GSM BASED MULTI INTERFACE INDUSTRIAL

AUTOMATION, MONITORING AND CONTROL

SYSTEM
(GSM-MIIAMS)

A BS Final Year Project by

AMIR HAIDER
983/FET/BSEE/F08
SHAHBAZ HAIDER
973/FET/BSEE/F08
HASNAIN HAIDER
974/FET/BSEE/F08
IRFAN ALLAHI
984/FET/BSEE/F08
Supervised by

Engr. Suheel Abdullah Malik

Department of Electronic Engineering

Faculty of Engineering & Technology
International Islamic University, Islamabad.
June 2012

Department of Electronic Engineering

Faculty of Engineering & Technology
International Islamic University, Islamabad

Certificate of Approval
It is certified that we have checked the project presented and demonstrated by Ali Imran, 433FET/BSEE/F06; Junaidullah, 687-FET/BSEE/F07 and Muhammad Bilal, 719-FET/BSEE/F07 and
approve of it.

____________________

External Examiner
Dr. Waqar Nabi,
Acting Deputy Vice Chancellor,
Assistant Professor,
Namal College [Associate College,
University of Bradford],
Mianwali.

____________________
Internal Examiner
Dr. Ihsanul Haq,
Assistant Professor,
Department of Electronic Engineering,
Faculty of Engineering & Technology,
IIUI

____________________

Supervisor,
Engr. Syed Irtiyaz Gilani,
Lecturer,
Department of Electronic Engineering,
Faculty of Engineering & Technology,
IIUI

A BS Final Year Project submitted to the

Department of Electronic Engineering
International Islamic University, Islamabad
In partial fulfillment of the requirements
For the award of the degree of
Bachelor of Science in Electronic Engineering

Dedicated to

Holy Prophet Muhammad (PBUH)

Who enabled us to recognize the Creator,
Our Parents, Brothers and Sisters
For their Love, Prayers and much more
&
All those
Who raise hands for our success !!!

GSM-MIIAMS

Declaration

Declaration
I/We hereby declare that this work, neither as a whole nor as a part thereof has been
copied out from any source. No portion of the work presented in this report has been
submitted in support of any application for any other degree or qualification of this or any
other university or institute of learning.

AMIR HAIDER
983/FET/BSEE/F08
SHAHBAZ HAIDER
973/FET/BSEE/F08
HASNAIN HAIDER
974/FET/BSEE/F08
IRFAN ALLAHI
984/FET/BSEE/F08

ACKNOWLEDGENENT
From the very beginning we are highly thankful to Almighty Allah who endowed us the
will, courage, energy, thought and made circumstances in our favor to complete the study
and this project. Without His blessings completion of anything was impossible. All
praises for His Holy Prophet Muhammad (SAW) who enabled us to recognize our Lord
and Creator and brought to us the real source of knowledge from Allah, The Quran, and
who is a role model for us in every aspect of life.
Then is the place of our respected supervisor Eng. Suheel Abdullah Malik. His all time
appreciation has been the motivating force behind the successful completion of this
project. He has been very kind and extra ordinarily cooperative to us during the whole
process of development.
Above all we owe our success not only to our loving brothers, Shahid Nasarullah and Adil
Israr, but also and most importantly to my loving Parents as well; without whose pure
prayers, true encouragements and undying moral support we would never have succeeded. It
was mainly due to our familys moral support during our entire academic career that enabled
us to complete our studies. We once again would like to admit that we owe all our
achievements to our most loving parents, who mean most to us, for their prayers are more
precious than any treasure in this universe.
AMIR HAIDER
983/FET/BSEE/F08
SHAHBAZ HAIDER
973/FET/BSEE/F08
HASNAIN HAIDER
974/FET/BSEE/F08
IRFAN ALLAHI
984/FET/BSEE/F08

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Project in Brief
Project Title: GSM BASED MULTI INTERFACE INDUSTRIAL
AUTOMATION, MONITORING AND CONTROL SYSTEM
Objective: Basic idea of project is to automatically control & monitor the industrial
appliances even when you are in remote areas. For this we adopted wireless mode of
transmission using GSM. Although there are many other technologies available for wireless
communication but we selected GSM for our project, as this is comparatively more efficient
and cheap solution, and we are much familiar with GSM technology and its easily
available.
Undertaken By:
AMIR HAIDER
983/FET/BSEE/F08
SHAHBAZ HAIDER
973/FET/BSEE/F08
HASNAIN HAIDER
974/FET/BSEE/F08
IRFAN ALLAHI
984/FET/BSEE/F08

Date Started:

September 2011

Date Completed:

June 2012

Tools Used:

Avr Studio 4
Proteus v 7.0
Sms Caster v 3.6
Dip Trace
AutoCAD

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ABSTRACT
Keeping in view the rapid growth of wireless communication, we are inspired to
work on this useful & interesting project. The idea behind this project is to meet the
upcoming challenges of the modern practical applications of wireless
communication and to facilitate our successors with such splendid ideas that should
clear their concepts about wireless communication and control systems. As we are
BS ELECTRONICS ENGINEERING students our project will reflect true picture
of our engineering capabilities.
The application of GSM Based Control & Automation of Industrial Appliances is
diverse. There are many situations in industries that require control of different
devices remotely. There is major possibility that wired connection between a
remote industry and control unit might not be feasible due to structural problems. In
such case wireless communication is the best option available.
Basic idea of project is to automatically control & monitor the industrial appliances
even when you are in remote areas. For this we adopted wireless mode of
transmission using GSM. Although there are many other technologies available for
wireless communication but we selected GSM for our project, as this is
comparatively more efficient and cheap solution, and we are much familiar with
GSM technology and its easily available.

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table of contents

page.no

CHAPTER :1 INTRODUCTION.................................................................................10
1.1 AUTOMATION......................................................................................................11
1.2 ADVANTAGES & DISADVANTAGES................................................................12
1.2.1 ADVANTAGES...................................................................................................12
1.2.2 DISADVANTAGES.............................................................................................12
1.3 METHODES BEEN IMPLEMENTED IN GENERAL.........................................12
1.4 ULTIMATE PURPOSE..........................................................................................13
1.5 AUTOMATION TECHNIQUE AVAILABLE........................................................13
1.6 SHORT DESCRIPTION OF SOME MAJOR AUTOMATION TECHNIQUES..14
1.6.1 DISTRIBUTED CONTROL SYSTEM(DCS)14
1.6.2 PROGRAMMABLE LOGIC CONTROLLER(PLCs)15
1.6.3 SCADA16
1.6.4 PROGRAMMABLE AUTOMATION CONTROLLER17
1.6.5 EMBEDDED CONTROL17
1.7 APPLICATIONS18
1.8 COMPARISON OF EXISTING TECHNOLOGIES.18
1.8.1 SCADA18
1.8.2 PLCs.19
1.8.3 EMBEDDED CONTROL SYSTEMS.19
1.9 OUR CHOICE19
CHAPTER:2 PROJECT DISCRIPTION......................................................................20
2.1 PROJECT'S MAIN IDEA.......................................................................................21
2.1.1 MOTIVATION.....................................................................................................21
2.1.2 MAIN TARGETS TO ACHIEVE........................................................................21
2.2 AUTOMATION..21
2.3 MONITORING...22
2.4 CONTROLLING22
222.5 BASIC BLOCK DIAGRAM..23
2.5.1 SHORT DISCRIPTION...23
2.5.2 FEATURES..24
2.6 MODULE DISCRIPTION..24
2.6.1 DETAILED BLOCK DIAGRAM...24
2.6.2 CONTROLLER MODULE.25
2.6.2.1VCC(10).............................................................................................................26
2.6.2.2 AVCC(30)..........................................................................................................27
2.6.2.3 AREF(32)..........................................................................................................27
2.6.2.4 GND(11,31)......................................................................................................27
2.6.2.5 XTAL1 (13) , XTAL2 (12)................................................................................27
2.6.2.6 Port A (PA7:PA0)..............................................................................................27
2.6.2.7 Port B (PB7:PB0)..............................................................................................28
2.6.2.8 Port C (PC7:PC0)..............................................................................................28
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2.6.2.9 Port D (PD7:PD0).............................................................................................29

2.6.3 CENTRAL CONTROL UNIT (CCU).................................................................30
CHAPTER: 3 AUTOMATIC TANK FILLING ...........................................................31
3.1 INTRODUCTION:.................................................................................................32
3.2 KEY FEATURES:...................................................................................................32
3.3 COMPONENTS:....................................................................................................32
3.4 CIRCUIT DIAGRAM33
3.5 WORKING.33
3.5.1 FILLING MODE.34
3.5.2 USAGE MODE...34
3.6 SIMULATION SNAPE SHOT..35
3.7 USER INTERFACES35
3.7.1 LCD.35
3.7.2 GUI..36
3.7.3 WIRELESSLY USING MOBILE (GSM) .36
3.8 APPLICATIONS36

