Technical Report: High Temperature Measurement and

Control

TECHNICAL REPORT
TROLENG LAB

SUBMITTED BY:
FLORESCA, AARON GABRIELLE FLORESCA
GALANG, KENNETH CHRISTIAN S.

SUBMITTED TO:
ENGR. PAUL M. CATALAN
 CHAPTER I: INTRODUCTION

1.1 Background of the Study

High-temperature measurement and control play a critical role in industrial processes

that require precise temperature management to ensure product quality, safety, and efficiency.
Industries such as metallurgy, glass manufacturing, chemical processing, and power generation
heavily depend on maintaining stable and controlled high-temperature environments (Smith,
2018). For instance, in metal processing, accurate temperature control is essential to achieve
desired material properties and prevent structural defects (Jones & Lee, 2020). In other cases,
such as chemical reactions, uncontrolled temperature variations can lead to inefficient reactions
or even hazardous conditions (Miller, 2019).

Modern high-temperature measurement systems commonly rely on advanced sensors

like thermocouples, infrared sensors, and resistance temperature detectors, which can
withstand extreme conditions (Brown et al., 2021). These sensors provide data that is then used
by control systems to adjust heating or cooling mechanisms in real-time, minimizing temperature
deviations and energy consumption (Taylor & Zhao, 2020). However, high-temperature
environments present unique challenges, including sensor degradation over time, thermal noise,
and slow response times due to the thermal mass of equipment (Chen & Patel, 2019). Effective
design solutions must address these issues to ensure reliable performance under continuous
operation in harsh environments.

Despite advancements in sensor technology, the demand for improved temperature

control and measurement systems continues to grow as industries seek higher accuracy,
durability, and responsiveness in extreme environments (Anderson, 2022). This report explores
these challenges and presents a design approach to a high-temperature measurement and
control system aimed at providing stable temperature regulation, efficient performance, and
user-friendly operation.

A real-world application of a DIY kalan de uling with an automatic and manual fan control
system could revolutionize how traditional cooking stoves operate in rural areas or off-grid
locations. By integrating a 12V DC fan powered by a battery, a temperature sensor, and a
microcontroller, this system can ensure efficient and controlled combustion. In automatic mode,
a temperature sensor (like a DS18B20 or thermistor) monitors the stove’s temperature. When
the temperature exceeds a set threshold, the microcontroller signals the fan to stop, preventing
overheating and conserving charcoal. In manual mode, users can adjust the fan speed via a
potentiometer, providing more control over the heat for specific cooking needs. This hybrid
system enhances fuel efficiency, reduces smoke, and allows for precise temperature
management, benefiting households and small businesses reliant on traditional stoves.

This application is particularly valuable in low-resource settings where access to modern

cooking appliances is limited. It combines affordable and accessible components, such as an
Arduino microcontroller, a 12V battery, and a motor driver, to create a user-friendly solution. The
design reduces health risks from excessive smoke inhalation and increases cooking efficiency,
supporting sustainable development goals for clean cooking technologies. Such innovations can
also be scaled for disaster relief operations or eco-tourism initiatives in remote areas. This
practical and cost-effective adaptation of traditional cooking technology offers a bridge between
modern engineering and sustainable practices, making it a vital tool in advancing energy equity.

1.2 Objectives

The report aims to:

● Explore the design and implement a high-temperature measurement and control system
using accessible components.
● Control the blower speed based on real-time temperature data and user-defined
threshold.
● Evaluate the performance of the system in maintaining stable temperature within a
specified range.

1.3 Significance of the Study

● Improves process efficiency, product quality, and safety in high-temperature industrial

applications.
● Serves as a resource for academic purposes, aiding students, researchers, and
engineers.
● Lays the foundation for developing more advanced and sustainable temperature control
systems.

CHAPTER II: REVIEW OF RELATED LITERATURE

Temperature measurement and control system

Temperature is both a thermodynamic property and fundamental unit of measurement.

Temperature measurement is a cornerstone in temperature control systems, playing a pivotal
role in ensuring safety, quality, and efficiency across various fields such as manufacturing,
healthcare, and environmental monitoring

Measurement of temperature is a crucial component of the majority of industrial

operations which is typically carried out using a temperature sensor. It is frequently utilized as a
crucial factor for the effective monitoring and control of various applications, particularly in
science and engineering (Bhatia, n.d.). Multiple elements need to be taken into account when
choosing the kind of sensor for a particular application: temperature range, precision, response
time, stability, linearity, and sensitivity. It is equally crucial to ensure the accuracy of temperature
measurements, as incorrect readings can lead to equipment malfunctions, inferior products, or
even serious health risks for individuals.. However, acquiring temperature sensors with
high-level accuracy is expensive (Meijer, 2018).

