Me Lab 2 Final Project
Me Lab 2 Final Project
Me Lab 2 Final Project
ENGINEERING
Visca, Baybay City, Leyte, PHILIPPINES
Telefax: (053) 565-0600 local 1029
Email: coe@vsu.edu.ph
Website: www.vsu.edu.ph
Members:
Ablen, John Mark R.
Albarico, Achilles C.
Alluso, Bryan R.
Atizon, Me-Ann L.
Arotcha, Verniel
Castil, Kian Mae L.
Flores, Earl Louwyndale N.
Hoyumpa, Gercel Niño E.
Paña, Patrick Anthony N.
Pepito, Justine Mae D.
Purca, Bacille John
Tan, Venus O.
TABLE OF CONTENTS
I. Introduction: ................................................................................................................. 3
II. Objectives: ................................................................................................................... 4
III. Theoretical Background: ......................................................................................... 5
IV. System Design and Construction: .......................................................................... 7
Materials............................................................................................................................ 7
........................................................................................................................................ 13
........................................................................................................................................ 13
Wiring Diagram................................................................................................................ 16
Sketch/Code .................................................................................................................... 16
Experimental Methodology .............................................................................................. 25
Project Device Development ........................................................................................... 26
V. Results and Discussions: ......................................................................................... 27
VI. Conclusion and Recommendation: ....................................................................... 28
VII. References: ............................................................................................................. 29
VIII. Appendix:................................................................................................................ 30
I. Introduction
Heat exchanger is a device that incorporates the process of heat transfer between two
fluids that are at different temperatures, either direct or indirect contact. The device is utilized
in many engineering applications, such as heating and air conditioning systems, refrigeration,
power plants, food processing systems, chemical processing systems, waste heat recovery
systems, and automobile radiators (Balaji, Srinivasan, & Sateesh Gedupudi, 2021). For every
process plant, heat exchangers are critical elements as it involves heat transfer throughout its
process. Majority of exchangers are shell-and-tube type, but there are several types of this
heat transfer equipment – finned tube, spiral, plate-and-frame, plate coil, and bare tube (Hall,
2012).
The project utilizes a radiator heat exchanger. The heat transfer process conforms
from two fluids at different temperatures from air to water resulting in a decrease in the
temperature of air flowing out and increased in the temperature of water flowing out. The
thermal analysis for quantifying the heat transfer from air to water involves parameters, namely
– overall heat transfer coefficient that considers fouling factors, logarithmic mean temperature
difference, surface area of heat exchanger, pressure drop equation, Darcy friction factor
equation, specific heat capacity, mass flow rate or volume flow rate. According to Serth (2007),
assumptions are also considered, where overall heat transfer coefficient throughout the heat
exchanger is constant, no heat losses (no heat transfer between heat exchanger and its
surroundings), and no heat generation occurs within the heat exchanger. These are all
theoretically-base but on actual settings, it varies.
A comprehensive analysis of the project's theoretical basis necessitates a nuanced
exploration of different heat exchanger designs, ranging from coil to plate heat exchangers.
This exploration is crucial in identifying the most suitable design that ensures optimal heat
transfer efficiency. In addition, a profound understanding of fluid dynamics is imperative as it
guides the optimization of the system's air and water circulation to minimize energy losses
and enhance overall performance.
Despite the theories involve in designing the project, it adds a control system to
maintain the temperature of the air throughout the process. The system utilizes a servo motor
to alter the fixed water flow rate that is coming to the system, and this variation of flow rates
helps to maintain the temperature of the air that is coming out of the system. The servo motor
is accompanied with a code that is intended for the purpose of the project.
In summary, this project approaches the knowledge of combining the heat transfer,
fluid dynamics, and control systems. The substantial knowledge foundation acts as the
intellectual cornerstone of the project, paving the way for a thoughtful and innovative
implementation strategy in developing a durable and efficient air-to-water heat exchanger
system.
II. Objectives
● To use a servo motor to alter the fixed water flow rate that is coming into the system.
● To create a program for the air-to-water heat exchanger with a control system.
● To cool and maintain the temperature of the air that is coming out into the system.
