Closed-loop Control System: Temperature Control

Loop of Hair Dryer Using Arduino

Nichole Xavier D. Asa
Electronics Engineering Department
College of Engineering
Bulacan State University
City of Malolos, Bulacan
ECE-3A

interfaced with the Arduino board to increase / decrease the

I. INTRODUCTION control loop's setpoint. [2]
Earlier handheld hair dryers remained difficult to operate.
Their (often aluminum) metallic casings made them difficult B. Zero Cross Detection
to manipulate. In addition, drying times were significantly Equal time is spent below 0V and above 0V for a 230V
longer than they are today, as the devices drew only 100 watts Sine wave. Therefore, it is essential to detect the moment
of electricity as opposed to 2,000 watts for modern versions. when the wave transitions from negative to positive or vice
This made them exhausting to use for the lengthy drying times versa. Because, if we send a firing pulse to the TRIAC after
required. Some early models featured pedestals to rest weary the zero-cross, we can control the amount of power and the
arms. Nonetheless, these dryers were regarded as a amount of wave passing through. Therefore, we must detect
convenience marvel. [1] the zero-cross in order to synchronize. Fig. 2 depicts the zero
Automation has become an integral component of heating cross detection circuit. A full-bridge rectifier and a
and cooling systems, and their utilization is increasing photocoupler are used to detect zero cross. Negative voltages
exponentially. Temperature control is the process of and voltages above 5V render the microcontroller inoperable.
monitoring and regulating the flow of heat energy into or out [2]
of a system in order to maintain the desired temperature. It is The complete bridge rectifier will only produce positive
a closed loop feedback control system; a common example of waves, and the photocoupler will reduce the voltage to 5Vpp.
a closed loop control system is the home thermostat, which Therefore, we can interpret the signal using an Arduino. This
constantly monitors the current room temperature and controls circuit is utilized to conform Arduino to the heating source.
a heater and/or air conditioner. The software platform, such as This is required for taking a control action. Fig. 3 depicts the
Arduino IDE, also includes a PID control library, which experiment's final diagram. The following is a description of
facilitates the user's implementation of a three-term PID the flow chart:
controller. Due to Arduino's benefits, a PID command can be 1. System is started up.
implemented with an Arduino board for a variety of industrial 2. A comparison is made between the set point and the
process control loops. Utilizing temperature sensors, such as measured value.
K-type thermocouples, the temperature is continuously 3. If the values differ, the TRIAC signal is sent.
calculated and regulated. Using a MAX 6675 module, a
4. Altering the firing angle of a TRIAC transforms its
thermocouple of type K is connected to an Arduino board.
Both data acquisition and control functions have been input into a full-bridge rectifier.
performed by the Arduino Uno board. The desired 5. The fan speed of a hair dryer varies with the output
temperature range is set using push buttons. TRIAC is of a full bridge rectifier. [2]
connected to the hair dryer via an Arduino Uno module. This III. IMAGES OF THE SYSTEM
will regulate the quantity of energy transferred to the AC
heater. This causes a change in fan speed and ultimately
regulates the temperature. In this test, Arduino controls the
frequency of a 230V AC-powered hair dryer, which
necessitates zero cross detection. Using a rectifier bridge and
a photocoupler. [2]
II. SYSTEM DESCRIPTION
Consideration of closed loop control system divides the
experimental design into two sections: Temperature
Measurement and Zero Cross Detection. [2]
A. Temperature Measurement
With the aid of the MAX6675 module, a K-type
thermocouple is used to measure temperature and interfaced
with the Arduino Board. The I2C LCD board displays the
temperature in degrees Celsius. The temperature regulation
chain is depicted in Figure 1. Two pushbuttons are also Figure 1. Temperature Detection Circuit
 IV. BLOCK DIAGRAM AND ITS EXPLANATION