Temperature sensors are the backbone of temperature control systems, as they convert
thermal information into a readable signal, allowing automated systems to respond to
temperature variations effectively (Fraden, 2016). Temperature control systems rely heavily on
feedback from these sensors to maintain optimal conditions, making sensor selection and
calibration a critical part of system design. Advanced technologies, such as digital sensors and
wireless monitoring, are increasingly being integrated into these systems to enhance reliability
and efficiency (Jones, 2021). Proper sensor maintenance, calibration, and periodic validation
are essential to sustain accuracy over time, particularly in environments with fluctuating or
extreme conditions (Kim & Chen, 2018).

Arduino Microcontroller

Arduino is a programmable open source board. It is known to be a simple and powerful

single board computer that has gained a remarkable reputation in the hobby and professional
world (Kaswan, et. al., 2020). This open-source hardware was developed to be an easy-to-use
microcontroller hardware and software such that processing power would be available for
everyone (Barrett, 2022). It is designed to provide an inexpensive and easy way to create
devices that can interact with their environment using sensors and actuators (Louis, 2016).
Arduino microcontrollers can easily be programmed and updated at any time. Information can
be received by the device through inputs and outputs and based on acquired data Arduino can
send output, this microcontroller can also send and receive data via the internet utilising HTTP
requests (Ismailov, et. al., 2022) . Therefore, it is capable of acting as a mini computer in the
same way as microcontrollers.
Arduino utilizes hardware known as the Arduino development board and software for
developing the code known as the Arduino IDE or Integrated Development Environment (Louis,
2016). Like any microcontroller, an arduino is a circuit board with chip that can be programmed
to do numerous of tasks, it sends information from the computer programme to the Arduino
microcontroller and finally to the specific circuit or machine with multiple circuits in order to
execute the specific command (Badasmasi, 2014). The Arduino IDE provides a simplified
integrated platform which can run on regular personal computers using C or C++ programming
language (Louis, 2016). This enables more adaptable programming and the utilization of
devices with Arduino interface compatibility. Due to Arduino's open source nature, anyone who
wishes to use the circuit blueprints and build their own board using the schematics can do so for
free online, provided they share their finished product (Pan & Zhu, 2017).
The use of Arduino has been extensively explored in multiple fields due to its versatility
and accessibility. From wearable fashion to space research, the possibilities of utilizing Arduino
has developed endless ideas. Arduino boards are now being used in industries such as
engineering, medicine, and even aerospace (Kaswan, et. al., 2020).

Fan Control in Temperature Regulation

An electric fan is one of the most popular electrical appliances that is found in every
household. It is primarily used in homes to control room temperature and become an integral
part of every home environment in giving comfort. Nowadays, fans come in different forms such
as ceiling fan, table fan, wall-mounted and pedestal fans. There is a motor in the fan that
produces mechanical energy from electrical energy. The fan's blades slice the hot air as it rises
and force it downward. Air circulates around the room as a result of this ongoing activity. The
constant circulation lowers the room's temperature to an average level by combining hot and
cold air (Kommey, et. al., 2022).

Over the years, the mechanism of fans has changed and improved. The demand for
accurate temperature control has conquered many industrial domains. Therefore, there has
been a growing concern for automation of fans to ensure comfortability by offering remote and
intelligent control. Achieving the ideal room temperature is necessary because the temperature
varies throughout the day. Normally, the usage of the fan is controlled manually by pressing on
the switch button. This lack of innovation prevents it from turning on automatically in accordance
with variations in temperature. In addition, those who are physically challenged or have other
mobility issues, this is very detrimental. Automation of fans is also becoming more popular since
it not only saves electricity by turning off when not in use, Therefore, numerous studies
concentrating on the use of automatic temperature control systems have increased, especially,
that it will be a big benefit in various fields (Rizman, et. al., 2013).
 CHAPTER III: DESIGN APPROACH

3.1 Overview of the Design

The system is designed to automate temperature regulation in a charcoal stove. It uses

a MAX6675 thermocouple to monitor the stove's temperature, an Arduino microcontroller to
process data, and an L298N motor driver to control a blower. The blower's speed is adjusted
based on user-defined thresholds or real-time temperature feedback. Users can set these
thresholds using a 100kΩ potentiometer. The system operates in both manual and automatic
modes to cater to user preferences.

