IoT BASED TEMPERATURE AND pH CONTROL

USING FUZZY-PID CONTROLLER

A PROJECT REPORT

Submitted by

BOOMIKA S 813820112003

HARI VARSHINI S 813820112006

SHERENE AMALIA G 813820112018

LEENA R 813820112301

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
IN

INSTRUMENTATION AND CONTROL ENGINEERING

SARANATHAN COLLEGE OF ENGINEERING

TIRUCHIRAPPALLI

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2024
 ABSTRACT

The proposed project work describes the usage of fuzzy-PID (Proportional-Integral-

Derivative) controller with Internet of Things (IoT) technologies to manage pH. Creating
multiregional supervisory fuzzy-PID control for pH reactors is the focus of this project
work. The suggested work primarily focuses on two themes. The first is to suggest a fuzzy-
based multiregional supervisory cascade control framework. It would make dynamics
modification possible and improve system stability. The PID controller (slave loop) has
been selected to be tuned by the fuzzy system (master loop). Real-time temperature
monitoring and control can be accomplished remotely by combining the fuzzy logic with
the PID controller and use of IoT technologies. A temperature control system is used to
design, implement, and test the suggested Fuzzy-PID controller. The Fuzzy-PID controller
works better than the traditional PID controller in terms of accuracy, stability, and
disturbance rejection, according to experimental results. Convenience and efficiency are
afforded by the IoT integration, which makes remote monitoring and control of the
temperature system possible. The size and cost issues that occur with using traditional
methods for measuring pH would be resolved by the suggested estimation. The
compatibility between LabView and the final end-user-interface (EUI) front panel have
been used to provide the results that assess the supervisory fuzzy PID-based control system's
performance. They ultimately lead to the conclusion that the suggested algorithms are
suitable for the nonlinearities in pH reactor systems

i
 TABLE OF CONTENTS
CHAPTER TITLE PAGE NO.
NO.
ABSTRACT i
LIST OF TABLES vi
LIST OF FIGURES vii
LIST OF ABBREVATION ix

1 INTRODUCTION 1
1.1 NEED FOR OUR PROJECT 2
1.2 OBJECTIVE OF THE PROJECT 2
2 LITERATURE REVIEW 3
3 SYSTEM DESIGN 6

3.1 EXISTING SYSTEM 6

3.2 PROPOSED SYSTEM 6

3.3 BLOCK DIAGRAM 6

3.4 CONTROLLER IN TEMPERATURE 8
PROCESS
3.4.1 ON-OFF CONTROLLER 8

4 MODELLING OF THE PROCESS 9

4.1 MATHEMATICAL MODELLING 9
5 PROPOSED METHODOLOGY 10

5.1 COMPONENTS DESCRIPTON 10

5.1.1 TEMPERATURE SENSOR 10
5.1.1.1 RESISTANCE 10

TEMPERATURE
DETECTOR (RTD)

ii
 5.1.1.2 PLATINUM 10
RESISTANCE
5.1.1.3 RTD CALIBRATION 12
5.1.1.4 ADVANTAGES OF 13
RTD

5.1.1.5 LIMITATIONS OF RTD 13

5.1.1.6 APPLICATIONS OF 13

RTD

5.1.1.7 FACTORS AFFECTING 13

RTD RESPONSE
5.1.2 RELAY 13
13
5.1.2.1 CONCEPT OF RELAY
14
5.1.2.2 BASIC DESIGN
15
5.1.2.3 TYPES OF RELAY
16
5.1.2.4 ENERGIZED AND
DE- ENERGIZED
RELAY OPERATION

17
5.1.2.5 HEATER LOAD
17
5.1.2.6 APPLICATIONS
18
5.1.2.7 ADVANTAGES
18
5.1.2.8 DISADVANTAGES
18
5.1.3 MICROCONTROLLER-myRIO
28
5.2 CONTROLLERS
5.2.1 FUZZY LOGIC SYSTEM 28

5.2.1.1 INTRODUCTION 28

iii
 29
5.2.1.2 FUZZIFICATION
31
5.2.1.3 FUZZY RULES
32
5.2.1.4 DEFUZZIFICATION

5.2.2 PID SYSTEM 33

5.2.2.1 P CONTROLLER 33
34
5.2.2.2 I CONTROLLER
35
5.2.2.3 D CONTROLLER
36
5.2.2.4 PID CONTROLLER
37
5.2.2.5 APPLICATIONS

5.2.3 pH CONTROL SYSTEM 38

38
5.2.3.1 INTRODUCTION
39
5.2.3.2 pH ANALYSER
39
5.2.3.3 THE THEORY OF pH

MEASUREMENT
40
5.2.3.4 MODEL OF pH REACTOR
40
5.2.3.5 CONTINUOUS

STIRRED- TANK

REACTOR (CSTR)

5.3 INTERNET OF THINGS 41

41
5.3.1 INTRODUCTION
41
5.3.2 THINGSPEAK
42
5.3.3 SYSTEM DESIGN
iv
 5.4 LABVIEW 43

43
5.4.1 INTRODUCTION
43
5.4.2 COMPONENTS OF LabVIEW
43
5.4.2.1 FRONT PANEL
44
5.4.2.2 BLOCK DIAGRAM
45
5.4.3 GRAPHICAL PROGRAMMING

5.4.4 BENEFITS OF LabVIEW 45

5.4.5 BLOCK DIAGRAM 45

TOOLS
5.4.6 PROCESS 45
CONTROL AND
FACTORY
AUTOMATION
5.5 SIMULATION AND 46
IoT RESULTS
5.5.1 FUZZY LOGIC 46
SYSTEM
5.5.2 FUZZY-PID WITH 46
IoT
5.5.3 pH MEASUREMENT 47
WITH IoT
5.5.4 LABVIEW FRONT PANEL 47

5.5.5 PROTOTYPE DIAGRAM 47

6 CONCLUSION 48
7 REFERENCES 49

v
 LIST OF TABLES

TABLE NO. DESCRIPTION PAGE NO.

5.1 myRio PINS 21
5.2 Descriptions of 22
Signals on MXP
Connector A and B
5.3 Descriptions of 22
Signals on MSP
Connector C

vi
 LIST OF FIGURES

FIGURE NO CONTENT PAGE NO.

3.1 Block Diagram 6

3.2 Block Diagram with Sensor 7

3.3 Block Diagram for ON-OFF 8

Controller

4.1 Block Diagram for 9

Mathematical Modelling
5.1 Energizing and 17
De-Energizing Operation Of
Relay
5.2 NI-myRIO 18

NI myRIO-1900
5.3 HardwareBlock 20
Diagram
5.4 NI myRIO-1900 Analog 23
Input Circuitry
5.5 NI myRIO-1900 Analog 24
Output Circuitry
5.6 Different types of shapes in 28
the fuzzy graph

Input Variable
5.7 30
MembershipFunction
5.8 Output Variable 30
Membership Function

vii
 Rules For
5.9 31
Membership Function
5.10 Rule Table 32
Test System in Fuzzy
5.11 32
Design
5.12 Front Panel in LABVIEW 44
Block Diagram
5.13 44
in LABVIEW
Output of the fuzzy rules in
5.14 46
graph
Real-Time monitoring in
5.15 46
IOT for Fuzzy-PID
Real-Time monitoring in
5.16 47
IOT for pH
Real-Time monitoring
5.17 Temperature Control with 47
Fuzzy-PID
Protype Diagram for
5.18 Temperature Control 47

viii
 LIST OF ABBREVIATIONS

ABBREVIATION DEFINITION
myRIO My Re-Configurable Input/Output
SSR Solid State Relay
IoT Internet of Things
VI Virtual Instrument
LABVIEW Laboratory Virtual Instrument
Engineer Workbench
DAC Data Acquisition Card
MXP myRIO Expansion Port
MSP Mini System Port
RTD Resistance Temperature Detector
FPGA Field Programmable Gate Array
GPIB General Purpose Interface Bus
PXI PCI eXtensions for Instrumentation
CSTR Continues Stirrer-Tank Reactor
OPC Open Platform Communications

ix
 CHAPTER 1
INTRODUCTION

Process control systems are collections of electrical apparatus and gadgets that provide accuracy
and stability while removing hazardous transition states from the production process. Process control
is widely used in industry to enable continuous processes to be produced in large quantities.
Temperature control is the process of keeping an eye on temperature variations and modifying the
quantity of heat energy entering or leaving water to obtain a desired temperature. It is essential for both
domestic and industrial uses since it provides a necessary ingredient for chemical reactions, distillation,
drying, calcinations, fermentation, and other processes. Inadequate temperature control can lead to
major problems with security, quality, and productivity. During the early industrial revolution,
especially in the 1960s and 1970s, relays were used to power mechanical machines. Cables that were
located inside control panels connected them. Consequently, the control gets more and more complex.
Processes are automated using an industrial computer known as a programmable logic controller. More
complex process control systems made it more difficult to quickly identify a system issue. Because
these panels were so rigid, there was an immediate need for a robust and dependable controller, which
sparked the creation of new hardware and software. These days, computer-based systems are used in
the measurement and instrumentation fields to control and monitor process elements and devices in the
field or in the laboratory. This application covers both networked computerized instrumentation
systems, like the distributed control system, and standalone computerized instrumentation systems.
Before reaching their current forms, advancements in instrumentation and measuring systems
underwent several stages of development. The measuring and instrumentation fields have advanced
greatly, but they still have certain drawbacks, such as the need for expensive and large-scale real
instruments. Additionally, because the instrument is industrial oriented, its processing capabilities are
limited and unable to handle new processing approaches.
As a result, the field of measurement and instrumentation experienced a shift in circumstances,
leading to the creation of a new generation of instruments known as Virtual Instruments (VI). The main
goal of this effort is to create a virtual pH analyser that can take the place of the real, traditional
equipment used in continuous process applications. The pH meter and pH controller were the two
components of the development that were separated. The primary idea behind the creation of the virtual
pH analyser was to use an inexpensive, ordinary personal computer and software to create a strong,
accurate, and versatile equipment. After obtaining the response with a PID controller, the process is
once more run via a fuzzy logic controller. The outcomes are contrasted.

