INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY

VOLUME 22 ISSUE 1 – April 2017 - ISSN: 2349 – 9303

Wireless Industrial Automation System Using

Python.
MANU PRASAD.M
(M.E-Communication Systems)
SriGuru Institute of Technology, Coimbatore

Abstract---The paper that shows with design and implementation of Industrial Alerting System and it is based on Raspberry PI
Processor using PYTHON Program. In this paper it implements how to monitor and control the industrial parameters. The system
consists of two modules they are coordinator module and sensor module. The coordinator module which is the centralized unit
that connected with monitoring of computer/mobile phone. It collects all the information from all sensor modules and it provides
that informations to the end user through TCP/IP network. The sensor module is raspberry pi for monitoring and controlling the
various parameters of an industrial plant. The communication between these two systems is done using wifi technology for
changing the preset values and controlling the industrial plant parameters from a remote location.

Keywords: Coordinator Module, Industrial Alerting System, Python, Raspberry Pi, Sensor Module, Wifi Technology.
electroplating was presented in [8]. Biomimetic robots
1.INTRODUCTION: generates the test biological hypotheses abouts the animal
Industrial Automation System that implements with function and their evolution; these are all flexible
whole industrial process is monitored and controlled by modelling methodology which uses the biological
wireless sytems, here it is fully done by an industrial robot mechanisms was represented in [9]. The reference [10]
using raspberry pi. The first industrial robot which was proposed a learning vibration control that allows the
introduced by the U.S in 1960s, then the technology was robots to learn the vibration characteristics for higher level
improved drastically created many applications of robots. accelerations and speeds, learning control also reduces the
The reference [1] implements a soft real-time vision cycle time of robotic motion which involves suppressing
system that enables an interactive robot which analyzes all the vibration of the robotic arm. The robotic system that
the faces of interaction partners not only to identify them allows all the users to instructs and programs the robot
but also to recognize all their respective facial expressions which has a higher level abstraction from the robotic
which as dialog-controlling non-verbal cue. The robotic language. It also offers a practical method to program the
controllers which can be generally integrated easily into robots by means of gestures and speech; it improves the
the manufacturing system environment and they are all consumption of time and working efficiency. It represents
capable of communicating with the other programmable an alternative typical robotic teaching process which
controllers which was represented in [2]. The extended the concepts of human-robotic interaction was
advancement in the robotics also makes the robots to presented in [11]. The industrial robotic controller has a
become more widely spread across various industries that good capability of their Input-Output communication and
ranging from manufacturing to healthcare was presented it shows like a cell controller that has a typical set-up of
in [3]. The assertion of case studies and the explanation of flexible manufacturing cell or system was represented in
how the arc-flash hazards were to be identified and [12].
measured in various industrial processing facilities were
represented in [4]. The programming robotical behaviors I. MATHEMATICAL BACKGROUND:
are in Pyro, which is mainly useful to programming in a In this Wireless Industrial Alerting System the only
high-level general purpose languages; Pyro means Python mathematical equation used here to find the obstacles in
Robotics. Pyro provides the abstractions for low-level the path by the ultrasonic sensor, it shows below.
robotic specification features which are same to the
abstactions provided in high-level programming Test distance = (High Level Time X Velocity of
languages were presented in [5]. The reference [6] Sound (340M/S)) / 2.
proposed a self-making fuzzy proportional derivative
controling method which exploits the simplicity and Using above fornula we can detect the obstacles present
from short distance to very long distance. The sensor is
toughness of the plain PD control which enhances the gain
high sensitive to detect obstacles in the path.The digital
and was offered for robotic manipulators. Robots can
make changes to a very high level of economics of the ultrasonic sensor detects the obstacles in any distance
because of the medium is ultrasonic wave. Distance
commercial utilization of space which was represented in
measurement can be done through a formula which is
[7]. The expected uses of robotics with the vision and
improved feedback control which includes assembly, shown below
inspection, heat treatment, grinding, buffing and