3.2 Components and their Function

1. Arduino
○ Acts as the main controller for the system.
○ Reads temperature data from the DHT11 sensor and user input from the
potentiometer.
○ Controls the relay and fan based on temperature readings.
2. Thermocouple Sensor (MAX6675)
○ Measures ambient temperature and provides real-time data to the Arduino.
3. L298N Motor Driver
○ Controls the blower's motor speed based on signals from the Arduino.
4. Potentiometer
○ Allows users to set the desired temperature threshold for the system.
○ Allows users to manually control the speed of the blower
5. Blower
○ Supplies airflow to the charcoal stove to regulate combustion intensity.
6. Power Supply (12V)
○ Provides the necessary voltage and current for the blower and motor driver..
7. Kalan de Uling
○ The application setup where the temperature regulation system is implemented.

3.3 Functional Requirements

1. Monitor temperature using a thermocouple sensor and display real-time data.

2. The blower speed should automatically adjust based on the real-time temperature and
the user-defined threshold.
3. Provide temperature and fan status feedback on the display.

3.4 Design Requirements

1. The temperature measurement system must update the readings continuously, with a
refresh rate of at least once per second to provide real-time monitoring.
2. The system must react to temperature changes in less than 1 second to ensure
immediate adjustments to control systems, such as activating fans
 3. The system must achieve a measurement accuracy of ±0.5% of the actual temperature
value across the entire measurement range.

3.5 Circuit Diagram

3.6 Calibration

TRIAL OFFSET SYSTEM STANDARD % ERROR

FACTOR

1 5 59.75 54.5 9.63

2 3 58.25 55.3 5.33

3 0 54.75 51.10 7.14

4 -1 55.25 58.8 6.03

5 -2 56.25 58.8 4.33

6 -2.5 54.75 54.6 0.27

Note: Due to the unavailability of a standard temperature measuring device (Pyrometer) for
temperature, we were advised by our instructor to utilize an alternative temperature measuring
device (Thermal Gun) to ensure accurate and reliable measurements for the project.

CHAPTER IV: COMMISSIONING

4.1 Introduction

Commissioning ensures that the kalan de uling temperature regulation system operates
as intended. This phase involves verifying hardware and software performance, testing all
components, and calibrating the system to meet functional and design requirements. Proper
commissioning guarantees reliability, accuracy, and safe operation under real-world conditions.

4.2 Pre-Commissioning Plan

The pre-commissioning phase involves preparatory activities to confirm that all

components are correctly installed, configured, and functional before full system operation. Key
steps include:

1. Visual Inspection
○ Verify all electrical connections, including thermocouple wiring, potentiometer,
motor driver, and blower connections.
○ Check for proper insulation of wires and secure mounting of components.
2. Hardware Testing
○ Test individual components such as the blower, thermocouple, and motor driver
for standalone functionality.
○ Ensure power supply delivers the correct voltage and current.
3. Software Debugging
○ Upload and test the Arduino code to confirm proper communication with sensors
and actuators.
○ Simulate inputs (e.g., temperature thresholds) to check logic flow.
4. Calibration
○ Calibrate the thermocouple to ensure accurate temperature readings by
comparing against a reliable reference thermometer.
○ Adjust the potentiometer’s range to match the desired threshold values.

4.3 Commissioning Activities

1. System Integration Testing

○ Connect all components to the Arduino and test the full setup under controlled
conditions.
 ○ Verify that the blower adjusts its speed based on temperature readings and
potentiometer input.
2. Mode Verification
○ Test automatic mode to ensure the system adjusts blower speed dynamically
based on the threshold temperature.
○ Test manual mode to confirm the blower can be controlled independently of the
temperature sensor.
3. Operational Testing
○ Operate the system with the kalan de uling to validate real-world performance.
○ Measure response time for blower adjustments to temperature changes.
4. Safety Checks
○ Ensure no overheating occurs in wiring, motor driver, or other electrical
components.
○ Validate safe operation under high-temperature conditions.

