Petrochemical Level Indicator and Controller for Automation of cotton purification process in spinning mills with IoT monitoring

Petrochemical Level Indicator and Controller For automation of cotton purification process in spinning mills with IOT

Technical specifications


Project title                              :           Petrochemical level indicator and controller for

automation of cotton purification process in

spinning mills with IOT

Domain                                   :           Embedded Systems Design

Software                                  :           Embedded C, Keil, Proload


Microcontroller                       :           AT89S52

Power Supply                          :           +5V, 500mA Regulated Power Supply

Display                                    :           LCD

LCD                                        :           HD44780 16-character, 2-line (16X2)

Crystal                                     :           11.0592MHz

Sensor                                     :           Reed Switch / Magnetic sensors

Applications                            :           Spinning Mills, Cotton Process Industries




In spinning mills Petrochemical based cleaning solutions are used for cleaning of raw cotton. This petrochemical liquid is pumped from tank to the process container by using an AC motor. The process container is the capacity of 2000 liters. The motor takes more than one hour to fill the process container. An operator has to pay attention to the container to switch off the motor to avoid overflow of petrochemical. During the process 390C temperature has to be maintained.


This project has a unique system for this application by using magnetic sensors. The sensors are fixed at specified locations on the container. A floating magnet floats on the liquid and triggers the magnetic sensors one-by-one based on the liquid level. Microcontroller monitors the liquid level and the level displayed on LCD. If the maximum level is reached, the microcontroller switches off the motor. If the liquid reaches the lower level, the controller drives the driver circuit and switches on the motor and message will be send to mobile phone or computer  in either levels using IOT.A thermistor is used as temperature sensor.


The microcontroller compares the temperature with a reference constant and if the temperature increases beyond 390C, the controller drives the siren circuit to alert the operator.


This project is specially designed for spinning / cotton process Industries. Direct contact of level probes with the content / liquid is completely avoided in this project. Magnetic sensors / Reed switches are used as level sensors. Thermistor is used as temperature sensor. The level of the content and its temperature is monitored by the microcontroller and displayed on LCD and message will be send to mobile phone in either levels using IOT.


Relay driver circuit can be activated by sensing “Level Full” and “Low Level” indicators and operates the motor automatically. Siren driver circuit would be activated by thermistor sensor.


As magnetic sensors / reed switches are used, the problem of oxidization of level probes is completely eliminated. This is an advanced, trouble-free, fit and forget system for industrial applications.


This project uses regulated 5V, 500mA power supply. 7805 three terminal voltage regulator is used for voltage regulation. Bridge type full wave rectifier is used to rectify the ac out put of secondary of 230/12V step down transformer.

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