INDUCTION COOKER SENSOR

CHAPTER ONE

1.1              INTRODUCTION

This application note describes an induction cooking design which can be used to evaluate component or to get started quickly with your own induction cooking development project.

Induction cooking is not radically new invention, it has been widely used all around the world. With recent improvement in technology and consequent reduction of component costs, induction cooking equipment is now more affordable than ever. The design provides an opportunity to understand how an induction cooker works and to make an in debt examination of the various blocks and part of this type of cooking application such the driving topology, how the resonant tank works, how the pot get hot and to remove it safely from the cooking plates. The design is entirely controlled by a simple ST7FNITE09Y0 8-bit controller, and drives the fan and relay control to the plate feedback.

1.2       BACKGROUND AND JUSTIFICATION

This presentation report is based on the design and construction of a microprocessor based induction steel sensor cooker. The project is mainly concerned with the development of an electric device for fast and hygienic cooking, and warming food for human consumption thereby reducing human energy wasted in the use of firewood and stove and the dirtying of cooking utensils will also be minimized. The microprocessor based induction ferrous sensor electric cooker can be very easy to manage and operate but for safety usage there must be total adherence or compliance to the prescription and procedure of handling the cooker. This is inevitable to prevent electric hazard or burn i.e. adequate care must taken by the user. Cooked food is commonly consumed by all classes in the society. The commonly used means of cooking is the firewood which is likely to expose the food to toxics by-product of wood combustion and smoke hence rendering the process unhygienic. The large scale consumers

are and have no choice than to consume the food irrespective of the size, type and sometimes the low quality as produced and supplied by local cooks who maximizes their profit at the expense of the consumer.

The microprocessor based induction steel sensor electric cooker makes the combine work of cooking, baking, drying of food items an easy household task. It is faster, hygienic and easily operated. Heat conduction issue is one of the hot topics in research area. It has wide applications in industry and our daily life, such as electrical furnaces, electrical heating appliances, and ventilation of computer chips. Among those heat conduction problems, the heating elements are the core topic of the heat conduction problems. Different heating elements demonstrate different characteristics in heat conduction. Among many different structures of the heating elements, the coil has been used in many areas because of its compact structure and large thermal expansion (McLain, 2003).

Heat conduction issue is one of the hot topics in research area. It has wide applications in industry and our daily life, such as electrical furnaces, electrical heating appliances, and ventilation of computer chips. Among those heat conduction problems, the heating elements are the core topic of the heat conduction problems. Different heating elements demonstrate different characteristics in heat conduction. Among many different structures of the heating elements, the coil has been used in many areas because of its compact structure and large thermal expansion ( Ololade, 2007).

This study has analyzed the heat transfer of the heating coils under different conditions by using an induction based cooker. It provides some useful information on designs and applications of heating coils. Therefore, the concept of induction cooker is a special kind of transformer. When a good-sized piece of magnetically conducting material such as, for example, a cast-iron frying pan, is placed in the magnetic field created by the cooking element, the field transfers ("induces") energy into the metal. That transferred energy causes the metal the cooking vessel (cookware) to become hot ( Dorf, 2002 ).

1.3       AIM OF  RESEARCH

The aim of this project is as follows:

        i.               Offer the project executors the opportunity of self-employment after graduation.

      ii.               To offer an opportunity to the student to combine the theory and practical experience gathered in the course of study for man’s development.

    iii.               To produce home-made cooking device at an affordable price to the people.

1.4       OBJECTIVES

A comparative analysis of the cost of production of this electric cooker unit with oven and the relative cost of similar types available in the market indicates that the project is cheaper, maintainable and easy .to control. It therefore makes the project to be preferred over similar types and moreover it is constructed from locally available materials even discarded materials. Below are the main objectives for this project

           i.         To develop a device that can offer employment which will result in reducing the number of teeming youths on the labor market

         ii.         To stimulate more interest on the use of electrical principle on food processing such as confectionaries.

       iii.         To promote economic industrial growth of the nation by the design and construction of cooker unit that is exportable.

1.5       MOTIVATION

The rate at which stainless kitchen utensils are been stained is alarming and discomfort on the side of the users. In most cases hard and sharp substances like sand or ashes have to be applied or used to remove the stain.

Hence, this project aims at eliminating the aforementioned above in order to create the ease of cleaning of kitchen utensil.

