Design And Construction Of A Machine Overheat Detection With Alert

The Design And Construction Of A Machine Overheat Detection With Alert (PDF/DOC)

Overview

ABSTRACT

Malfunction or failure of mechanical, electrical and electro-mechanical equipment, for example equipment used in manufacturing operations, is often preceded by an increase in the operating temperature of at least some portion of the equipment. A temperature-sensitive, active material-containing actuator is pre-selected to operate at a pre-determined temperature indicative of impending equipment failure and placed in thermal contact with the equipment. If the equipment achieves the pre-selected temperature the actuator signals this by displaying a flag or providing some other passive visual indication

CHAPTER ONE1.0 INTRODUCTIONAs this article gives you the information of about the project which is the machine overheat detection with alert. This project is used to detect the temperature of the devices which are overheated. This project is very useful in the industries or factories which have many big machines where the action must have taken place when the machines are overheated. In this system we use the digital sensor of temperature which is used to detect the temperature and after detecting the temperature it sends the signals towards the microcontrollers which are attached in this project. The microcontrollers which are attached in this ,computes on the data and then transfer the temperature reading and then this reading is displayed onto the screen. The display screen consist of the seven segments which are used to display the three numbers on the LED screen. This system consist of the different push buttons. These buttons are used to set the temperature whether it set high or it set low. When we set the buttons it allows the user to do increment or do decrement in the temperature of the whole system. In this project we can use the 12 volts of transformer which is used to supply the power to the system. In this system we can set the specific temperature of the machine. If the temperature exceeds the given value which is given to it, the temperature sensor sends signals towards the microcontrollers and then microcontrollers shows message or we use the buzzer in this system which produces the beep sound on exceeding the specific value of temperature which is given to the system.This proposed system is used to detect temperature of devices that are overheated. This project is very beneficial especially in places like factories or industries consisting of big machines where it is very necessary to take some action in case the machine is overheated. The system uses a digital temperature sensor in order to detect temperature and pass on the data to the microcontroller. The 8051 microcontroller processes data and sends the temperature to be displayed on LCD screen. The display consists of 7 segment display unit to display up to 3 numbers. It consists of 4 push buttons for setting the high and low temperatures. Pressing set button allows user to increment and decrement the temperature of the system. The system uses 12V transformer to supply power to the system. We can set a limit to the temperature and in case if the system exceeds the temperature limit, an alarm rings to indicate that the system has exceeded the set temperature.As we can make this project as the final year project. So I will describe the apparatus which are required in this project. In the project of machine overheat detection alert we use microcontrollers, seven segment display, crystals, resistors, LED, temperature sensors, voltage regulator, diodes, push buttons are used in it whereas transformer which supplies the 12 volts also used in it. As microcontrollers are used in this project so we should use the software for this project. In it we use programming language of MC. We also use software in this project that is Keil software. As in this project microcontrollers are also used in it. There are many capabilities of that microcontrollers. They have internal RAM and ROM. Input and output parts with programmable pins. There are timers and counters in it.These microcontrollers are capable of serial transfer of data and serial communication of data. We can give the 5 volts to the microcontrollers. Buzzer is also used in this project. Buzzer is actually used to produce the beep sound which can inform to us about the temperature. This project is very useful. It has many advantages in the industries and on many other places.1.1 BACKGROUND OF THE PROJECTModern manufacturing operations and other operating devices use many types of equipment that are subjected to loads that cause heating in portions of the particular machine or unit. Sometimes the heating occurs in electrically powered equipment, such as electric motors, welding transformers, and welding guns. The heating may also occur in equipment such as gear boxes and machining equipment that experience frictional loading. Often the equipment is used in circumstances that make maximum use of its design capabilities and may result in substantial heat generation within a particular heavily loaded, manufacturing unit. Further, the equipment may be expected to operate with minimal operator attention or oversight.Thus, there is a need for inexpensive and low energy-consuming devices that may be adapted to function autonomously as a temperature monitor, providing an overheat signal or over-temperature signal, for the particular environment of many different machines used in manufacturing or other operations. There is a need for such devices to fit, non-obtrusively, on or in thermal contact with the equipment, or within the equipment, and to give a visible warning signal if, or when, some portion of the equipment reaches a temperature that indicates that it is overheating, which is likely to be harmful to its continued operation.This invention provides devices that are adapted for placement on (or in thermal contact with) a surface of an operating unit of equipment, machine, or the like, for the purpose of raising a visible, tabular, warning flag when the operating machine unit is