1
 Fuzzy logic controllers are more flexible and produce a smoother output than PID controllers,
which are more traditional and practically focused. The entire process is tracked and managed by
LabVIEW (Laboratory Virtual Instrumentation Workbench) software. This research aims to provide
the solution by integrating PID and fuzzy logic controllers on the two previously described processes.
Because it makes it simple to interface processes with software, LabVIEW is easy to use. Programming
is made easier by the use of graphical programming techniques in LabVIEW.

1.1 NEED FOR THIS PROJECT

In today's market, real-time monitoring, simple control over multiple variables, and prompt
defect detection and correction are essential. The cooling process takes time, so the system needs to be
sped up.

1.2 OBJECTIVE OF THIS PROJECT

The heat treatment process makes strict demands on the stability of furnace temperature, so
does the testing of tank temperature uniformity in the field of furnace verification. Therefore, tank
temperature control and measurement should be made. Here, challenge is the heater in the tank has
to be turned off when the temperature crosses the desired set value and it has to be turned again
when the temperature gets lowered than the set value.

2
 CHAPTER 2
LITERATURE REVIEW

1. S Nithya, A Abhay Singh Clour, N. Sivakumaran, T K Radhakrishnan and N

Ananthaaman "Model Based Controller Design for Shell and Tube Heat
Exchanger, Sensors and Transducers" Journal, Vol. 84, Issue 10, pp.1677-1 686,
The reports stated that, For demonstrating any automated system in process control
instrumentation, many test and measuring instruments like CRO, signal generator, function
generator, multimeters etc., are required in thea laboratory. Taking readings by connecting these
instruments, limits the expansionof the system and in turn makes the system complex and bulky. So,
there is a needfor a new system which will make complex process automation systems simpler,
smart, efficient and cost effective. A fast and effective equivalent circuit model was proposed and
implemented with the attempt is to make a design and develop Real time System for on-off
temperature controller by using LabVIEW an NI USB Data acquisition card. As the use of
computers in data processing and control applications is trend that one sees in today's industrial
environment and virtual instrumentation is a current technology that is making a significant impact
in industries and Research. Using this Technology, Data acquisition, experimentation and Analysis
of readings can be efficiently performed.

2. Shiferaw, D., Hailegnaw, A., Assefa, A., Abebe, D., Dagne, E., & Fekadie, G.
(2019). “LabVIEW based fuzzy logic controller for PLC”. 2019 International
Conference on Computer, Control, Electrical, and Electronics Engineering
(IEEE).
LabVIEW is a graphical programming environment that provides virtual instrumentation for
control applications (National Instruments, 2012). It allows for modeling and simulation of control
systems without requiring physical hardware. Prior research has explored connecting LabVIEW to
PLCs using open connectivity (OPC) communication protocols to read sensor dataand send control
signals (National Instruments, 2010; Ren et al., 2016).
Specifically, OPC tags can be created in LabVIEW to interface with a Siemens S7 PLC
simulator or hardware over TCP/IP or serial connections (Hans-Petter, 2011; Siemens, 2017). The
current study develops a fuzzy logic controller in LabVIEW to regulate water level based on inputs
from a level sensor and flow rate sensor connected to a PLC (Shiferaw et al., 2019).

3
Membership functions are defined to classify the inputs and output for the controller rule base.
Preliminary simulation results show the fuzzy logic design is able to maintain water level to the
setpoint.

3. Kudinov, Y. I., Kolesnikov, V. A., Pashchenko, F. F., et al. (2017).

“Optimization of fuzzy PID controllers parameters”. Procedia Computer
Science, 103, 618-622.
Temperature control of warplane skin is crucial for infrared stealth testing and simulation
of aerodynamic heating (Xiong et al., 2019). Traditional PID control methods have limitations in
controlling the nonlinear temperature dynamics of warplane skin (Xin et al., 2013). Fuzzy logic
control addresses this issue by incorporating human-like decision-making (Bousiog et al., 1996).
Research has shown fuzzy PID controllers achieve better control performance than conventional
PID controllers for nonlinear systems (Kudinov et al., 2017). Particle swarm optimization (PSO)
is an effective metaheuristic algorithm for optimizing fuzzy controller parameters (Poli et al.,
2009). Rebai et al. (2015) designed an optimized fractional fuzzy PID controller using PSO that
demonstrated superior control of a piezoelectric actuator compared to a nonoptimized controller.
Similarly, Kutasi et al. (2017) proposed an adaptive model predictive temperature controller
optimized with PSO that outperformed traditional PID control. For multi-channel temperature
control needed for warplane skin simulation, PSO can optimize the parameters of a fuzzy PID
controller to minimize temperature errors across channels. This paper proposes a multi-channel
adaptive fuzzy PID temperature control method optimized by PSO for warplane skin (Fu et al.,
2022). STM32 microprocessors enable precise multi-loop control. A fuzzy PID controller
addresses nonlinear temperature dynamics, while PSO optimizes parameters like in Rebai et al.
(2015).

Simulation and testing indicate the method achieves temperature control within ±0.5°C,
faster than traditional PID by 51% and with 75% lower overshoot (Fu et al., 2022). This research
advances capabilities for infrared stealth testing of warplanesBharath Kumar, V., Rao, K. S.,
Charan, G., & Kumar, Y. V. P. (2022).

Industrial heating furnace temperature control system design through fuzzy-PID

controller.

4
4. Bharath Kumar, V., Rao, K. S., Charan, G., & Kumar, Y. V. P. (2022).
“Industrial heating furnace temperature control system design through fuzzy-
PID controller”. IEEE Conference on Mechatronics and Electronics in
Engineering

Temperature control is crucial in industrial heating furnaces to ensure product quality

(Bharath Kumar et al., 2022). Conventional PID controllers are commonly used but have
limitations in disturbance rejection (V. Bharath Kumar et al., 2022). Fuzzy logic controllers can
address this issue due to their ability to handle nonlinear systems without an explicit
mathematical model (Bharath Kumar et al., 2022).
Previous research has explored fuzzy logic-based PID (FLP) controllers for industrial
heating furnaces. Bharath Kumar et al. (2022) developed an FLP controller that externally feeds
gain values to a PID controller based on error and change in error. Their results showed improved
dynamic performance, rapidity, and robustness over traditional PID methods. Similarly,6
Godavarthietal. (2021) used an FLP controller that adaptively tunes PID gains online.

Testing in MATLAB/Simulink demonstrated enhanced disturbance rejection compared

to conventional controllers. Other studies have investigated different fuzzy logic approaches.
Aneuro-fuzzy controller incorporating an artificial neural network was found to achieve optimal
temperature regulation in industrial furnaces (Sandeep & Charan, 2020). Genetic algorithm-
tuned Takagi-Sugeno fuzzy models also demonstrated effective control of a heating furnace
system In summary, fuzzy logic control shows promise for industrial heating furnace temperature
regulation due to its ability to handle nonlinear dynamics.

5. M. Kassim, M.N. Ismail and C.K.H. Che Ku Yahaya, A Web Based

Temperature Monitoring System, International Journal of Multidisciplinary
Sciences and Engineering, Vol. 2, March 2011

This paper described about the system and also the monitoring of the system process
parameters that included temperature, pressure, flow and level control using NI-DAQ. This paper
emphasize the importance on the acquiring of sensor signals, monitoring in LabVIEW Program.

5
 CHAPTER 3
SYSTEM DESIGN

3.1 EXISTING SYSTEM

To properly regulate process temperature, an RTD or thermocouple need a lot of user
intervention; a temperature control system has a controller that gets information from temperature
sensors to do this. It sends an output to a control element after comparing the set point, also known
as the planned control temperature, and the actual temperature.
When choosing a controller, the following factors are taken into account:
 The desired output type, which may be an analog output, SSR, or electromechanical relay.
 The input sensor type and temperature range (thermocouple, RTD).
 You need to use proportional, on/off, or PID control algorithms.
 The kind and quantity of outputs (limit, alert, cold, and hot).
 Control methods are required to keep a process operating in a steady state once the model
has been constructed.

3.2 PROPOSED SYSTEM

Using the myRio controller, fuzzy controller, PID controller, LabVIEW software, and
CSTR tank, this project enables pH monitoring and control. This method aims to provide efficient
pH management by attempting to modify the difference between the measured temperature, various
types of solutions, and the expected set point. The entire process will be monitored via the Internet
of Things (IoT).