CHAPTER: 4 AUTOMATIC TEMPERATURE CONTROL SYSTEM

38
4.1 INTRODUCTION..................................................................................................39
4.2 KEY FEATURES:...................................................................................................39
4.3 COMPONENTS:....................................................................................................39
4.4 CIRCUIT DIAGRAM:............................................................................................40
4.5 WORKING:............................................................................................................40
4.5.1 SAFE MODE:......................................................................................................41
4.5.2 HIGH TEMPERATURE MODE.41
4.5.3 LOW TEMPERATURE MODE..41
4.5.4 EMERGENCY MODE41
4.6 SIMULATION SNAP SHOT.42
4.7 USER INTERFACES.42
4.7.1 LCD..42
4.7.2 GUI...43
4.7.3 WIRELESSLY USING MOBILE (GSM)...43
4.8 APPLICATION..43

CHAPTER: 5 AUTOMATIC LIGHTING SYSTEM...44

5.1 INTRODUCTION:.................................................................................................45
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5.2 KEY FEATURES:...................................................................................................45

5.3 COMPONENTS:....................................................................................................45
5.4 CIRCUIT DIAGRAM46
5.5 WORKING.46
5.5.1 OFF MODE..47
5.5.2 DIM MODE.47
5.5.3 FULL MODE...47
5.6 SIMULATION SNAPE SHOT...48
5.7 USER INTERFACES.48
5.7.1 LCD..48
5.7.2 GUI...50
5.7.3 WIRELESSLY USING MOBILE (GSM)...50
5.8 APPLICATIONS50

CHAPTER:6 AUTOMATIC FIRE DETECTION & EXTINGUISHING..51

6.1 INTRODUCTION:.................................................................................................52
6.2 KEY FEATURES:...................................................................................................52
6.3 COMPONENTS:....................................................................................................52
6.3.1SMOKESENSOR.52
6.3.1.1TGS813GASSENSOR...53
6.3.1.2CHARACTERISTICS...53
6.3.1.3APPLICATIONS...54
6.3.2 LM 741 OPERATIONAL AMPLIFIER.54
6.3.2.1 GENERAL DISCRIPTION..54
6.3.2.2 CONNECTION DIAGRAM.55
6.4 CIRCUIT DIAGRAM.56
6.5 WORKING6.6 SIMULATION SNAPE SHOT.56
6.7 USER INTERFACES.56

CHAPTER :7 CONVEYER BELT & FILLING MECHANISM.57

7.1 INTRODUCTION:.................................................................................................58
7.2 KEY FEATURES:...................................................................................................58
7.3 COMPONENTS:....................................................................................................58
7.4 CIRCUIT DIAGRAM59
7.5 WORKING.59
7.6 SIMULATION SNAPE SHOT...59
7.7 USER INTERFACES.59
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7.7.1 GUI..59
7.8 APPLICATIONS60
CHAPTER: 8 GSM MODULE INTERFACE..61
8.1 INTRODUCTION:.................................................................................................62
8.2 KEY FEATURES:...................................................................................................62
8.3 COMPONENTS:....................................................................................................62
8.3.1 CELL PHONE63
8.3.2 SMS CASTER E-MARKETER GSM ENTERPRISE VERSION 6...64
8.3.2.1 SCHEDULER...64
8.3.2.1.1 0NE TIME SCHEDULE64
8.3.2.1.2 DAILY SCHEDULE.64
8.3.2.1.3 CREATING A SCHEDULE.65
8.3.2.1.4 SAVING THE SCHEDULE.66
8.3.2.1.5 WAITING FOR SCHEDULE TO RUN66
8.3.2.1.6 ICON MEANING..66
8.3.2.2 COMPOSE67
8.3.2.3 CONTACT68
8.3.2.4 GROUPS...69
8.3.2.5 INBOX..70
8.3.2.6 PHONE IFORMATION...71
8.3.2.7 SENT.72
8.3.2.8 RESPONDER...73
8.3.3 DATA CABLE79
8.4 WORKING 80
8.5 USER COMAND81
8.6 GRAPHICAL USER INTERFACES (GUI).81
CHAPTER: 9 GRAPHICAL USER INTERFACE.82
9.1 INTRODUCTION..83
9.1.1 SYSTEM LOGIN83
9.1.2 SYSTEM MAIN MODULE84
9.1.3 SYSTEM PORT SETTING.85
9.1.4 USER PROFILE SETTING86
9.1.5 USER LOG..87
9.1.6 SYSTEM LOG.88
9.1.7 SYSTEM SCHEDULING..89.
CHAPTER: 10 FYP CIRCUITS & PROTOTYPE PICTURES90
10.1 FYP CIRCUITS..91
10.1.1 POWER BOARD UNIT..91.
10.1.1.1 CIRCUIT DIAGRAM..91
10.1.1.2 POWER BOARD PICTURE92
10.1.2 MAIN CONTROLLING UNIT (CPU) ...92
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10.1.2.1 PCB LAYOUT OF MAIN CONTROLLING UNIT92

10.1.2.2 CIRCUIT DIAGRAM OF MAIN CONTROLLING UNIT.93
10.1.3 RELAY ARRAY BOARD...94
10.2 PROTOTYPE PICTURES...95

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CHAPTER 1

INTRODUCTION

1.1: Automation:-

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Automation is the use of machines, control systems and

information technologies to optimize productivity in the production of
goods and delivery of services. The correct incentive for applying
automation is to increase productivity, and/or quality beyond that
possible with current human labor levels so as to realize economies of
scale, and/or realize predictable quality levels. The incorrect application
of automation, which occurs most often, is an effort to eliminate or
replace human labor. Simply put, whereas correct application of
automation can net as much as 3 to 4 times original output with no
increase in current human labor costs. Incorrect application of
automation can only save a fraction of current labor level costs. In the
scope of industrialization, automation is a step beyond mechanization.
Whereas mechanization provides human operators with machinery to
assist them with the muscular requirements of work. Automation greatly
decreases the need for human sensory and mental requirements while
increasing load capacity, speed, and repeatability. Automation plays an
increasingly important role in the world economy and in daily
experience.
Automation has had a notable impact in a wide range of industries
beyond manufacturing (where it began). Once-ubiquitous telephone
operators have been replaced largely by automated telephone
switchboards and answering machines. Medical processes such as
primary screening in electrocardiography or radiography and laboratory
analysis of human genes, sera, cells, and tissues are carried out at much
greater speed and accuracy by automated systems. Automated teller
machines have reduced the need for bank visits to obtain cash and carry
out transactions. In general, automation has been responsible for the
shift in the world economy from industrial jobs to service jobs in the 20th
and 21st centuries.

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Fig: 1.1
1.2: Advantages & disadvantages: 1.2.1: Advantages :The main advantages of automation are:

Increased throughput or productivity.

Improved quality or increased predictability of quality.
Improved robustness (consistency), of processes or product.

1.2.2: Disadvantages :The main disadvantages of automation are:

Security Threats/Vulnerability: An automated system may have a

limited level of intelligence, and is therefore more susceptible to
committing an error.
Unpredictable development costs: The research and development cost
of automating a process may exceed the cost saved by the
automation itself.
High initial cost: The automation of a new product or plant requires a
huge initial investment in comparison with the unit cost of the
product, although the cost of automation is spread among many
products.

In manufacturing, the purpose of automation has shifted to issues

broader than productivity, cost, and time.

1.3: Methods being implemented in general:The following methods are often employed to improve productivity,
quality, or robustness.

Install automation in operations to reduce cycle time.

Install automation where a high degree of accuracy is required.
Replacing human operators in tasks that involve hard physical or
monotonous work.
Replacing humans in tasks done in dangerous environments (i.e.
fire, space, volcanoes, nuclear facilities, underwater, etc.)
Performing tasks that are beyond human capabilities of size,
weight, speed, endurance, etc.
Economy improvement: Automation may improve in economy of
enterprises, society or most of humanity. For example, when an
enterprise invests in automation, technology recovers its
investment; or when a state or country increases its income due to
automation like Germany or Japan in the 20th Century.
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Reduces operation time and work handling time significantly.

Frees up workers to take on other roles. Provides higher level jobs
in the development, deployment, maintenance and running of the
automated processes.

