diagram.
Conclusions

In this work, the temperature control system was available for real-time display of the
temperature inside the box. By setting the temperature through the fan and the heating
plate, PID control algorithm was introduced to control the temperature of the box to
achieve the temperature control needs. With Siemens PLC as the controller, system
control was quite impressive with high precision, stability and reliability, being not
susceptible to outside interference. On-site commissioning revealed that box
temperature could be successfully controlled by the system. This work is expected to
bring about a good application prospect.