Automated Electric Furnace

Project Title

Automated Electric Furnace

Project Area of Specialization RoboticsProject Summary

Summary

In this project, we made a  furnace which heats the material at different temperatures, gives the indication of heating and place the material to Charpy impact test machine with the help of robotic arm in less time. An automated electric furnace has a specialty that it does not require any human help once the work has been started. Once the command has been given it heats the material at the desired temperature and gives the indication of heating with help of thermocouple which gives an indication to the robotic arm and robotic arm pick up the material and place it to the Charpy impact test machine at the accurate area. 

Components of the project:

Temperature Controller, Thermocouple Sensor, Relay, Chamber, plaster of Paris, Heating Element, Wires, Switches, Frame, DC Gear motors, Motor driving Circuit, Aurdino Nano, Links.

Project Objectives

Objectives:

• Heat material at different temperatures.
• Place material accurately
• Perform repetitive tasks.
• Time efficient
• Low-Cost Furnace
• Reduce human efforts for placing hot materials

Project Implementation Method

  Solid works design, Mechanical design, Electronics design, Programming:

int m1_cw=3;

int m1_acw=4;

int m2_cw=5;

int m2_acw=6;

int m3_cw=7;

int m3_acw=8;

int c=0;

void setup() {

  Serial.begin(9600);

  pinMode(m1_cw,OUTPUT);

  pinMode(m2_cw,OUTPUT);

  pinMode(m3_cw,OUTPUT);

  pinMode(m1_acw,OUTPUT);

  pinMode(m2_acw,OUTPUT);

  pinMode(m3_acw,OUTPUT);

 digitalWrite(m1_cw,LOW);

 digitalWrite(m2_cw,LOW);

 digitalWrite(m3_cw,HIGH);

 digitalWrite(m1_acw,LOW);

 digitalWrite(m2_acw,LOW);

 digitalWrite(m3_acw,LOW);

}

void loop() {

 if(analogRead(A5)>900){ digitalWrite(m3_cw,HIGH);digitalWrite(m3_acw,HIGH);}

 else if(analogRead(A5)<200){

if(c==0)

  {

  digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,HIGH);delay(4000);//// UP MOVE

digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,LOW);

digitalWrite(m2_acw,HIGH);digitalWrite(m2_cw,LOW); delay(5000);// FURNACE

digitalWrite(m2_cw,LOW);digitalWrite(m2_acw,LOW);

digitalWrite(m1_cw,HIGH);digitalWrite(m1_acw,LOW);delay(3000);//// DOWN MOVE

digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,LOW);

    while(analogRead(A5)<200);c=1;Serial.println("c=0");}

    else if(c==1)

  {

  digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,HIGH);delay(4000);//// UP MOVE

digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,LOW);

digitalWrite(m2_acw,LOW);digitalWrite(m2_cw,HIGH); delay(5000);// IMPACT Testing

digitalWrite(m2_cw,LOW);digitalWrite(m2_acw,LOW);

digitalWrite(m1_cw,HIGH);digitalWrite(m1_acw,LOW);delay(3000);//// DOWN MOVE

digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,LOW);

digitalWrite(m3_cw,LOW);digitalWrite(m3_acw,HIGH);delay(6000);/// GRIPPER OPEN

digitalWrite(m3_cw,LOW);digitalWrite(m3_acw,LOW);

digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,HIGH);delay(3000);//// UP MOVE

digitalWrite(m1_cw,LOW);digitalWrite(m1_acw,LOW);

digitalWrite(m2_acw,HIGH);digitalWrite(m2_cw,LOW); delay(2000);// FURNACE

digitalWrite(m2_cw,LOW);digitalWrite(m2_acw,LOW);

    while(analogRead(A5)<200);c=0;}

  }

 if(analogRead(A7)>900){

  digitalWrite(m3_cw,LOW);digitalWrite(m3_acw,HIGH);delay(1000);/// gripper OPEN

digitalWrite(m3_cw,LOW);digitalWrite(m3_acw,LOW);;}

 else if(analogRead(A7)<200){

  digitalWrite(m3_cw,HIGH);digitalWrite(m3_acw,LOW);delay(1000);/// gripper CLOSE

digitalWrite(m3_cw,LOW);digitalWrite(m3_acw,LOW);