1.4: Ultimate purpose:-

The old focus on using automation simply to increase productivity and

reduce costs was seen to be short-sighted, because it is also necessary
to provide a skilled workforce who can make repairs and manage the
machinery. Moreover, the initial costs of automation were high and often
could not be recovered by the time entirely new manufacturing
processes replaced the old. (Japan's "robot junkyards" were once world
famous in the manufacturing industry.)
Automation is now often applied primarily to increase quality in the
manufacturing process, where automation can increase quality
substantially. For example, internal combustion engine pistons used to be
installed manually. This is rapidly being transitioned to automated
machine installation, because the error rate for manual installment was
around 1-1.5%, but has been reduced to 0.00001% with automation.

1.5: Automation techniques available:-

Information technology, together with industrial machinery and processes,

can assist in the design, implementation, and monitoring of control
systems. One example of an industrial control system is a programmable logic
controller (PLC). PLCs are specialized hardened computers which are
frequently used to synchronize the flow of inputs from (physical) sensors
and events with the flow of outputs to actuators and events.

(HMI) or computer human interfaces (CHI), formerly

known as man-machine interfaces, are usually employed to
communicate with PLCs and other computers. Service personnel who
monitor and control through HMIs can be called by different names. In
industrial process and manufacturing environments, they are called
operators or something similar. In boiler houses and central utilities
departments they are called stationary engineers.
Human-machine interfaces

Different types of automation tools exist:

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ANN - Artificial neural network

BPM - Bonita Open Solution
DCS - Distributed Control System
HMI - Human Machine Interface
SCADA - Supervisory Control and Data Acquisition
PLC - Programmable Logic Controller
PAC - Programmable automation controller
Instrumentation
Motion control
Robotics

1.6: Short description of some major automation

techniques: 1.6.1: Distributed Control System (DCSs):are used to control industrial processes such as electric
power generation, oil and gas refineries, water and wastewater
treatment, and chemical, food, and automotive production. DCSs
are integrated as a control architecture containing a supervisory
level of control, overseeing multiple integrated sub-systems that
are responsible for controlling the details of a localized process.
DCSs

Product and process control are usually achieved by deploying feed

back or feed forward control loops whereby key product and/or
process conditions are automatically maintained around a desired
set point. To accomplish the desired product and/or process
tolerance around a specified set point, only specific programmable
controllers are used.

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Fig: 1.2
1.6.2: Programmable logic controller(PLCs)
PLCs provide Boolean logic operations, timers, and (in some
models) continuous control. The proportional, integral, and/or
differential gains of the PLC continuous control feature may be
tuned to provide the desired tolerance as well as the rate of selfcorrection during process upsets. DCSs are used extensively in
process-based industries. PLCs are computer-based solid-state
devices that control industrial equipment and processes. While
PLCs can control system components used throughout SCADA and
DCS systems, they are often the primary components in smaller
control system configurations. They are used to provide regulatory
control of discrete processes such as automobile assembly lines
and power plant soot blower controls and are used extensively in
almost all industrial processes.

Fig: 1.3
1.6.3: Scada:SCADA's history is rooted in distribution applications, such as power,
natural gas, and water pipelines, where there is a need to gather remote
data through potentially unreliable or intermittent low-bandwidth/highlatency links. SCADA systems use open-loop control with sites that are
widely separated geographically. A SCADA system uses RTUs (remote
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terminal units, also referred to as remote telemetry units) to send

supervisory data back to a control center. Most RTU systems always did
have some limited capacity to handle local controls while the master
station is not available. However, over the years RTU systems have
grown more and more capable of handling local controls.
The boundaries between these system definitions are blurring as time
goes on. The technical limits that drove the designs of these various
systems are no longer as much of an issue. Many PLC platforms can now
perform quite well as a small DCS, using remote I/O and reliable that
some SCADA systems actually manage closed loop control over long
distances. With the increasing speed of today's processors, many DCS
products have a full line of PLC-like subsystems that weren't offered
when they were initially developed.

Fig: 1.4
1.6.4: Programmable automation controller:This led to the concept of a PAC (programmable automation controller or
process automation controller), that is an amalgamation of these three
concepts. Time and the market will determine whether this can simplify
some of the terminology and confusion that surrounds these concepts
today.
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1.6.5: Embedded control:Another option is the use of several small embedded controls attached
to an industrial computer via a network. Examples are the Lantronix Xport ,
Atmel8051, Atmega32, PIC controller and Digi/ME .

Fig: 1.5
1.7: Applications:

Automated video surveillance

Automated highway systems
Automated manufacturing
Home automation
Industrial automation
Agent-assisted Automation

1.8: Comparison of existing technologies: 1.8.1: Scada:

Very high tech & complex system to create

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Used for very large industries, instead of small

industries like in Pakistan.
Very high cost to implement, small scale industries
cant afford that.
No flexibility, once designed then it cant be modified

1.8.2: PLC:

Used for high tech industries & mostly for mechanical machine
controlling.
Complex system to build & to understand by a non technical common
user.
High building & implementation cost.
No flexibility, once designed then it cant be modified

1.8.3: Embedded control systems:-

Used for small scale implementation

Easy to build & understand
Lowest in implementation cost
Flexible for changes

1.9: So our choice of automation technique

for small scale industries is through
EMBEDDED SYSTEM CONTROLS

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CHAPTER 2

PROJECT DISCRIPTION

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CHAPTER 2:2.1: PROJECTS MAIN IDEA: 2.1.1: MOTIVATION:The application of GSM Based Control & Automation of Industrial
Appliances is diverse. There are many situations in industries that
require control of different devices remotely. There is major possibility
that wired connection between a remote industry and control unit might
not be feasible due to structural problems. In such case wireless
communication is the best option available.
In Pakistan where majority of the industries lie under the banner
of small scale industries like packing, low tech processing, filling etc.
there is an extreme need of automated functions because immense
expenses of time, money and efforts. The output gain for the
industrialists is reduced by unwanted descriptions created by human
involvement and by slow processing rate as well.
So here we are striving to build such a mechanism by which an
industrialist can not only automate his industrial processes but he can
also monitor and control those processes whether he is on spot in the
industry or he is sitting in a remote area, thousands of miles away from
industry anywhere in the world. His industry control will be available to
him at his palm, through GSM technology.

2.1.2: Main targets to achieve: Automation

Monitoring
On field control
Remote controlling

2.2: AUTOMATION:Out of three main features of our project, automation was the first goal
to achieve. In our project we have tried to automate a few different
industrial processes. The main idea is to reduce the human dependency
and to increase the precision & accuracy of an industrial process. Our
prototype of a small industry we have shown five different industrial
processes that can be present in any normal industry. These processes
are
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TANK FILLING
CONVIER BELT MECHANISM
TEMPERATURE MAINTAINANCE
FIRE SAFETY
LIGHTENING SYSTEM

Just imagine if all these functions are to be done manually without use of any automatic
process, then how much of our time and effort is needed to complete these tasks?
Filling a tank without use of any technology, maintaining temperature through human
monitoring, turning the lights ON and OFF by hand, all of these tasks require intense
labor and we also have to face the risk of human error.
Observing all these issues, we have designed such a system that your tank will
automatically be filled by concerned liquid when it gets empty and then it will
automatically turn OFF filling the tank when its completely filled. Similarly we have3
used temperature sensors light sensors and smoke sensors to automatically sense the
situation and accordingly perform the necessary actions. We have automated the
conveyer belt so that belt can automatically change its speed and direction according to
the program fed in the central controller.

2.3: Monitoring:We have provided the much needed facility of monitoring for the
industrial supervisors. Normally a supervisor have to physically visit and
see each and every process in industry whether system is working
properly or not , but we have facilitated the industrialists by providing
all the important information related to industry on his finger tips. Some
of the status can be seen on the LCD fixed in industry, but detailed visual
description can be monitored on GUI designed especially for monitoring.
Similarly you can remotely monitor the industry through your cell phone
by just sending a text message. The main advantage of this facility of
monitoring is that, the industrialists can keep an eye on their industry all
the time and whenever they feel any irregularity they can take action to
prevent any possible damage to property or human life.

2.4: Controlling:Third and most fascinating feature of our project is that you can also
control the industrial processes according to your needs through control
panel available at GUI screen. You can ON or OFF or simply change the
function of any module by making changes on the GUI, you dont have
to personally visit the industry, you can just control your industry sitting
in the central control room. GUI is on field control panel but most
extraordinary facility we have provided is that you can remotely control
your industry using your cell phone, yes, by texting the specific
command for the specific process industrialist can make any change he
wants.

