Controlling and Monitoring Of Industrial Parameters by Using GSM GUIDE: Mr. S. CHANDRA SHEKAR, PROFESSOR IN ECE P.WASEEM NAZMA, G.SUDHA PRIYANKA, S.DHANA LAKSHMI, SK.SHAHID DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING RISE KRISHNA SAI PRAKASAM GROUPS OF INSTITUTIONS, ONGOLE, AP, INDIA ABSTRACT- In the modern era industrial sector has a rapid growth. To meet the present demand of market there must be continuous control and monitoring of different parameters like temperature, gas, speed of the motors. This can be achieved by using GSM technology. This project is built on AT89S52 micro controller 3, Temperature sensor 1, Gas sensor, Fire sensor, and IR sensor is interface to the micro controller. Two push buttons are also interfaced to the controller to control the speed o f the motor. If SW1 is pressed, motor will rotate with slow speed, if SW2 is pressed the motor will rotate with high speed. IR sensor is used to measure the speed of the motor. If we send a message to the system, it will send a reply with the status of all the sensors. If the sensors exceed the threshold limit then an automatic SMS 2 will be sent to the registered mobile number. A Buzzer is also made high for abnormal values. Keywords- GSM, AT89S52 microcontroller, IR sensor, Temperature sensor and gas sensor. I. INTRODUCTION Increasing the production and safety of the plant is necessary criteria. There is no time limit for the production. For this we must present at the industry all the time but wireless technology made this process easier. We can have the benefits by using GSM technology getting status of Industrial Parameters to registered mobile number in the form of message. This project uses embedded technology from Atmel 8051 microcontroller and built for application to have proper remote monitoring and controlling. The principle in which the project is First, the sent SMS is stored and polled from the receiver mobile station and then the required control signal is generated and sent to the intermediate hardware that we have designed according to the command received in form of the sent message. In this project SIM300 GSM 5 module is used. The messages are sent from the mobile set that contain commands in written form which are then processed accordingly to perform the required task. A microcontroller based system has been proposed for our project. IC LM35 is used as sensor for detecting accurate centigrade temperature MQ2 fire sensor is used to detect smoke and flammable gases like LPG, butane, propane, methane, hydrogen and alcohol. An infrared sensor is used to detect the speed and measures the heat of the objects. The micro controller used here is AT89S52. It has 4K bytes internal ROM, 128 bytes internal RAM, Four 8-bit I/O ports (P0-P3), Two 16-bit timers / counters, One serial interface, 64K external memory for code, 64K external memory for data and 210 bit addressable. II. STRUCTURE OF THE SYSTEM GSM module connected with controller for send emergency alert to the supervisor. In one port of AT89S52 connected peripherals for control parameters and sensors for measurement parameters.lcd 16x2 for display current temperature and speed. Figure 1: Block diagram ISSN: 2348 8549 www.internationaljournalssrg.org Page 148
III. DESCRIPTION OF MICROCONTROLLER AT89C52 is an 8-bit Microcontroller and belongs to Atmel's 8051 family. ATMEL 89C52 has 4KB of Flash programmable and erasable read only memory (PEROM) and 128 bytes of RAM. It can be erased and program to a maximum of 1000 times. In 40 pin AT89C52, there are four ports designated as P 1, P 2, P 3 and P 0. All these ports are 8-bit bidirectional ports, i.e., they can be used as both input and output ports. Except P 0 which needs external pull-ups, rest of the ports have internal pull-ups. When 1s are written to these port pins, they are pulled high by the internal pull-ups and can be used as inputs. These ports are also bit addressable and so their bits can also be accessed individually. Port P 0 and P 2 are also used to provide low byte and high byte addresses, respectively, when connected to an external memory. Port 3 has multiplexed pins for special functions like serial communication hardware interrupts, timer inputs and read/write operation from external memory. AT89C52 has an inbuilt UART for serial communication. It can be programmed to operate at different baud rates. Including two timers & hardware interrupts, it has a total of six interrupts. Figure 3: Pin diagram of AT89S52 V. SENSORS AND THEIR INTERFACING WITH MICRO CONTROLLER A sensor is a device that measures a physical quantity and converts it into an equivalent digital signal. The basic parameters which are measured in the industrial monitoring are temperature, gas and speed. For this, temperature, gas and IR sensors are used. A. Temperature Sensor \ LM35 IC which was manufactured by National Semiconductors is used to measure temperature. The temperature sensor has three terminals as shown in figure. The data pin is connected to the chanel-3 of the inbuilt ADC. The sensor gives electrical output proportional to the temperature (0C). Figure 2: Microcontroller AT89S52 IV. PIN DIAGRAM OF AT89S52 MICRO CONTROLLER It has 40 pins with four 8 bit I/O ports. Figure 4: Temperature sensor ISSN: 2348 8549 www.internationaljournalssrg.org Page 149