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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY
VOLUME 22 ISSUE 1 – April 2017 - ISSN: 2349 – 9303
Distance Measurement Formula is expressed as Circuit, Cooling Fan, Buzzer, DC Motors, Wifi Dongle
L = C X T, where L is the measured distance, C is the and Mobile Phone/Personal Computer.
ultrasonic spreading velocity in air also T represents
time (T is half the time value from transmitting to II. MORPHOLOGICAL OPERATIONS:
receiving).
The morphological operation consists of Circuit
As ultrasonic spread velocity is 340m/s in the air based on Diagram, Project Operation, Prototype Diagram and
timer record t, so calculate the distance (s) between the Comparison between existing system and proposed
obstacle and transmitter s = 340t/2 which is called time system are shown below.
difference distance measurement principle. The distance of the
obstacles of the industrial path is sensed by the sensor in any CIRCUIT DIAGRAM
range with a precised manner.

2.PROPOSED METHODOLOGY:
The proposed methodology consists with Block
diagram of Wireless Industrial Alerting System with
Transmitter Section, Receiver Section and discription of
all main blocks related to it.

Transmitter Section:

Figure 2: Circuit Diagram of Industrial Alerting System.

Camera Ultrasonic
Sensor The circuit diagram of industrial alerting system
is shown above, the diagram which is drawn through
Power QCAD software. This is available for Linux, UNIX,
Apple and Microsoft Windows. It is a free computer-aided
Supply Relay design (CAD) software application for Two-Dimensional
Circuit design and drafting. The QCAD GUI is based on the Qt
Temper framework and which is released under the GNU General
Public License Precompiled packages will available for all
ature Cooling 32-bit and 64-bit GNU/Linux platforms, MS Windows OS
Sensor Raspberry
fan and OS X. This QCAD is developed by RibbonSoft.
pi
Gas PROJECT OPERATION:
Buzzer
Sensor The main operation of Wireless Industrial Alerting
System is to Monitor and Control the Industrial
WIFI Parameters without any human interface in efficient
Motor1 Motor 2
Dongle manner.The main operation of the industrial alerting
system is to monitor and control the machine temperature,
room temperature in the industry. It also monitors and
controlls the unwanted gas that comes out from the
Wifi machines in the industry and through the harmful gas
Dongle from the chimmanies of the industries. The automatic
movement as well as the obstacle detection is also done by
the robot while it travels along the path of the industry.
Receiver Section:
The temperature sensor monitors the temperature level
increases above the threshold value then the controller
Personal computer alarms the survivors through the buzzer and the cooling
Ethernet (or) Mobile Phone fan is on. Gas Sensor monitors the gas level increases
above the threshold value then the controller alarms the
survivors through the buzzer. Ultrasonic Sensor is used to
Figure 1: Block Diagram for Proposed Methodology detects the obstacles in the path and the robot can also
Figure 1 illustrates the block diagram of proposed deviates from the obstracles while travels along the path.
methodology. It consists of many blocks they are We can see the system working in the industry on our
mobile phones/personalcomputers through live streaming
Raspberry Pi, Power Supply, Temperature Sensor,
camera placed in the system, movement of the system can
Ultrasonic Sensor, Gas Sensor, USB Camera, Relay be controlled through phone or pc through wifi

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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY
VOLUME 22 ISSUE 1 – April 2017 - ISSN: 2349 – 9303
technology. The directions of the system can be III. EXPERIMENTAL RESULTS:
controlled through arrow keys of our mobile phone or The experimental result includes the resulatant
through our personal computer using wifi technology. The experimental table consists with all the sensor values to
usb camera of sytem having lights in the four edges to output voltage.
improve the night vision in the system while travelling
through the industrial path. The system is fully controlled RESULTANT EXPERIMENTAL TABLE
by RASPBERRY PI processor that is programmed with
PYTHON. Temperature Gas Ultrasonic Output
Sensor Sensor Sensor Voltage
PROTOTYPE DIAGRAM

0 – 350Cs 0 (Not 0–50 CMs 0 V DC

Present)

