MAINTENANCE MANAGEMENT

X
INTERNET OF THINGS

USING NODE MCU, SMOKE DETECTION SENSOR, DHT SENSOR& VIBRATION

DETECTION SENSOR WITH BLYNK APP FOR MACHINE
MAINTENANCE.

SUBMITTED BY: GAGAN SINGHVI(BFT/17/77)

HARSH RAJ(BFT/17/437)
NEERAJ SINGH DHAKA(BFT/17/137)
 ACKNOWLEDGEMENT
We would like to thank NIFT Mumbai for giving us this opportunity and
facilitating our project. It was a great learning experience throughout. We
take the opportunity to thank all the people who guided us through the
entire process and made our project a success by sharing their
knowledge. We are grateful to our College mentor Mr. Sandeep Kidille&
Rahul Gupta sir for guiding us at every stage and making this project a
success.
COMPONENTS USED
1. BREADBOARD
2. JUMPING WIRES
3. USB-CABLE
4. NODE-MCU ESP-8266
5. 4X RELAY
6. SMOKE DETECTING SENSOR
7. VIBRATION SENSOR
8. DHT SENSOR
9. BUZZER
10. DC MOTOR
11. FAN
12. BULB
13. BULB HOLDER
14. CARTON BOX

BREADBOARD
A breadboard is a solderless device for temporary prototype with electronics and test
circuit designs. Most electronic components in electronic circuits can be
interconnected by inserting their leads or terminals into the holes and then making
connections through wires where appropriate. The breadboard has strips of metal
underneath the board and connect the holes on the top of the board. The metal strips
are laid out as shown below. Note that the top and bottom rows of holes are connected
horizontally and split in the middle while the remaining holes are connected vertically.

JUMPING WIRES
Jumper wires are simply wiring that have connector pins at each end, allowing them
to be used to connect two points to each other without soldering. Jumper wires are
typically used with breadboards and other prototyping tools in order to make it easy
to change a circuit as needed. Fairly simple. In fact, it doesn’t get much more basic
than jumper wires.
Though jumper wires come in a variety of colours, the colours don’t actually mean
anything. This means that a red jumper wire is technically the same as a black one.
But the colours can be used to your advantage in order to differentiate between types
of connections, such as ground or power.

Jumper wires typically come in three versions: male-to-male, male-to-female and

female-to-female. The difference between each is in the end point of the wire. Male
ends have a pin protruding and can plug into things, while female ends do not and are
used to plug things into. Male-to-male jumper wires are the most common and what
you likely will use most often. When connecting two ports on a breadboard, a male-
to-male wire is what you’ll need.

NODE MCU ESP-8266

This small module allows microcontrollers to connect to a Wi-Fi network and make
simple
TCP/IP connections using Haye s- style commands. However, at first there was
almost no English-language documentation on the chip and the commands it
accepted. The very low price and the fact that there were very few external
components on the module, which suggested that it could eventually be very
inexpensive in volume, attracted many hackers to explore the module, chip, and the
software on it, as well as to translate the Chinese documentation.

4X RELAY
4-Channel Relay interface module, for controlling various appliances, and other
equipment’s with large current. It can be controlled directly by microcontroller
(Raspberry Pi, Arduino, 8051, AVR, PIC, DSP, ARM, ARM, MSP430)

SMOKE DETECTING SENSOR

4-Channel Relay interface module, for controlling various appliances, and other
equipment’s with large current. It can be controlled directly by microcontroller
(Raspberry Pi, Arduino, 8051, AVR, PIC, DSP, ARM, ARM, MSP430).
Internal structure of MQ2 Gas Sensor

The sensor is actually enclosed in two layers of fine stainless-steel mesh called
Anti-explosion network. It ensures that heater element inside the sensor will not

cause an explosion, as we are sensing flammable gases.

It also provides protection for the sensor and filters out suspended particles so that
only gaseous elements are able to pass inside the chamber. The mesh is bound to
rest of the body via a copper plated clamping ring.

This is how the sensor looks like when outer mesh is removed. The star-shaped
structure is formed by the sensing element and six connecting legs that extend
beyond the Bakelite base. Out of six, two leads (H) are responsible for heating the
sensing element and are connected through Nickel-Chromium coil, well known
conductive alloy.
The remaining four leads (A & B) responsible for output signals are connected using

Platinum Wires. These wires are connected to the body of the sensing element and

convey small changes in the current that passes through the sensing element.

The tubular sensing element is made up of Aluminium Oxide (AL2O3) based

ceramic and has a coating of Tin Dioxide (SnO2). The Tin Dioxide is the most

important material being sensitive towards combustible gases. However, the

ceramic substrate merely increases heating efficiency and ensures the sensor area

is heated to a working temperature constantly.