1.6       SCOPE AND LIMITATION OF THE PROJECT

Certainly, studying the potential of raw materials and applying basic engineering principles for design and construction is a very essential task. Though, several studies have exploited some tactical principles to generated heat for constructive deeds. Based on this study the limitation is based on the design and construction of a cooker unit using electromagnetic effects.

1.7       STATEMENT OF THE PROBLEM

The problem in which this project work is aimed at solving is the challenges associated with power failure and fuel scarcity which among others include:

The erratic power supply from Power Holding Company of Nigeria  (PHCN).

Excessive uses of wood and charcoal for cooking which is thereby associated with harmful effects especially on cardiovascular infection.

The high cost of production for small and large scale business owners as a result of lack of constant power supply.

The high cost of fuel and seasonal fuel scarcity in Nigeria.

The high cost of generating sets and close down of industries and companies.

1.8       SIGNIFICANCE OF THE REPORT

The microprocessor based induction steel pot sensor electric cooker equipment which is of importance to the economic growth of the nation. Induction cooking has several advantages over traditional methods of cooking as outline below:

                    i.            It makes cooking faster

                  ii.            Speed: conductive heat transfer to the food is very direct because the cookware is heated uniformly and from within. Induction cooking is even faster than gas cooking

                iii.            Safety: there are no open flames. This reduces the chances of fire and the cold stove top is also more child safe

                iv.            Efficiency: around 90%. Heat is generated directly in the pot, while for electric and gas the efficiency is around 65% and 55% respectively due to heat transfer loss.

                  v.            It helps to preserve foods like fish and meat.

                vi.            It is used for baking food such as cake and bread etc.

              vii.            The cooker is commonly used to remove moisture, steam liquid of any material that is placed inside it.

            viii.            The cooker can also be used to heat materials to the desire temperature.

1.9       STRUCTURE OF THE REPORT

Chapter 1: introduction, background and justification, aim of research, objectives, motivation, scope and limitation, statement of the problem and significant of the report.

Chapter 2: Will look at literature on implementation of induction steel sensor cooker using microprocessor.

Chapter 3: This involved adopting engineering methodology, then implement the methodology of the research.

Chapter 4: This section will discuss test result, all measurement and analysis will be carried out in this chapter.

Chapter 5: Will state the conclusion, project appraisal, and recommendation the implementation of implementation of induction steel sensor cooker using microprocessor.

CHAPTER TWO

2.0       LITERATURE REVIEW  

INTRODUCTION

A microprocessor based induction steel sensor electric cooker, dry or warm any food materials placed inside a cooking pot and placed on the top of it. The cooker burner is in the form of plate with an enclosed spiral alloy metal or spiral tungsten wire. Other relative ways of generating heat are solar, coal, firewood, and combustible gas forced to flow through metallic tiny holes. The cooking procedures dated back to the history of the early man which is the ancient and the local way of cooking by setting three stones, set fire on the firewood already in the center of the stones. The heat radiated by the burning firewood heats the body that is set on the stones. In the rural or urban areas of many developing countries, today cooking is achieved by burning charcoal inside perforated metal container to radiate heat when set on fire. It is the advent of scientific invention that brought about the idea of induction technique to generate heat energy. The idea is developed on the principle of heat dissipation when current flow through resistive element in an electric circuit. The earliest recorded oven was associated to the history of Egypt which was made of “Beehive” (large clay). Fire was built on the oven floor and as the fire reaches the desire range, the clay will be raked out and food would be placed inside (McLain, 2003).

In the midst 20th century gas oven and cooker came into use. The cooker was located at the top with a circular opening to enable flow of combustible gas while the oven burner is located at the floor of the oven chamber with single opening to allow transfer and circulation of combustible air. A regulator is there to control the outflow of air and thermostat for temperature control to avoid overheating. The hot plate and the use of spiral metal alloy was a later development over the gas cooker and oven. Aside the regulator and thermostat there is timer for duration control, and indicator lamp and oven lamp for illumination of the chamber.

Another development at present is the solar cooker. The set back of the solar cooker is that it can only be used when there is sun and the cooking process is slow down on a cloudy day. One is also faced with the challenges of having to cook one’s food before sunset make the food subject to cold before dinner. As for the oven the microwave type came into used just about a recent past. It is an electromagnetic wave whose is in the range of 1-3000GHz and a boxlike appliance for cooking, baking, and drying of food which it achieved by penetrating and vibrating the molecules of anything put in the inside of it. The Nigeria baking industry dated back to 1900 with the Brazilian expatriate setting up bakeries in Lagos State and since then wheat has been imported into the country ( Bacon, 1983).