experiencing overheating. The up-standing warning flag is sized and located to inform nearby operating personnel that the operating unit is in danger of being damaged by its overheated condition.Each such in-situ, overheating-detection device is shaped, or otherwise adapted, to be placed on a selected surface of the equipment, often a surface that is visible to someone in the vicinity of the equipment as it is being operated. The selected surface region of the equipment unit will serve as a useful sensing location if the unit experiences an overheating condition of operation. During operation of the equipment, heat will be transferred from the selected surface of the unit into a special material portion of the in-situ device. The special material is sometimes referred to in this specification as an “active” material or as a “smart” material. The material is characterized as active or smart because it is composed or adapted to experience a physical transformation when it is heated to a temperature range indicative of overheating in the equipment on which it is placed or in intimate thermal contact. This transformation of the active material is used to raise (or otherwise re-position) the tabular flag member to a position in which it is visible, or may otherwise give its notice of machine overheating.As will be more fully described in this specification, examples of suitable active materials include linear shapes of shape memory alloy compositions, sheets or other suitable shapes of shape memory polymers or other polymer compositions, and certain confined volumes or bodies of organic paraffin materials. As stated, the active material is selected, composed, or otherwise adapted to experience a useful physical transformation when it is heated by its contacting equipment unit to a temperature, or narrow temperature range, indicative of overheating within the machine that it serves. Often such a temperature may be in the range of about 70° C. to about 100° C. and higher. The active material will lie inactive, in suitable close heat transfer relationship with the equipment surface, during normal temperature operation of the equipment. But when the active material is heated to a temperature, indicative of overheating of the equipment, the active material will transform in its composition and shape so as to serve as an actuator of a warning flag, stored on the subject in-situ device. The actuated flag or tab will be moved (sometimes simply rotated) to a position away from the surface of the overheated equipment so as to give appropriate notice of the sudden and potentially damaging, over-temperature condition of the equipment unit.In many embodiments of the invention, an in-situ device will comprise an over-temperature, alarm-giving, tabular flag and a suitable body of active material for sensing an over-temperature condition of a unit of manufacturing equipment. The flag tab is suitably formed of metal, polymer, wood, or other solid material and may often have a generally flat rectangular shape. It may be brightly colored or coated to more-readily present its alarm-giving message. The flag member is usually stored in a concealed position near the surface of the equipment that the in-situ warning device is serving. In many embodiments of the invention, the flag is held in its stored condition against the force of a coiled spring, capable, upon a release, of quickly rotating the flag about one of its ends into its over-temperature, notice-giving position. When the active material is heated above its selected transformation temperature, the material changes shape in a manner that triggers the spring to move the flag from its stored position to its notice-giving or alarm-giving position. The flag may be brightly colored so as to be readily visible, and to give prompt notice to a worker in the vicinity of the over-heated machine, so that it may be shut down or its work-load reduced. In some embodiments of the invention, the movement of the flag to its notice-giving position may also be used to initiate an audible signal, or a more widely visible bright-light signal, of the over-temperature condition of the manufacturing unit. In other embodiments, the relocated flag may also close a circuit to initiate an electronic signal to a computer or other device for recording the over-temperature event or for a computer-initiated change in the loading or operation of the equipment unit or associated equipment.It will be appreciated that the respective components of the in-situ over-temperature device may be contained within a suitable housing for maintaining the working relationship of the active material, spring(s), flag tab(s), and other components of the subject device. The overall shape of the device is managed to enable it to fit the active material in suitable heat transfer contact with a surface of the equipment to be protected or in a position nearby the equipment in a suitable heat transfer relationship with the equipment. The device may also be constructed for re-setting of the flag-member to its stored position after the device has cooled from an overheat condition.1.2 OBJECTIVE OF THE PROJECTThe objective of this work is to design a device such as is used, for example, in manufacturing operations, each fitted-device serving to give notice of overheating of the machine to which it is attached or thermally connected The release of the visible overheat sign can be further used to initiate an audible warning signal, and can also initiate a signal for preserving a record of the overheating event.1.3 SIGNIFICANCE OF THE PROJECTThis device that is adapted for placement on (or in thermal contact with) a surface of an operating unit of equipment, machine, or the like, for the purpose of raising a visible, tabular, warning flag when the operating machine unit is experiencing overheating. The up-standing warning flag is sized and located to inform nearby operating personnel that the operating unit is in danger of being damaged by its overheated condition. Advantages of Microcontroller based Overheat detector using Temperature sensor with Buzzer indication. This project is easy to use.