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2.5: Basic block diagram

Fig: 2.1
2.5.1: Short description
The general hierarchy of the system is, first of all, all the industrial
processes will keep on doing what they are normally programmed to do.
This program is saved in central controller. The output from each process
is fed into the controller, then controller sends this information serially to
the GUI, which displays all the current status on a screen panel. Smoke
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sensor, temperature sensor and LDR keep on sensing the environment

and send this information to the controller, controller analysis the
information and performs the necessary reaction automatically.
A GSM module is also connected to the PC displaying GUI.
GSM module is interfaced with GUI and gets all the status shown on GUI.
This information can be extracted by sending text messages. Now when
you want to turn ON and OFF any process you just have to click on the
buttons displayed on GUI, this click will send a specific character to the
controller serially. Controller will receive and analyze this character and
will perform the action accordingly by turning ON or OFF that related
process

2.5.2: Features

PROTOTYPE MODELING OF INDUSTRY

IMPLEMENTATION OF CONTROL UNIT USING CONVENTIONAL
CONTROLLERS.
GSM MODULE FOR WIRELESS MONITORING
DATA ACQUISITION FROM CONTROL UNIT
IMPLEMENTATION OF MANUAL CONTROL PANEL
AUTOMATIC LIGHTING SYSTEM
SECURITY ALARM
FIRE EXTINGUISHING SYSTEM
AUTOMATIC TANK FILLING SYSTEM
CURRENT STATUS DISPLAY ON LCD
COMPLETE VISUAL DISPLAY ON GUI
FIRE DETECTION THROUGH SMOKE SENSING
AUTOMATIC TEMPERATURE MAINTAINING
LCD DISPLAY
GUI DISPLAY & CONTROL PANELS
DATA ACQUISITION
DATABASE MAINTENANCE
USER LOGIN SECURITY
TIME SCHEDUALING OF MODULES WORKING

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2.6: MODULES DISCRIPTION : 2.6.1: DETAILED BLOCK DIAGRAM:-

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Fig: 2.1
2.6.2: CONTROLLER MODULE:This module is basically controlling our entire system. We had following
options for the controllers to be used in this module:
AT 89C52.

AT mega AVR.

PIC controllers

We have chosen ATmega32 (DIP 40) microcontroller in our project GSMMIIAMS as it is fulfilling all the requirements of our project. As we are
using smoke, temperature and LDR sensors and their outputs are
analogue so in this regard AtMega32 has built in ADC which reduced the
extra circuitry required for a separate ADC in case of 89C52.
Moreover we have studied AtMega32 in our course of embedded system
and have practiced C language of the controller during the course so to
have on hand experience of programming of AtMega32 in C language
which was just introduced in the course we have chosen AtMega32.
Following is diagram showing the pin configuration of AtMega32.

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PIN CONFIGURATION OF ATMega32:ATmega32, of the 40 pins, a total of 32 are set aside for the four Ports A,
B, C, and D, with their alternate functions. The rest of the pins are
designated as VCC, AVCC, AREF, GND, XTAL1, XTAL2, and RESET.
2.6.2.1: VCC(10)
VCC(10): This pin provides typically +5V supply voltage to the chip.
Some AVR family members have lower voltage for VCC pins in order to
reduce the noise and power dissipation of the AVR system.
2.6.2.2: AVCC(30)
AVCC is the supply voltage pin for Port A and the A/D Converter. It should
be externally connected to VCC, even if the ADC is not used.
2.6.2.3: AREF(32)
AREF is the analog reference pin for ADC.
2.6.2.4: GND(11,31)
Two pins are also used for ground. In chips with 40 pins and more, it is
common to have multiple pins for VCC and GND. This will help reduce
the noise (ground bounce) in high-frequency systems.
2.6.2.5: XTAL1 (13) , XTAL2 (12)
The ATmega32 has many options for the clock source. Most often a
quartz crystal oscillator is connected to input pins XTAL1 and XTAL2. The
quartz crystal oscillator connected to the XTAL1 and XTAL2 pins , also
needs two capacitors. One side of each capacitor is connected to the
ground. ATmega32 microcontrollers can have speeds of 0 Hz to 16 MHz.
We can choose options for the clock source and frequency by setting
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some
bits.

fuse

2.6.2.6: Port A (PA7:PA0)

Port A serves as the analog inputs to the A/D Converter.
Port A also serves as an 8-bit bi-directional I/O port, if the A/D Converter
is not used. Port pins can provide internal pull-up resistors (selected for
each bit). The Port A output buffers have symmetrical drive
characteristics with both high sink and source capability. When pins PA0
to PA7 are used as inputs and are externally pulled low, they will source
current if the internal pull-up resistors are activated. The Port A pins are
tri-stated when a reset condition becomes active, even if the clock is not
running.

Table 1 Port A Pins Alternate Functions

2.6.2.7: Port B (PB7:PB0)
Port B is an 8-bit bi-directional I/O port with internal pull-up resistors
(selected for each bit). The Port B output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port
B pins that are externally pulled low will source current if the pull-up
resistors are activated. The Port B pins are tri-stated when a reset
condition becomes active, even if the clock is not running.
Port B also serves the functions of various special features of the
ATmega32A as listed below
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Table 2 Port B Pins Alternate Functions

2.6.2.8: Port C (PC7:PC0)
Port C is an 8-bit bi-directional I/O port with internal pull-up resistors
(selected for each bit). The Port C output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port
C pins that are externally pulled low will source current if the pull-up
resistors are activated. The Port C pins are tri-stated when a reset
condition becomes active, even if the clock is not running. If the JTAG
interface is enabled, the pull-up resistors on pins PC5(TDI), PC3(TMS) and
PC2(TCK) will be activated even if a reset occurs. The TD0 pin is tristated unless TAP states that shift out data are entered. Port C also
serves the functions of the JTAG interface and other special features of
the
ATmega32A as listed below

Table 3 Port C Pins Alternate Functions

2.6.2.9:
Port D
(PD7:PD0)
Port D is an 8-bit bi-directional I/O port with internal pull-up resistors
(selected for each bit). The Port D output buffers have symmetrical drive
characteristics with both high sink and source capability. As inputs, Port
D pins that are externally pulled low will source current if the pull-up

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resistors are activated. The Port D pins are tri-stated when a reset
condition becomes active, even if the clock is not running. Port D also
serves the functions of various special features of the ATmega32A as
listed below

Table 4 Port D Pins Alternate Functions

Following are the features of ATmega32 microcontroller
It has 32Kbytes of In-System Self-programmable Flash program memory
It has 2Kbytes Internal SRAM.
It has 1024Bytes EEPROM.
It has 32 programmable I/O lines.
It contains 10 bit ADC and 2 timers/counters of 8 bits and 1
timer/counter of 16 bits Separate Prescalers and Compare Modes.
It has Programmable Serial USART.
It has External and Internal Interrupt Sources.
It comes in 40 pin package.

2.6.3: Central control unit (CCU):Controller module is the brain of our system. It has multiple functions to
perform. It has most extensive & reliable work to do. Some of the major
functions which ATmega32 perform are:
Receive the outputs of all the sensors of sub modules
Convert the analogue sensor output to digital form for further
processing
Analyzing the sensor information whether its a normal process or
emergency situation(fire alert)
Display the current status on LCD
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Continuously send the specific character serially against each

sensor status to update the GUI
Receive characters coming from GUI serially(controlling process)
Analyze these characters and send commands accordingly to
make changes in concerned sub module
As the smoke sensing module senses the smoke controller gets
informed, controller at the same moment shuts down all the
industrial processes running at that time in normal mode
processing and raise the fire alarm, sends a character to update
GUI and displays fire alert on LCD simultaneously
Now after resolving all the problems, you can reset the controller
through a push button, which will restart the industry to work in
safe mode process

CHAPTER 3

AUTOMATIC TANK FILLING

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3.1: INTRODUCTION:One of the modules implemented in our project is automatic tank filling mechanism. We
monitor the status of water tank and switch water pump on and off accordingly. We are
monitoring three levels in our project which are:
1. Quarter
2. Half
3. Full
We are also monitoring the status of reserve tank in which water pump is installed. Water
pump starts only when there is water in the reserve tank.

3.2: KEY FEATURES:

The key features of the automatic tank filling mechanism are as

under:
Monitoring of current status of water tank
Insuring availability of water in tank for different processes
Water pump starts automatically when the tank is empty
Water pump turns off automatically when tank is full
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Status of reserve tank is continuously monitored.