III. Theoretical Background
A water to air heat exchanger is a crucial component in various heating and cooling
systems, designed to transfer thermal energy between water and air streams. The integration
of advanced control mechanisms, such as a controlled servo motor and a temperature sensor,
enhances the efficiency and adaptability of such systems. This theoretical background
explores the key components and principles behind a water to air heat exchanger equipped
with a temperature control system, aiming to optimize the exchange of heat while providing
real-time monitoring through an LCD display.
The primary function of the water to air heat exchanger is to facilitate the transfer of
thermal energy between the water and air streams. As cold water flows through a tube, it
passes through a radiator that is exposed to the ambient air. Heat is exchanged between the
warm air and the cold water, leading to a temperature change in both mediums.
Temperature Control
To enhance the efficiency of the heat exchange process, a temperature control system
is implemented. A temperature sensor is strategically placed within the tube, constantly
monitoring the temperature of the water. The feedback from the temperature sensor is utilized
to regulate the flow of water through the heat exchanger using a controlled servo motor.
Valve Control
The controlled servo motor acts as the valve for regulating the flow of cold water
through the heat exchanger. The servo motor is programmed with a series of codes to adjust
the valve's position based on the real-time temperature readings from the sensor. This
dynamic control mechanism ensures that the heat exchange process is optimized, preventing
overcooling or undercooling of the air.
Figure 2. 30 kg-cm Servo Motor
Monitoring
Materials
Power Supply
A 12V 4.2A Switching Power Supply 50W (LRS-50-12) can supply a DC voltage
of 12V DC, and a current of up to 4.2A, it also features a trim potentiometer to fine tune
the output voltage.
Water Pump
A 12 Volt water pump is a DC electric water pump motor that powered by a 12V
direct current power supply. It uses centrifugal force that generated by high speed
rotated impeller to booster, transfer, lift or circulate liquids like water, oil, coolant for
sprayers, car, fountain, shower & garden
Servo Motor
A servo motor is a high torque coreless motor with 30 kg-cm (3 Nm) stall torque,
220° angle sensor, steel gear and double ball bearings, selectable 6V or 7.4V
operating voltage. This type of servo motor can be used in projects that requires a lot
of torque or for any heavy actuating such as valve turning.
Buck Converter
A buck converter is used to step down voltage of the given input in order to
achieve required output. Buck converters are mostly used for USB on the go, point of
load converters for PCs and laptops, Battery Chargers, Quad Copters, Solar Chargers,
and power audio amplifiers. There are two types used in this project, a 5V and a 7.7V
buck converter.
Terminal Block
Terminal blocks are commonly used in electrical wiring, circuit connections,
and control systems. They provide a secure and organized way to connect and
disconnect wires without the need for soldering or specialized tools. Terminal blocks
are often found in industrial automation, control panels, distribution boards, and other
areas where reliable electrical connections are required. A specific "1 in 2 out" terminal
block allows you to take one incoming wire or signal and split it into two separate
outgoing connections. This can be useful in various applications where you need to
distribute a signal or power source to multiple devices or components.
Breadboard
A breadboard consists of plastic block holding a matrix of electrical sockets of
a size suitable for gripping thin connecting wire, component wires or the pins of
transistors and integrated circuits (ICs). The sockets are connected inside the board,
usually in rows of five sockets.
Acrylic Sheet
An acrylic sheet, often referred to simply as "acrylic" or "plexiglass," is a
versatile and widely-used material known for its transparency, durability, and ease of
fabrication. Acrylic sheet is utilized as the backing part of the project that holds the
components because it offers remarkable optical clarity, almost as clear as glass, while
being significantly lighter and less prone to shattering.
Shown in the figure above is the wiring diagram of the components connected
together to make the device. This was done using the application called “Fritzing”
which is an electronics design and prototyping platform to visualize the wiring
connection of the project. As shown, the NodeMCU ESP32 is powered using 12V 4.2A
Switching Power Supply 50W (LRS-50-12). The VCC, GND, SCL, and SDA pinouts of
the 20x4 LCD module, DHT22, flowmeters and servo motor are connected to the 3V3,
GND, G4, G14, G21, G22, G25, G26, and G32 of the NodeMCU ESP32 WROOM
respectively. The fans and submersible pump are connected to the 7.7V and 5V buck
converters which is then connected to the 12V power supply.