3.3 BLOCK DIAGRAM

Fig.3.1: Block Diagram

7
 The aim of the project is to control or to uphold the temperature of a plant by turning off the
heater once it exceeds its set point. The Temperature sensor used is RTD Pt 100. The sensor
senses the temperature and output resistance. The Set point is compared with the current
temperature and the error is the deciding factors. Based on the error, the on-off action is
proceeded. The controller output is fed to the process in the aim of minimizing the error. The
current temperature is continuously detected and monitored using the temperature sensor
connected in feedback to the process.

The Temperature of water in the tank is maintained to be within the specified range using on
off controller implementation in LabVIEW software. The temperature sensor used in the system
is a two wire RTD Pt00. This sensor outputs resistance change with respect to the temperature
changes in the output. For the conversion Resistance to voltage, voltage divider circuit is used.
Since NI myRIO accepts signal in the form of voltage or current, the effective conversion of
Resistance to voltage is done in myRIO board.

In the LabVIEW Software, the acquired voltage is calibrated for its conversion totemperature
in degree Celsius. The temperature conversion enables user-friendly while involving
comparisons with the set point in the LabVIEW program. If the temperature goes beyond the
set point, then it turns off the heater by cutting off the supply to relay circuit, which consequently
turns off the heater.

Fig.3.2 Block Diagram with sensor

8
3.4 CONTROLLER IN TEMPERATURE CONTROL PROCESS
3.4.1 ON-OFF CONTROLLER

An on-off controller is the simplest form of temperature control device.The output

from the device is either on or off, with no middle state. An on-off controller will switch the
output only when the temperature crosses the set point.For heating control, the output is on
when the temperature below and the off above setpoint. Since the temperature crosses the set
point to change the output state, the process temperature will be cycling continually, going
from below set point to above, and back below. In cases where this cycling occurs rapidly. and
toprevent damage to contactors and valves, an on off differential, or "hysteresis," isadded to the
controller operations. This differential requires that the temperatureexceed setpoint by a certain
amount before the output will turn off or on again. On-off differential prevents the output from
"chattering" (that is, engaging in fast,continual switching if the temperature's cycling above and
below the set point occurs very rapidly). On-off control is usually used where a precise control
is not necessary, in systems which cannot handle the energy's being turned on and off
frequently, where the mass of the system is so great that temperatures change extremely slowly,
or for a temperature alarm. One special type of on-off control used for alarm is a limit
controller. This controller uses a latching relay, which must be manually reset, and is used to
shut down a process when a certain temperature is reached

Fig.3.3 Block Diagram for ON-OFF Controller

9
 CHAPTER 4
MODELLING OF THE PROCESS

4.1 MATHEMATICAL MODELLING

The experimental determination of the dynamic behavior of the process in called SI

(system identification). System identification can be done mainly in two ways one is the
mathematical modelling and the other is the empirical modelling. The mathematical modelling
equations relating the input and the output are formed. Empirical methods use data gathered
from experimental setupto define the mathematical model of a system. In this project, empirical
method is used for the temperature process. The transfer function for the process model is
obtained from step response. The liquid tank temperature control system measured here can be
assumed as a (FOPDT) first order process with dead time the parameters that are to be
determined are the process gain (K), Delay time (td)and the time constant. Most often it has units
of minutes or seconds, Step test dataimplies that the process is manual mode (open loop) and
initially at steady state The transfer functions of the process models are required only for the
simulationstudies of the controller design. In this project, we are commonly used model to
describe the dynamics of the industrial temperature process is general First Orderplus Time
Delay Process (FOPTD). And the FOPTD model structure is given inthe equation

G(S)=KTs+1-tds. 4.1

where,
i. td- Time delay
ii. K-process gain.

Fig.4.1 Block Diagram for Mathematical Modelling

10
 CHAPTER 5
PROPOSED METHODOLOGY

5.1 COMPONENTS DESCRIPTION

5.1.1 TEMPERATURE SENSOR

Resistance temperature detectors (RTD) monitor temperature by creating a link between the
temperature and the resistance of the RTD element. The pure material that makes up the RTD
element has had its resistance measured and recorded at various temperatures. The anticipated
change in resistance that a material undergoes as its temperature changes is used to calculate its
temperature. Platinum is the material used this time. At 0°C, the resistance of a device called a
platinum resistance temperature detector (RTD) Pt100 is typically 100 Ω. Resistance changes with
temperature along a positive slope (resistance increases as temperature increases).

5.1.1.1 RTD SIGNAL CONDITIONING CIRCUIT

The process of altering an analog signal to determine what is needed for the next processing
step is known as signal conditioning. For example, an analog-to-digital converter (ADC) cannot
probably process the output of an electronic temperature sensor directly because it is too low in
voltage. Here the voltage level needs to be boosted via signal conditioning and amplification to the
level required by an ADC. Broadly speaking, signal conditioning can refer to any required
processing, including conversion, amplification, or any other action to get sensor output ready for
digital format conversion.
5.1.1.2 PLATINUM RESISTANCE THERMOMETER (PRT)
PRT offers excellent accuracy over a wide temperature range (from -200 to850°C) Standard
sensors are available from many manufacturers with various accuracy specifications and numerous
packaging option to suit most application.Unlike thermocouples, it is not necessary to use special
cables to connect the sensor. The principle of operation is to measure the resistance of the platinum
element. The most common type (PT100) has a resistance of 100 ohms at 0°C and138.4 ohms at
100°C. There are also PT1000 senses that have resistances of 25 ohms and 1000 ohms respectively
at 0°C.
The relationship between temperature and resistance is approximately linear over a small
temperature range: For example if you assume that it is linearover the 0 to 100°C range, the error at
50°C is 0.4°C.

11
 For precision measurement,it is necessary to linearize the resistance to give on accurate
temperature.
The most recent definition of the relationship between resistance and temperature is
International Temperature Standard 90 (ITS-90). The linearization equation is

Rt = RO * (A * t + B * t2 + C * (t-100) * t3) 5.1

A=3.9083 E-3
B=-5.775 E-7
C = (below 0°C) -4.183 E-12
(Above 0°C) zero
For a PT100 sensor, a 1°C temperature change will cause a 354 Ω change in resistance, so
even a small error in measurement of the resistance (for example the resistance of the wires leading
to the sensor) can cause a large errorin the measurement of the temperature. For precision work,
sensors have four wires to carry the sense current, and two to measure the voltage across the sensor
element. It is also possible to obtain three wire sensors, although these operate on the (not
necessary valid) assumption that the resistance of each of thewires is the same.
The current through the sensor will cause some heating: For example, a sense current of
1mA through a 100 Ω resistor will generate 100 W of heat. Ifthe sensor element is unable to dissipate
this heat, it will report an artificially hightemperature. This effect can be reduced by either using a
large sensor element, orby making sure that it is in good thermal contact with its environment
Using a 1mA sense current will give a signal of only 100mV, because thechange in resistance
for a degree Celsius is very small, even a small error in the measurement of the voltage across the
sensor will produce a large error in the temperature measurement. For example, a 100uV voltage
measurement error willgive a 0.4°C error in the temperature reading. Similarly, a µA error in the
sense current will give 0.4°C temperature error.
Because of the low signal levels, it is important to keep any cables awayfrom electric cables,
motors, switchgear and other devices that may emit electricalnoise. Using screened cable, with the
screen grounded at one end, may help to reduce interference. When using long cables, it is
necessary to check that the measuring equipment is capable of handling the resistance of the cables.
Most equipment can cope with up to 100 ohms per core.
The type of probe and cable should be chosen carefully to suit the application. The main
issues are the temperature range and exposure to fluids (corrosive or conductive) or metals.
Clearly, normal solder junctions on cables should not be used at temperature above about 170°С.

12
 Sensor manufacturers offer a wide range of sensors that comply with BS1904 class B
(DIN 43760): these sensors offer an accuracy of +/- 0.3°C at 0°C.For accuracy, BS1904 class A
(+/- 0.15°C) or tenth-DIN sensors (+/- 0.03°C). Companies like Isotech can provide standards
with 0.001°C accuracy, please notethat these accuracy specifications relate to the sensor only.
It is necessary to addon any error in the measuring system as well.

5.1.1.3 RTD CALIBRATION

NI-myRIO accepts voltage signals at its analog input channels for efficient acquiring of
signals. The voltage limits are -10 volts to +10 volts. It has three channels for means of acquiring
and transmitting signals. A voltage divider circuitconsisting RTD at an end is given to any one of
the channel.

Since RTD provides temperature changes in terms of resistance, it cannot be directly

acquired. So, a voltage divider is implemented to convert the corresponding resistance changes
to voltage. The input voltage Vin = 5 volts andthe resistance Rd= 112 ohms. It's calibrated to
obtain exact temperature in the program, from resistance values. Vb is the voltage that is
acquired using NI- myRIO to LabVIEW program voltage obtained from the circuit changes with
respect to temperature. The process variable need to be in same parameter, so the voltage from the
divideris acquired from the analog channel and feed to the scaling VI for RTD conversion. The
divider current is measured manually and given a constant in the VI control signal lex. The
scaling VI with respect to the divider current and voltage, derives the temperature value
(PROCESS VARIABLE).

