Intelligent System Design of Micro-Controller-Based Real-Time

Process Control Trainer.

Anthony Nosike Isizoh1, Kelvin Ndubuisi Nnamani2, Emmanuel Ugochukwu Chiboka3
1
Senior Lecturer Department of Electronic and Computer Engineering Nnamdi Azikiwe University
2,3
M.ENG scholar, department of Electronic and Computer Engineering, Nnamdi Azikiwe University,
Awka, Anambra State

Abstract-This project analyzes the intelligent system design of a real-time process control trainer.
The system was designed using AT89C52 microcontroller as the controlling device for three real-
time processes, namely temperature, traffic lights, and intruder alert. These were developed into
three different modules and later interconnected together. The entire system operates based on the
execution of the stored program in the microcontroller. In this project, an algorithm was designed for
the system of operation, and the control program was developed from the algorithm in Assembly
language; though it could be written in any embedded system programming language like C++. Real-
time simulation was done using Proteus software so as to ascertain the workability of the design in
real life. The Bill of Engineering Measurement and Evaluation (BEME) not were carried out to
determine the cost of the project. The prototype was constructed and it tested ok.
Keywords- Real-time Process Control Trainer, Proteus Software, AT89C52 Microcontroller, control
module, Temperature Sensor, modularization, Assembly Language, Pseudo code, Flowchart.
I. INTRODUCTION
Process control is an engineering discipline that deals with architectures, mechanisms and algorithms
for maintaining the output of a specific process within a desired range in real-time. Industrial process
control trainer has been harnessed in industrial processes such as waste water treatment, oil and gas
purification, chemical, pulp and paper production, and food production[1].Process control enables
automation, with which a small staff of operating personnel can operate a complex process from a
central control room.
The trainer has an in-built educational board with a pressurized vessel [2] and a set of sensors and
actuators for level, pressure, temperature and flow. The sensors and actuators have control modules
with interface circuits.
A major characteristic of process control is that it occurs in real-time. And to real-time systems,
timeliness is as important as the correctness of the output. In other words, they process information
within specified interval or risk system failure. More elaborately, the computer is required to perform
its tasks within the time restraints of some process or simultaneously with the system it is assisting
and also to process systems data (inputs) from sensors for the purpose of monitoring and computing
system control parameters (outputs) required for the correct operation of a system or process. The
type of monitoring and control functions provided by the computer for subsystem units ranges over a
wide variety of tasks, such as turn-on and turn-off signals to switches; feedback signals to controllers
(such as motors, servos, and potentiometers) to provide adjustments or corrections; steering signals;
alarms; monitoring, evaluation, supervision, and management calculations; error detection, and out-
of-tolerance and critical parameter detection operations; and processing of displays and outputs.
Digital control is a branch of control theory that uses digital computers to act as system controllers.
Depending on the requirements, a digital control system can take the form of a microcontroller to a
standard desktop computer.

DOI : 10.23883/IJRTER.2019.5040.WYJMC 102

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Since process control is a digital real-time process, it is important that technical know-how and skills
be acquired in order to efficiently control the installed devices and systems. From statistics, the
National Institute for Standards and Technology (NIST) and the Abnormal Situation Management
(ASM) Consortium estimate that U.S. process industries lose over $20 billion each year from
abnormal situations. They have determined that 50% of abnormal situations are directly attributable
to human error by plant personnel. Abnormal situations require the utmost operator skill, knowledge,
and critical thinking. Despite significant losses from abnormal situations, process manufacturers
continue to rely on operator intervention during start up, shutdown, and other operational scenarios.
Training is fundamental to reducing these losses, whether at new or existing plants, industrial
facilities need to consider use of an operator process trainer in their training programs [3].
A typical digital process trainer is multi-purpose digital experiment equipment comprising different
built-in circuits. Trainers can be used to demonstrate a complete range of process control methods
and strategies. Digital trainers can offer process modeling and even simulation, something that can
improve the operator’s training a great deal.

II. METHODOLOGY
Trainers are built according to the concept that is to be taught, giving rise to so many types of them.
But this paper presents a Real-time process control trainer. The trainer has a control module,
containing the interface circuits for sensors and the actuators [2] and the ON/OFF, proportional,
integral and derivative control circuits (PID) Real-time processes are basically sensor based. These
sensors provide input to four modules interfaced with the central controlling unit, that is, the
temperature control unit, traffic light unit, intruder alert unit and security light unit. However, to
effectively explain how these units are integrated together to achieve the intended system, a
methodology is followed.
Methodology is necessary for the success of complex digital hardware design [4] and is categorized
into system analysis, design, program coding, debugging, testing, and program maintenance using
flowcharts, pseudo codes and modules.

