WIRELESS MOTOR DATA LOGGING

The data logging of various sensed parameters is done in all, practical fields. The
parameters may be from process control, from automobile, bio- medical or electrical machines.
Sometimes flight data is also required to record in order to investigate the root causes of flight
crushes and accident and accordingly take the actions so that such incidents should not take
place repeatedly. Till date parameter collection done with the transducers and after processing
through a digital processor say microcontroller, microprocessor, DSP, which is send to PC which
is known as data for further analysis, hence data storage facility was included inside the PC. It
was wired communication. It requires maintenance and space.
In order to overcome this difficulty, the wireless data logging is adopted. The RF
modems are used. The transmitter is at microcontroller side and the receiver module is at PC
side.
This method sends the data serially to microcontroller. The front end software
developed at pc front end, manages to store the data in tabular form with current date and
time. The readily of every 10 secs will be logged.
Advantages:
No wiring cost and maintenance
Range can be increased upto 100meters
Data logging provides the off line services also
Data observed on PC and LCD locally
Disadvantages:
The RF modems are antistatic.
These are expensive data loggers


Applications:
Industry, hospitals
Agriculture etc
Technical features:
Multichannel data logger
Logic - microcontroller based , pC based
Language - assembly
Communication- RF based wireless
Range- up to 100 mtrs

CIRCUIT DIAGRAM EXPLANATION:
The project is electrical parameters monitoring of a single phase/three phase
induction motor, is based on electrical and thermal transducers, analog signal
conditioning, digital processors i.e. microcontrollers and indicating displays. In case of
data acquisition and logging the PC interface is required. In order to indicate these
parameter in a tubular or graphical on PC screen, the front end software is required we
can choose either VB or C#.net as our front end.
Also, the interface between c and PC is wired till today. But we introduce an innovative
way of wireless data transfer and logging by using the RF Tx and Rx does this function
very successfully to achieve our goals. The detail explanation of each block in the above
project is as below.

Transducers:
Transducer does the function of converting the physical energy into an
electrical energy. We have used four important parameters and their transducers.
Potential transformer:
It is voltage transducer which senses the main AC voltage. It is step down the
potential transformer. For 415VAC input, the step down output of transistor is 9V. it will
output 4.5V for 210Vac input. Thus the potential transformer can be used for single
phase as well as 3 phase applications. The potential transformer output in AC form is
given to the signal conditioning block.
Current transformer:
It is used to sense the current passing through load. The current ratio is 1 amp, 1
ma and the maximum load bearing capacity is 30 amp e.g. if 10 a current is passed
through the conductor (which is routed through the current transformer). We get 10ma
current at the secondary of the current transformer. This is AC current. A 100E, W
resistor is connected across the current transformer. The current is then given to the
analog signal conditioning for further calibration purpose.
PT- 100 RTD:
It is resistance temperature detector sensor. It senses temperature. If the
temperature increases PT -100 i.e. at 0C the sensor resistance is 100E. Hence the name,
PT 100. The resistor is connected in one of the arm of the Whetstones meter bridge
to convert into voltage and for further signal conditioning and calibration purpose.
Speed sensor:
Different types speed measurement sensors are there. To count the events , is
nothing but speed sensing. The photo electric transducer may be used for this purpose. The
arrangement is as below. The rotating disc is mounted on a shaft. The rotation is sensed.






Vcc Vcc
TO c




PHOTO-EMITTER DISC LDR TO MICROCONTROLLER
The transducer section of the project is followed by analog signal conditioning of each
parameter.
Voltage section:
The output of potential transducer is ac voltage. First of all AC voltage is
converted into DC with diode rectifiers. The output of rectifier is used, in order to filter the
ripple. The capacitor filter is used, in order to filter the ripple. At the output of filter pure DC
supply is there. The input AC supply is available in the form of DC here. The DC voltage is
stepped down to convert the voltage I volts in voltage in mv. 230V AC is converted into
230mv DC. Later operation amplifier in non inverting mode is used, with gain 10 to get 2.3V
of 230mv DC, which can be given to ADC.
Current section:
The output obtained from current transformer and shunt resistor is in AC volts.
The ckt requires the dc voltage. The AC voltage is converted into DC with precision rectifier.
The AC current in the form of DC voltage, is divided into milivolts and then can be given to
ADC for further processing.
Temperature section:
The PT 100 is connected in one of the arm of the meter bridge. The bridge is
provided with 5V DC supply and GND. The output of bridge is the milivoltage signal. The
signal is then given to difference amplifier. Here we can increase the range up to certain
level i.e. the output of bridge and amplifier is 1000mv for 100C and 0 mv for 0C. This is
given to ADC for further processing.
Speed section:
Speed is one of the important motor parameter. The sensing conditioning
arrangement is already provided in sensor section. The circular disc of non transparent
nature is fixed on the shaft of the induction motor. The disc rotates, as per the rotor. The
disc is provided with a hole. The photo transmitter and photo emitter is aligned in such a
way that they are interrupted during the entire travel of the disc only during hole area the
transmitter is incident on receiver. This happens once during each cycle. At each instant,
logic pulse changes over takes place. It is inverted and converted to a standard 0 and 5V
logic signal which is acceptable by the microcontroller.
Thus the analog signal conditioning provides the sensed process parameter in a
particular scale so as to provide the maximum and minimum range.
ADC:
It is 12 bit ADC I.E. ICL7135 CPL. It is 12 bit ADC with 28 pin dip, interfaced serially
with c and thus reduces the pin consumption of c. the clk and busy pins play an
important role during the interface. The IC requires the clk and reference. An astable
multivibrator is used with IC 555 to generate the clk. The reference of 2.5V is generated
from +5V DC by using a potential divider with two resistors we have to input 3 different
parameters to ADC. The multiplexer CD4051 from CMOS family does this function. It is 8:1
multiplexer. The select lines are controlled by the c. the remaining discrete components
with ADC as per the application guidelines. All the three parameter are connected to ADC
input sequentially on time sharing basis. These are then transferred to c for further
processing. The speed is not the analog signal hence no ADC is required. It is directly fed to
the c at its input port.

