Wireless Based System for Monitoring and Controlling Industrial Parameters

ABSTRACT

The use of wireless sensor networks in industrial automation sector is proving to be advantageous over traditional wired industrial monitoring and control systems, owing to lesser wiring, ease of deployment, increased safety, decreased installation and maintenance cost, in addition to feature like inherent intelligent processing capability. A wireless sensor network consists of sensor nodes, deployed across a wide area (industrial environment), senses various parameters in the field and forwards it to a base station or sink. Automation of an industrial area requires monitoring by a large number of nodes spread across a wide area. This large scale wireless sensor network usually consists of hundreds or thousands of nodes which have low-memory, low processing power, and limited communication capacity. However, to collaboratively monitor and obtain information, centralized data processing and transmission by Base Station is necessary. A Base Station is a powerful device which has much higher processing power, more memory and much higher communication capabilities. The Industrial Wireless Base Station (iWase) is a standalone panel mountable device which can acquire and process sensor readings from nodes in the wireless sensor network and make it available to the external world (user) via wireless or wired interface. This project deals with the development of an wireless base station for monitoring and controlling industrial parameters using wireless sensor networks. Here in this project the wireless base station acquires and process sensor values from sensor nodes in the wireless sensor network of Industry and direct the information to a server (or user) for monitoring or data acquisition purposes using Xbee protocol and GSM interface. In this project, temperature of the industrial furnace and carbon dioxide content in the smoke emitted by the factories are analysed using respective sensors and sent to controlling section so that if any potential problems are notified to the plant personnel as an advanced warning system, it enables plant personnel to control before their efficiency drops or they fail entirely. If the temperature exceeds the threshold level the power supply to the furnace is automatically turned off and in addition Blower circuit can be switched ON/OFF according to the industrial requirements to maintain the plant operation stable.

EXISTING SYSYTEM

The wireless sensor nodes, installed across the industrial environment, monitor the parameters critical to the efficiency of equipments, based on combination of measurements such as vibration, temperature, pressure, coolant level, lubrication oil level and power quality. Sensor nodes have very limited energy and computational resources , low data rate and communication over short distances. The hardware ability of sensor nodes is limited by its small size and battery system which is a drawback indeed.
PROPOSED SYSYTEM

In this system the wireless sensor nodes records the Gas level (CO2) of the industrial furnace. Then the data is then wirelessly transmitted to a Base Station that analyzes the data from each sensor and relays the information to a central monitoring station. Using Ethernet interface or to a remote monitoring station using GSM interface. If any potential problems are notified to the plant personnel as an advanced warning system, it enables plant personnel to monitor and control before their efficiency drops or they fail entirely.

BLOCK DIAGRAM User Mobile

POWER SUPPLY

(((

MESSAGE

XBEE )))

GSM )))

LPC 2148 ARM CONTROLLER DAC

A D C
TEMPERATURE SENSOR GAS SENSOR

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XBEE

FURNACE

LOCAL HOST

HARDWARE REQUIREMENTS

LPC2148 ARM PROCESSOR TEMPERATURE SENSOR AND GAS SENSOR WITH CLOSED LOOP GSM AND XBEE MODULE POWER SUPPLY CIRCUIT DAC

SOFTWARE REQUIREMENTS

IAR software FLASH MAGIC

ADVANTAGES

Lesser wiring Inherent intelligent capability Supports long distance protocols Resistant to Electromagnetic Interference

DISADVANTAGE

The Xbee module used in this project covers only a small range (10-20m). To overcome this disadvantage,

APPLICATION

This concept can be used to monitor the furnace setup in industries and a safe environment can be maintained.
FUTURE ENHANCEMENTS

Zigbee module which offers a larger coverage area (upto 100m) can be used instead of the Xbee module. Fuzzy Logic can be used in which in stead of setting up only one set point for the temperature value, two or more indication levels can be added along so that the controlling of tempetature can be more accurate.