So, the Nickel-Chromium coil and Aluminium Oxide based ceramic forms a Heating

System; while Platinum wires and coating of Tin Dioxide forms a Sensing System.
How does a gas sensor work?
When tin dioxide (semiconductor particles) is heated in air at high temperature,
oxygen is adsorbed on the surface. In clean air, donor electrons in tin dioxide are
attracted toward oxygen which is adsorbed on the surface of the sensing material.
This prevents electric current flow.

In the presence of reducing gases, the surface density of adsorbed oxygen

decreases as it reacts with the reducing gases. Electrons are then released into the
tin dioxide, allowing current to flow freely through the sensor.

Hardware Overview – MQ2 Gas Sensor Module

Since MQ2 Gas Sensor is not breadboard compatible, we do recommend this handy
little breakout board. It’s very easy to use and comes with two different outputs. It
not only provides a binary indication of the presence of combustible gases but also
an analog representation of their concentration in air.
The analog output voltage provided by the sensor changes in proportional to the
concentration of smoke/gas. The greater the gas concentration, the higher is the
output voltage; while lesser gas concentration results in low output voltage. The
following animation illustrates the relationship between gas concentration and output
voltage.

The analog signal from MQ2 Gas sensor is further fed to LM393 High Precision
Comparator (soldered on the bottom of the module), of course to digitize the signal.
Along with the comparator is a little potentiometer you can turn to adjust the
sensitivity of the sensor.
You can use it to adjust the concentration of gas at which the sensor detects it.

Calibrate MQ2 Gas Sensor Module

To calibrate the gas sensor, you can hold the gas sensor near smoke/gas you want
to detect and keep turning the potentiometer until the Red LED on the module starts
glowing. Turn the screw clockwise to increase sensitivity or anticlockwise to decrease
sensitivity.
The comparator on the module continuously checks if the analog pin (A0) has hit the

threshold value set by potentiometer. When it crosses the threshold, the digital pin (

D0) will go HIGH and signal LED turns on. This setup is very useful when you need

to trigger an action when certain threshold is reached. For example, when the

smoke crosses a threshold, you can turn on or off a relay or instruct your robot to

blow air/sprinkle water.

MQ2 Gas Sensor Module Pinout

VCC supplies power for the module. You can connect it to 5V output from your Arduino .

GND is the Ground Pin and needs to be connected to GND pin on the Arduino .

D0 provides a digital representation of the presence of combustible gases .

A0 provides analog output voltage in proportional to the concentration of smoke/gas.

VIBRATION DETECTOR SENSOR

PRINCIPLE

Usually at any angle switch is ON state, by the vibration or movement, the rollers of
the conduction current in the switch will produce a movement or vibration, causing the
current through the disconnect or the rise of the resistance and trigger circuit. The
characteristics of this switch is usually general in the conduction state briefly
disconnected resistant to vibration, so it's high sensitivity settings by IC, customers
according to their sensitivity requirements for adjustments.

Sensor Details SW-420

Single-roller type full induction trigger switch. When no vibration or tilt, the product is
ON conduction state, and in the steady state, when a vibration or tilt, the switch will
be rendered instantly disconnect the conductive resistance increases, generating a
current pulse signal, thereby triggering circuit. These products are completely sealed
package, waterproof, dustproof.
Use

1. The module does not vibrate, vibrate switch is closed conduction state, the
output low, the green indicator light comes ON.
2. Vibration state, vibration switch instantly disconnect the output high, the
green light is not on.

3. The output is directly connected to the microcontroller to detect high and low,
thereby detecting the vibration environment, play an alarm role.

Application Ideas:

1) Vibration detecting
2) Burglary protection system
3) Object Movement detecting
4) Triggering effect reported theft alarm
5) Smart car
6) Earthquake alarm
7) Motorcycle alarm

It is useful for a variety of shocks triggering, theft alarm, smart car, an earthquake
alarm, motorcycle alarm. This module when compared with a normally open
pneumatic shock sensor module, shock triggered much longer can drive relay module
the use of the company’s production of SW-420 normally closed type vibration
sensors. comparator output signal clean wave well, driving ability, 15mA rated voltage
and 3.3V-5V output:
digital switching output (0 and 1) a bolt-hole for easy installation small Board PCB
dimensions: 3.2cm x 1.4cm. using the wide LM393 voltage comparator.

DHT SENSOR

This DHT11 Temperature and Humidity Sensor features a calibrated digital signal
output with the temperature and humidity sensor capability. It is integrated with a high-
performance 8-bit microcontroller. Its technology ensures the high reliability and
excellent long-term stability. It has excellent quality, fast response, anti-interference
ability and high performance.
Each DHT11 sensors features extremely accurate calibration of humidity calibration
chamber. The calibration coefficients stored in the OTP program memory, internal
sensors detect signals in the process, we should call these calibration coefficients.
The single-wire serial interface system is integrated to become quick and easy. Small
size, low power, signal transmission distance up to 20 meters, enabling a variety of
applications and even the most demanding.

