CE 3.1: Design and Fabrication of Temperature Controller System

This project report details the design and fabrication of a temperature controller system, undertaken by a student as part of their engineering coursework. The project utilizes a Programmable Logic Controller (PLC) and a microcontroller (Microchip PIC18F4550) to automate temperature control, converting byte values to a Centigrade scale. Key objectives included designing the system, optimizing costs, eliminating hazards, and accurately measuring and controlling temperature using a temperature sensor (LM35DZ) and a microcontroller programmed in C. The report covers the student's role as project developer, their responsibilities, and the engineering knowledge applied, including electronics, microprocessor understanding, and analog/digital circuit design. It also addresses issues encountered, such as voltage stabilization and microcontroller selection, and their corresponding solutions. The report further outlines the collaborative efforts with a supervisor and the department head, including the process of design, software and hardware integration, and also testing the system. The student effectively demonstrates a solid understanding of temperature control systems and the practical application of engineering principles.

CE 3.1 Project Information
Name of the project: Design and Fabrication of Temperature Controller System
Location of the project: Please fill
Project Duration: Please fill
Organization: Please fill
Role and Designation during the time: Project Developer
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
The temperature control is the process, which helps in maintaining the temperature at
a specific maximum or minimum level and also within the specified range. Hence, there is an
extreme necessity of temperature controlling in the several regular activities. In the project, I
have provided a proper design of the temperature controller system for ensuring that the
thermal comfort is being maintained properly. The temperature controller system is more like
the programmable thermostat at the desired temperature irrespective of the fluctuating
weather. For this project, I have used PLC or programmable logic controller for the proper
automation of the industrial processes. I had the knowledge of output voltages and hence had
the core idea of conversion of voltage to the byte values. I made the project for converting the
respective byte values to Centigrade scalar. Hence, for executing this project, I checked the
functions and operations of all the components in driver circuit and provided the design of
this system.

CE 3.2.2 Objectives developed for the project
This particular project of Design and Fabrication of Temperature Controller System
was a major project in my engineering career and professional life. I made the project for
converting temperature from byte value to Centigrade scale effectively and efficiently.
Therefore, for obtaining accurate results from the project, I eventually developed few
objectives, which are given below:
 To propose a proper and complete design for the temperature controller system.
 To optimize the overall cost of living and production in both industries and buildings.
 To eliminate the major hazards, which could result from the respective accidental
neglect of cooling or heating appliances.
 To convert the byte value temperature to Centigrade scale.
 To detect the current temperature and feeding it as the input to the project’s
microcontroller by a highly sensitive temperature sensor.
 To ensure that the microcontroller is initiating the sequence of control processes on
the basis of configuration of control programs.
CE 3.2.3 My area of work
I was hired as the project developer for this particular project of Design and
Fabrication of Temperature Controller System as I have enough field experience in core
electronics projects. I have executed several projects in my career and thus executing this
project alone was not a difficult task for me. Moreover, I had knowledge of temperature
controlling effectively and thus proposing the design of this temperature control system was
much easier. My supervisor had enough trust and confidence upon me and he was sure that I
would be able to complete the project all by myself. Thus, I was selected as the project
developer within the project.

Project Supervisor
Project
Developer (Me)
Head of the
Department
CE 3.2.4 Project Group
Figure 1: People involved in the project
CE 3.2.5 My responsibilities throughout the project
For completing the tasks, I was subsequently assigned for the work to propose a
compressed design for the temperature controller system. I had to use the formula for
converting the byte values to centigrade scalar and to make the project proper. I checked the
output voltages from this temperature sensor and then converted these output voltages to the
byte values. My other responsibilities included the programming of microcontroller and even
the development of the control programs. Since, I was the project developer in this project, I
even had to regulate the temperature changes by simply triggering the correct equipment and
influencing the respective temperature. I also checked the function and operation of each and
every project element. I, finally initiated the entire sequence of the control processes on the
basis of control program configurations.

CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the Theory of Project
In this project, I had used the terminologies of temperature control system. The major
terminologies are controlled variables, temperature sensor, effectors, controllers for
processing the temperature, set point by the external operator, thermostat function for
comparing the temperature status and temperature breach. I have utilized some of the major
components of this proposed system of temperature controller. These components are power
supplies, sensors, LCD or displays, controls, menu as well as functional unit and finally alarm
unit. I have checked the step down transformer in this project. This transformer eventually
steps down the received voltage from power outlet from 230V to 15V. Within the 15V
voltage, I checked that around 5V is responsible for driving the microcontroller.

Figure 2: Flowchart of Project Methodology
I have selected the type of the input temperature sensor and the temperature range.
Moreover, I selected the control algorithm of PID or proportional integral derivative. I also
chose the on/off control. I followed the entire flowchart of the project methodology and
combined the hardware and software components properly.
CE 3.3.2 Engineering knowledge and skills applied in the project
I had properly used my understanding of core acquaintance of electronics engineering.
For the designing purpose, I had used the understanding of microprocessor and the elements

of electronics engineering. Moreover, I also have better understanding of vector calculus,
differential equations and complex variables for the proper integration of the project. I even
applied my skill of analog and digital integrated circuit designing to make the circuit
properly. For the software development purpose, I had to use my skill and understanding of C
programming in this project.
CE 3.3.3 Accomplishment and Task Performed
For the accomplishment of the project, I have to test the functionality of the several
sections of system. I had to design the entire system circuit and then develop the controlling
algorithm. For software and hardware sequences, I made an entire system properly. I made
the project channel perfectly for the temperature controller system.
Figure 3: Block diagram of Temperature Controller System
For the temperature display, I have used LCD and hence the values were displayed.
The PIC microcontroller has read the data from temperature sensor that is within the output

voltage. This specific system could operate in three distinct conditions on the basis of
temperature range. I have used the microcontroller of Microchip PIC18F4550 and
temperature sensor of LM35DZ. I also selected the alphanumeric LCD for having 2 lines of
16 characters each.
For the control program, I have used C language and hence executed the project
properly. Regarding the hardware architecture, I kept the temperature sensor to read
temperature and fan to cool the sensor. I even kept a bulb to heat the sensor and switches to
set the lower and upper limit of temperature and a character LCD module to display the
current temperature. Regarding the voltage, I have selected 5V and thus detected the
temperature easily.
CE 3.3.4 Identified issues and their solutions
3.3.4.1 Issues
One of the problems, which I have confronted within the project was during
stabilizing the output voltage of the temperature controller system. Between the ranges of 0 V
to 15 V, I had selected the voltage of 10 V. As a result of this high voltage, I was not able to
complete the project properly. Moreover, my experimental results was not equal to the
desired results. The second issue that I had faced here was while choosing the microcontroller
for the project. I selected microcontroller 8051 for this project and hence was not getting
proper results.
3.3.4.2 Solutions
To resolve the first issue faced within the project, I had provided the solution that we
should use 5 V as the output voltage. When this voltage was lower, I was able to reduce the
errors and complexities of the project. Furthermore, finally the experimental results matched

with the desired results. For the next issue of microcontroller, I gave the idea of selecting
microcontroller Microchip PIC18F4550 and temperature sensor of LM35DZ. Hence, my
issues were resolved easily and promptly.
CE 3.3.5 Plan to produce creative and innovative work
My chief plan was for to produce an advanced along with original effort by
effectively working with my project supervisor. I also subdivided my works perfectly and
then significantly ensured that I have completed every individual part with higher efficiency
and effectiveness.
CE 3.3.6 Collaborative Work
I as well as my supervisor of project have completed this work collaboratively. I have
tested the project functionalities repeatedly for the identification of the errors in this project
and finally completed the work perfectly. Besides, I also arranged various meetings for the
work with my head of the department.
CE 3.4 Project Review
CE 3.4.1 Project Overview
I have effectively ordered all the materials required for this work. I also have
documented and noted the results while integrating my experiments. I have even utilized my
understanding of analog circuit designing for making the design appropriately and perfectly. I
have also used C programming language to provide the software architecture in this project.
CE 3.4.2 My Contribution to work
I have effectively proposed the design of temperature controller system, since I was
the project developer. My other contribution to this project was to integrate the entire system

properly and efficiently. I also found the various flaws of the project with proper solutions. I
also compared my results with the desired results.