  }

 else{digitalWrite(m3_acw,HIGH);digitalWrite(m1_cw,HIGH);}

}

Benefits of the Project

Benefits:

• Lab Experiments
• Industries
• Research Purposes

Technical Details of Final Deliverable

Solid Works design:

Matlab Code and DH Parametersof Robotic Arm:

DH Matrix:

DH Parameters:

XYZ Line:

GUI:

Mechanical design:

Specifications of Robotic Arm:

The robot arm for this project is the revolute type that closely resembles the human arm. Shoulder that mounted on base can move the arm through 180 degrees, from horizontal to vertical on each side. The shoulder uses dc motor, provide the torque needed to lift the rest of the arm, as well as any object that it may be grasping. Attached to the shoulder piece is an elbow that can move through 180 degrees, also powered by a dc gear motor. Gripper is attached to the elbow.

• 1.  Robotic Arm Mechanical Components:
• DC Gear motors
• Designing the base plate
• Link
• Gripper and Brake cable

Robotic Arm Electronic Components:

• Aurdino Controller
• Motor driving Circuit
• Battery

Electric Furnace Mechanical Components:

• Frame
• kiln plates
• Plaster of Paris
• Chamber

Electric Furnace Electronic Components:

• Relay
• Temperature Controller
• Thermocouple Sensor

Limitations of Electric Furnace:

This electric furnace has some limitations regarding heating element, temperature range, and heat losses.

• Heating Element: The melting point of the heating element is 1400? that’s why temperature provided to the electric furnace not more than 600?.
• Heat Losses: Heat losses from this electric furnace due to opening from the top .. Anywhere or anytime there is an opening in the furnace enclosure, heat is lost by radiation, often at a rapid rate.

Future Recommendations:

Heat losses can be reduced by increasing the wall thickness, or through the application of insulating bricks. In addition to the proper control on furnace pressure, it is important to keep the openings as small as possible and to seal them in order to prevent the release of high-temperature gas and intrusion of outside air through openings such as the charging inlet, extracting outlet and peephole on furnace walls or the ceiling.

Ceramic coatings in the furnace chamber promote the rapid and efficient transfer of heat, uniform heating and extended life of refractories. The emissivity of conventional refractories decreases with increase in temperature whereas for ceramic coatings it increases. This outstanding property has been exploited for use in hot face insulation. Ceramic coatings are high emissivity coatings which when applied has a long life at temperatures up to 1350°C. The coatings fall into two general categories-those used for coating metal substrates, and those used for coating refractory substrates. The coatings are non-toxic, non-flammable and water based. Applied at room temperatures, they are sprayed and air dried in less than five minutes. The coatings allow the substrate to maintain its designed metallurgical properties and mechanical strength.  Installation is quick and can be completed during shut down. Energy savings of the order of 8–20% have been reported depending on the type of furnace and operating conditions.

Final Deliverable of the Project Hardware SystemType of Industry Manufacturing Technologies Robotics, Shared EconomySustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	70750
Frame	Equipment	1	2800	2800
Chamber	Equipment	1	870	870
Kilin Plates	Equipment	11	600	6600
Heating Element	Equipment	20	200	4000
Temperature Controller	Equipment	1	9560	9560
Aurdino	Equipment	2	1260	2520
Relay 80A	Equipment	2	1700	3400
DC Gear Motors	Equipment	6	2840	17040
Plaster of Paris	Equipment	3	500	1500
Limit Switches	Equipment	6	30	180
Relays on Circuit	Equipment	15	20	300
Lead Acid Battery	Equipment	1	3500	3500
Thermocouple Sensor	Equipment	2	1470	2940
Material for Robotic arm	Equipment	3	1290	3870
Welding	Equipment	3	400	1200
Report Print	Miscellaneous	6	200	1200
Thesis Book	Miscellaneous	6	1400	8400
Screws	Equipment	30	5	150
Switches for furnace	Equipment	8	90	720