Remote monitoring of thermal chamber using PLC and IoT

The fourth industrial revolution, Industry 4.0, concentrates on the individual customer and life cycle of products rather than organization and control. Industrial internet, smart sensors, manufacturing and control with the cloud can be achieved through the Internet of Things (IoT). Central h

Project Title

Remote monitoring of thermal chamber using PLC and IoT

Project Area of Specialization

Internet of Things

Project Summary

The fourth industrial revolution, Industry 4.0, concentrates on the individual customer and life cycle of products rather than organization and control. Industrial internet, smart sensors, manufacturing and control with the cloud can be achieved through the Internet of Things (IoT).

Central heating has become the main heating method in cold winter areas. As the heating control system is gradually improved, the requirements for monitoring system also increase.

Reactor is one of the most important equipment in pharmaceutical industry which requires continuous measurement and monitoring of process parameters like reactor mass temperature, reactor inner volume level and internal mass pressure of reactor. There are possibilities of errors in the measurements various stages involved with human workers. So advanced measurement and monitoring system is required to avoid failures, and are achieved by Programmable Logic Controller (PLC) and Supervisory Control And Data Acquisition system (SCADA).

Based on the concept of remote monitoring, the remote monitoring of a thermal chamber using a PLC controller is presented in this project. Temperature monitoring and control occupy a very important role in many fields of scientific research and practice, especially in industrial production. This project includes two parts: Interfacing PLC (Programmable logic controller) with RTU (Remote Terminal Unit) and the development of a SCADA system for real-time monitoring. By interfacing PLC with RTU, data transmission will be done wirelessly. The proposed system is capable of executing real-time measurement of data of temperature sensors that can be efficiently transferred from PLC to SCADA system which is stored and will graphically be viewed for comparing all the sensors and the temperature of the thermal chamber will be controlled accordingly.

Project Objectives

This project targets the following main objectives:

1. In a thermal chamber the main goal is to run a temperature teston various products before releasing to market. Therefore our first objective isdesigning of thermal chamber.

2. Thermal Chamber automation is the automatic centralized control of a thermal chamber heating, temperature control and cooling. Therefore our second objective is automation of thermal chamber using PLC and temperature sensor.

3. Automatic-control-instrumentation plays the most important role in any modern industrial plant. Therefore our third objective is interfacing RTU with PLC forremote monitoring and wireless data accusation.

4. SCADA systems are used to monitor and control equipment used in industry. Automate complex process and the gathering of data in real time from remote locations.Therefore our fourth objective is development of a SCADA system for real time data accusationandmonitoring.

5. Finally this system will be installed to carry out various environmental test, monitored remotely to check effects of temperature on various products offered in market.

Project Implementation Method

The parameter, such as temperature is monitored and controlled through remote monitoring. The data can be accessed from one server to another server by using IoT. Temperature is measured through a thermocouples. The measured data can be monitored by the SCADA, where the data outputs will be displayed. The temperature output will be monitored by Celsius (0C) and Fahrenheit (0 F). These data were given to the PLC and the required amount of data can be controlled. The process will be handled automatically with PLC. So it reduces the manpower requirement in the industrial monitoring field. It also attains good stability at high temperatures.

Block Diagram:

Benefits of the Project

In a rapidly changing world, time is the most precious thing. To shorten and manage time, this project is a small implementation useful to the industry. We will create a sustainable, reliable, and resilient infrastructure which will be affordable in the marketplace and will help the small firms. Following are some benefits points:

1.    Exceptionally useful for a wide range of ventures to dissect and observe information from more no. of information sources.
2.    More secure for large-scale industrial processes.
3.    Flexible for the changes in various parameters such as temperature.
4.    Energy and cost consumption will be minimized.
 

Technical Details of Final Deliverable

We are using Fatek PLC(FBS-20MAR-2AC) for automation of thermal chamber and FBs-2TC module interface with PLC and type K thermocouples in a thermal chamber connected with FBs-2TC module and ladder logic in WinProLadder will collect and store the temperature readings.

Fatek PLC will be connected with the Remote Terminal Unit(RTU) which acts as a wifi-router for other RTU and other RTU will connect with the computer/laptop and with the help of SCADA and HMI we will display the data on the computer/laptop.

After collecting data we will apply ladder logic algorithms and make 4-bit combination output of PLC and these 16 combinations will be an input of R-2R logic Digital to Analog (DAC) converter and in DAC we are using a 1-channel 5V DC relay and L7805 voltage regulators and 10k,20K resistor’s and 741 op-amp ic and output of DAC will be an input of Triac driving circuit.

In the Triac driving circuit, with the help of a voltage divider circuit, we will control the gate of Triac(BT136) and gate control the phase angle of 220V and 220V will be in series with the coil in the thermal chamber and according to temperature reading and combinational output we can maintain and control the temperature of the thermal chamber to a specified range.
 

Component:

1. Resistor’s
2. Relay’s
3. Voltage Regulators
4. Op-Amp
5. Triac
6. Thermocouples
7. Nichrome Wire(coil)
8. PLC(FBS-20MAR-2AC)
9. PLC Module (FBs-2TC)
10. RTU(Remote Terminal Unit)

Mathematical Model:

4-bit R-2R Ladder DAC:-

1. (0001)

A.(0010)

  B. (0100)

C. (1000)

B3

1

0

0

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Health , Telecommunication

Core Technology

Internet of Things (IoT)

Other Technologies

Cloud Infrastructure, Others

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com