B. Gas Sensor MQ2 fire sensor is sensitive to smoke and flammable gases like LPG, butane, propane, methane, hydrogen and alcohol. Resistance of the sensor is different depending on the type of the gas. In built potentiometer allows adjusting the sensor sensitivity according to the gas that wanted to detect. data on to the LCD. When RS=0 and EN pin is made high to low command is sent to LCD. When RS=1 and EN pin is made high to low data is sent to LCD. VEE is used to adjust contrast. Figure 7: Interfacing of LCD VII. ANALOG TO DIGITAL CONVERTER (ADC) Figure 5: Gas Sensor An electronic IC MCP3202 which transforms a signal from analog to digital form. Microcontrollers can only perform complex processing on digitized signals. It provides a link between the analog sensors, microcontroller and data handling. C. IR Sensor An infrared sensor is an electronic device that emits in order to sense some aspects of the surroundings. It measures the heat of object as well as detects the speed. It is used in security systems and speed detection system. Figure 8: ADC VIII. BUZZER A buzzer is a mechanical, electromechanical, magnetic, electromagnetic, electro-acoustic or piezoelectric audio signaling device. A piezo electric buzzer can be driven by an oscillating electronic circuit or other audio signal source. A click, beep or ring can indicate that a button has been pressed or gives alert. Figure 6: IR Sensor VI. LCD INTERFACING TO MICROCONTROLLER A liquid crystal display (LCD) is use to display temperature, Relative Humidity and Pressure. Its major features are its lightweight construction, and portability. Four data lines are used to send Figure 9: Buzzer ISSN: 2348 8549 www.internationaljournalssrg.org Page 150
IX. GSM Modem cannot be used to control the process. A GSM modem provides the communication interface. It transports device protocols transparently over the network through a serial interface. A GSM modem is a wireless modem that works with a GSM wireless network. This GSM Modem can accept any GSM network operator SIM card and act just like a mobile phone with its own unique phone number. Advantage of using this modem will be that you can use its RS232 port to communicate and develop embedded applications. Applications like SMS Control, data transfer, remote control and logging can be developed easily. The modem can either be connected to PC serial port directly or to any microcontroller. Proposed System: We propound on GSM based industrial process control and monitoring. The design of standalone embedded system can monitor and control various process, equipment and critical systems. The systems are controlled by mobile phone by sending commands via SMS. GSM provides the communication between authority and system. Figure 10: GSM Modem X. DC MOTOR A motor is an electrical machine which converts electrical energy into mechanical energy. The principle of working of a DC motor is that "whenever a current carrying conductor is placed in a magnetic field, it experiences a mechanical force". Figure 11: DC motor Existing System: The use of single chip Data acquisition system (DAS) method in Instrumentation and process control application is not only limited in processing capacity but also the problem of poor real time and reliability. General web server requires more resources and huge amount of memories. This system can only measure the remote signals and it Figure 12: Screenshot of Hardware Kit A. Conclusion This project is used for sensing malfunctioning in industrial machines and making corrective measures in it. There is no limit for future scope in the monitoring and control operation. More and more automation is being handled via remote communication. The GSM network is used to help the user to control the system from a distant area by sending secret code. By this method we can easily interact with the device and the user. B. REFERENCES 1. Peng Wang Design of Temperature and Humidity Intelligent Control System Based on C8051F. 2011 International Conference on Electronics and Optoelectronics. 2. Wang, Y, Yin, Y, & Jiang, Y. Chinese real-time dynamic monitoring of system development and implementation of the Strategy [J]. 2005, 29(11): 44-48. ISSN: 2348 8549 www.internationaljournalssrg.org Page 151
3. Tang, B, Zeng, N, & Zheng, X. Web-based Embedded System Design and Implementation Of Remote Monitoring and Control [J]. 2004, 43(5): 632-635. 4. Rakesh Trivedi, Prof. Vishal Vora Wireless Monitoring and Control System, AICON-13, paper id: CSIT/AICON/2013/EI/005, April 2013. 5. Hardware Manual of SIM300 GSM module from SIMCOM www.simcom.us/act_admin/.../sim300_hd_v1.01(09 1226).pdf. 6. Datasheet of LM35 Temperature Sensor from TI www.ti.com/lit/ds/symlink/lm35.pdf. ISSN: 2348 8549 www.internationaljournalssrg.org Page 152