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## Implementation of the heating unit controller for the bending station for thermoplastic materials

### Marcin Wiesław Łykowski

#### Abstract

This thesis presents the design and implementation of a heating unit controller. The work contains a theoretical introduction presenting the most important information on the applied temperature control techniques. The fuzzy logic, on-off, PID (Proportional–Integral– Derivative) and MFC (Model Following Control) algorithms are characterized. Line bending of thermoplastic materials has also been described. The most popular plastics subjected to thermoplastic shaping and their applications are listed. Then, the existing temperature control solutions connected with industrial regulators are presented. The third chapter includes the design of the heating unit controller. The device is based on the Arduino Mega2560 chip equipped with the Atmega2560 microcontroller. The technical requirements of the controller are listed. In addition to maintaining the set temperature in the place of material bending, the regulator should measure the bend angle of the thermoplastic material and provide a user-friendly control by ergonomic graphical interface. Special attention was paid to ensure the safety of usage. The device can turn off the heater after a certain period of inactivity or when the bending machine overheats. In the following subsections, the choice of the regulation algorithm is justified and the individual components of the system are characterized. The provided data flow diagram eases the understanding of the operation’s principle of the controller. In the following parts of the work the design of the PCB together with the electrical diagram are presented and the process of making the printed circuit is also described. In the programming part, the applied Microsoft Visual Studio 2017 development environment with the addition of Visual Micro is briefly characterized. The work contains a summary of the external libraries used in the program and a description of the implementation of the discrete PID control algorithm in the microcontroller. An important element of the work is the presented block diagram of the main program function, which is responsible for controlling the heating unit during material heating. At the end of the programming part, a graphical user interface for the developed controller is presented. Numerous device tests were carried out on the line bending station for thermoplastic materials, which are described in the next chapter of the work. Graphs of the temperature of the heater dependence on time are presented, showing the operation of the regulator. During the tests, the difference between the temperature indicated by the pyrometer and the temperature measured with a higher accuracy thermal imaging camera was observed. In order to minimize indication errors, a series of measurements was carried out, on the basis of which a calibration curve is prepared. The next chapter presents the conclusions from the performed work. The most important features of the system were shown against the background of solutions available on the market. There were also described engineering problems which had to be solved during the project implementation. The last chapter summarizes the work and describes the possibilities of further development of the controller.
Diploma type
Engineer's / Bachelor of Science
Diploma type
Engineer's thesis
Author
Marcin Wiesław Łykowski (FM) Marcin Wiesław Łykowski,, Faculty of Mechatronics (FM)
Title in Polish
Realizacja sterownika zespołu grzewczego stanowiska do gięcia materiałów termoplastycznych
Supervisor
Andrzej Skalski (FM/IMBE) Andrzej Skalski,, The Institute of Metrology and Biomedical Engineering (FM/IMBE)Faculty of Mechatronics (FM)
Certifying unit
Faculty of Mechatronics (FM)
Affiliation unit
The Institute of Metrology and Biomedical Engineering (FM/IMBE)
Study subject / specialization
, Mechatronika
Language
(pl) Polish
Status
Finished
Defense Date
07-02-2019
Issue date (year)
2019
Reviewers
Andrzej Skalski (FM/IMBE) Andrzej Skalski,, The Institute of Metrology and Biomedical Engineering (FM/IMBE)Faculty of Mechatronics (FM) Marcin Słoma (FM/IMBE) Marcin Słoma,, The Institute of Metrology and Biomedical Engineering (FM/IMBE)Faculty of Mechatronics (FM)
Keywords in Polish
Regulacja temperatury, mikrokontroler, gięcie materiałów termoplastycznych
Keywords in English
Temperature regulation, microcontroller, bending of thermoplastic materials
Abstract in Polish
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Identyfikator pracy APD: 31444

Uniform Resource Identifier
urn:pw-repo:WUTda449f24c8834a77adf8eef9738b4af7