RTD (Resistance Temperature Detector) calibration is a meticulous process crucial for

ensuring accurate temperature measurements across various applications. It involves comparing
the resistance of the RTD sensor to known temperature values and adjusting it accordingly. This
adjustment is typically done by applying precise electrical currents or voltages to the RTD and
observing its response. Calibration curves are generated, mapping resistance values to
corresponding temperatures, allowing for precise temperature determination. Factors such as
lead wire resistance, ambient temperature, and self-heating effects must be accounted for during
calibration to achieve optimal accuracy. Calibration standards, like ITS-90, provide guidelines
for consistent and reliable calibration procedures. Regular calibration ensures that RTDs
maintain their accuracy over time, crucial for industries such as pharmaceuticals, aerospace, and
manufacturing, where precise temperature control is essential for quality and safety compliance.
13
5.1.1.4 ADVANTAGES OF RTD
 It is linear over wide range of temperatures.
 It allows inter changeability over wide range of temperatures.
 It provides good stability at high temperatures.

5.1.1.5 LIMITATIONS OF RTD

 RTD is costlier than Thermocouple.
 It is difficult in handling at three or four wire operation of RTD.

5.1.1.6 APPLICATIONS OF RTD

RTD finds its applications in places where it meets the 3A standard requirement. It can
measure temperatures even when exposed to identical heatingand cooling cycles. It provides
solutions to many industrial problems and is applied in cases where monitoring temperatures
using waterproof and rugged RTDs.

5.1.1.7 FACTORS AFFECTING RTD RESPONSE

 Influences from vessel.
 Thermal lag factors.
5.1.2 RELAY
5.1.2.1 CONCEPT OF RELAY
A relay is an electrically operated switch. Many relays use an electromagnet to operate
a switching mechanism mechanically, but other operating principles are also used. Relays are
used where it is necessary to controla circuit by a low-power signal (with complete electrical
isolation between control and controlled circuits) or where several circuits must the controlled
by one signal. The first relays were used in long distances telegraph circuits, repeating the signal
coming in from one circuit and re-transmitting it to another. Relays were used extensively in
telephone exchanges and early computers to perform logical operations.
A type of relay that can handle the high power required to directly controlan electric
motor or other loads is called a contractor. Solid-state relays control power circuits with no
moving parts, instead using a semiconductor device to perform switching. Relays with calibrated
operating characteristics and sometimes multiple Operating coils are used to protect electrical
circuits from overload or faults in modern electric power systems these functions are performed
by digital instruments still called "protective relays". Automotive- style miniature relay, dust
cover's taken off.
14
5.1.2.2 BASIC DESIGN AND OPERATION

A simple electromagnetic relay consists of a coil of wire wrapped arounda soft iron yoke which
provides a low reluctance path for magnetic flux, a movable iron armature and one or more sets
of contact (there are two in the Relay pictured) The armature is hinged to the yoke and
mechanically linked to one of more sets of moving contacts. It is held in place by a spring so
that when the relay is de-energized there is an air gap in the magnetic circuit. In this condition,
one of the two sets of contacts in the relay pictured is closed and the other set is open. Other
relays may have more or fewer sets of contacts depending on their function.

When an electric current is passed through the coil it generates a magnetic field that
activates the armature and the consequent movement of the movable contact(s) either makes or
breaks (depending upon construction) a connection with a fixed contact. If the set of contacts
was closed when the relay was de-energized, then the movement opens the contacts and breaks
the connection, and vice-versa if the contents were open. When the current to the coil is switched
off,the armature is returned by a force, approximately half as string as the magnetic force, to its
relaxed position. Usually this force is provided by a spring, but gravityis also used commonly in
industrial motor starters. Most relays are manufactured to operate quickly in a low-voltage
application this reduces noise in a high voltageor current application it reduces arcing.
When the coil is energized with direct current, a diode is often placed across the coil to
dissipate the energy from the collapsing magnetic field at deactivation, which would otherwise
generate a voltage spike dangerous tosemiconductor circuit components. Some automotive relays
include a diode inside the relay case. Alternatively, a contact protection network consisting of a
capacitor and resistor in series (snubber circuit) may absorb the surge. If the coilis designed to be
energized with alternating current (AC), a small copper "shadingring" can be crimped to the
solenoid, creating a small phase current which increases the minimum pull on the armature during
the AC cycle.

A solid-state relay uses a thyristor or other solid-state switching devices,activated by the

control signal, to switch the controlled load, instead of a Solenoid. An optocoupler a light
emitting diode (LED) coupled with a phototransistor can be used to isolate control and
controlled circuits.

15
5.1.2.3 TYPES OF RELAY

 Latching Relay
A latching Relay has two states. These two states are called impulse Keep or tray relays.
When the current is switched off, the relay remains in last position. This is achieved with a solenoid
valve operating a ratchet and cam mechanism, or by having two opposing coils with over-centre
spring or permanent magnet to hold the armature und contacts in position while the cost is relaxed,
or with a permanent magnetic core.

 Reed Relay
A Reed switch is enclosed in a solenoid, the switch has a set of contactinside an evacuated or
inert gas filled glass tube which protects the contacts against atmospheric corrosion. The contacts
are made of magnetic material that makes them move under the influence of the field of enclosing
solenoid or external magnet.
Reed relays are switches that can switch faster than larger relays and require little power
for controlling. The reeds can become magnetized over time,which makes them stick on even when
no current is present.

 Mercury Relay
A Mercury relay uses mercury as the switching element. They are used where contact
erosion would be a problem for conventional relay contacts Owing to the environmental
consideration about significant amount of the mercury used and modern alternatives, they are
now uncommon.

 Solid stare contactor Relay

This is a heavy duty solid state relay, includes the necessary heat sink, used wherefrequent
on-off cycles are required such as with electric heater small electric motor and lighting loads.
There are no moving parts to wear out and there is no contact bounce due to vibrations. They
are activated by AC and DC control signals.

16
 Ratchet Relay

This is a clapper type relay which does not need continuous current through its coil to
retain operation. A Ratchet holds the contacts closed after the coil is momentarily energized. A
second impulse, in the same or a separate coil, releasesthe contacts.

 Polarized Relay

A Polarized relay places the armature between the poles of permanent magnets toincrease
sensitivity. Polarized relays were used in the middle 20 century telephone exchange to detect
faint pulses and correct telegraphic distortion. The poles were on screws so a technician could
first adjust them for a maximum sensitivity and then apply a bias spring to set the critical current
that would operate the relay.

 Coaxial Relay

Where Radio Transmitters and Receivers share a common antenna, often coaxialrelay is
used as a TR (transmit-receive) relay, which switches the antenna from the receiver to the
transmitter. Such relays are often used in transceivers which combine transmitter and receiver in
one unit. This protects the Receiver from highpower of the Transmitter.

Such Relays are often used in Transceiver which combine transmitter and receiver in one
unit. The Relay contact are designed not to reflect any radio frequency power back toward the
source and that provide very high isolation between receiver and transmitter. The characteristic
impedance of the relay to transmission line impedance of the system.

5.1.2.4 ENERGIZED RELAY AND DE-ENERGIZED RELAY OPERATION

The current in the circuit, the current through the coils represented by the pins 1 and 3
causes a magnetic field to arise. This magnetic field causes the closing of the pins 2 and 4. Thus
the switch plays an important role in the relay working. As it is a part of the load circuit, it is used
to control an electrical circuit that is connected to it. Thus current flow will be through the pins
2 and 4.

17
 Fig.5.1 Energizing and De-Energizing Operation of Relay

As soon as the current flow stops through pins 1 and 3, the switch opens and thus the open
circuit prevents the current flow through the pins 2 and 4. Thus the relay gets de-energized and
goes to off-position.

When the voltage is applied to pin 1, the electromagnet activates, causing a magnetic field
to be developed, which goes on to close the pins 2 and 4 causing a closed circuit. When there is
no voltage on pin 1, there will be no electromagnetic force and thus no magnetic field. Hence, the
switches remain open.

5.1.2.5 HEATER LOAD

The Relays are connected to 230 V AC heater which utilizes 300 Watts power. This
heater operated under the control of Relays using the LabVIEW program. The two phase heater
operation works similar to an on-off controller operation.

5.1.2.6 APPLICATIONS
 Relays are used to realize logic functions. They play a very important role inproviding
safety critical logic.

 They are used as protective relays. By using this function, all the faults duringthe
transmission and reception can be detected and isolated.

 Relays are used to control high voltage with the help of low voltage signals.They are used
to control high current circuits with the help of low current signal

18
5.1.2.7 ADVANTAGES
 Relays can switch AC and DC, transistors can only switch DC.
 Relays can switch higher voltages than transistors.
 Relays can switch many contacts at once.
 Relays are often used to switch higher currents.

5.1.2.8 DISADVANTAGES
 Relays are bulkier than transistors, in case of switching small currents.
 Relays cannot switch rapidly but transistors can switch many times per second.
 Relay uses more power than transistors, because of the high current.
 Relays require more current than many integrated chips can provide, so a lowpower
transistor may be needed to switch the current for relay's coil.

