INDUSTRIAL PROCESS MONITORING SYSTEM USING ESP32 [1]Thimmapuram Swati

INDUSTRIAL PROCESS MONITORING SYSTEM USING ESP32
1Thimmapuram Swati ,2 Dr. K. Raghavendra Rao
1Ph.D scolor, Depatment of Electronics, Sri Krishnadevaraya University, [email protected]
2Professor, Department of Physics, Sri Krishnadevaraya University, Anantapur, Ananthapuramu.
[email protected]
ABSTRACT: Abstract- Today’s word is internet world, Internet of Things (IoT) is expanding at rapid rate increasing technology. A network of connected computers hidden in every corner of our life monitoring and controlling things with minimal IOT supports to connect hard ware devices to the internet to process the data for monitoring and security. This system uses ESP32 and sensors helps to monitor the different parameters like temperature, humidity, smoke etc are accessed and monitored from remote area by cloud computing the data using Blink and automatically controls the motor or system operation by computer or smartphone. This system is very useful for small scale industry for to achieve maximum through put and to avoid from accidents though SMS alerts and email, it is a simple, smart monitoring and security system and also tells the importance of IOT in industrial applications. Proposed method very well suitable for smallscale industries monitoring and controlling.

Index Terms— IOT, Wi-Fi, ESP32, BLYNK, SCADA, Zigbee, Bluetooth ;
INTRODUCTION
Now a day’s intelligent monitoring system playing a major role in present day to day life. IoT playing a vital role in designing smart and intelligent system in industrial and information technology applications. IoT is a combination of embedded and communications system which interconnects hard ware devices to the internet.

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In this project IoT network is implemented to monitor several common parameters used in industries such as Smoke, Gas, Fire, Humidity and machine control using IoT. In this proposed system ESP32 Wi-Fi module is used for collecting data from equipments and transfer it into a wireless internet. ESP32 is the most unified Wi-Fi module in the industry, it consists of inbuilt microcontroller and antenna with less expense. Industrial process
Monitoring system consists of 5 applications, these are Machine Control, Harmful gases level monitoring, Humidity measuring, Fire and Gas alert detection can be controlled from remote place.

Trends driving IoT:
1. Moore’s law
2. Connectivity
3. Sensors and Actuators
1. Moore’s law: Exponential increasing power consumption because of number of transistors in a chip doubled and tripled for every 18-24 months due to evolution in VLSI technology.

The Moore’s theory predicts that processors and electronic devices used in the IoT applications will become power full, cheaper and smaller.

Sinking of Integrated circuits

Fig 1: shows moor’s law
2. Connectivity: By 2020-20 it is expected there will be will be 30-50 billion connected devices in worldwide, processing can be done by the device itself and part of the processing service on the cloud and utilization of bandwidth and protocol used left the challenge for researchers.

Temperature
Humidity
Flame
Smoke
Light
Cloud Server

Wireless
communication
IoT gateway

Mobile app

Sensor
Fig 2:Shows IoT connectivity
Connectivity controlled from cloud will become very simple to operate.
3. Sensors and Actuators: Due to the availability of number of compatible sensors activators. Sensors allow processors to aware of this environment. Activators are counter parts of sensors allow the processor to do something about the information it has act on through digitally controlled motors, servers piezoelectric drivers etc.
Sensor
Actuators
Processor

Fig 3: Shows function of Sensors and Actuators
Sensors: Detects what happening in the world
Processor: Analyze and process digital data, and sends commands to the actuators.

Actuators: Transforms the data in to useful output (visualization/action/response)
Proposed paper consists of 5 modules, II represents related work, III represents proposed method IV related to design and implementation, V and VI describes results and conclusion.