1.4 APPLICATIONS OF THE PROJECT

Applications of Microcontroller based Overheat detector using Temperature sensor with Buzzer indication:This project can be used in Industries, Companies and Home to monitor High temperature condition.1.5 PROJECT WORK ORGANISATIONThe various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:Chapter one of this work is on the introduction to machine overheat detector with alert. In this chapter, the background, significance, objective limitation and problem of machine overheat detector with alert were discussed.Chapter two is on literature review of a machine overheat detector with alert. In this chapter, all the literature pertaining to this work was reviewed.Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.Chapter five is on conclusion, recommendation and references. CHAPTER TWO2.0 LITERATURE REVIEWIn this chapter we review car engine overheating and their causes and solutions:2.1 ENGINE OVERHEATING

Most engines are designed to operate within a “normal” temperature range of about 195 to 220 degrees F. A relatively constant operating temperature is essential for proper emissions control, good fuel economy and performance. But problems can arise that cause the engine to run hotter than normal, resulting in engine overheating.Your engine’s cooling system is filled with a 50/50 mixture of water and ethylene glycol antifreeze. The coolant will boil at 225 degrees unless it is held under pressure by the radiator cap. A 15 PSI radiator cap will increase the boiling temperature of a 50/50 coolant blend up to 265 degrees F. If the concentration of antifreeze to water is upped to 70/30 (the maximum recommended), the boiling temperature with a 15 psi radiator cap goes up to 276 degrees. So obviously the radiator cap plays a significant role in preventing the coolant from boiling and the engine from overheating.Anytime temperatures climb beyond the normal range, for any reason, your engine is in danger of overheating.

2.2 POSSIBLE CAUSES OF OVERHEATING

Overheating can be caused by anything that decreases the cooling system’s ability to absorb, transport and dissipate heat: A low coolant level, a coolant leak (through internal or external leaks), poor heat conductivity inside the engine because of accumulated deposits in the water jackets, a defective thermostat that doesn’t open, poor airflow through the radiator, a slipping fan clutch, an inoperative electric cooling fan, a collapsed lower radiator hose, an eroded or loose water pump impeller, or even a defective radiator cap.One of nature’s basic laws says that heat always flows from an area of higher temperature to an area of lesser temperature, never the other way around. The only way to cool hot metal, therefore, is to keep it in constant contact with a cooler liquid. And the only way to do that is to keep the coolant in constant circulation. As soon as the circulation stops, either because of a problem with the water pump, thermostat or loss of coolant, engine temperatures begin to rise and the engine starts to overheatThe coolant also has to get rid of the heat it soaks up inside the engine. If the radiator is clogged with bugs and debris, or if its internal passages are blocked with sediment, rust or gunk, the cooling efficiency will be reduced and the engine will run hot. The same thing will happen if the cooling fan is not engaging or spinning fast enough to pull air through the radiator.The thermostat must be doing its job to keep the engine’s average temperature within the normal range so the engine does not overheat. If the thermostat fails to open, it will effectively block the flow of coolant and the engine will overheat.Exhaust restrictions can also cause the engine to overheat. The exhaust carries a lot of heat away from the engine, so if the catalytic converter is restricted, or a pipe has been crimped or crushed, exhasut flow can be restrricted causing heat to build up inside the engine.It’s also possible that your engine really isn’t overheating at all. Your temperature gauge or warning lamp might be coming on because of a faulty coolant sensor. Sometimes this can be caused by a low coolant level or air trapped under the sensor.