Water pump does not start if reserve tank is empty
Run time status of water level in tank is displayed on LCD
Run time status of water level in tank is displayed on GUI
Run time status of reserve tank is displayed on LCD and GUI

3.3: COMPONENTS:

WATER TANKS
AC water pump
Transistors
AVR microcontroller
LCD
Resistors

BC547
ATmega32

3.4: CIRCUIT DIAGRAM:-

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Fig: 3.1
3.5: WORKING:The water level sensors are self designed using transistor BC 547. We have used the emitter
follower configuration. The bases of the four transistors i-e the inputs of the sensors are
fixed in both tanks at desired levels. A 5V supply source wire is fixed at the base of both
tanks. Water acts as a conductor and until it is not touching any sensor, the output of sensor
going to microcontroller is zero. This output is fed to controller which sets level status as
empty and starts the motor if and only if the reserve tank sensor is giving output 1 i-e
showing the presence of water in the reserve tank.
There are two modes which are:
Filling mode
Usage mode

3.5.1: FILLING MODE:-

The water pump turns ON depending upon the reserve tank status sensor output. When the
water level starts increasing, the water touches first sensor i-e the QUARTER level sensor
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making its output 1 due to input 1. This output is fed to controller which then changes level
status from EMPTY to QUARTER keeping water pump ON depending upon the reserve
tank status sensor output.
When, the water touches second sensor i-e the HALF level sensor, makes its output 1 due to
input 1. This output is fed to controller which then changes level status from QUATER to
HALF keeping water pump ON depending upon the reserve tank status sensor output.
When, the water touches third sensor i-e the FULL level sensor, makes its output 1 due to
input 1. This output is fed to controller which then changes level status from HALF to
FULL and water pump is automatically turned OFF by switching of relay.

3.5.2: USAGE MODE:When the water level starts decreasing, the water contact with first sensor i-e the FULL
level sensor ends, its output becomes 0 due to input 0. This output is fed to controller which
then changes level status from FULL to HALF keeping water pump OFF.
When, the water contact with second sensor i-e the HALF level sensor ends, its output
becomes 0 due to input 0. This output is fed to controller which then changes level status
from HALF to QUATER keeping water pump OFF.
When, the water contact with third sensor i-e the QUATER level sensor ends, its output
becomes 0 due to input 0. This output is fed to controller which then changes level status
from QUATER to EMPTY and water pump is automatically turned ON depending upon the
reserve tank status sensor output by switching of relay.

3.6: SIMULATION SNAP SHOT:-

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Fig: 3.2
3.7: USER INTERFACES:As our project has multi-interfaces, So to show the status for
monitoring or controlling authority, We have presented two
interfaces facility which are:
LCD

GUI.
3.7.1: LCD:-

The run time status of the water tank and water pump are displayed on LCD as
LEVEL:HALF

MOTOR ON

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3.7.2: GUI:The run time status of the water tank, reserve tank and water pump are displayed on GUI
as:

3.7.3: Wirelessly using Mobile (GSM):The run time status and control of the conveyer belt is displayed on Mobile wirelessly
and can be obtained anywhere across the country.

3.8: APPLICATIONS:There is vast application of water or chemical usage tanks automatic filling and it can boost
up the whole manufacturing process by providing assurance of full time availability of
water or chemicals in the tank. Mainly this process is implementable in:
Water filling plants

Chemical filling plants

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Soft drink filing plants

Mixing plants
Cooling and refining plants
Paint industry
Smart home systems etc.

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CHAPTER 4

AUTOMATIC TEMPERATURE
CONTROL SYSTEM

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4.1:INTRODUCTION:Second module of our project is temperature maintenance. Its a very important and
multitask function commonly present in most of the modern industries. Nearly every
industry has heating process or anything related to temperature whether its higher
temperatures or the lower ones. We have introduced both of the temperature situations in
this module as we are not only detecting and calculating the system temperature but we are
trying to maintain some specific temperature required by the industrial supervisor. This
module is very helpful in the sense automating the system temperature and the monitoring it
continuously.

4.2: KEY FEATURES:We have provided a few very impressive features in our temperature maintenance module.
These features are given below:
DETECTING THE SYSTEM TEMPERATURE
AUTO DECISION WHETHER TEMPERATURE IS IN SAFE LIMIT OR NOT
MAINTAINING A USER FED TEMPERATURE
AUTO SWITCHING THE FANS, AC & HEATERS TO MAINTAIN SPECIFIC
TEMPERATURE
RAISING THE FIRE ALARM IF TEMPERATURE EXCEEDS MAXIMUM
TEMPERATURE LIMIT

4.3: COMPONENTS:

LM-35 TEMPERATURE SENSOR

ELECTRONIC FANS(DC)
AC(COOLING MECHANISM)
HEATERS
ALARM
AVR ATmega32

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4.4: CIRCUIT DIAGRAM:-

Fig: 4.1
4.5: WORKING:The temperature sensor we have used in our project is LM35. Its a very small, three legged
transistor looking device. It senses the temperature and changes its output voltage according
to the temperature. Increasing temperature will increase the output voltage and vice versa.
The sensors output voltages are very small. In the range of 0.1V to 6.0V, so this output if
directly fed into the central controller. As the sensor output is in the form of an analogue
voltage changing, so to use this voltage for temperature measurements we have to convert
this analogue voltage into digital voltage form. As ATmega32 has a very attractive edge of
being having a built in ADC. So after converting this voltage into digital form we get the
exact temperature values of the system. This temperature is than continuously shown on the
LCD display and GUI display as well. After getting the exact value of present temperature,
it analysis that in what mode this temperature lies. If Its safe mode than fan will be turned
ON automatically by the controller. If it is high temperature mode than ac switch will be
ON, and if its low temperature mode than controller will send a command to ON the
heaters. If the temperature exceeds from max temperature range 40 degree centigrade, then
emergency mode will be activated and controller will raise the alarms.
There are 4 different modes in which this module will be working in four different
situations. Keeping in mind a normal generalized industry we have added only 4 modes.
But as we have stated before embedded systems control has enough flexibility to change
any desired reasonable modifications according to the specifications of the controller we are
using. So we can add any further modes if needed, but for the time being we have
introduced only these modules named below:
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SAFE MODE
HIGH TEMPERATURE MODE
LOW TEMPERATURE MODE
EMERGENCY MODE

As we have defined the modes of this module, now we will briefly describe each of them
with a little detail.

4.5.1: Safe mode :First of all we start from the safe mode. This mode is the normal mode function. It means in
this mode temperature value will be in safe or you can say default temperature. Like we
have temperature limit as safe temperature limit from 15 degree centigrade to 25 degree
centigrade. Now whenever the temperature will be in this defined limit only fans will
remain ON to just normally cool down the machinery or any system environment.

4.5.2: High temperature mode:Second mode is high temperature mode. This is the mode when system temperature has
raised from a certain defined temperature. We have defined temperature limit from 25
degree centigrade to 40 degree centigrade as a high temperature limit. Whenever
temperature rises from 25 degree centigrade our controller senses it as high temperature
case and automatically switches the AC to turn ON and try to cool down the temperature.
High temperature mode is very much appealing in sense of industrial applications. We will
discuss its applications later in this section.

4.5.3: Low temperature mode:This mode is the one when temperature drops from a normal
temperature limit due to any cause. Temperature limit for this
mode is less than 15 degree centigrade. Our central control is
programmed to take action whenever temperature is reported less
than 15 degree centigrade. As the controller receives this situation
of less temperature, it automatically turns ON the heaters to
increase the temperature to normalize it.

4.5.4: Emergency mode :Last mode is emergency or alert mode. This is an unwanted situation, in which system
temperature rises drastically out of control due to any reason. The possible reasons could be
over heating due to fire eruption, short circuit, heat up machinery or anything else. As
system designed according to our own assumptions we have fixed 40 degree centigrade
temperature as the max. temperature limit. Whenever sensor detects the temperature raise

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above 40, microcontroller takes it as a emergency situation and immediately raises the
emergency alarms, and also declares the fire alerts on displays on LCD & GUI.

4.6: SIMULATION SNAP SHOT:-

Fig: 4.2
4.7: USER INTERFACES:As our project has multi-interfaces, So to show the status for
monitoring or controlling authority, We have presented three
interfaces facility which are:
LCD

GUI
Wirelessly using Mobile (GSM)
4.7.1: LCD:-

the run time status of temperature is displayed on LCD as:

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4.7.2: GUI:The run time status and control of the level of lights are displayed on GUI as:

4.7.3: Wirelessly using Mobile (GSM):The run time status and control of the level of temperature are displayed on Mobile
wirelessly and can be obtained anywhere across the country.