III. SYSTEM ANALYSIS

System analysis is the process of studying an activity typically in order to define its goals or
purposes [5] and to discover operations and procedures for accomplishing them most efficiently. So
in order to effectively do this in this section, block diagram of the basic functionality of the system is
utilized and the component used to realize the system is also described. The block diagram as shown
in Figure 1, comprises the power supply, input interface, the control and output interface.

Figure 1 Block Diagram of Real-Time Process Control Trainer.

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IV. SYSTEM DESIGN

This chapter is a continuation of top-down approach to effectively analyze the system. The design of
the digital process control involves mostly small scale integration components, the component
counts with usually high for a fairly complex circuit [6]System design in most cases are based on
modularization be it software or hardware systems and this project design is based on
modularization. It allows for easy and effective design as the supra system is broken down into
smaller units, modules or systems and the design for each module is carried out independently.
Modularization facilitates easy troubleshooting and correction or easy debugging (in case of software
development). In the light of the foregoing, the design of the real control system is divided into:

Temperature control module

Traffic light control module
Intruder alert system module
Automatic light control module
CentralContolModule

4.1 Temperature Control Module

This module interfaces LM35 Temperature Sensor 8052 Microcontroller AT89C52. LM35 gives
analog reading and microcontroller process digital data so a midway converter is used to convert
from Analog to Digital i.e. ADC0804 and display the result of a temperature on LCD, while an LED
is used to indicate when the temperature limit (in this case 29oC) is exceeded. The output voltage
from the LM35 is linearly proportional to the measuring temperature.

The network of resistors and zener diode supplies 1.28V to Vref/2 pin of ADC0804 as its reference
voltage. This is the voltage by which the step size of the ADC0804 will be set to 10mV. LM35
output voltage varies by 10mV per 0C change in temperature. Hence both the LM35 and ADC0804
are now working at 10mV change. So for a range of 0 to 100 0C, LM35 outputs 10mV per 0C and
ADC0804 processes 0V to 1V. The state of the module and the ambient temperature as sensed by the
LM35 in displayed on an LCD. For control, a switch is connected to the microcontroller to be used to
activate the module.

• Pin connection
The data pins (DB0 to DB7) of the ADC0804 are interface with the port 3 of the
microcontroller.
The LED indicator is connected to the pin 0.7 of the microcontroller.
The pin2 of the LM35 is connected to the VN+ pin of the ADC; while its pin 1 and 3 are
connected to voltage source and ground respectively.
The control switch for the temperature is connected at the pin 1.2.The schematic diagram of
the Temperature control module is shown below.

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Figure 2. Temperature Control Modules.

4.2 Traffic Light Control Module

Figure 4 is a circuit diagram of traffic light control, and nine LEDs are used for the purpose of traffic
light control.

Figure 3 Traffic Light Control Modules

An 8052 Microcontroller is the brain of this module with a control switch at the pin 1.0 to activate
the module. The LEDs are interfaced to the Port two of the microcontroller and are powered with 5v
power supply. LCD is used to display the status of the module. The LEDs get automatically switched
on and off by making the corresponding port pins of the microcontroller LOW, based on the 8052
microcontroller and its programming done by using assembly language. At a particular period of
time, only the green light holds ON for one lane and the other lights remains OFF, and after
sometime, the changeover traffic light control from green to red takes place by making the
succeeding change for glowing of yellow LED while for the other lanes, yellow and red light is ON.
This process continues as a cycle.

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The cathodes of the LED are connected to port 2 and pin 0.0 of the microcontroller while the anodes
are connected to a 5volts battery through a 220 ohms resistor. Green, yellow and red LEDs have a
forward voltage of 2.2V and current of 20mA, so a resistor with a suitable value must be placed at
anode. To obtain the value of such resistor, this formula is applied

Limiting resistor for all led used in this work

From database, LED allowable current is taking as 23mA, and 5v across it.
But = V/I
= 5/23x 10
=217Ω
But for this work, 220 Resistor was used since it is readily available in the market.

4.3 Intruder Alert Module

Figure 5 is a schematic diagram of the intruder alert module. This module produces a buzz when the
sensor detects an obstacle.