2.1       REVIEW ON INDUCTION STEEL SENSOR

The major controls of a microprocessor based induction steel pot sensor electric cooker include:

§     IGBT Automatic Self Protection: Insulated-Gate Bipolar Transistor (IGBT) is the key component of the induction cooker. IGBT works under high voltage and high power conditions. However, considering the high cost and rigid parameters, IGBT is designed with several conditions. Any of the following factors can destroy IGBT: excess voltage, instantaneous impingement generated when power is switched on or off, proliferated current and excess temperature. IGBT can be damaged even when the iron pan is removed from the ceramic panel or if no pan is placed on the panel. It is necessary to protect the IGBT from these factors.

§     Temperature Control in the Iron Pan Bottom: The heat in the iron pan bottom is directly transferred to the ceramic panel. The ceramic panel is the heat conducting material, so thermal sensors are often fixed in the panel bottom to detect the temperature of the iron pan bottom.

§      Stable Power Control: The output power of the induction cooker can be automatically regulated to improve the adjustment of the power supply and load.

§     User Interface Control: Collect the customer input from the steel Sense button or slider, then decide the working mode and display it on relevant light emitting diode (LED).

§     CY8C22x45 Overview

CY8C22x45 is a product of the PSoC family. It is an enhancement of CY8C21xxx PSoC family, and is targeted at applications that integrate both system control and steel Sense control. CY8C22x45 is compatible with other PSoC device architecture, as shown in Figure 2. CY8C22x45 is a Mixed-Signal Array with On-Chip Controller device. Each CY8C22x45 PSoC device includes eight digital blocks and six analog blocks. Depending on the PSoC package, CY8C22x45 provides up to 38 general-purpose I/Os (GPIO), 16 K flash memory, and a 1 K SRAM data memory. Following other PSoC products, CY8C22x45 has fixed function on-chip resources such as I2C, MAC, and more. In addition, CY8C22x45 includes optimized modules such as 10-bit SAR ADC, dedicated CSD digital logic, and dedicated RTC. In this example, CY8C22x45 handles the input of twelve steel Sense buttons. It is also responsible for the entire system control, including current, voltage and temperature sampling, PWM generation for the MOSFET control, induction cooker power control, and system status display.

2.2       SYSTEM   FEATURES

In addition to the features that CY8C22x45 provides for Cap Sense control, the induction cooker design also contains the system control. It has common features that are found in existing products. The features are:

§  AC 220 V/50 Hz power supply

§  1800W rated power

§  Resonant circuit for induction cooker control

§  More than ten LEDs and four digital LED segment display

§  Buzzer for alarm

§  Fan On/Off and PWM control

§  Adjustable fixed temperature cooking mode that Supports 60, 80, 100, 120, 140, 160, 180, 200, 220, 240, and 260 °C.

§  Multilevel of firepower selection (200 W, 400 W, 600 W 800 W,1000 W, 1200 W, 1400 W, 1600 W and 1800 W) and Stable Power Control

§  Cooking Pan Auto Detect

§  Multi Cooking Mode Selection

§  Multiple protection

§  Auto Power Off When Not Cooking on Pans

§  AC Over Voltage and Under Voltage Protection

§  AC Over Current Protection

§  Pan Overheat Protection

§  IGBT Overheat Protection

§  Time-switch cooking function

§  12 steel Sense buttons for Menu Selection

2.3       SYSTEM HARDWARE

There are two PCB boards in the design viz. power control board and main controller board. They are connected by an 11-pin ripple cable.

2.4       ALARM

The alarm circuitry is necessary for monitoring any possible malfunctions, and to prevent the IGBTs, the driver, or any other circuitry from burning or being damaged. The applications for the alarm management are

§  over-temperature on the heat-sink

§  over-temperature on the plate

§  over-current 

§  wrong pot on the plate

An alarm is generated when the heat-sink temperature exceeds 115 °C, or when the plate reaches a temperature of 200 °C. If for any reason the current flowing through the plate goes over the limit, an alarm occurs.

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