4.8: APPLICATIONS :This module has very versatile applications in lots of industrial processes. Some of the
possible industrial applications are listed below:
FIRE SAFETY SYSTEMS
MAINTAINANCE OF ROOM TEMPERATURE
MAINTAINANCE OF ANY SPECIFIED TEMPERATURE LIMITS FOR ANY
PROCESS
INCUBATION SYSTEMS
PRESERVATION OF ANY TEMPERATURE SENSITIVE ITEMS

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CHAPTER 5

AUTOMATIC LIGHTING SYSTEM

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5.1: INTRODUCTION:One of the modules implemented in our project is automatic lighting system mechanism.
Nowadays, human has become too busy and he is unable to find time even to switch the
lights wherever not necessary. The present system is like; the lighting system will be
switched on in the evening before the sun sets and they are switched off the next day
morning after there is sufficient light. But the actual timings for the lights to be switched on
are when there is absolute darkness. For this purpose, we are using LDR(Light Dependent
Resistor), which varies according to the amount of light falling on its surface, this give an
indication for us whether it is a day/night time. Moreover, we monitor the status of Lights
and control it manually too through our GUI and GSM. We are monitoring three levels in
our project which are:
1. OFF
2. DIM
3. FULL

5.2: KEY FEATURES:The key features of the automatic lightening system mechanism are as under:
Monitoring of current status of lights
Automatic switching On and Off of Industry lights according to the
sunlight
Automatic increase in lights level from Off, Dim to Full according to
the sunlight
Run time control of lights level through GUI
Run time control of lights level through GSM
Run time status of lights level is displayed on LCD
Run time status of lights level is displayed on GUI
Run time status of lights level on Mobile through GSM

5.3: COMPONENTS:

LDR(Light Dependent Resistor)

Potentiometers
Comparator
LM324
AVR microcontroller
ATmega32
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LCD
Resistors
Relays
Bulbs

5.4: CIRCUIT DIAGRAM:-

Fig: 5.1

5.5: WORKING:In this module, we are going to switch off the lights automatically as the day starts. The
duration of the day differs from season to season, accordingly our module works based
upon the light intensity so as to when to start or stop. For this we are using Light Dependent
Resistor (LDR) as the light sensor, which communicates with the required information to
the micro controller (ATmega32).
Here we are using AVR micro controller ATmega32. By using the LDR we can operate the
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lights, i.e when the light is available then it will be in the OFF state and when it is dark then
the light will be in ON state, it means LDR is inversely proportional to light. When the light
falls on the LDR it sends the commands to the micro controller that it should be in the OFF
state then micro controller switch offs the light, all these commands are sent to the
controller then, according to that , the devices operate. We are using comparator IC LM324
for different levels (Off, Dim, Full) of lights. Moreover, we are monitoring the status of
lights according to their different levels on LCD and GUI using micro controller.
There are three modes (levels) which are:
OFF mode
DIM mode
FULL mode

5.5.1: OFF MODE:By using the LDR we can operate the lights, i.e when the light is
available then it will be in the OFF state and comparator IC LM324
is there to send the micro controller the command in shape of
voltage that this is OFF mode so all the lights are off in off state as
LDR is detecting sun light.

5.5.2: DIM MODE:In Evening when dark is growing and sun light is fading there is
need of some more light, so LDR will be in on state and comparator
IC LM324 is there to send the micro controller the command in
shape of voltage that this is DIM mode so half of the lights are on
in Dim state.

5.5.3: FULL MODE:When there is absolute darkness and sun sets down completely i.e
it is grown night there is need of lights to be turn on completely, so
LDR will be in on state and comparator IC LM324 is there to define
that it is Full level and all the lights should be turned on so it send
the micro controller the command in shape of voltage that this is
FULL mode so all the lights are on in Full state.

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5.6: SIMULATION SNAP SHOT:-

5.7: USER INTERFACES:-

As our project has multi-interfaces, So to show the status for

monitoring or controlling authority, We have presented three
interfaces facility which are:
LCD

GUI
Wirelessly using Mobile (GSM)
5.7.1: LCD:the run time status of the level of lights are displayed on LCD as:

L=0

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Here L indicates the levels of lights and 0 here representing OFF mode of lights.
Others are L=D and L=F representing DIM mode and FULL mode of lights respectively.

L=D
Here L indicates the levels of lights and D here representing DIM mode of lights.

L=F
Here L indicates the levels of lights and F here representing FULL mode of lights.

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The run time status and control of the level of lights are displayed on GUI as:

5.7.3: Wirelessly using Mobile (GSM):The run time status and control of the level of lights are displayed on Mobile wirelessly and
can be obtained anywhere across the country.

5.8: APPLICATIONS :There are vast applications of automatic lightening system, its multi interface monitoring
and control. Mainly this process is implementable in:
Power Efficient for any Industry

Multi level lights requirements in Incubator

Smart Home System
Reduce man power with the help of intelligent systems
Cost effective for any industry

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CHAPTER 6

AUTOMATIC FIRE DETECTION AND

EXTINGUISHING SYSTEM

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6.1: INTRODUCTION :The 4th module of our prototype industry is the process of automatic fire detection
by using smoke detection. In this module our self made smoke detector will detect the
presences of smoke particles and then according to this detection it will take any necessary
actions, like raising the fire alarms and announcement of evacuation and automatic
activation of any type of fire extinguishing system.
Its a very demanding key feature for any modern standardized industry because fire
safety system is most required by all of the national & international standards and
regulation authorities to insure the safety of human life and property as well.

6.2: KEY FEATURES:The simplest function of a smoke sensor could be only to detect the smoke
and raise the alarm, but as we are working inside of an industry, so we have to be very
precise in our purpose and we have to take care of some extra scenarios, like what happens?
If alarm starts sounding unnecessarily when just a boiler released its heat or when an
employee smokes a cigarette or anything else happens due to which a small amount of
smoke is produced which is harmless and there is no need to raise the emergency alarm. So
we have to leave some minor limit for such scenarios.
To do so we have raised the potentiometers value of resistance, which
ultimately reduces the alarm sensitivity factor to a certain required level, where we can
entertain the situations like we have discussed above.
Moreover we can set up 1st, 2nd or 3rd degree smoke alerts by just using
more comparators and assigning them different reference voltages. Hence you can issue a
caution or warning when you get the least smoke detection level alert.

6.3: COMPONENTS:

FIGARO TGS813 (SMOKE SENSOR)

LM741 (OP-AMP as comparator)
VARIABLE RESISTOR
FIRE ALARM
RELAYS
FIRE EXTINGUISHER

6.3.1: SMOKE SENSOR:We all know that during combustion or burning of any substance smoke
is involved. This smoke is generally a mixture of a number of gases like
carbon dioxide, carbon monoxide, carbon hydroxide, methane, propane,
butane, isobutene, etc., to name a few. These emanate due to the
breaking of the chemical bonds of substances being consumed under the
influence of heat or fire.

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A gas sensor, as can be understood from the name itself, is a device

which can detect or sense the presence of any gaseous element in the
atmosphere surrounding it.
They find an important place in numerous applications, with the most
common being in fire alarm systems where they are configured as
sensors to detect the presence of any smoke content in the air due to a
possible fire. Thus an alarm is raised before the fire is able spread to
drastic levels.
In our project we will discuss the technical data of smoke sensor which
we have used in our project which is Japanese made Figaro TGS-813 gas
sensor and study its specifications.

6.3.1.1: TGS 813 GAS SENSOR:The gas sensor which we have used in our project in TGS 813. It can
detect the following gases:
LPG.

LNG.

ISO-BUTANE.

NATURAL GAS.

PROPANE TOWN GAS.

6.3.1.2: CHARACTERISTICS:The TGS-813 is basically a sintered type of semiconductor primarily

made up of tin dioxide (SnO2). When it comes in contact with any
gaseous element, its internal resistance immediately drops.
As the concentration of the gas rises, its resistance drops proportionately
and can become as low as 20 times to its normal value.
The TGS-813 is rated as one of the most reliable and longest lasting gas
sensors.

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As shown in the diagram, it consists of six terminals, two of which are

connected to a heater coil, while the other four contacts are wired across
a gas sensing resistor.
To initiate the sensor, a preheating of the heater coil is necessary. It may
take approximately three to five minutes before the actual sensing of the
gases can take place.

The electrical parameters of the sensor are as follows:

1. As discussed above the heater coil needs preheating for about five
minutes; to do this a 5-volt DC supply is applied across it.
2. The resistance of the heater coil is around 30 Ohms, and thus the
current required is quite significantly high, about 200mA.Ideally a
voltage regulator is recommended for this purpose. The versatile
IC 7805, which should be able to supply 5 volts at 1 amp maximum
current, can be used,.
3. The dynamic resistance of the sensing element of TGS-812 in
normal conditions, i.e. in clean air, is approximately 50 K and may
fall to about 3 K in the presence of a gas around it. Even a puff of
cigarette smoke when released from a distance of about 3 meters
would make its resistance fall significantly.

6.3.1.3: APPLICATION:They are used in smoke detection and gas leakage detecting equipments
in Homes and industry, are suitable for detecting of LPG, natural gas,
town gas, avoid the noise of alcohol and cooking fumes and cigarette
smoke. Also used in Portable Gas Detector.