CHAPTER V: RESULTS AND ANALYSIS

Results

The kalan de uling temperature regulation system performed successfully during testing.
The MAX6675 thermocouple provided accurate temperature readings within ±.1°C, ensuring
reliable monitoring of the stove’s environment. The blower adjusted its speed dynamically in
response to the temperature threshold set via the potentiometer, with a response time of
approximately 0.5 second. Both automatic and manual modes functioned as intended, offering
flexibility and control based on user preference.
 Figure 5.1: Transient and Steady State Response

The graph illustrates the transient and steady-state response of the temperature-based
fan control system. During the transient phase, the temperature rises sharply, indicating the
system's response to an increasing heat source. Around 50 seconds, the rate of increase slows
as the system transitions towards equilibrium, suggesting the fan is dynamically adjusting to
manage the temperature. By approximately 70 seconds, the system reaches a steady state,
where the temperature stabilizes with minimal fluctuations just below 600°C. This steady
behavior demonstrates the system's ability to regulate temperature effectively and maintain
stability. However, the steep rise in the transient phase suggests room for improvement in the
fan's initial response to temperature changes, which could help achieve faster stabilization.

Analysis

The system operated stably, maintaining consistent temperature regulation through

proportional control. This minimized combustion fluctuations, enhancing the stove’s efficiency.
The automatic blower adjustment reduced energy consumption compared to constant-speed
systems.

However, slight delays in blower response to rapid temperature changes were observed
and could be optimized. Thermocouple accuracy depended on proper placement, and further
improvements in hardware insulation could enhance durability. Overall, the system effectively
achieved its objectives, providing reliable, energy-efficient temperature control for the kalan de
uling.

Appendix

Appendix I: Circuit Diagram

Appendix II: Program

#include <max6675.h>

// Thermocouple MAX6675 pins

int thermoSO = 12;

int thermoCS = 10;

 int thermoSCK = 13;

MAX6675 thermocouple(thermoSCK, thermoCS, thermoSO);

// Toggle switch pin

#define MODE_PIN 8 // Toggle switch pin

int mode = 0; // 0 = Manual, 1 = Automatic

// Potentiometer pins

#define FAN_SPEED_POT A0 // 10kΩ Potentiometer for fan speed (manual mode)

#define TEMP_THRESHOLD_POT A2 // 10kΩ Potentiometer for temp threshold

(automatic mode)

// L298N Motor Controller pins

#define ENA 5 // PWM pin for fan speed

#define IN1 6 // Control pin 1

#define IN2 7 // Control pin 2

// Variables

float temperature = 0; // Current temperature

float calibratedTemperature = 0; // Temperature after applying offset

float tempOffset = -2.5; // Calibration offset (positive or negative)

int fanSpeed = 0; // Fan speed (PWM value)

int tempThreshold = 0; // Temperature threshold

void setup() {
 // Pin modes

pinMode(MODE_PIN, INPUT_PULLUP); // Internal pull-up for toggle switch

pinMode(ENA, OUTPUT); // PWM for fan

pinMode(IN1, OUTPUT);

pinMode(IN2, OUTPUT);

// Initialize fan (stopped)

digitalWrite(IN1, LOW);

digitalWrite(IN2, LOW);

// Initialize serial monitor

Serial.begin(9600);

void loop() {

// Read toggle switch mode

mode = digitalRead(MODE_PIN); // HIGH = Automatic, LOW = Manual

// Read thermocouple temperature and apply offset

temperature = thermocouple.readCelsius();

calibratedTemperature = temperature + tempOffset;

// Read temperature threshold and fan speed potentiometers

tempThreshold = map(analogRead(TEMP_THRESHOLD_POT), 0, 1023, 0, 600); //

Map to 0-300°C
 int manualFanSpeed = map(analogRead(FAN_SPEED_POT), 0, 1023, 0, 255); // Map
to PWM 0-255

// Manual or Automatic Mode

if (mode == LOW) { // Manual Mode

Serial.println("Manual Mode");

fanSpeed = manualFanSpeed; // Use manual potentiometer to control fan speed

} else { // Automatic Mode

Serial.println("Automatic Mode");

// Fan behavior: start at max RPM and slow down as temp approaches the threshold

if (calibratedTemperature < tempThreshold) {

// Scale fan speed inversely with temperature

fanSpeed = map(calibratedTemperature, 0, tempThreshold, 255, 0);

} else {

// Turn off the fan if temperature exceeds or meets the threshold

fanSpeed = 0;

// Set fan speed

analogWrite(ENA, fanSpeed);

if (fanSpeed > 0) {

digitalWrite(IN1, HIGH);

digitalWrite(IN2, LOW); // Fan direction forward

 } else {

digitalWrite(IN1, LOW);

digitalWrite(IN2, LOW); // Fan off

// Debugging output

Serial.print("Calibrated Temperature: ");

Serial.print(calibratedTemperature);

Serial.print(" °C, Fan Speed: ");

Serial.print(fanSpeed);

Serial.print(", Threshold: ");

Serial.println(tempThreshold);

delay(500); // Adjust delay as needed

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