To activate the module, the intruder alert switch (designated I_A) connected to pin1.3 is turned on.
The obstacle avoidance infrared sensor is connected to pin 1.4 and once an obstacle is detected, the
photodiode (infrared receiver) of the sensor module receives the reflected ray generates a potential
difference or changes its electrical resistance. Due to the design of the obstacle avoidance sensor
module, a low is sent to MUC and then the buzzer is activated.

Figure 4 Intruder Alert Modules.

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4.4 Automatic Light Control Module

This module involves the control of the on and off of a security light by the action of a light sensor.
The module is activated by a switch (designated S_L) and connected to pin 1.1 of the
microcontroller.
The circuit can be used for implementing any type of automatic light control. The circuit uses an
LDR to sense the light .When there is light the resistance of LDR will be low, so the voltage drop
across potentiometer (POT) RV2 will be high. This keeps the transistor Q2 ON and 0 volt at the
collector hence activating pin 1.5.When night falls the resistance of LDR increases to make the
voltage across the POT R2 to decrease below 0.6V. This turns transistor Q2 OFF and causes a high
at the collector, hence deactivating the P1.5. Once the MUC detects a high, at pin 1.1, it biases the
base transistor at the pin 1.6 and then the security light is turned On.

Figure 5 Automatic Light Control System

4.5 Central Control Module

This includes the microcontroller and the switches that activate each module. The microcontroller is
AT89C52. This is where the assembly language program is installed. It has the central processing
unit with an internal memory which makes it a good choice. From the family of 8052, it was chosen
because its program and data memory meets the requirement for the project.

From the schematic diagram of the control module, the port 0 of the MCU is pulled up by 10K
resistor pack to 5V, port 2 is used for LCD and traffic light, port 3 for data pins of ADC0804, port 1
for the control switches, LDR, the security light and infrared sensor module, finally port 0 is used for
the special function pins of the LCD and ADC0804 (that is, RS, E, RD, WR.INTR etc). The design
was planned in such a way that the number of pins can be enough for the interfacing of the numerous
components with the MCU.

The control switches are Single pole single throw switch. They are designated T_L (Traffic light
module), S_L (security light), TEM (temperature module) and I_A(intruder alert module) in order to
identify them. They are used to activate or deactivate the modules,

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Finally, the RESET button which is a normal open switch, used to reset the whole system when
necessary.

Figure 6 Schematic Diagram of The Central Control Module.

4.6 The Integrated System Schematic Diagram

For the reason of neatness, clarity and out of necessity, so that all components will cater for and fully
captured, I replaced the LDR, the control switches and infrared were replaced with logic probes. So
there is discrepancy in feature but similarity in functionality .The effect is seen in figure 4.6 below.

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Figure 7 Schematic Diagram of The Integrated System.

4.7 Pseudo code and flowchart

PSEUDOCODE
1. Program BEGINS

2. Initialize ports and assign logic levels

3. Display WELCOME MESSAGE

4. Check Button Press

a. IF Pin1.0 is equal to ZERO THEN Activate TRAFFIC LIGHT UNIT and Repeat Until

b. ELSE IF Pin1.1 is equal to ZERO THEN Activate SECURITY LIGHT UNIT and Repeat
Until

c. ELSE IF Pin1.2 is equal to ZERO THEN activate TEMPERATURE CONTROL UNIT and
Repeat Until

d. ELSE IF Pin1.3 is equal to ZERO THEN activate INTRUDER ALERT and Repeat Until

e. ELSE LONG JUMP to Welcome Message.

f. Else. END.

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Begin

Initialize

Display
Wcome

Check button
press

Activate
YES
IS P1.0 = 0?
Traffic Light
Module
NO
YES Activate
IS P1.1 = 0? Security Light
Module
NO
YES Activate
IS P1.2 = 0
Temp. Module
NO
YES
Activate
IS P1.3 = 0
Intruder Alert
Module

End

Figure 8 Flowchart of the Real-Time Process Control Trainer.

V. MODULE IMPLEMENTATION, TESTING AND RESULTS

The project is a combination of different modules, so it was implemented according to the modules
involves. It was divided into compartments for each module with the microcontroller and switch
which constitutes the central control module at the center location. Figure 9 below shows the
modules being implemented on amber colored printed circuit board.