SPECIFICATION

• Supply Voltage: +5 V
• Temperature range :0-50 °C error of ± 2 °C
• Humidity :20-90% RH ± 5% RH error
• Interface: Digital

BUZZER
The Buzzer Passive 5V Module is a passive piezo buzzer module useful for creating
sound in a project.

Passive buzzers are similar in function to a small speaker and need to be driven by a
waveform with enough drive current capability to create the desired sound. This is
typically done using PWM from a uC (control voltage). The advantage of a passive
buzzer is that the tone and loudness of the buzzer can be controlled by the frequency
and drive power of the waveform that is used to drive it.
CODEX
#define BLYNK_PRINT Serial
#include <ESP8266WiFi.h>
#include <BlynkSimpleEsp8266.h>
#include <SimpleTimer.h>
#include <SPI.h>
#include <DHT.h>

char auth[] = "mIYCUlYUmZI4D2WYrRl4chTOr4ZyrJyb";

char ssid[] = "Redmi";

char pass[] = "gagan5729";

#define DHTPIN 2
#define DHTTYPE DHT11

DHT dht(DHTPIN, DHTTYPE);

SimpleTimer timer;

float h;
float t;
float data;
float relayPin = 5;
int sdata = 0;
int mq135 = A0; // smoke sensor is connected with the analog pin A0

String vdata = "";

void myTimerEvent()
{
 Blynk.virtualWrite(V1, millis() / 1000);

void setup()
{
// Debug console
pinMode(14, OUTPUT);
pinMode(0, OUTPUT);
pinMode(5, OUTPUT);
Serial.begin(9600);
Blynk.begin(auth, ssid, pass);
dht.begin();

timer.setInterval(10L,sensorvalue);
}
void sensorvalue()
{
float h = dht.readHumidity();
float t = dht.readTemperature();
if (isnan(h) || isnan(t)) {
Serial.println("Failed to read from DHT sensor!");
return;
}
// You can send any value at any time.
// Please don't send more that 10 values per second.
Blynk.virtualWrite(V2, h); //V5 is for Humidity
Blynk.virtualWrite(V3, t); //V6 is for Temperature

Serial.println(data);

data = analogRead(mq135);
 Blynk.virtualWrite(V5, data); //virtual pin V3

if (data > 500 )

{
Blynk.notify("Smoke Detected!!!");
}

void loop()
{
sensorvalue();
Blynk.run();
timer.run();
if ( dht.readTemperature() > 34 or analogRead(mq135) > 400 )
{
digitalWrite(14, HIGH);
digitalWrite(0, LOW);

else if (dht.readTemperature() < 34)

{
digitalWrite(14, LOW);
digitalWrite(0, HIGH);

if ( dht.readHumidity() > 80 )
{
tone(5, 349); //F
delay(1000);
 }

else if (dht.readHumidity() < 80)

{
tone(5, 0); //F
delay(1000);

if ( analogRead(mq135) > 400)

{
tone(5, 349); //F
delay(1000);
digitalWrite(14, HIGH);
delay(100000000000);
digitalWrite(0, HIGH);
delay(100000000000);

if (analogRead(mq135) < 400)

{
tone(5, 0); //F
delay(1000);

}
IOT IN MAINTENANCE
IoT is the connection between devices and to the internet. The idea of the IoT is so
massive that it has been referred to as the 4th industrial revolution or in other
words, Industry 4.0.
Nowadays, we can control our home heating systems through our phones to set the
right temperature in the house when we get home. Technicians and mechanics are
able to see equipment failures on in real time as the breakdown is happening….
In the near future, IoT will be crucial for increasing efficiency and productivity in
every aspect of business. IoT will lead to more efficient power and energy
management at manufacturing facilities and plants by adjusting environment control
systems automatically based on the data received from IoT devices to reduce
energy consumption. IoT can also enhance maintenance management processes
through automation and analysis based on real time data.
Six examples of how the IoT can improve maintenance management processes;
A. PREDICTIVE MAINTENANCE
One of the biggest reasons to invest in IoT is to be able to manage your assets
through predictive maintenance. Instead of performing calendar-based inspections
and spare parts replacement, predictive maintenance allows you to monitor
equipment and predicting failures. For example, notify you when a part is worn off
and needs replacement, or the temperature in boiler has reached a specific point
and might overheat soon. Sensors implemented in the equipment can check for
conditions you have set up and trigger work orders when specific limits are
breeched.
With predictive maintenance strategy in place, maintenance jobs are only performed
when it is needed and required, leading to reducing costs of spare parts and labour
costs.