2.3 POSSIBLE CONSEQUENCES OF ENGINE OVERHEATING

If your engine is overheating, it may start to detonate. The engine may rattle and ping and lose power. If detonation continues, it may damage the rings, pistons and/or rod bearings.Overheating can also cause pisto scuffing. As the engine gets hotter and hotter, the pistons may swell to the point where there is no more room for expansion and they scrape against the cylinders, damaging the pistons and cylinders.Exhaust valves may also stick or scuff in their guides. This can damage the valves, guides and lead to a loss of compression.Another consequence of engine overheating may be a blown head gasket. Heat makes aluminum swell almost three times faster than cast iron. Thermal stress can distort the head and make it swell in areas that are hottest like those between exhaust valves in adjoining cylinders, and areas that have restricted coolant flow like the narrow area that separates the cylinders. The typical aluminum head swells most in the middle, which can crush the head gasket if the head gets too hot. This will usually cause the head gasket to leak compression between adjacent cylinders, or leak coolant into the cylinders.Engine overheating can also cause an overhead cam to seize and break.Engine overheating may also stress old radiator and heater hoses and cause they to burst under the additional pressure. Steam that is generated inside the cooling system can also damage radiators with plastic end tanks.A HOT warning lamp should never be ignored. Though a few high tech cars like Cadillacs with the Northstar engine can disable cylinders to “air-cool” the engine and keep it running at reduced power in the event of coolant loss, most engines will suffer serious damage if they overheat. So advise your customers to stop driving at the first sign of overheating. Turn the engine off, let it cool down and try to find and fix the cause before risking further travel.2.4 ENGINE OVERHEATING TROUBLE SHOOTING TECHNIQUESBad Thermostat — Severe engine overheating can often damage a good thermostat. If the engine has overheated because of another problem, therefore, the thermostat should be tested or replaced before the engine is returned to service.One way to check the thermostat is to start the engine and feel the upper radiator hose (or use an infrared noncontact thermometer to read its temperature). The hose should not feel uncomfortably hot until the engine has warmed-up and the thermostat opens. If the hose does not get hot, it means the thermostat is not opening.Another way to test the thermostat is to remove it and dip it into a pan of boiling water (it should open). The exact opening temperature can be checked by using a thermometer.If the thermostat needs to be replaced, install one with the same temperature rating as the original. Most cars and light trucks since 1971 require thermostats with 192 or 195 degree ratings. Using a cooler thermostat (160 or 180) in an attempt to “cure” a tendency to overheat can increase fuel and oil consumption, ring wear and emissions. On newer vehicles with computerized engine controls, the wrong thermostat can prevent the computer system from going into closed loop resulting in major performance and emission problems if the engine fails to reach its normal operating temperature.TIP: When refilling the cooling system, air can become trapped under the thermostat. This will form a steam pocket that prevents the thermostat from opening and may cause the engine to overheat. Some cooling systems have one or more bleeder valves that can be opened to vent air from the system while refilling the system. If your cooling system does not have a bleeder valve, you can drill a small hole in the thermostat as shown. This will allow air to escape past the thermostat so it is not trapped inside the engine block. Some thermostats come with a similar feature called a “jiggle valve.” There is a small hole in the thermostat with a pin that allows air to escape. Cooling system leaks — Loss of coolant because of a coolant leak is probably the most common cause of engine overheating. Possible leak points include hoses, the radiator, heater core, water pump, thermostat housing, head gasket, freeze plugs, automatic transmission oil cooler, cylinder head(s) and block.Make a careful visual inspection of your entire cooling system, and then PRESSURE TEST the cooling system and radiator cap. A pressure test will reveal internal leaks such as seepage past the head gasket as well as cracks in the head or block. A good system should hold 12 to 15 psi for 15 minutes or more with no loss in pressure. If it leaks pressure, there is an internal coolant leak (most likely a bad head gasket but possibly also a cracked cylinder or engine block).It is important to pressure test the radiator cap, too, because a weak cap (or one with too low a pressure rating for the application) will lower the coolant’s boiling point and can allow coolant to escape from the radiator.* Leaky Head Gasket — Bad news because repairs are expensive. A leaky head gasket can allow coolant to seep into the engine’s cylinders or crankcase. Symptoms include a loss of coolant with no visible external leaks, and white steam in the exhaust, especially after restarting the engine when it has sit for awhile. A leaky head gasket can be diagnosed by pressure testing the cooling system, or by using a “block checker” that pulls air from the cooling system into a cylinder that contains a special blue colored leak detection liquid. If there are any combustion gases in the coolant, the color of the liquid inside the detector will change from blue to green. A leaky head gasket can often be temporarily sealed by adding a sealer product to the cooling system. But for bad leaks or ones that cannot be stopped with sealer, the head gasket has to be replaced. CHAPTER THREE3.0 CONSTRUCTION METHODOLOGYBefore carrying out any project, the block diagram must be drawn and fully understood. Block diagram gives a pictorial understanding of any work. The block diagram of the system is as below:3.1 SYSTEM BLOCK DIAGRAMThe block diagram of the system is as below: 3.2 HARDWARE SPECIFICATIONS

8051 series Microcontroller
7-Segment Displays
LED
Voltage Regulator
Transformer
Crystal
Push Buttons
Temperature Sensor
Diodes
Buzzer

Chapter Two

LITERATURE REVIEW
This section presents a review of related literature that supports the current research on the Design And Construction Of A Machine Overheat Detection With Alert, systematically identifying documents with relevant analyzed information to help the researcher understand existing knowledge, identify gaps, and outline research strategies, procedures, instruments, and their outcomes…

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