Smart Industrial Temperature Controller — Dual-Relay Architecture
- Client
- Processing & manufacturing industry
- Year
- 2023
- Category
- Industrial Automation
NELSco designed a custom, production-ready, STM8-based single-loop industrial temperature controller targeting greenhouses, packaging machines, and industrial heating systems. Fully digital sensing with the DS18B20 eliminates the EMI susceptibility of analog sensing over long cable runs.
Fully digital DS18B20 sensing over 1-Wire at ±0.5°C accuracy that eliminates analog EMI susceptibility over long cables, and dual relay outputs: Relay 1 for primary ON/OFF control with adjustable hysteresis and Relay 2 for alarm and auxiliary devices.
Configurable hysteresis to prevent relay chatter and extend equipment life, sensor-fault detection, a power-on delay for protection, non-volatile EEPROM parameter storage, and a DIN panel-mount form factor with 100–240V AC / 24V DC input.
The Challenge
Analog thermocouples over long cables are prone to noise and EMI, relays without proper hysteresis suffer chatter and wear, and a power loss must not erase configured parameters. The client needed a precise, durable, affordable controller that drops in to replace expensive analog units.
Our Approach
Fully digital sensing was implemented with the DS18B20 over the 1-Wire protocol at ±0.5°C accuracy (-10°C to +85°C). Two relay outputs were provided: Relay 1 for primary ON/OFF control with adjustable hysteresis that prevents chatter and extends equipment life, and Relay 2 for alarm and auxiliary devices (fans, backup heaters). Intelligent sensor-fault detection, a power-on delay for compressor/equipment protection, and non-volatile EEPROM parameter storage (surviving power loss) were added. A compact DIN panel-mount form factor takes 100–240V AC or 24V DC input.
The Result
The result is a drop-in replacement for expensive analog-based controllers: longer lifespan, plug-and-play installation, and lower maintenance cost, with precise control in industrial environments.
Results
- Drop-in replacement for expensive analog controllers with lower maintenance cost
- Eliminates relay chatter and extends equipment life via configurable hysteresis
- Retains settings after power loss via non-volatile EEPROM
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