Sketch/Code
#define FLOWMETER1 32
#define FLOWMETER2 4
#define THERMISTOR1 34
#define THERMISTOR2 35
#define DHTPIN1 25
#define DHTPIN2 26
#define DHTTYPE DHT22
#define STARTBUTTON 18
#define STOPBUTTON 19
#define RESETBUTTON 13
static const int SERVOPIN = 14; // PWM pin for servo motor
float Average1 = 0;
float Average2 = 0;
const float alpha = 0.1; // Filter coefficient, adjust as needed
Servo_ESP32 servo1;
int angle = 0;
int angleStep = 5;
int angleMin = 5;
int angleMax = 90;
void setup() {
Serial.begin(115200);
lcd.begin(20, 4);
lcd.init();
lcd.clear();
lcd.backlight();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM ON");
analogReadResolution(10);
WiFi.begin(ssid, pass);
Blynk.config(auth);
pinMode(FLOWMETER1, INPUT_PULLUP);
pinMode(FLOWMETER2, INPUT_PULLUP);
DHT1.begin();
DHT2.begin();
pinMode(THERMISTOR1, INPUT);
pinMode(THERMISTOR2, INPUT);
pinMode(STARTBUTTON, INPUT_PULLUP);
pinMode(STOPBUTTON, INPUT_PULLUP);
pinMode(RESETBUTTON, INPUT_PULLUP);
pulseCount1 = 0;
flowRate1 = 0.0;
flowMilliLitres1 = 0;
totalMilliLitres1 = 0;
previousMillis1 = 0;
pulseCount2 = 0;
flowRate2 = 0.0;
flowMilliLitres2 = 0;
totalMilliLitres2 = 0;
previousMillis2 = 0;
servo1.attach(SERVOPIN);
servo1.write(angleMin);
delay(5000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
Serial.print("SYSTEM STABILIZING");
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("0 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("10 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("22 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("36 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("44 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("59 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("66 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("78 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("85 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("97 %");
delay(1000);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM STABILIZING");
lcd.setCursor(8, 1);
lcd.print("100 %");
delay(1000);
//if (!SD.begin(15)) {
//Serial.println("SD card initialization failed!");
//while (1)
// ;
//}
Serial.println();
lcd.clear();
servo1.write(angleMax);
delay(2500);
servo1.write(angleMin);
delay(2500);
servo1.write(angleMax);
delay(2500);
servo1.write(angleMin);
delay(2500);
servo1.write(angleMax);
delay(2500);
servo1.write(angleMin);
delay(2500);
Serial.println("System Ready");
lcd.setCursor(0, 0);
lcd.clear();
lcd.print(" SYSTEM READY");
lcd.setCursor(0, 2);
lcd.print(" PRESS START");
}
void loop() {
Blynk.run();
if (digitalRead(RESETBUTTON) == LOW) {
// Reset the system
Serial.println("System Reset (5 seconds)");
lcd.clear();
lcd.setCursor(0, 0);
lcd.print(" SYSTEM RESET");
lcd.setCursor(0, 2);
lcd.print(" (10 SECONDS)");
delay(2000);
lcd.clear();
servo1.write(0);
delay(2000);
isRunning = false;
delay(5000); // Reset for 5 seconds
ESP.restart();
}
if (isRunning) {
currentMillis1 = millis();
currentMillis2 = millis();
lcd.clear();
Serial.print("Flowmeter 1: ");
Serial.print(F1);
Serial.print(" LPM\t");
lcd.setCursor(0, 0);
lcd.print(F1, 2);
lcd.print(" LPM");
// Serial.print("Total Volume 1: ");
// Serial.print(totalMilliLitres1 / 1000);
// Serial.println(" L");
}
Serial.print("Flowmeter 2: ");
Serial.print(F2);
Serial.print(" LPM\t");
lcd.setCursor(10, 0);
lcd.print(F2, 2);
lcd.print(" LPM");
// The rest of your loop code for DHT and THERMISTOR readings
float dhttemperature1 = DHT1.readTemperature();
float dhthumidity1 = DHT1.readHumidity();
float dhttemperature2 = DHT2.readTemperature();
float dhthumidity2 = DHT2.readHumidity();
lcd.setCursor(10, 3);
lcd.print(temperature2, 2);
lcd.print(char(223));
lcd.print("C");
// Blynk uploads
char fFM1[30];