35 – 1250 Cs 1 50-100 3-5 V DC

(Present) CMs

Figure 5: Tabular Column Showing Comparison of All Sensor

Values to the Output Current.
Figure 3: Prototype Diagram of Industrial Alerting System.
TEMPERATURE SENSOR
3.COMPARISON BETWEEN EXISTING SYSTEM When the machine temperature and room temperature
AND PROPOSED SYSTEM goes beyond 350C at any condition the temperature sensor
Resultant Comparison Table: detects this condition and according to this fan starts to
rotates and controls the temperature in the industry, Below
sl.no Specification Existing Proposed 350C temperature in machine or room it also detects by
System System the sensor but the sensor remains off because it is
programmed like that. When the machine temperature,
1 Response Time >8 Minutes 53 Seconds
room temperature reaches upto 35 0C also the sensor
2 Operating 24 VDC 5V to 12V detects this condition according to that the fan starts to
Voltage rotate.
3 Total Current Max 0.5A Max 0.3A
Consumption @ 24VDC @ 12VDC
4 Operating 0oC to 00C to VOLTAGE
Temperature 60oC 150oC 4
5 Control System IndustrialP IndustrialP
C with C with
High High Speed 2
Speed
6 Operating C++ and C++,
Program Aurdino Linux,Java, 0 Temperature
Only Python 0 20 40 60 in Deg CS
Figure 4: Tabular Column Showing Comparison of Existing
System and Proposed System.
Figure 6: Temperature Sensor Graph Values for Industrial
Alerting System.
The comparison between existing system and proposed
system with their technical specifications includes in the
The graph shows the temperature sensor values, The X-
tabular column that is shown below. Technical
AXIS shows the OUTPUT VOLTAGE used by the sensor
specifications include with Response Time, Operating and the Y-AXIS shows TEMPERATURE in DEGREE
Voltage, Total Current Consumption, Operating
CELSIUS by the sensor.
Temperature, Control System and Operating Program is
shown in resultant comparison table.
GAS SENSOR
The gas sensor detects the gases like Isobutane, Propane,
Carbon Dioxide and LPG. When the gas is available in the
industry it gives the value 1 in the gas sensor that means

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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY
VOLUME 22 ISSUE 1 – April 2017 - ISSN: 2349 – 9303
the gas value compares with the comparator circuit in the
sensor and this condition senses by the sensor and it gives
buzzer sound indication and fan starts to rotate till the
VOLTAGE
gases removes from the industry. When the gas is not 4
available in the industry so the value is 0 and this 3
condition also senses by the gas sensor it is off state, so
the buzzer will not give beeps indication and fan will not 2
rotate. All these condition compared by the comparator 1
circuit in the gas sensor and gives the indication by the
0 Distance in CM
sensor.
0 100 200
The graph shows the gas sensor value detection, The X-
AXISshows the OUTPUT VOLTAGE used by the sensor
and the Y-AXIS shows the GAS LEVEL present in the Figure 7: UltraSonic Sensor Graph Values for
sensor. If gas is present it shows 1 i.e. 5voltage and no gas Industrial Alerting System.
is present means 0 i.e. no voltage is present.
4.CONCLUSION:
We presented this paper has introduced the concept of a
VOLTAGE
6
system in which industrial robots were applied to monitor
and control the various industrial parameters like Machine
Temperature , Room Temperature, Hazardous gas
4 removal, Obstacle Detection and Automatic Movement of
robot. The sensor module is Raspberry Pi processor used
2 for controlling the full function of robot in very much
precised manner and the coordinator module is the
0 centralized unit, which collects all the information from
Gas Level in Density all sensor modules and which is connected with
0 0.5 1 1.5 monitoring computer. Communication between the
systems is done by wifi technology and controlling the
Figure 6: Gas Sensor Graph Values for Industrial Alerting industrial plant parameters from a remote location. All
System. these things by using advanced sensing technology,
control technology and mechanics technology with
ULTRASONIC SENSOR industrial robots.
The ultrasonic sensor is used to detect the obstacles while
traveling through the path; the ultrasonic sensor detects REFERENCES
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 INTERNATIONAL JOURNAL FOR TRENDS IN ENGINEERING & TECHNOLOGY
VOLUME 22 ISSUE 1 – April 2017 - ISSN: 2349 – 9303
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AUTHOR PROFILE:

MANUPRASAD.M (M.E-Communication Systems ) is

currently pursuing Master Degree in Communication
Systems from Anna University, Chennai. He received
Bachelor Degree in Electronics and Communication
Engineering from Anna University, Chennai. Ph No:
+919562505758, E-Mail id: [email protected]

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