6.3.2: LM741 Operational Amplifier

6.3.2.1: General Description:The LM741 series are general purpose operational amplifiers which
feature improved performance over industry standards like the LM709.
They are direct, plug-in replacements for the 709C, LM201, MC1439 and
748 in most applications.
The amplifiers offer many features which make their application nearly
foolproof: overload protection on the input and output, no latch-up when
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the common mode range is exceeded, as well as freedom from

oscillations.

The LM741C/LM741E are identical to the LM741/LM741A except that the

LM741C/LM741E have their performance guaranteed over a 0C to
+70C temperature range, instead of 55C to +125C.
6.3.2.2: Connection Diagram:Metal Can Package

Note 8: LM741H is
available per
JM38510/10101

Ceramic Dual-In-Line
Package

DS
00
93
412

DS009341-5

Order Number LM741H,

LM741H/883 (Note 8),
LM741AH/883 or LM741CH
See NS Package Number H08C
Dual-In-Line or S.O. Package

Note 9: also available per

JM38510/10101
Note 10: also available per
JM38510/10102
Order Number LM741J-14/883
(Note 9), LM741AJ-14/883 (Note
10)
See NS Package Number J14A

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6.4: CIRCUIT DIAGRAM:-

Fig: 3.1
6.5: WORKING:While describing the working of this module, we will start from the presence of smoke
and gradually by completing all the stages we will present all the outcome forms of module. So
first of all, as the smoke shows its presence in the industrial atmosphere the smoke particles
containing different types of gas particles like CO2, CO ETHAN METHAN or any other thing
else due to which fire and smoke is produced get in contact with the external grill of the
TGS813(gas sensor), Some of the smoke particles make contact with the internal ionization
heater. As the smoke/gas particles react with the heater, the molecules of the gases get ionized,
hence raising the output voltage of sensor from 0.2volts to maximum 5.0volts.
This output voltage is then fed to the LM741s one input inverting in our case, On the other input
of LM741 reference voltage is provided. This is the thing which will setup the reference of
comparison which will also determine the sensitivity level of smoke sensor, Our reference
voltage is 3.5volts, Now as the smoke sensor senses enough smoke particles to raise its output
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voltage above 3.5volts, The comparators output goes on logic 1 and this logic fed to one
specific input pin of the AVR Atmega32 which is our Central Control Unit.
As the controller gets 1 at that pin it works immediately on its predefined program and
shuts down all the other industrial processes running in the industry and raises the alarms
immediately. At the same time controller triggers our fire extinguishing system by sending 5volts
to a relay which then gets magnetized and makes the connection of fire extinguishing system.
Fire extinguisher works and fire gets controlled. Purpose of module is served by sensing the
smoke to extinguishing the fire. Now the industry will remain shut until all the safety measures
are reset and all the reason of fire breakup are solved. When the authorities are perfectly satisfied
with the solutions of problem then industry could be restarted manually.

6.6: SIMULATION DIAGRAM:-

Fig: 6.2

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In simulation LDR sensor is used as TGS813 is not available in proteus

library.

6.7: USER INTERFACES:-

As our project ha s multi-interfaces, So to show the status for

monitoring or controlling authority, We have presented two interfaces
facility, One on LCD and other is on GUI.
On the LCD we dont show the status of this module until the fire
is detected. Normally status of all the other running processes can be
seen on LCD but when fire is detected, The symbol

FIRE FIRE
Check the system disorder_
Is shown constantly, unless the industry is manually reset by authorities.
The other interface, GUI is more expressive to the user. In normal routine, the lower right
block which is detected to the smoke detection module shows
NO FIRE
indication in green means fire is not activated and indication

FIRE EXTINGUISHER & ALARM

in red, meaning extinguishing system is not

active.
Now in case fire is erupted, the AVR Atmega32 serially send character() to GUI, in reaction of
which
NO FIRE
is shown in red means fire is detected and the indication

FIRE EXTINGUISHER & ALARM

is shown in green meaning that fire

extinguishing system is working on extinguishing the fire.

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CHAPTER 7

CONVEYER BELT AND FILLING

MECHANISM

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7.1: INTRODUCTION:One of the modules implemented in our project is Conveyer belt and Filling mechanism. A
conveyor belt (or belt conveyor) consists of two or more pulleys, the conveyor belt itself - that
rotates about them. In this module, conveyer belt is used to fill the bottles/glasses using
Electronic valve(It is attached to the bottom of Tank) automatically. Bottles are placed on
conveyer belt. Bottles are placed in such a fashion that whenever bottles are under the Electronic
valve they stopped (conveyer belt stopped at that instant) for a delay to get filled with liquid. So,
Bottles are filling automatically without any human aid. We are monitoring and controlling the
conveyer belt through GUI and wirelessly on Mobile (GSM).

7.2: KEY FEATURES:The key features of the Conveyer belt and Filling mechanism are as under:
Monitoring of current status of Conveyer belt
Automatic switching On and Off of Conveyer belt according to the
position of Bottles under the valve
Automatic switching On and Off of Electronic valve according to the
position of Bottles under it
Run time control of Conveyer belt through GUI
Run time control of Conveyer belt through GSM
Run time status of Conveyer belt is displayed on GUI
Run time status of Conveyer belt on Mobile through GSM

7.3: COMPONENTS:

Conveyer Belt
DC Power window motor
Electronic Valve
Pulleys
AVR microcontroller
ATmega32
Relays

Fig: 7.1
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7.4: WORKING:-

Working of conveyer belt and Electronic valve is very simple.GUI sends

a character to Avr at mega 32 to start the conveyer belt and similarly it
sends a character after a delay to stop the conveyer belt and start
(open) the Electronic valve to fill the bottle under it. As bottles are
fixed on conveyer belt so time that bottles reached under the valve is
constant and that is our delay to stop the conveyer belt and start
(open) the valve similarly there is a delay for electronic valve to remain
open, this delay is the time that valve takes to fill a bottle which is also
constant for all the bottles and when bottle gets filled electronic valve
stop (closed) and conveyer belt starts and this procedure continues till
we stopped the conveyer belt manually through our GUI or Mobile.

7.5: USER INTERFACES:-

As our project has multi-interfaces, So to show the status for

monitoring or controlling authority, We have presented two interfaces
facility which are:
GUI

Wirelessly using Mobile (GSM)

7.5.1: GUI:The run time status and control of the conveyer belt mechanism is displayed on GUI as:

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7.5.2: Wirelessly using Mobile (GSM):The run time status and control of the conveyer belt is displayed on Mobile wirelessly and
can be obtained anywhere across the country.

7.6: APPLICATIONS :There are vast applications of Conveyer belt and automatic Filling Mechanism. Mainly this
process is implementable in:
used to transport industrial and agricultural materials such as grain,
coal etc
Automatic Filling process used in several companies e.g. Pepsi, coke
etc
used in conveyor transport such as moving sidewalks

Reduce man power with the help of intelligent systems

Stores often have conveyor belts at the check-out counter to move
shopping items

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CHAPTER 8

GSM MODULE INTERFACE

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GSM MODULE INTERFACE:8.1: INTRODUCTION:One of the major interfaces of our project is the GSM module interface. It is the wireless module
of communication to control the industrial applications and monitor their run time status from
anywhere outside of the industry. The feature of remote access via reliable, cheap, user friendly
and every where available GSM communication makes this project more unique, portable and
expands its scope of application in industries.
We used licensed version of SMSCaster E-Marketer GSM Enterprise version
3.6

8.2: KEY FEATURES:As sms gateway processing unit for our project we used SMSCaster EMarketer GSM Enterprise version 3.6. Its an open source software and has
multiple control options. The key features of the GSM module interface are as under:
Reading sms from the cell phone connected to pc via com port
Retrieving sms from phone inbox to pc
Verification of cell number
Extracting command from sms
Deleting sms from inbox of cell phone
Auto replying of status of command to authorized user
Saving sms log for database
Scheduler etc

8.3: COMPONENTS:

Cell phone
SMSCaster E-Marketer GSM Enterprise version 3.6
Data cable

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8.3.1: CELL PHONE:We used Qmobile model q3i in our project as the GSM modem. It
is connected to laptop via data cable and serves as sms gate
way to forward and receive sms for wireless monitoring and
control of industry.

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8.3.2: SMSCaster E-Marketer GSM Enterprise version

3.6
we used smscaster E-marketer GSM enterprise version 3.6 in our project.

8.3.2.1: SCHEDULER:The scheduler is used to perform automatic sending and receiving of SMS. It works like the
"Start Button" is being pressed at a specific time. You can also control when a schedule should
stop by specifying the stopping time of schedule. It has been re-designed to accommodate
multiple schedules. There are two types of schedule: One time and Daily.

8.3.2.1.1: One Time Schedule:It is a simple schedule type which runs one time only. You can specify a starting time and
optionally a stopping time. If the stopping time is omitted, it runs until the Outbox is all
cleared.