5.1.3 MICROCONTROLLER-myRIO

Fig.5.2 NI-myRIO

19
The National Instruments NI-myRIO is the microcontroller used in this project. It has the following
specifications:

 An in-built processor and memory.

 3 Channel input output.
 Compatible with LabVIEW software.

myRIO is basically a sort of micro controller introduced by National Instruments (NI), that
is why it is sometimes known as NI myRIO. RIO is basically abbreviated from Re-configurable
Input/Output.

myRIO is a portable device. It operates on the frequency 667 MHz. myRIO has dual core
ARM cortex A9 programmable processor. It has a Xilinx Field Programmable Gate Array
(FPGA). FPGA support in myRIO helps to design real life developing systems and to solve real
problems quite faster as compared to the other micro controllers. Using FPGA support the
complicated syntax used in C language and in many other can be avoided. It is student friendly
device and is very easy to use. The processing speed of myRIO is quite higher than the standard
micro controllers. So, it can be used to solve real life problems and it can be easily used in
efficient systems which need a quick output response.It supports different languages e.g. C, C++
and graphical language (FPGA). myRIO has two ports named as port A and port B. It has a built
in WiFi shield and on board LED's. At the bottom side of the myRIO, it has power pin, PC
connection point, and USB port.

 NI-my RIO Hardware

The NI myRIO-1900 provides analog input (AI), analog output (AO), digital input and
output (DIO), audio, and power output in a compact embedded device. The NI myRIO-1900
connects to a host computer over USB and wireless802.11b,g,n.

20
Fig.5.3: NI myRIO-1900 Hardware Block Diagram

21
 CONNECTOR PINOUTS
NI myRIO-1900 Expansion Port (MXP) connectors A and B carry identical sets of signals.
The signals are distinguished in software by the connector name, as in Connector A/DIO1 and
Connector B/DIO1. The following figure and table show the signals on MXP connectors A and B.
Note that some pins carry secondary functions as well as primary functions.

myRIO PINS
PIN NUMBER PIN NAME PIN NUMBER PIN NAME
1 +5V 18 DIO11 / ENC.A
2 AO0 19 DIO4
3 AI0 20 DGND
4 AO1 21 DIO5 /SPI.CLK
5 AI1 22 DIO12 / ENC.B
6 AGND 23 DIO6 / SPI.MISO
7 AI2 24 DGND
8 DGND 25 DIO7 / SPI.MOSI
9 AI3 26 DIO13
10 UART.RX 27 DIO8 / PWM0
11 DIO0 28 DGND
12 DGND 29 DIO9 / PWM1
13 DIO1 30 DGND
14 UART.TX 31 DIO10 / PWM2
15 DIO2 32 DIO14 / I2C.SCL
16 DGND 33 +3.3V
17 DIO3 34 DIO15 / I2C.SDA

Table.5.1: myRIO PINS

22
 Signal Name Reference Direction Description
+5V DGND Output +5 V power output.
AI <0..3> AGND Input 0-5 V, referenced, single-ended analog
input channels. Refer to the Analog
Input Channels section for more
information.
AO <0..1> AGND Output 0-5 V referenced, single-ended analog
output. Refer to the Analog Output
Channels section for more information.
AGND N/A N/A Reference for analog input and output.
+3.3V DGND Output +3.3 V power output.
DIO <0..15> DGND Input or General-purpose digital lines with
Output 3.3 V output, 3.3 V/5 V-compatible
input. Refer to the DIO Lines section for
more information.
UART.RX DGND Input UART receive input. UART lines are
electrically identical to DIO lines.
UART.TX DGND Output UART transmit output. UART lines are
electrically identical to DIO lines.
DGND N/A N/A Reference for digital signals, +5 V, and
+3.3 V.
Table 5.2. Descriptions of Signals on MXP Connectors A and B
The following table show the signals on Mini System Port (MSP) connector C. Note that some pins
carry secondary functions as well as primary functions.

Signal Name Reference Direction Description

+15V/-15V AGND Output +15 V/-15 V power output.
AI0+/AI0-; AGND Input ±10 V, differential analog input
AI1+/AI1- channels. Refer to the Analog Input
Channels section for more information.
AO <0..1> AGND Output ±10 V referenced, single-ended analog
output channels. Refer to the Analog
Output Channels section for more
information.
AGND N/A N/A Reference for analog input and output and
+15 V/-15 V power output.
+5V DGND Output +5 V power output.
DIO <0..7> DGND Input or General-purpose digital lines with
Output 3.3 V output, 3.3 V/5 V-compatible
input. Refer to the DIO Lines section for
more information.
DGND N/A N/A Reference for digital lines and +5 V
power output.

Table 5.3. Descriptions of Signals on MSP Connector C

23
 ANALOG INPUT CHANNELS
The NI myRIO-1900 has analog input channels on myRIO Expansion Port (MXP) connectors
A and B, Mini System Port (MSP) connector C, and a stereo audio input connector. The analog
inputs are multiplexed to a single analog-to-digital converter (ADC) that samples all channels.

MXP connectors A and B have four single-ended analog input channels per connector, AI0-
AI3, which you can use to measure 0-5 V signals. MSP connector C has two high-impedance,
differential analog input channels, AI0 and AI1, which you can use to measure signals up to ±10 V.
The audio inputs are left and right stereo line-level inputs with a ±2.5 V full-scale range.

Fig.5.4 NI myRIO-1900 Analog Input Circuitry

24
 ANALOG INPUT CHANNELS
The NI myRIO-1900 has analog output channels on myRIO Expansion Port (MXP)
connectors A and B, Mini System Port (MSP) connector C, and a stereo audio output connector.
Each analog output channel has a dedicated digital-to-analog converter (DAC), so they can all
update simultaneously. The DACs for the analog output channels are controlled by two serial
communication buses from the FPGA. MXP connectors A and B share one bus, and MSP
connector C and the audio outputs share a second bus. Therefore, the maximum update rate is
specified as an aggregate figure in the Analog Output section of the Specifications.
MXP connectors A and B have two analog output channels per connector, AO0 and AO1,
which you can use to generate 0-5 V signals. MSP connector C has two analog output channels,
AO0 and AO1, which you can use to generate signals up to ±10 V. The audio outputs are left and
right stereo line-level outputs capable of driving headphones.

Fig.5.5 NI myRIO-1900 Analog Output Circuitry

25
 NI-myRIO SPECIFICATIONS

The following specifications are typical for the 0 to 40 °C operating temperature range
unless otherwise noted.

 Processor

Processor type linx Z-7010

Processor speed 667 MHz

Processor cores 2

 Memory

Nonvolatile memory 256 MB

DDR3 memory 512 MB

DDR3 clock frequency 533 MHz

DDR3 data bus width 16 bits

 FPGA

FPGA type XilinxZ 7010

 USB Ports

USB host port USB 2.0 Hi-Speed

USB device port USB 2.0 Hi-Speed

 Analog Input

Aggregate sample rate 500 kS/s

Resolution 12 bits

Overvoltage protection ±16 V

26
  Wireless Characteristics

Radio mode IEEE 802.11 b,g,n

Channels USA 1-11, International 1-13

TX power +10 dBm max (10 mW)

Outdoor range Up to 150 m (line of sight)

Antenna directivity Omnidirectional

Security WPA, WPA2, WPA2-Enterprise

Frequency band ISM 2.4 GHz

Channel width 20 MHz

Channels USA 1-11, International 1-13

TX power +10 dBm max (10 mW)

Outdoor range Up to 150 m (line of sight)

Antenna directivity Omnidirectional

Security WPA, WPA2, WPA2-Enterprise

 Analog Output
All AO channels on MXP 345 kS/s
connectors

All AO channels on MSP 345 kS/s

connector

Resolution 12 bits

Overload protection ±16 V

Startup voltage 0 V after FPGA initialization

27
  Power Output

 +5 V power output
Output voltage V to 5.25 V
Maximum current on each connector 100 mA

 +3.3 V power output

Output voltage V to 3.6 V
Maximum current on each connector 150 mA

 +15 power output

Output voltage +15 V to +16 V
Maximum current 32 mA (16 mA during startup)

 -15 V power output

Output voltage ..-15 V to -16 V
Maximum current 32 mA (16 mA during startup)

 Power Requirements
NI myRIO-1900 requires a power supply connected to the power connector.
Power supply voltage range 6-16 VDC

Maximum power consumption 14 W

Typical idle power consumption 2.6 W

28
5.2 CONTROLLERS

5.2.1 FUZZY LOGIC SYSTEM

5.2.1.1 INTRODUCTION
A fuzzy system is a set of variables connected by fuzzy logic. A fuzzy controller utilizes
established rules to regulate a fuzzy system based on the current values of the input variables. A
fuzzy system is made up of three main parts: linguistic variables, membership functions, and rules.
Language Terms and Variables Linguistic variables are the words used to express the input and
output variables of the system that needs to be regulated. Linguistic variables frequently have an
odd number of linguistic terms, with symmetric terms at each end and a middle term. Every
linguistic variable has a range of predicted values. For both the anticipated and actual temperatures,
the language terms "cold," "moderate," and "hot" may be included in the variables. In the linguistic
variable heater setting, the terms "off," "low," and "high" could be present. Membership Purposes
Membership functions are numerical functions that correspond to concepts in language. A
membership function represents the degree of membership of linguistic variables within their
linguistic terms. A continuous scale with 0 denoting 0% membership and 1 denoting 100%
membership makes up the membership degree. Among the different types that are accessible are
the Ϋ-type (triangular shape), Π-type (trapezoidal shape), singleton-type (vertical line form),
Sigmoid-type (wave shape), and Gaussian-type (bell shape) membership functions.