5.1 Power supply

External power pack was also used in order to reduce the complexity and bulkiness of the project,
since it involves very sensitive components and space is needed for more clarity.

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Figure 9 Modules Implementation On PCB.

5.2 Packaging
In order to achieve a more standard implementation and a world class project, packaging is of utmost
importance. So in the light of this, I used transparent Perspex and a plastic platform.

Figure 10 The Complete Project.

5.3 System Testing

Since the system is modularized, the bottom – up approach was adopted. Bottom – up approach
testing is an approach to integrated testing where the lowest level modules and components are tested
first, then used to facilitate the testing of higher level modules. So each module was tested, then the
whole system was tested to ensure conformity with.
These tests include:
• All the components were checked to see if they are okay before they were used in the circuitry.
• Potentiometer was adjusted to the proper range.

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• The components which were not functioning properly were changed as soon as possible to avoid
other components being affected by the damage.
• Testing equipment was in proper range of the output measured at any point of the circuit, or
component so as to avoid wrong readings.
• The obstacle avoidance infrared sensor module was tested appropriately to see if its ranging is
accurate.
• As the modules were installed they were tested and confirmed to be in order.

Table 1 Test For Intruder Alert Module.

Test data Expected Test Result Actual Test
Result
Obstacle detected Sensor output changes from 1 to 0 and Confirmed
Buzzer makes ten blipping sound
Potentiometer on Obstacle detecting range should change. Confirmed
sensor is adjusted

Table 2 Test for Automatic Light Control Module

Test data Expected Test Result Actual Test result

LDR detects darkness Security light is turned ON Confirmed
Light falls on LDR Security light is turned OFF Confirmed

Table 3 Test for Temperature Control Module

Test data Expected test Result Actual test

result
Low temperature applied Display temperature on Confirmed
to sensor LCD
o
29 C temperature applied LED indicator turns ON Confirmed
to sensor and display temperature on
LCD

Table 4 Test for Traffic Light Control Module

Test data Expected test ResultActual test

result
Traffic control Display status on LCD Confirmed
Switch turned On and operate Traffic
LED

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Table 5 Test for Central Control and Display Module

Test data Expected test Result Actual test

result

Intruder alert Activate intruder alert module and Confirmed

switch turned on display status on LCD
Light control Activate Automatic light control Confirmed
switch turned on module and display status on LCD
Temperature Activate Temperature control Confirmed
control switch module and display status on LCD
turned on
Traffic light Activate Traffic light control module Confirmed
control switch and display status on LCD
turned on

VI. CONCLUSION
The project, titled, “Real-time Process Control Trainer” used AT89C52 microcontroller as its
intelligent device. The system was programmed in Assembly language to achieve the required
system control. It shows how electronic sensors can be used to control some basic components
automatically by sensing the condition of the environment. This is however the basics of real-time
projects and devices.

The temperature sensor which is the LM35 senses the temperature of a room and sends out a
corresponding voltage signal, the obstacle sensor which is the obstacle avoidance infrared sensor
senses the presence of an obstacle and activate an alarm and the Light detecting resistor senses
amount of light and on or off the security light. An LCD is used to display the functional status of
this sensor which already is grouped into modules with the components they control.

REFERENCES

I. Mr. khushal k. Agrawal. 2017-2018, “Multi-process control Trainer Using Distributed control
system”, pp 1-55. https://lecturenotes.in/download/project-report/21370-multi-process-control-
trainer-using--distributed-control-system.
II. Infinit Technologies(2019), “IT-5200 Process Control Trainer”. Retrieved from: infinit-
technologies.com/our-products/it-5200-process-control-trainer/.
III. “The Role of Simulator Technology in Operator Training Programs. [Online]”, The Role of Simulator
Technology in Operator Training http://www.controleng.com/channels/process-control/process-
control-news/single-article/the-role-of-simulator-technology-in-operator-training-program
IV. Nwankwo Vincent Ifechi, “Design and implementation of a microcontroller-based versatile
Y- and Cross-Junction Traffic Light control system/Trainer”, Nnamdi Azikiwe University
Open Educational Resources, October 2010.pp 1-112.
V. https://en.m.wikipedia.org/wiki/systems_analysis.
VI. Udeze Chidiebere et al, “A cost-effective Approach to the design and implementation of
micro-controller-based universal process control trainer”, International Journal of Advanced
Computer Science and applications, Vol.3, No.1, January 2012. Pp 142-147.

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