2. RELATED WORK
Different control technologies are used for monitoring and control of the systems, whereas the
communication between a system and a user is generally realized online via wireless communication techniques such as RF, ZigBee and Bluetooth. Also, SCADA programs are utilized for developing user interfaces. However, SCADA programs do not provide adaptability for users because of their expensive libraries. RF, ZigBee and Bluetooth technologies are widely preferred in easy-to-use applications due to the short range between the sender and the receiver, and the small volumes of data transferred. The ZigBee, RF and Bluetooth wireless communication techniques are generally restricted to simple applications because of their slow communication speeds, distances and data security. Nowadays, timer controlled systems have been easily replaced with remote controlled systems after the internet became widespread. In these systems, it is known as an important issue to get information about not only the control, but also the conditions of the machines or devices through internet. In accordance with this need, there are some works about implementation of condition monitoring of system through internet and development of internet-based remote controlling or monitoring practices.

KomalS.Shinde,PrachiH.Bhagat descried industrial monitoring system using ESP8266. Implementation of PLC based liquid level monitoring, DCmotor speed control,color mixing and energy monitoring1.
Elizabeth Kadiyala,Shravya Meda, Revathi Basani, S.Muthulakshmi described indudtrial process monitoring using Rasberrypi measurement of temperature, light intensity, liquid level monitoring3.

Kannamma, Manivannan Chanthini presented a paper on industrial auto mationusng Zigbee. Zigbee system is based on wireles sensor network used for regulating and supervising different processes in industries without distracting other processes4.

Mukhopadhyay and Mukhopadhyay presented paper on home automization using IoT. IoT is forepart of this system to minimize human efforts. The main aspect of this system to monior and control the home appliances through mobiles3.

Pavithra.D , Ranjith Balakrishnan “IoT based Monitoring and Control System for Home Automation” The implemented automation system provides an efficient, comfortable and flexible user interfacefor controlling electric appliances remotely2.

Above mentioned work gives knowledge about industrial parameters monitoring from remote area by inter connecting modules to cloud through Wi-Fi, Bluetooth or Zigbee module. Online supervising of industrial process helps to improve throughput, decreases process time and provides security.

In the proposed system related work implemented in smarter way with simple module using ESP32 Dev module which consists of in built Wi-Fi Blue tooth module no need to connect external board to provide Wi-Fi, and also consists of inbuilt temperature, touch and hall effect sensor industrial process parameters monitored efficiently from remote area using smartphone by downloading Blynk application program in smartphone.
3. PROPOSED WORK
This system is implemented with ESP32DEV module by interfacing DC motor and distinctive sensors like temperature, smoke, flame sensor are interfaced to cloud by enabling inbuit Wi-Fi module of ESP32. The sensor parameter variation are checked through IoT. Cloud used in this application is Blink application tool kit, Blink can be accessed through mobile or Laptop. If the sensor parameters limit exceeds than specified limit motor or load which is connected to the load automatically turned off and informed through SMS or electronic mail to the registered users.

Industrial processes like DC speed control, smoke level monitoring, temperature monitoring and flame monitoring using android mobiles, laptops etc. using IoT.

The basic block diagram for industrial process monitoring using IoT as shown in figure.

CLOUD

MACHINE
ESP32 DEV MODULE

Fig 4: shows master module
Interfacing of sensors like temperature, smoke sensor, flame sensor, All the parameters that are connected to ESP32 are monitored by IOT. Shown in figure,
CLOUD

ESP32 DEV MODULE

Temperature
Smoke
Flame
Smart Phone
(BLYNK APP)
Sensors
Fig 5: Shows interconnection of sensors to the ESP32 module
4. DESIGN AND IMPLEMENTATION
Hardware and software requirement for module implementation:
i. ESP32 ii. DC motor iii. DHT11 sensor iv. Smoke sensor v. Flame sensor vi. Bazer vii.4 channel Relay . viii. Blynk Application toolkit ix Arduino 1.8.7 CC
i.ESP32: ESP32 is aseries of low-cost, low-power system on chip. The microcontrollers with integrated Wi-Fi and dual-mode Bluetooth.The ESP32 series employes a Tensilica Xtensa LX6 microprocessor in both dual-core and single –core variations and includes in-built antenna switches, RF balun, power amplifier,low noise receive amplifier, filters and power-management modules.ESP32 is created and developed by Espress if systems, a Shanghai-based Chinese company, and is manufactured by TSMC using their 40nm process. It is a successor to the ESP8266 microcontroler.