Fig.5.6 Different types of shapes in the fuzzy graph

29
5.2.1.2 FUZZIFICATION
 FUZZY SETS
Uncertain Input and Output In our project, two inputs are used, and the output is created by
combining the two inputs. Each of these inputs consists of seven subsets.
 Input 1: Temperature Error
 Input 2: Temperature Error Rate
 Output: Fuzzy output to Heating rod or Pump Subsets
 INPUTS
 Input 1(Temperature Error): Positive Big, Positive Medium, Positive Small, Zero, Negative
Small, Negative Medium, Negative Big.
 Input 2(Temperature Error Rate): Positive Big, Positive Medium, Positive Small, Zero,
Negative Small, Negative Medium, Negative Big.
 OUTPUTS
 Positive Big, Positive Medium, Positive Small, Zero, Negative Small, Negative Medium,
Negative Big.

 MEMBERSHIP FUNCTION
A membership function (MF) is a curve that defines how each point in theinput space is
mapped to a membership value between 0 and 1. The input space is sometimes referred to as the
universe of discourse a fancy name for a simple concept. Mathematical function to grade the
association of a value to a set. A function which for each fuzzy set assign a physical value on the
abscissa to a truthvalue which describe to which extent this value belongs to the set. An indicator
function representing the degree of truth as an extension ofvaluation. Membership of the element
is the base set in the fuzzy set. Membership functions return value in the range [0,1] indicating
membership degree. A function that quantifies the grade of membership of a variable to a
linguistic term. A function that describes the degree of an element's membershipin a fuzzy set.
A membership function quantifies the grade of membership of a variable to a linguistic term. It
is a function that quantifies the grade of membership of a variable to a linguistic term.
Reasonable functions are often piecewise linear functions, such as triangular and trapezoidal
functions.

30
 Fig.5.7: Input Variable Membership Function

Fig.5.8: Output Variable Membership Function

An indicator function representing the degree of truth as an extension of valuation. The

set of elements that have a non-zero membership is called the support of the fuzzy set. The
function that ties a number to each element of the universe is called the membership function.
Membership function indicates the collection of possible values that an object may have when it
is defined as a factorof another object. For example tallness can be defined as low, medium, tall
by the help of membership function of tallness as a factor of low, medium and tall.

31
5.2.1.3 FUZZY RULES
The Basic Rules Table Rules translate the relationships between input and output linguistic
variables into words based on their linguistic language. The total number N of possible rules for a
fuzzy system is defined by the following formula: N = p1 × p2 × … × pn is the number of linguistic
phrases for the input linguistic variable n. If every input linguistic variable has the same number of
linguistic terms, then the total number N of feasible rules is defined by the following equation: N is
equal to p^m, where p is the quantity of linguistic phrases for every input linguistic variable and m
is the total number of input linguistic variables. Plotting a rule base as a matrix could be helpful in
finding discrepancies, such as contradicting rules. However, matrix plotting of a rule basis works
best for relatively small rule bases. Large rule bases make discrepancies difficult to discover. Huge
rule bases in fuzzy systems with several controller inputs can be avoided with the usage of cascaded
fuzzy systems.

Fig.5.9 Rules for Membership Function

32
 Fig.5.10 Rule Table

5.2.1.4 DEFUZZIFICATION
Fuzzy rule based systems evaluate linguistic if-then rules using fuzzification,
inference and composition procedures. They produce fuzzy resultswhich usually have to be
converted into crisp output. To transform the fuzzy results in to crisp, defuzzification is
performed. Defuzzification is the process ofconverting a fuzzified output into a single crisp
value with respect to a fuzzy set. The defuzzified value in FLC (Fuzzy Logic Controller)
represents the actionto be taken in controlling the process.

Fig.5.11 Test System in Fuzzy Designer

33
Defuzzification is the process of producing a quantifiable result in fuzzy logic, given fuzzy sets
and corresponding membership degrees. It is typically needed in fuzzy control systems. Some
process of defuzzification is required to convertthe resulting fuzzy set description of an action
into a specific value for a controlvariable.

5.2.2 PID SYSTEM

5.2.2.1 PROPORTIONAL CONTROLLER

A P-controller, also known as a proportional controller, is a type of feedback controller used

in control systems. It is a fundamental component of many control systems and is widely used in
various industries and applications. The purpose of a P-controller is to regulate a system output by
adjusting an input based on the difference, or error, between the desired setpoint and the actual
measured value of the system. The controller output is directly proportional to the error, hence the
name "proportional controller." The action of a P controller can be mathematically expressed as
follows:
Output = Kp * Error 5.2
where:
 Output is the control signal or the manipulated variable applied to the system.
 Kp is the proportional gain, which determines the controller's response to the error. It is a
constant multiplier that scales the error to produce the output.
 Error is the difference between the desired setpoint and the measured value of the system.
The proportional gain, Kp, determines the sensitivity of the controller. A higher Kp value makes
the controller respond more aggressively to the error, resulting in a faster but potentially more
oscillatory response. Conversely, a lower Kp value makes the controller respond more slowly. One
limitation of a P controller is that it cannot eliminate steady-state errors, as it only considers the
present error without any memory of past errors. It is best suited for systems with small or negligible
steady-state errors or in combination with other types of controllers, such as integral (I) and
derivative (D) controllers, to form a PID controller. Overall, a P controller provides a simple and
effective means of controlling a system by adjusting the input signal in proportion to the error
between the desired and actual values, making it a fundamental building block of control systems.

34
5.2.2.2 INTEGRAL CONTROLLER
An I-controller, also known as an integral controller, is a type of feedback controller used
in control systems. It is one of the three components of a PID (Proportional-Integral-Derivative)
controller. The purpose of an I controller is to eliminate steady-state errors in a control system. It
achieves this by integrating the error signal over time and using the cumulative error to generate the
control output. The integral action of the controller allows it to continuously adjust the output based
on the history of the error. The action of an I controller can be mathematically expressed as follows:
Output = Ki * ∫(Error) dt 5.3
where:
 Output is the control signal or the manipulated variable applied to the system.
 Ki is the integral gain, which determines the controller's response to the integrated error. It
is a constant multiplier that scales the integrated error to produce the output.
 Error is the difference between the desired setpoint and the measured value of the system.
 ∫(Error) dt represents the integral of the error with respect to time, which accumulates the
error over time.
The integral gain, Ki, determines the rate at which the controller accumulates the error. A higher
Ki value causes the controller to respond more aggressively to the accumulated error, leading to a
faster correction of steady-state errors. However, excessively high Ki values can result in overshoot
or instability in the control system. By continuously integrating the error, the I controller effectively
eliminates the steady-state error by gradually adjusting the control output. It is particularly useful
in systems with non-zero steady-state errors, such as those affected by disturbances or biases. When
used in combination with a proportional controller (P) and a derivative controller (D) as part of a
PID controller, the I controller helps to provide a well-rounded control response that addresses both
transient and steady-state errors. In summary, an I controller is a key component of a control system
that integrates the error over time to eliminate steady-state errors. It provides a means of adjusting
the control output based on the accumulated error, thereby improving the system's overall
performance and accuracy.

35
5.2.2.3 DERIVATIVE CONTROLLER
A D-controller, also known as a derivative controller, is a type of feedback controller used
in control systems. It is one of the three components of a PID (Proportional-Integral-Derivative)
controller. The purpose of a D controller is to anticipate and counteract the rate of change of the
system's error. It uses the rate of change of the error signal to generate a control output that helps to
stabilize the system and improve its transient response. The action of a D controller can be
mathematically expressed as follows: 5.4
Output = Kd * d(Error)/dt
where:
 Output is the control signal or the manipulated variable applied to the system.
 Kd is the derivative gain, which determines the controller's response to the rate of change
of the error. It is a constant multiplier that scales the derivative term to produce the output.
 d(Error)/dt is the derivative of the error with respect to time, representing the rate of change
of the error.
The derivative gain, Kd, determines the sensitivity of the controller to the rate of change of the
error. A higher Kd value makes the controller respond more aggressively to rapid changes in the
error, leading to a faster correction of the system response. However, excessively high Kd values
can cause the controller to amplify noise or result in an unstable control system. The D controller
is particularly effective in reducing overshoot and damping oscillations in the system response. By
anticipating the rate of change of the error, it can provide a corrective action that counteracts sudden
changes and helps to stabilize the system. When combined with a proportional controller (P) and
an integral controller (I), the D controller forms a PID controller. The PID controller combines the
advantages of all three components, providing a balanced and robust control response that addresses
both transient and steady-state errors. In summary, a D controller is a component of a control system
that uses the rate of change of the error to generate a control output. By anticipating and
counteracting rapid changes in the error, it helps to stabilize the system and improve its transient
response.