B. DATA ANALYSIS IN REAL TIME

Machine-to-machine, or M2M, is a term that can be used to describe technology
that enables other connected devices to exchange information and execute actions
without the manual assistance of humans. The internet of things takes M2M even
further by including additional element: data. Having access to all data from
machinery in one network gives manufacturers the ability to accumulate and
analyse the data and transform it to better predictive maintenance. Instead of
waiting for a failure, manufacturers can accurately predict breakdown because IoT
devices reports when operating conditions are out of specification. By identifying
failure patterns and quickly recognizing issues, manufacturers are able to improve
their production and significantly reduce downtime. That leads to increased
customer satisfaction and less warranty claims.
 C. PERFORMANCE MATRIX
By using IoT devices, key performance indicators (KPI's) like mean time between
failures (MTBF) or mean time to repair (MTTR) can be calculated automatically by
the system and send back to reporting dashboards. This then excludes the manual
human work of capturing downtime and ensuring accuracy and availability of data.

D. AUTOMATIC REPAIR RECOMMENDATIONS

When equipment breaks down, failure data can be gathered from various different
sources, accumulated and analysed in real time within the cloud. Options for repairs
can be done automatically by the system, even actions to take can be recommended
to the technician if necessary. Failure data can be used to address the repair,
including system operating conditions at the time of breakdown together with
previous repair data from the Enterprise Asset management (EAM). Accordingly,
the technician or mechanic will be given all the information he needs for more
effective decision-making. Deploying EAM or Maintenance management software
with an application programming interface (API) that integrates with IoT devices will
be essential for ensuring accurate and usable information.

E. INVENTORY MANAGEMENT
Efficient inventory management can have a powerful impact on reducing equipment
downtime and controlling maintenance budget. Connected stock that monitor
inventory levels ensures the organization only has what is needed on their stocks.
If the spare part level drops to specific level you have set up, with Integrated ERP
and EAM system, you can notify procurement department automatically to order
more. With predictive maintenance and data analysis, manufacturers are able to
optimize spare parts stocks, freeing up needed capital and increasing accuracy of
spare parts as well as maintenance budgets.

F. REMOTE ASSETS
When it comes to unplanned failure maintenance, the IoT enabled devices can make
it easier and more efficient to maintain assets in remote locations. As it was
mentioned before, IoT reduces unnecessary visits to remote locations where you
need to inspect assets through predictive maintenance. For example, connecting
assets through IoT like wind farms or pumps would make assets generate work
orders based on their condition.
 OUR PROJECT AND SOME FUTURE PROSPECTS

Our final model is planned by using various sensors to show a machine maintenance
program and its importance in coming future.

We used smoke detection sensor, vibration sensor& DHT11 sensor connected with
nodeMCU and finally controlling two machines through the IOT codes.

Our project was:

a) If temperature exceeds a certain value automatically cooler should start

working and the machine should stop (preventive maintenance) & vice versa.
b) If humidity increases from a certain value buzzer should start till the ideal
humidity is achieved again. (can be both preventive and breakdown
maintenance); in here, we are mainly speaking of quality control room where
a specific value of relative humidity is needed for proper study.
c) If smoke density increases from a certain value buzzer should start with all
machines stop till maintenance is done. (breakdown maintenance)

With the help of blynk app we have designed our project in such a way that the
manager can see all the data and monitor it in such a way to avoid any accident or
machine breakdown by proper maintenance by management.

This is just one way how it can be used. Many more such are:

1. There can be a garment that can automatically maintain the body temperature
of a person. For this we can use the DHT sensor which will measure the
temperature and humidity level around a person and a device should be
connected to it that will cool or heat the garment whenever the temperature
and humidity falls or increase beyond a certain level.
2. The DHT sensor can also be used in the garment industry where some
machines require air conditioners to keep them cool. We can use the DHT
sensor to analyze the temperature of the room and it should be directly
connected to the air conditioner so whenever the temperature increases in
becomes automatically on which will be connected through a relay. This will
save a lot of energy.
3. Here we can use a smoke detector sensor and a vibration sensor in
reference with the maintenance of costly industrial machines. The
vibration sensor will recognize the wear and tear of machines as
whenever there is any problem inside a machine, its vibration increases.
We can use a smoke sensor to avoid accidents and to know where the
problem is as sometimes, we can smell smoke but can’t detect from
where it is coming from. The various smoke detector attached to the
huge machine will tell us from which part of the machine smoke is
coming out from. Other than the industry the vibration sensor can also
be used as an earthquake detection in earthquake prone areas to avoid
accidents.