char fFM2[30];
char fNTC1[30];
char fNTC2[30];
char fDHTtemp1[30]; // Adjust the size based on your needs
char fDHTtemp2[30];
char fDHThum1[30];
char fDHThum2[30];
Blynk.virtualWrite(V1, fFM1);
Blynk.virtualWrite(V2, fFM2);
Blynk.virtualWrite(V3, fNTC1);
Blynk.virtualWrite(V4, fDHTtemp2);
delay(1000);
lcd.clear();
}
}
Experimental Methodology
The project device for water to air heat exchanger is developed, incorporating
the DHT22 for temperature and humidity data acquisition, flowmeters for the flow rate
of the water, fan for suction and discharge and servo motor for the valve control. The
device is configured to maintain a certain temperature during operation. All the
materials mentioned above are used for this development and assembled as shown in
the wiring diagram above. The sketch/code also shown above is used for the project
device to work as programmed in order to attain the objectives set.
Testing/Assessment
The accuracy of the project device is assessed by activating the device and
observing accuracy of the temperature by setting the program to the actual
temperature needed. The group conducted a test in the Department of Mechanical
Engineering Visayas State University, Baybay City Leyte. The group conducted
observations on the output of the developed equipment with various presets and
adjustments to help gather data about the efficiency and accuracy.
Data Collection
In order to have a visual evidence and representation of the functionality of the
project and its success to work as intended, data from the sensors used in the projects
are collected. The uploaded code/sketch used in the testing phase of the project is set
to reduce and maintain the temperature of the outlet air temperature in the range of
18.00°C to 20.00°C, which can be seen in the LCD of the project. The data can be
extracted from the Blynk IoT application which logs the readings it receives from the
ESP32.
V. Results and Discussions
The results and discussions on the air-to-water heat exchanger are presented
in this chapter, which largely includes the constructed prototype, and the reading of
data in the system.
The figure above shows the set up in the data collection. Cold water is supplied
to the system which absorbs the heat from the air inside the heat exchanger/radiator
which in turn produces cold air.
Shown in Figure 23 is the graph showing the decrease of the outlet air
temperature as time progresses and that the when the temperature drops in the range
of in the range 18.00°C to 20.00°C, it autonomously maintains that temperature range.
This serves as evidence that the system functions as intended of generating cold air
and maintaining its temperature.
30
25
20
15
10
5
0
0 20 40 60 80 100 120
Time (seconds)
(n.d.). Clear Acrylic Perspex Sheet Cut to Size Plastic Panel Plexiglass. Retrieved September
30, 2023, from https://www.lazada.com.ph/products/clear-acrylic-perspex-sheet-cut-
to-size-plastic-panel-plexiglass-i1204178430.html
Mean well switching power supply, LRS-50-12, 12V DC, 4.2A, 50W, 1 output, 120 → 373 V
DC, 85 → 264 V AC (no date) RS. Available at: https://ph.rs-
online.com/web/p/switching-power-supplies/1065830
Quick Connector 1 Input 2 Output Electrical Splitter Push-in Terminal Block. (n.d.).
RoboticsDNA. Retrieved September 30, 2023, from
https://roboticsdna.in/product/quick-connector-1-input-2-output-electrical-splitter-
push-in-terminal-block/
Stranded Wire (Black, 22 AWG, 50 Feet) in Canada Robotix. (n.d.). Canada Robotix.
Retrieved September 30, 2023, from
https://www.canadarobotix.com/products/2411?variant=14423860969521
VIII. Appendix
20 x 4 LCD 1 pc 305.00
Breadboard 1 pc 50.00
½” Tube/Hose 10 m 295.00
Pump 1 pc 420.00
Epoxy 1 pc 180.00
Bolts & Nuts 720.00