36
5.2.2.4 Proportional-Integral-Derivative (PID) CONTROLLER
A PID controller, which stands for Proportional-Integral-Derivative controller, is a feedback
control algorithm widely used in control systems to regulate and stabilize a system's output to a
desired setpoint. It combines the proportional, integral, and derivative control actions to achieve
accurate and responsive control. The working principle of a PID controller involves continuously
measuring the error between the desired setpoint and the actual output of the system. The controller
then calculates the control output based on three components:
 Proportional Control (P): The proportional term produces an output that is directly
proportional to the current error. It is calculated by multiplying the error by a constant gain
factor, known as the proportional gain (Kp). The proportional control action provides a rapid
response to the present error. However, it cannot eliminate steady-state errors.
 Integral Control (I): The integral term integrates the error over time, taking into account the
cumulative error. It is calculated by multiplying the integrated error by the integral gain (Ki).
The integral control action helps to eliminate steady-state errors by continuously adjusting the
control output based on the accumulated error. It provides a long-term correction mechanism.
 Derivative Control (D): The derivative term considers the rate of change of the error over time.
It is calculated by multiplying the derivative of the error by the derivative gain (Kd). The
derivative control action provides a control output that counteracts rapid changes in the error,
helping to stabilize the system and reduce overshoot and oscillations.
The control output of the PID controller is determined by the sum of the proportional, integral,
and derivative control actions:
Output = Kp * Error + Ki * ∫(Error) dt + Kd * d(Error)/dt 5.5
where:
 Output is the control signal or the manipulated variable applied to the system.
 Error is the difference between the desired setpoint and the measured value of the system.
 ∫(Error) dt represents the integral of the error with respect to time.
 d(Error)/dt denotes the derivative of the error with respect to time.
The gains Kp, Ki, and Kd are constants that are manually tuned or adjusted through an
automated tuning process to achieve the desired control performance. The tuning process involves
finding the appropriate gains that provide stability, responsiveness, and minimal overshoot for a
specific control system. By combining the three control actions, a PID controller can respond to
both transient and steady-state errors, providing accurate and stable control in a wide range of
control systems. It is widely used in various applications, including temperature control, speed
control, robotics, and industrial automation.
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5.2.2.5 APPLICATIONS
PID controllers have a wide range of applications across various industries and control
systems. Some common applications of PID controllers include:

 Temperature Control: PID controllers are extensively used in heating, ventilation, and air
conditioning (HVAC) systems to regulate temperature. They help maintain a desired
temperature setpoint by adjusting heating or cooling inputs based on temperature measurements.
 Process Control: PID controllers are widely employed in industrial processes such as chemical
manufacturing, power plants, and food processing. They regulate variables like pressure, flow
rate, level, and pH by adjusting control inputs to minimize deviations from the desired setpoints.
 Motor Speed Control: PID controllers are utilized in motor control systems to regulate motor
speed. They adjust the motor's input voltage or current based on the difference between the
desired speed and the actual speed measured by sensors. This enables precise control of motor
speed in applications like robotics, conveyor systems, and machine tools.
 Robotics: PID controllers play a crucial role in robot control systems. They help robots achieve
accurate and smooth motion control by adjusting joint positions or velocities based on sensor
feedback. PID controllers are used in applications such as robotic arms, autonomous vehicles,
and unmanned aerial vehicles (UAVs).
 Stabilization of Unstable Systems: PID controllers are effective in stabilizing unstable
systems. By providing appropriate control actions, they can counteract instabilities and
oscillations in systems, ensuring stability and improving the overall system response.
 Automotive Systems: PID controllers are utilized in automotive applications such as engine
control units (ECUs) to regulate parameters like fuel injection, throttle position, and idle control.
They help optimize engine performance, fuel efficiency, and emissions control.
 Level Control: PID controllers are employed in systems that require precise control of liquid
or material levels, such as tanks, reservoirs, and chemical reactors. They adjust inlet or outlet
valves to maintain the desired level by compensating for disturbances and variations.
 pH Control: PID controllers are used in applications where precise control of pH levels is
critical, such as water treatment plants, chemical processing, and bioreactors. They adjust
chemical dosing or flow rates based on pH measurements to maintain the desired pH setpoint.
 Aircraft and Flight Control Systems: PID controllers are utilized in aircraft autopilot systems
and flight control systems. They help stabilize the aircraft by adjusting control surfaces, such as
ailerons, elevators, and rudders, to maintain desired flight characteristics.
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 These are just a few examples of the wide-ranging applications of PID controllers. The
versatility, simplicity, and effectiveness of PID control make it a widely adopted control strategy in
numerous industries and systems requiring precise and stable control.

5.2.3 pH CONTROL SYSTEM

5.2.3.1 INTRODUCTION
These days, computer-based systems are used in the measurement and instrumentation
fields to control and monitor process elements and devices in the field or in the laboratory. This
application covers both networked computerized instrumentation systems, like the distributed
control system, and standalone computerized instrumentation systems. Before reaching their current
forms, advancements in instrumentation and measuring systems underwent several stages of
development. The measuring and instrumentation fields have advanced greatly, but they still have
certain drawbacks, such as the need for expensive and large-scale real instruments. Additionally,
because the instrument is industrial oriented, its processing capabilities are limited and unable to
handle new processing approaches. This system uses a pH sensor to monitor the solution's pH in
the reaction tank. The pH analyzer is then used to compare this measured signal to the intended
value. The signal to the actuator regulating the addition of reagent is always set in one of two
positions: fully open (ON) or fully closed (OFF), thanks to an analyzer that offers an ON/OFF
control system. On the other hand, this causes fast cycling and may harm the last control element.
Thus, it is necessary to have an ON/OFF controller with upper and lower hysteresis
limitations. These boundaries will keep the last control element "ON" for an extended period of
time, resulting in seamless functioning devoid of frequent cycling. When the process variable
changes, the parameters automatically adapt to the new situation, resulting in the desired result. For
the aim of real-time monitoring, the microcontroller and IOT module will be attached.

5.2.3.2 pH ANALYSER
A pH meter is essentially a high input impedance microprocessor-based electronic device
that measures the voltage of an electrode that is sensitive to the concentration of hydrogen ions in
relation to another electrode that displays a constant voltage. an illustration of a conventional, actual
pH meter. With a memory capacity of only 100 measurements, the meter spans the spectrum from
basic to sophisticated and costly laboratory instruments. Customary pH measuring device Any
solution's pH is typically measured using a number of instruments, including a pH electrode and pH
analyser that are coupled to a strip chart recorder and other data gathering devices.
39
 Each of these instruments performs a specific purpose to increase the number of functions
performed, additional, potentially expensive hardware and instruments must be purchased.

5.2.3.3 THE THEORY OF pH MEASUREMENT

An electrode can be used to measure the pH of the fluid. The Nernst equation, which
describes how an electrode creates a potential that yields a voltage output proportional to pH value,
can be used to explain the behavior of the electrode. The following equation explains how
temperature affects the pH electrode's voltage output.

5.6

where Tk is the recorded temperature in Kelvin, v0 is the intersect point value, and v is the
total measured voltage in millivolts. The measurement of pH is significantly impacted by
temperature. primarily, how electrode slope is affected by temperature. Furthermore, the variation
in the temperature coefficient affects the substance that the sensor is measuring. The pH electrode
is impacted by the Nernst slope variation with temperature.
5.2.3.4 MODEL OF pH REACTOR
It has been examined how the pH value, a master process variable, and the base streams, a
controlled variable, relate logarithmically. Three operational zones—two linear ranges and one
nonlinear range are separated by this relation. Its primary goals are to change the pH control's close-
loop response and expand its operating range. In our instance, the strong acid (HCL) in the titration
procedure under consideration has a constant flow value of [2 mL/sec] and a concentration of [0.95
mol/L]. The strong base (NaOH) flow at a concentration of [1.9 mol/L] will be the variable that is
adjusted. At this point, the following formula would be used to determine pH.

5.7

where V is the volume, k is a constant that varies with acid strength, and Ca, Cb are the
concentration values of acid and base, respectively, in the outlet stream. Qa, Qb are the volumetric
flow rates of acid and base, respectively. For our particular strong acid-strong base system, k = 1.

