Annealing Furnace temperature control using PID

Electric Annealing Furnace is a furnace which is used for metallurgical causes, which is used to alter the chemical & physical properties of a metal to make it more ductile. In the current scenario, we are controlling the Electric Annealing Furnace with the help of PLC (Programmable Logic Contro

Project Title

Annealing Furnace temperature control using PID

Project Area of Specialization

Blockchain

Project Summary

Electric Annealing Furnace is a furnace which is used for metallurgical causes, which is used to alter the chemical & physical properties of a metal to make it more ductile. In the current scenario, we are controlling the Electric Annealing Furnace with the help of PLC (Programmable Logic Controller) to obtain the maximum efficiency without any risk.

The inner body of anElectric Annealing Furnace made-up of bricks & glass wool material which makes its to bare the heat & the outer body is made up of brass metal.our project which is an Electric Annealing furnace which will be controlled by the PLC s7-200 of siemens, we are using this PLC because it has built-in PID in it which will be used for the constant and desired output along with it we are using the Thermocouple sensors which will sense the temp of furnace and we are also using HMI for the easy interaction of human with machine and it also has advantage of that it shows all the statistics and with it we can control the furnace rather than controlling it with PLC itself which will save time as well as it will be safe for operator to do so, then we have Android app which connects the mobile phone with the running system and allows the operator to keep an eye on readings and statistics coming from the system at that moment and then GSM comes in to the equation if any kind fluctuation or any error as such temperature change or any sort of occurs the GSM module generates a sms to warn the operator that things are not going according to the plan.Annealing is a heat treatment process that is used to alter the chemical or physical properties of a metal to make it more ductile and reduce its hardness.An annealing furnace works by heating an annealing furnace above its recrystallization temperature and then cooling once the sample has been maintained at this temperature for a suitable amount of time.During the annealing process, the atoms within a sample diffuse in the crystal lattice and the number of dislocations reduce, changing the ductility and hardness properties of the sample. Recrystallisation occurs as the sample cools down.Heating the sample is what increases the rate of diffusion by providing the energy required to break bonds. Atom movement has the effect of redistributing and eradicating the dislocations in the sample.

Project Objectives

The idea or the thought of the controlling the Furnace through the PLC (Programmable Logic Controller) was something appealing to work on. The first things is that this project is basically focuses on improved and efficient methodology of making a system more efficient, precise & risk free. Secondly, many organizations are moving towards this step of technology to get better results allowing a luxury to there worker to work efficiently . The person in the field of industries are very hard-working & there is always a constant work load so, in case of being tired or exhausted they may not be able to keep up the same quality of work so, in order to assure the making of quality product that’s why we have selected this project to work on which we will be a honour for us contribute something in the field engineering. Pakistan is a developing country and we have to take these sort of initiatives to provide every chance to our beloved homeland to compete with the other countries which are quite ahead of us in terms of technology.

Project Implementation Method

Electric Annealing Furnace is a furnace which is used for metallurgical causes, which is used to alter the chemical & physical properties of a metal to make it more ductile. In the current scenario, we are controlling the Electric Annealing Furnace with the help of PLC (Programmable Logic Controller) to obtain the maximum efficiency without any risk.

The inner body of anElectric Annealing Furnace made-up of bricks & glass wool material which makes its to bare the heat & the outer body is made up of brass metal.our project which is an Electric Annealing furnace which will be controlled by the PLC s7-200 of siemens, we are using this PLC because it controls the on/off function . we are also using PID in it which will be used for the constant and desired output along with it we are using the Thermocouple sensors which will sense the temp of furnace and we are also using HMI for the easy interaction of human with machine and it also has advantage of that it shows all the statistics and with it we can control the furnace rather than controlling it with PLC itself which will save time as well as it will be safe for operator to do so, then we have Android app which connects the mobile phone with the running system and allows the operator to keep an eye on readings and statistics coming from the system at that moment and then GSM comes in to the equation if any kind fluctuation or any error as such temperature change or any sort of occurs the GSM module generates a sms to warn the operator that things are not going according to the plan.

Benefits of the Project

Science is changing way of living revolutionary and intent to convert all things into electrical and electronic to protect the humans and there lives because we know how  much worthy a human life is. Many organization has started to use the PLC (Programmable Logic Controller) in their industries to make the system efficient and more safe etc. In order to limit or minimize the product’s cost and safe the workers from getting in the working area which can prove to be dangerous, we are looking forward for such design which helps us to achieve these goals in a convenient way. There are several categories metallurgical furnace to work on with but We have decided to work on Electric Annealing Furnace due to its versatility and wider range. We are determined to our vision and has hope to fulfill this vision with efficiency & delicacy.

Now a days globally the organizations are providing a better & risk free environment to there workers. On the other hand, the other many other organizations are switching from manual to automate their working system. One which is important that with this project we will be able reduce numerous injuries that occurs to the workers while spending ample amount of time near the furnace, that is what we are trying to eliminate. Many companies are already working on it. So all of above discussion shows the significance of our project, which is a small initiative from us as contribution for society which will be efficient & risk free along with it our industries will be able to produce the goods of the same quality as of industries abroad.

Technical Details of Final Deliverable

The main purpose of this project is to control automatically the temperature of

Annealing-furnace at different levels according to heat required for  material.The

temperature controlling done by programming with programmable logic controller.

PID is used for maintains stability during gradually rising temperature like ramp function

 Thermo-couple is used for fetching the data on run-time from Annealing-furnace continuously,

All data which we fetch from furnace by thermo-couple are in Analog-form and we convert it into form of Digital bits by using Analog to Digital converter either using built-in ADC which are available in different PLCs or by external ADC modules.

 Control system Architecture:

• Analog Signal Detection
• PLC programming.
• PID controlling

• Matlab Programming.
• Interfacing with heaters.

• Human Machine Interface with PLC
• GSM based Alarming system
• Android Application.

Final Deliverable of the Project

Hardware System

Type of Industry

Manufacturing

Technologies

Blockchain

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

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