Fig.6 ESP32 module internal organization
2. Flamesensor:
Flame sensor is very sensitive to light that is why it is generally used as flame alarm purposes. This module can detect flame in 760nm to 1100nm range of light source. The detection distance is up to 100cm. The detection angle is 60 degrees. Sensor gives output as digital or analog signal.

3.Smokesensor:
The smoke sensor is based on the free scale semiconductor MC145012DW smoke detector chip. The IC consists of infrared photoelectric chamber. It detects by sensing scattered light from minute smoke particle or it will take approximately 20seconds for relay to fire.

4. Tempareturesensor:
Temperature sensors tend to measure heat or temperature in the industrial process, and often used in hazardous environment.

5.Humiditysensor:
Relative humidity in the environment is measured effectively, they measure both moisture and temperature in the air and gives relative humidity as percentage . most of the humidity sensors are capacitive measurement sensors, moisture from the air collects on the film and causes changes in the voltage levels between the two plates, change in the voltage then converted in to digital measurement.

5.Blynk:
Blynk was designed for the internet of things . It can control hardware remotely, it can display sensor data.
3-major components in the blynk platform:
Blynk app allows you to create projects using various widgets available.

Blynk server: Which interconnects smartphone with hardware. Blynk server is a open source, and easily handles thousands of devices.

Blynk libraries: Blynk libraries supports all popular platforms and enables communication with the server and process all commands.

over all set of the project with different sensors connected ESP32 sensed values are updated in the cloud shown in the figure

Fig 7:Shows proposed module setup
Proposed module connected to the cloud through In built Wi-Fi module of ESP32 distinct parameters of the sensors are computed to the cloud, updated values are monitored through smartphone using Blynk application toolkit (BLYNK APP), If sensed values exceeds the specified limit automatic SMS or electronic mail send to the registered users by the cloud.

Industrial parameters displayed in the smartphone shown in figure

Fig 8: the updated values are monitored through smartphone using Blynk application toolkit (BLYNK APP).

5. RESULTS
Proposed module implemented wirh DC motor and distinct sensors by connecting to the ESP32Dev at different conditions and displayed and stored in the cloud, monitored and controlled by the industrialist even from remote areas. For example, If industry caught with any fire accident based on the updating values of the sensors (smoke, temperature values exceeds specified limit), machinery or production automatically stopped from the remote area by the responsible person of the industry. These results in the correctness working of the system at every instant of time the values are automatically updated
in the cloud.

6. CONCLUSION
The proposed system, presents the advancement of
Internet technology in day to day life. The system is suitable for real time small scale industrial process monitoring and controlling applications. proposed module implemented on ESP32,one of the advances embedded circuit consists dual core processor and inbuilt Wi-Fi and Bluetooth module.The module outline was tried, actualized and the accuracy and working of the system was verified.

Benefits of use IoT in industry:
Elimination of long wiring
Web based remote monitoring
Immediate action on failures.

Ease of maintenance.

6.REFERENCE
1. KomalS.Shinde,PrachiH.Bhagat “Industrial process monitoring using IoT” International conference on I-SMAC-2017.

2. Pavithra.D , Ranjith Balakrishnan “IoT based Monitoring and Control System for Home Automation” communication technologies (GCCT), 2015 IEEE.

3.Elizabeth Kadiyala,Shravya Meda, Revathi Basani, S.Muthulakshmi, “Global Industrial Process monitoring through Raspberrypi “,978-1-5090-5913-3, IEEE-2017
3. Raja Mukhopadhyay, I. Mukhopadhyay, “Home Automation and Grid Mapping Technology Using IoT”,2016I EEE 7th Annual Information Technology, Electronics and Mobile Communication Conference
(IEMCON), Year: 2016, Pages:1-5.

4. M.Barathi Kannamma, B.Chanthini, D.Manivannan, “Controlling andMonitoring Process in Industrial Automation using Zigbee”
,2013 International Conference on Advances in Computing, Communications and Informatics (ICACCI), Year: 2013,Pages: 806 –810.

5. John A. Stankovic, “Research Directions For The Internet of Things”, 2014 IEEE Journal of Internet of Things, ear: 2014, Volume: 1, No:
1,Pages: 3 – 9.