Bronze Melting Process Control Unit

The system is a hardware-software complex designed to control the bronze melting technological process according to user-defined parameters.

The unit can be easily adapted to control the heating of other metals or materials that share a similar thermal cycle.

Technological Operating Cycle

In its current implementation, the system’s technological cycle consists of the following phases:

1. Delayed start;
2. Temperature ramp-up at a preset rate until the upper target temperature is reached;
3. Holding the upper target temperature for a preset duration (thermal soaking);
4. Audio signal output and transition to the lower target temperature;
5. Holding the lower target temperature for a preset duration;
6. Loop back to step 2.

Parameter Configuration

The unit allows users to input custom settings to strictly control the technological process based on specific thermal profiles. Configurable parameters include:

• Delayed start time: 0-99 min;
• Temperature ramp-up rate: 1-200 °C/min;
• Upper target hold temperature (T_upper): 20-2000 °C;
• Upper temperature hold duration: 1-240 min;
• Lower target temperature (T_lower): 20 to T_upper °C;
• Lower temperature hold duration: 1-240 min.

Data input is performed using the three right-hand buttons and a seven-segment LED display. The leftmost digit displays the current settings menu item, while the four rightmost digits show the selected parameter’s value.

Real-time temperature measurement is acquired via a thermocouple paired with an operational amplifier (Op-Amp). A TRIAC is utilized as the primary power-switching element to control the furnace heating coils.

To ensure the delayed start timer functions correctly even during mains power failures, the unit is equipped with a Li-ion battery backup that maintains power to the control logic during grid outages.