40
5.2.3.5 CONTINUOUS STIRRED-TANK REACTOR (CSTR) SYSTEM
Using the MyRio controller, fuzzy controller, PID controller, LabVIEW software, and
CSTR tank, this project enables pH monitoring and control. This method aims to provide
efficientpH management by attempting to modify the difference between the measured temperature,
various types of solutions, and the expected set point. The entire process will be monitored via the
Internet of Things (IoT). Three inputs the auxiliary variable, the pH value error (e), and the change
in error (de) are fed into the fuzzy system, which outputs three different values: the proportional
gain (Kp), the integral gain (Ki), and the derivative gain (Kd). Qb is the modified variable that
shows the base flow, and U is the control action. Three divided titration regions are served by the
suggested control system. These three areas were selected in accordance with the base flow rate Qb
value, which controls the reactor's pH level. The variables can only be evaluated qualitatively and
imprecisely because they are linguistic values in and of themselves. As a result, a method is required
to explain these ambiguous values. One of the best instruments for processing linguistic data is the
fuzzy set.
5.3 INTERNET OF THINGS

5.3.1 INTRODUCTION
The term "Internet of Things" (IoT) describes a network of actual physical objects, including
cars, appliances, and other items, that have sensors, software, and network connectivity built into
them. These systems continuously monitor temperature levels by utilizing real-time sensors that are
integrated inside the surroundings. Cloud computing is used to transmit the data that these sensors
have gathered to a centralized monitoring platform.
 IoT Temperature Control System Components:
 A fuzzy logic system called ThingSpeak is utilized in the process of monitoring the
temperature.
 To obtain the data, the MyRio and IOT module are connected.
 How It Operates:
 To maintain a constant temperature range, establish a temperature setpoint and hysteresis.
 Make a LABVIEW VI and add parts to read ThingSpeak palette data.
 Configure the ThingSpeak connection by entering the channel ID and API key.
 Connect the output Data from the IOT device to the input of the VI.
 Run the VI and the data to be monitor will be sent to the application.

41
5.3.2 THINGSPEAK
ThingSpeak is an IoT analytics platform service that allows you to aggregate, visualize, and
analyse live data streams in the cloud. Here are some key points about ThingSpeak:
 Data Collection and Visualization:
 You can send data from your IoT devices to ThingSpeak.
 ThingSpeak provides instant visualizations of the data you post.
 Whether it’s sensor readings, environmental data, or any other live stream, ThingSpeak
helps you visualize it.
 Built-in MATLAB Integration:
 ThingSpeak allows you to analyze and process data using MATLAB.
 You can create custom models, perform analytics, and develop applications based on your
data
 Use Cases:
 Environmental Monitoring: Build IoT services for remote monitoring of air quality
sensors and create MATLAB models to predict pollution levels.
 Energy Monitoring: Develop IoT applications to monitor energy usage and identify power
signatures using MATLAB.
 Smart Farming: Monitor sensors deployed on farms remotely, and use MATLAB models
to increase crop yields and reduce costs.
 Privacy Options:
 You can keep your data private or make it public by sharing it through channels.
 ThingSpeak offers RESTful and MQTT APIs for communication.

42
 Supported Devices:

 ThingSpeak works with various platforms, including:

 MATLAB & Simulink

 Arduino
 Particle devices
 ESP8266 and ESP32 WiFi Modules
 Raspberry Pi
 LoRaWAN via The Things Network

5.3.3 SYSTEM DESIGN

With LabVIEW, evaluate the fuzzy-PID controller with simulated or actual pH data. Check
to make sure the control system performs as anticipated and achieves the intended control goals. To
enhance performance, change the PID gains, fuzzy logic, or other parameters as needed. Install the
LabVIEW program on the chosen platform or system. Make sure the system can interact with the
IoT platform and is correctly connected to the IoT devices. Keep an eye on the temperature control
system and adjust as needed based on practical use.

5.4 LABVIEW

5.4.1 INTRODUCTION
LabVIEW (short for Laboratory Virtual Instrumentation Engineering Workbench) is a
platform and development environment for a visual programming language from National
Instruments. The graphical language is named "G". Originally released for the Apple Macintosh
in the year, 1986. LabVIEW programs are called virtual instruments or VIs, because their
appearance and operation intimate physical instruments, such as oscilloscopes and millimeters.
LabVIEW contains a comprehensive set of tools for acquiring, analysing displaying and storing
data, as well as tools to help you troubleshoot code that was developed. The Block Diagram
consists of the code. LabVIEW can be used to communicate with hardware such as data
acquisition, vision and motion control devices as well as GPIB, PXI, VXI, RS232, RS485.

43
5.4.2 COMPONENTS OF LabVIEW
5.4.2.1 Front Panel
The front panel is the user interface of a VI. The front panel was built by wang controls
and indicators, which are the interactive input and output terminals of the VI, respectively.
Controls are knobs, push buttons, dials, and other located on the control palette. Controls
simulate instrument in put mechanisms and supply data to the block diagram of the VI.
Indicators are graphs, LEDs, and other displays. Indicators simulate instrument output
mechanisms, and display data the block diagram acquires or generates.

Fig.5.12 Front Panel in LABVIEW

5.4.2.2 Block Diagram

The block diagram contains the graphical source code, also known as G code or block
diagram code for how the VI runs. The block diagram code uses graphical representations of
functions to control the front panel objects. Front panel objects appear as icon terminals on the
block. Wires connect controls and Indicator to express VIs and functions VIs. This movement
of data is known as dataflow Programming.

44
 Fig.5.13 Block Diagram in LABVIEW

5.4.3 GRAPHICAL PROGRAMMING

LabVIEW ties the creation of user interfaces into development. LabVIEW programs are
called as virtual instruments. Each VI has three components block diagram, front panel,
connector pane. The last is used to represent the V1 in block diagram of other calling VI.
Thus the virtual instrument can either be run as a program with the front panel serving as
user interface or when dropped as a node onto the block diagram, the front panel defines the
inputand outputs for the given node through the connector pane. This can be easily tested before
being embedded as a sub-routine into a larger program.
5.4.4 BENEFITS OF LABVIEW
 Powerful, flexible and scalable designing is possible.
 It finds its use in designing, prototyping and deployment.
 Easy interfacing with legacy and traditional instruments (GPIB, VME and soon)
 It helps in developing better and faster algorithm.
 It provides tight software and hardware integration, also supports data acquisition and
embedded control for device. It has high longevity and ability tosolve complex problems in
real time
 It takes shorter time for prototyping development, deployment
 It is multiplatform software.

45
5.4.5 BLOCK DIAGRAM TOOLS
The Positioning tool appears when you move the cursor an object in the front panel
window or on the block diagram. The cursor becomes an arrow that you can use to select,
position and resize objects. The Wiring tool when you movethe cursor over a terminal of Block
diagram object. The cursor becomes a spool that you can use to connect objects on the block
diagram through which you wantdata to flow.

5.4.6 PROCESS CONTROL AND FACTORY AUTOMATION

A pressing need in both factory automation and process manufacturing is taking
production and business systems work together. OPC gives the production and business
applications across the manufacturing enterprise access to real-time plant-floor information in a
consistent manner, making multi- vendor interoperability and "plug and play" connectivity a
real. OPC promises what, up to now, has been virtually unachievable to provide multi-vendor
plug-and-play components that manufacturing customers and system integrators can easily
integrate into enterprise-wide automation and business systems.
OPC removes harriers between traditionally proprietary factory floor devices, systems
and other manufacturing software.

5.5 SIMULATION AND IoT RESULTS

5.5.1 FUZZY LOGIC SYSTEM

Fig.5.14 Output of the fuzzy rules in graph

46
5.5.2 FUZZY-PID WITH IOT

Fig.5.15 Real-Time monitoring in IoT for Fuzzy-PID

5.5.3 pH MEASUREMENT WITH IOT

Fig.5.16 Real-Time monitoring in IoT for pH

47
5.5.4 LABVIEW FRONT PANEL

Fig.5.17 Real-Time monitoring Temperature Control with Fuzzy-PID

5.5.5 PROTOTYPE DIAGRAM

Fig.5.18 Protype Diagram for Temperature Control

48
 CHAPTER 6

CONCLUSION
In this project, we have presented a unique temperature control system that integrates fuzzy
logic and IoT technology in a novel way. By incorporating IoT-enabled smart devices, our system
provides users with enhanced convenience and personalized control over temperature settings. The
fuzzy logic controller, considering various factors such as desired temperature, occupancy patterns,
weather conditions, and user preferences, adapts intelligently to optimize temperature regulation.
The experimental results confirm the effectiveness of our unique approach in achieving precise and
personalized temperature control. The integration of fuzzy logic and IoT technology in our system
opens up new possibilities for temperature regulation in various domains, including smart homes,
office spaces, and commercial buildings. The use of voice commands and mobile interfaces
simplifies the user experience and enables seamless interaction with the temperature control system.
Additionally, the system's adaptability and intelligent decision-making contribute to energy
efficiency and user comfort. Future work can focus on further expanding the capabilities of our
unique system, such as incorporating advanced machine learning algorithms to continuously learn
and improve temperature control based on user preferences and environmental conditions.
Moreover, the integration of additional IoT devices and sensors can enhance the system's capabilities
for comprehensive environmental monitoring and control. Overall, the unique combination of fuzzy
logic and IoT technology in our temperature control system offers a promising solution for precise
and personalized temperature regulation, revolutionizing the way we interact with and manage
temperature in various settings.
In this project work, we have effectively used Internet of Things technology to manage temperature
with a fuzzy-PID controller. We have created a reliable and adaptive control mechanism that can
successfully manage nonlinearities and uncertainities in the temperature control system by
integrating the benefits of fuzzy logic with PID control. According to the experimental findings, the
accuracy, stability, and disturbance rejection of the Fuzzy-PID controller are better than those of the
traditional PID controller. We have created a reliable and adaptive control mechanism that can
successfully manage nonlinearities and uncertainties in the pH control system by integrating the
benefits of fuzzy logic with PID control.

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 CHAPTER 7

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