Figure 5. Block diagram of closed loop temperature control system

In control theory, a controller is an important device that

monitors, controls, and influences the operating conditions of
dynamical systems. In general, the operating conditions are
associated with the process output variables or the controllable
variables. The function of the controller is to modify the
system's dynamics for improved closed loop performance. For
optimal control system design, the operator must ensure that
the system follows the desired dynamics despite internal and
Figure 2. Zero Cross Detection Circuit
external disturbances. In this project, a closed-loop
temperature control system has been implemented using a
hardware platform such as Arduino, and output data is
continuously updated to the controller using a thermocouple
sensor. Fig. 3 depicts the block diagram of a closed loop
system. [2]
A. Hardware and Software Support
1. Arduino Uno Development Board: Arduino Uno is
an ATmega328P microcontroller-based
ATmega328P board. Certain components such as
crystal oscillator, serial communication, voltage
regulator, etc. provide the microcontroller in
addition to ATmega328P. 14 digital input/output
pins (6 of which can be used as PWM outputs), 6
analog input pins, an ICSP header, a USB
connection, and a reset button are included on the
Arduino Uno. [2]
2. Module MAX6675 and K-Type Thermocouple: The
MAX6675 Module and K Type Thermocouple
package is a ready-to-use combination for
Figure 3. Experimental Setup Schematic measuring temperatures greater than 1,000 °C. The
MAX6675 is a thermocouple sensor amplifier with
linearity correction, thermocouple break detection,
and serial ADC performance. Its temperature
resolution capacity is 0.25 degrees, its cold junction
compensation range is –20 to +80 degrees, and its
operating voltage range is 3.0 to 5.5 volts.
Thermocouples have existed forever and are an
excellent method for measuring temperature. They
have a vast selection, are durable, and come in a
variety of lengths, tip configurations, and sheaths.
The use of thermocouples is complicated by the
need for cold junction compensation and the
requirement to detect a very small voltage shift per
degree of temperature change. Fortunately, chips
like the MAX6675 make inexpensive thermocouple
attachment to Arduino a breeze. The device analyzes
the output of a K Thermocouple and transfers the
result to the Arduino via an SPI interface. [2]
Figure 4. Zero Cross Detection Flowchart 3. Full Bridge Rectifier: A bridge rectifier converts
Alternating Current (AC) to Direct Current (DC) by
rectifying mains AC input to DC output. Power
supplies that provide the necessary DC voltage for
 electronic components or devices frequently employ V. CONCLUSION
bridge rectifiers. [2] Traditional hair dryers usually have a simple process of
4. TRIAC is a three-terminal device that consists of blowing air unto a wet hair. When a hairdryer is plugged into
Main Terminal 1 (MT1), Main Terminal 2 (MT2), an electrical outlet and turned on, the electricity powers a
and Gate. TRIAC is equivalent to two SCRs heating element and an electric motor that drives the dryer's
connected in parallel with the gates in reverse. Once fan. The heating element transforms electrical energy into up
the gate is activated, the TRIAC functions as a to 2,000 Watts of heat. This process is referred to as resistive
bidirectional switch to allow current to flow in both heating, and it is utilized in other household appliances, such
directions. The MT1 and MT2 terminals connect the as the electric kettle and toaster [3]. In this method of heating,
Phase and Neutral lines while the Gate provides the the heat of the released air from the dryer is constant, therefore
triggering pulse. Both positive and negative voltages the temperature is sustained all throughout using it.
can activate the Gate. When the MT2 terminal By incorporating a temperature control loop into a hair
receives a positive voltage over the MT1 terminal dryer, it becomes a smart appliance that monitors and
and the Gate terminal receives a positive signal, the maintains a temperature as needed in response to changing
left SCR of the TRIAC is activated and the circuit is ambient temperatures. This added feature makes sure that
completed. The right SCR conducts, however, if the external temperature disturbances will not interfere with the
voltage polarity at terminals MT2 and MT1 is hair dryer, thus releasing air at temperatures that are most
reversed and a negative pulse is applied to the Gate. accurate to the user's desired temperature.
When the Gate current is removed, the TRIAC shuts
off. In order to keep the TRIAC conducting, the gate REFERENCES
must maintain a minimum holding current. [2] [1] M. T. Hart, “The Hair Dryer, Freedom's appliance,” The Atlantic, 17-
5. Arduino IDE and PID Library: The Arduino Jan-2018. [Online]. Available:
https://www.theatlantic.com/technology/archive/2017/08/hair-dryer-
software (IDE) makes it easy to write and upload history/535566/. [Accessed: 15-Feb-2023].
code to a computer. It is compatible with Windows, [2] J. Bhor, S. Pawar, and S. Das, “Design and development of temperature
Mac OS X, and Linux. The framework is written in control loop of hair dryer using ...,” Design and Development of
Java and is compatible with Processing-based Temperature Control Loop of Hair Dryer Using Arduino, 15-Feb-
2020. [Online]. Available:
Arduino boards and other open-source applications. https://www.researchgate.net/publication/344236099_Design_and_De
This library simplifies the use of PID in Arduino velopment_of_Temperature_Control_Loop_of_Hair_Dryer_Using_A
projects. The library only requires the Kp, Ki, Kd, rduino. [Accessed: 15-Feb-2023].
and setpoint values. When utilizing the library, the [3] O. Esu, “How does that work - electric hairdryers,” Ingenia, Dec-2020.
PID code is contained in its entirety. This facilitates [Online]. Available: https://www.ingenia.org.uk/ingenia/issue-
85/how-does-that-work. [Accessed: 15-Feb-2023].
the code's comprehension. Additionally, it is
capable of more complex operations, such as having
eight PIDs in the same system. [2]
 Open-loop Control System: PLC based Smart
Coffee Maker
Nichole Xavier D. Asa
Electronics Engineering Department
College of Engineering
Bulacan State University
City of Malolos, Bulacan
ECE-3A