8.3.2.1.2: Daily Schedule:It is a repeated schedule type which runs according to the days of week (Mon, Tue...). It has a
starting time and an optional stopping time. For example: starting time = 8am and stopping
time = 6pm means the running time is from 8am to 6pm in one day. If the stopping time is
earlier than the starting time, it means an overnight time period. For example, starting time =
6pm and stopping time = 8am means the running time is from 6pm to the next day's 8am.

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8.3.2.1.3: Creating a Schedule:Select "Scheduler" on the left and click "New" at the toolbar. A "New Schedule" dialog
appears. Choose the schedule type (One Time/Daily), schedule task (Send & Receive/Send
Only/Receive Only) and fill in other information. Press OK when done.

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8.3.2.1.4: Saving the Schedules:Schedules are saved as program settings automatically upon program exit. Therefore, no
explicit saving by the user is required.

8.3.2.1.5: Waiting for a Schedule to Run:When you expect a schedule to run soon, make sure the project file you want is opened
and the Outbox contains the SMS you want to send out by the Scheduler. Also check the
phone connection by pressing the "Update Button" at the Phone Information window. If
everything is fine, you can just leave SMSCaster running without extra intervention. Do
not close SMSCaster or the schedule will not be run.

8.3.2.1.6: Icon Meaning:A colorful icon means an active schedule

A grey icon means an inactive schedule

A green arrow icon indicates the next due schedule

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8.3.2.2: COMPOSE:We can manually send message to all concerned persons of the industry too by using
the message composing feature of Smscacter. The user interface of composing message
feature of smscaster is as following:

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8.3.2.3: CONTACTS:We can manage contact list of all authorized concerned persons of the industry too by
using the contact adding feature of Smscaster. The user interface of contact list, adding
contact feature of smscaster is as following:

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8.3.2.4: GROUPS:We can manage contacts of all authorized concerned persons of the industry into groups
too by using the grouping feature of Smscaster. We have three groups namely:

Students
Supervisor
All

The user interface of grouping feature of smscaster is as following:

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8.3.2.5: INBOX:We can see sms of all authorized concerned persons of the industry in inbox too by
using the inbox feature of Smscaster. The user interface of inbox of smscaster is as
following:

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8.3.2.6: PHONE INFORMATION:We can manage the phone port connection settings in phone configuration feature of
Smscaster. The user interface of phone information of smscaster is as following:

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8.3.2.7: SENT:We can see all sent status and command acceptance sms to all authorized concerned
persons of the industry in sent items too by using the sent box feature of Smscaster. The user
interface of sent box of smscaster is as following:

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8.3.2.8: RESPONDER:The Responder is used to reply to the sender of an incoming SMS

automatically. This is done based on pre-set keywords and reply
messages. You may store the keywords either in a project file or in an
external text file.
1.

Store the keywords in a project file

By default, when you add keywords and reply messages from the user
interface, they are stored in a project file. This means that they are
saved together with the Inbox, Outbox and Sent Box. This allows you
to have different set of keywords and reply messages with different
project files.

2.

Store the keywords in an external file

To enable an external keywords file, specify the file location at

Tool>Options->Responder. It is a text file, encoded in ANSI, UNICODE,
UNICODE (Big Endian) or UTF8 with the BOM mark. There is no user
interface within SMSCaster to edit the keywords stored in an external
file. The simplest way to create one is by using Notepad. Another way
is to prepare the data in Excel and Save As a CSV file.
It can be considered as an interface to control the Responder: by
producing the keywords text file from another program, you can
automate the Responder. The file will be checked periodically for any
changes and will be reloaded when necessary.
External keywords file is available to all projects and considered as
global. Keywords are case insensitive. If the same keyword appears
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both in the project file and in the external file, the one in the project
file will be used.
For the file format, each line contains a keyword and reply message
pair, for example:
Health, "Thank you for your inquiry..."
Win, "Please call 800-989-9877 for your chance to win"
*, "Sorry, we do not have the information you want"
The asterisk means matching anything and serves as the default reply
message when no keyword is matched. It should be put at the last line
of the file or it will override other keywords below it.

You may also put several keywords for the same reply message in one
line, for example:
Diet, Food, "Please call 800-989-9877 for info on food and diet"

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3.

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Enable and disable the Responder

Click the "Enable" button on the toolbar of the Responder Page to

enable the Responder. It does not work until the "Start" button is
pressed. See Persistent Connection if you need continuous autorespond.
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4.

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Send long and flash reply message

You may reply in long SMS or flash SMS (but not both). Go to Tool>Options>Responder for these settings.

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5.

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Blacklist File

A blacklist file contains blocked phone numbers which you do not

want to reply to. It is recommended that you enter the phone number
of your SIM card into the blacklist to avoid potential infinity reply-to
loop. It is a plain text file with each phone number on a new line.
6.

Log File

This is to log successfully replied phone numbers to a file for

reference.

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7.

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Others

Persistent Connection
If you want the Responder to work continuously, you should set
"Persistent Connection" at Tool->Options->Connection Tab. It will wait
for incoming SMS and reply automatically until the "Stop" button is
pressed.

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Delete Received Message from Phone

To avoid responding to incoming SMS saved at the phone again and
again when you re-start SMSCaster, you should enable "Delete
received message from Phone" at Tool->Options->Receive Tab.

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We used usb data cable for connecting cell phone to the comm. port of the laptop.

8.4: WORKING:The basic heraricy implemented in the GSM module is as under:

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User Sends
SMS
System Detects
SMS

Check Phone Number

Validaity

Invalid Phone No.

Valid Phone No.

Extract
Command

Check Command

Invalid Command

Get Status

Room Alias- Device

Alias-Status
Perform Task

Delete SMS

8.5: USER COMMANDS:-

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The user can send the following commands which will perform the tasks assigned via
programming in the Industry:
1. STATUS
2. LIGHTS OFF
3. LIGHTS DIM
4. LIGHTS FULL
5. FAN ON
6. FAN OFF
7. HEATER ON
8. HEATER OFF
9. AC ON
10.
AC OFF
11.
MOTOR ON
12.
MOTOR OFF
13.
CONVEYER BELT ON
14.
CONVEYER BELT OFF

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CHAPTER 9

GRAPHICAL USER INTERFACE (GUI)

9.1: INTRODUCTION:Our project is multi interface and GUI (Graphical User Interface) is one of the interfaces.
It consists of following features:
System Login
System Main Module
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System Port Setting

User Profile Setting
User log
System log
System Scheduling

9.1.1: System Login:-

GSM-MIIAMS

It provide the login option to the Authentic users only. If an

Authentic user want to monitor the status of the system
(Industry) he has to enter his ID and Password to login into the
system it is as:

9.1.2: System Main Module:When an authentic user login into the system then he enter
into the system main module where he monitor the status of the
system (industry) and can control it too if he want change
anything in any of the module of our system (Industry). it is as

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9.1.3: System Port Setting:If user want to change or see the Port setting of the system he
can simply go to setting then port setting where he can manage
the Comm. Port, Baud rate for data, Data bit, Stop bit and also
can check the port status whether it is connected successfully or
not serially it is as:

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9.1.4: User Profile Setting:If an Authentic user want to change his Login Id, Password
or Email ID then he can change it through User Profile Setting. It
is as:

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9.1.5: User log:-

The record of a users activity is constantly monitored and saved in the user
log to be used in maintaining system database. It is as:

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9.1.6: System log:-

The record of a total activity of all users is constantly monitored and saved in
the system log to be used in maintaining system database. It is as:

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9.1.7: System Scheduling:-

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A user (authentic) can schedule the system (Industry) for

any time period on any given date. He also can schedule the
system (Industry) on daily basis. It is as:

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CHAPTER 10

FYP CIRCUITS AND PROTOTYPE

PICTURES

FYP Circuits and Prototype Pictures: 10.1: FYP Circuits:-

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There are three units (circuits) in our FYP circuitry. They are:
Power Board unit

Main Controlling unit (CPU)

Relay array board
10.1.1: Power Board (Unit):-

It is the circuit of our power board which is providing power to our

modules and main controlling unit:

10.1.1.1: Circuit Diagram:-

10.1.1.2: Power Board Picture:-

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10.1.2: Main Controlling unit (CPU):Pcb layout and circuit diagram of Main controlling unit are:

10.1.2.1: PCB Layout of main controller unit:-

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10.1.2.2: Circuit Diagram of main controller unit:

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10.1.3: RELAYS ARRAY BOARD:For switching of all appliances in the industrial prototype of our project we
used relays. We did switching of both DC and AC voltages. The relays
array board circuit is as following:

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10.2: Prototype Pictures:Here are some pictures of our final Industry Protoype:

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98