Micro- controller:
It is P89C51RD2 provided by Phillips or even AT89C52 can be used. The c is 8
bit, with 40 pin dip. It has 8K internal flash memory. Internal RAM, 4, 8bit I/O ports, internal
timer and counters. The important feature is that the instruction set and hardware is
compatible with the 8051 family c. It acts as the system manager in our case. 5V DC
regulated power supply is required for the same. At the o/p port the LCD display is
interfaced. It is 16x2 alphanumeric display and shows the status of these parameters on PC.
So, serial communication is implemented at port 3. It is interfaced with PC via DB9
connector i.e. serial port.
Our project consists of wireless transmitters and detectors. The modems are
used. The data communication to PC is wireless. The PTR2000/ or equivalent RF modems
are utilized. In addition to indicate these parameters on LCD we require their control. So the
control of these parameters is provided. It is through analog comparison method. The signal
conditioned parameter which go to ADC are compared with fixed safety reference and the
comparator o/p is used to control a relay which stops the motor. At PC end, the front end
software is developed, which shows the received parameters in specific fashion.

Working principle;
The function of the wireless data logger for monitoring of electrical parameter is
illustrated in details as below. Different parameters are sensed with particular transducers
and converted into voltages. The voltage from potential transformer is rectified, filtered and
divided by using resistor potential divider.

8.2V DC
R1 R2
Vout
Vdc 230mv

When input to potential transformer is 230V AC the rectified o/p comes to be 8.2 V.
R1 and R2 are voltage dividing resistors. R2 is variable to change the o/p if required.

Vout= (R2

/ R
1
+R
2
) Vin

This is in milivolts, but the ADC requires 10mv input in order to indicate 1 unit on
LCD display. So in order to indicate 230V on LCD we require 2300mv i.e. 2.3V at the input.
230mv is amplified by using the noninverting amplifier (ref the dia). The gain is 10. Thus the
o/p is 2.3V. It varies as per the change in the input AC voltage.
In similar fashion the output from current transformer is in AC voltage form.




100E



CT secondary o/p

If suppose, 20 amp current passes through the primary of the CT, the output
generates 20ma. The drop across the resistor is
=100E x 20 ma
=100E x .02A
=2V
This AC voltage is given to precision rectifier for rectification purpose. The
purpose of using the precision rectifier is to rectify the voltage below 0.7V also. As the
current may be in milliampere. The output of precision rectifier is DC. This is given to
ADC through mux. Here also, calibration is done in order to get required voltage at the
output.

Temperature:
The PT 100 temperature sensor is located at motor winding, where a heavy
heat is generated if the motor is ON for a long time. The temperature is converted into
resistance. The PT-100 resistance increases if the temperature increases. This acts as an
arm of the bridge. Initially, the temperature signal conditioning circuit is calibrated with
the help of RTD simulator instead of PT-100 sensor. At 100E resistance value the bridge
is balanced with the help of variable potentiometer and the multimeter connected at
the output of signal conditioning difference amplifier. Thus at 0C the resistance
connected should be 0C. Then change the resistance value from the simulator i.e. for
150C. Then adjust the output voltage which will correspond to 150 reading at the
output on LCD display. Then repeat the above two stages, in order to get zero at
minimum and 150 reading at the maximum value. This is one of the inputs of the ADC. If
the temp increases, the output value on LCD also increases.
The voltage, current and temperature parameters are in analog form. Hence ADC
is mandatory to convert this signal into digital form. The digital data is given to c. The
c receives this data and as per the program developed and burned inside the chip, it is
processed. The select lines of the multiplexer are from c. Depending upon the status of
select lines the parameter is selected and connected to ADC 7135 is converting the data
into digital form and serially transferred to c. Microcontroller 89C52 is used. It is
programmed with assembly language program. Assembly language program is compiled
to get the hex file. This file is programmed inside the c. The parameters are displayed
on LCD. Simultaneously, the data is transferred to serial buffer then to max 232 for
sending to PC. The wireless modem is connected at the output of MAX232. It modulates
the data, transmits it over the specified distance and at the receiver side, again a
modem is provided. This receives the data available in free air and decodes it. The
decoded data is again in serial form. The serial data interface is done with the PC. Once
the data is received on PC side, front end software developed in VB. The data status is
received after every 1 min. We can store the data for later use.
The protection part of the system consists of the analog comparators. For
voltage dual comparator is provided, for current all dual comparator is there. The
voltage level is compared between two levels over voltage and under voltage. A window
detector is used.
If the single phase application is considered, the overvoltage limit is 270V and
the under voltage limitation is 170 volts. If the sensed voltage is within the limit then
only the motor is ON otherwise it is tripped and protected.
The current comparator circuit has two comparators, one for overload and
another for short circuit protection. Before short circuit occurs, the motor is tripped.
Similarly, if the temperature of the motor winding increases the motor is tripped and
protected. This is how the appliance can be protected for being damaged due to these
faults.