Table 2. List of outputs with PLC ladder logic diagram address

I. INTRODUCTION
Automation is a technology that enables processes to
operate independently of human intervention. Essentially,
"automating" tasks entails creating a system (or a portion of a
system) that runs by itself. Historically, automation primarily
referred to physical equipment that assists with laborious tasks
such as printing text or manufacturing automobiles. This has
changed significantly in the modern era. To automate tasks,
businesses and individuals can now adopt software from third-
party vendors [1].
To improve their products, modern manufacturers require Eleven inputs, including three toggle switches, three push
both high and rapid efficiency, which is achieved through the buttons, and five limit switches, comprise the system in
use of automated technologies. This type of automation is general. Five limit switches are used to stop the hot drink
being applied to every aspect of human life in order to increase preparation cup in the correct position for collecting coffee,
the convenience and standard of living. The Programmable tea, hot water, milk, and sugar based on the selected mode. In
Logic Controller (PLC) system is an essential component of addition, there are six outputs, which include the cup
the modern technological and industrial sectors. The PLC is a preparation motor conveyor, the coffee valve, the tea valve,
system that automates machine and process operation. It the hot water valve, the milk valve, and the sugar valve.
consists of three essential components: input, process, and
Depending on the selected mode, the output motor
output, all of which must work well and in harmony. In order
to achieve the desired result or output, it is necessary to conveyor transports the hot drink preparation cup to the
combine the input or data with the appropriate operation or appropriate valve location, and each valve supplies the raw
process. This controller is responsible for all industrial, material. Inputs and outputs used in this project are listed in
manufacturing, and entertainment expansion automation. Tables 1 and 2, along with their function, address, and
Without such a system, transportation, the creation of associated timer used in a ladder logic program to control the
amusement attractions, and filmmaking are impossible. operational time of output devices [2].
Therefore, PLC systems are crucial and required in virtually Figure 1 depicts the proposed project's flowchart. If the
every industry [2]. Main ON input is activated, the entire system is ON. The
system will then examine the state of the user's input. The
II. SYSTEM DESCRIPTION mode of operation to be executed will be determined by the
Table 1. List of inputs with PLC ladder logic diagram address user's choice. If the user selects mode 3 (black coffee mode),
for instance, the coffee will be added first, followed by hot
water, and then sugar. Once all necessary supplies have been
added, it will be prepared for delivery to the user. When input
main OFF is enabled and a full cycle has been completed, the
system will stop. Otherwise, the procedure for creating hot
beverages will be performed in a circular fashion [2].
Any automated system's implementation is a combination
of hardware and software. The software component can be
implemented using five distinct programming techniques:
Ladder Diagram (LD), Sequential Function Charts (SFC),
Function Block Diagram (FBD), Structured Text (ST), and
Instruction List (IL) (IL). Ladder logic is the most commonly
used programming language for PLCs. This is because it is
highly adaptable, straightforward to learn, and widely
understood. The Ladder Logic Program (LLP) / Ladder
Diagrams (LD) facilitate the graphical representation of the
required logic expressions for programming a PLC. It
represents conditional, input, and output expressions with
symbols. Creating a relay control circuit is comparable to III. IMAGES OF THE SYSTEM
using ladder diagrams to write a PLC program. Main Ladder
Diagram for the proposed project shown in figure 2 [2].

Figure 3. Hardware Implementation

IV. BLOCK DIAGRAM AND ITS EXPLANATION

Figure 1. Proposed System Flowchart

Figure 4. System Block Diagram

Figure 5. Alternative Block Diagram of the Proposed System

Fig. 4 shows the proposed system for the PLC-based smart

coffee maker, and Fig. 5 shows the system organized in a more
familiar open-loop diagram. The first box, from left to right,
refers to the system's input interface, which consists of the
buttons and switches. The next refers to the system’s
controller; since it is PLC-based, the controller is the PLC.
The third box refers to the output interface or the actuators of
the system, which are the indicating lamps, motors, and
various valves for the different beverage options and add-ons.
V. CONCLUSION
Automation is preferred in all production and service
fields in order to reduce human intervention and achieve
greater efficiency, dependability, and less labor. Depending
on the user's input, the proposed coffee machine features eight
distinct modes that offer hot beverages ranging from black
Figure 2. Main Ladder Logic Diagram
coffee to white tea. The proposed Smart Coffee Maker system
includes a PLC controller because of its durability and ease of
installation and maintenance [2]. This control system is combinations of its eight different modes can be achieved with
considered an open-loop system because of its linear the utmost precision and speed.
operation, wherein the user chooses all the options in line with
their desired kind of beverage, and the machine will combine REFERENCES
them in a cup of hot water. As long as the user knows what [1] Y. Fatehpour, “What is automation?: Complete Guide to Automation,”
combinations of add-ons are needed, they will get the right eWEEK, 19-Sep-2022. [Online]. Available:
kind of drink with the amount of sweetness and creaminess https://www.eweek.com/enterprise-apps/what-is-automation/.
[Accessed: 17-Feb-2023].
they want.
[2] M. Kamatchi, C. Mendoza, and K. Venusamy, “Design and
The smart coffee maker, by using the PLC as its controller, implementation of PLC based Smart Coffee Maker,” Design and
made ordering or serving coffee more efficient as it is now Implementation of PLC based Smart Coffee Maker , 2022. [Online].
Available: https://iopscience.iop.org/article/10.1088/1755-
automated. With this kind of coffee maker, all possible 1315/1055/1/012011. [Accessed: 16-Feb-2023].