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Implementation of an industrial automation system model using an Arduino

Article  in  Journal of Engineering Science and Technology · December 2018

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Journal of Engineering Science and Technology
Vol. 13, No. 12 (2018) 4131 - 4144
© School of Engineering, Taylor’s University

IMPLEMENTATION OF AN INDUSTRIAL
AUTOMATION SYSTEM MODEL USING AN ARDUINO

ARSHEEN MIR1,*, R. SWARNALATHA2

1Electronics and Instrumentation Engineering, Birla Institute of Technology and Science,
Pilani Dubai Campus, Academic City, Dubai, United Arab Emirates
2Electrical and Electronics Department, Birla Institute of Technology and Science,

Pilani, Dubai Campus, Academic City, Dubai, United Arab Emirates

*Corresponding Author: [email protected]

Abstract
This paper discusses a model of an industrial system on a small scale, which
performs sequential operations using relays. The system shuts down
automatically once it detects high water or temperature levels, which are
hazardous for industrial operation. This model is implemented using an
Arduino microcontroller as it proves to be the most viable alternative. Being
an open source platform with the minimal cost it helps prototype the system
with ease. Its compatibility with sensors helps provide the required feedback
and the Arduino controls the system by taking corrective measures. The status
of the system is depicted using devices like the Liquid Crystal Display (LCD),
buzzer, etc. The sensor data is derived and stored in a Data Acquisition System
(DAS), this data can then be used for control and monitoring purposes. Thus,
the designed system helps replicate an industrial application and reduce the
cost of setting up and maintaining an actual Distributed Control System (DCS),
Programmable Logic Controller (PLC) or Supervisory Control and Data
Acquisition (SCADA) in viable industrial environments. It also provides
flexibility, with rapid prototyping and ease in error rectification. However, the
additional hardware, certifications and technical support required to implement
the design in an industrial environment when compared to a conventional
industrial system can prove to be a drawback.
Keywords: Arduino, Data acquisition, Industrial automation, Temperature sensor,
Water sensor.

4131
4132 A. Mir and R. Swarnalatha

1. Introduction
With the recent developments in technology, all processes are being automated.
Apart from industrial automation, automation is prevalent in the domestic domain
making homes more smart and secure. It has also helped reduce human effort
enabling the control of devices/appliances with great ease while being energy
efficient [1]. Various home automation models have been implemented
incorporating Android platforms [1], Global System for Mobile communications
(GSM) modules [2], Wi-Fi-based systems [3], etc., into the fundamental
microprocessor, sensor and actuator network [4, 5]. The wide application of
microprocessors is not confined to domestic/home automation applications but can
also be further extended into the industrial environment.
In the industrial domain, a fundamental automation system model is a basic
control system, which includes an input/sensor, a controller and an output/actuator.
This model can help implement any industrial application with appropriate hardware
and software selection. The application discussed in this paper is level and
temperature control during a continuous sequential switching operation.
A repetitive sequential switching operation replicates a traditional production
line. Sequential operations are widely used in industries for packaging, production
and similar activities. A simple example of such an operation would be the
production of a batch of screws in a factory. The sequence of the process flow for
the mentioned activity would be cutting, heading, lathing, threading, heat treatment,
electroplating, and packaging. This repetitive sequential nature of activities is
widely observed in all industries and can be easily replicated on a small scale for
small factories.
Level determination and monitoring systems are used in wastewater treatment
plants, oil and gas industries, chemical and food processing industries, etc., for
several applications including liquid storage, monitoring and control. These
systems use sensors based on different working principles namely magnetic,
ultrasonic, and Radiofrequency technology. The controllers used are mostly PLC’s
or conventional Proportional-Integral (PI)/Proportional-Integral-Derivative (PID)
controllers, which communicate between the sensor and the output device (usually
a pump) to assist the inflow or outflow of fluid as required.
Temperature control and monitoring systems find its application in a wide range
of process control industries. The input is derived from contact temperature sensors
like thermistors, thermocouples or resistance temperature detectors or non-contact
sensors based on infrared or similar technologies. These devices provide the
required input to the system and trigger output as determined by the controller.
Depending on the entire system either conventional controllers like the PI/PID
controller or an ON/OFF controller is used. The latter is used if the temperature is
not a very critical parameter in the system.
As evident, industrial processes are mostly based on PLC, DCS or SCADA
systems. These systems prove to be complex for small-scale industries and also
expensive because of their high initial cost of setup. As commented by Darandale
and Gunjal [6] and Sobota et al. [7], Arduino being an open source hardware
platform enables us to replicate any industrial process and experiment with it on a
small scale at a very minimal cost, with a workflow like industrial controllers.
Using PLC’s and conventional systems requires a lot of wiring and technical

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 Implementation of an Industrial Automation System Model using . . . . 4133

expertise, thus, an Arduino helps reduce assembly, manufacturing and maintenance

cost in such scenarios. With all these facts stated, an Arduino cannot completely
replace the existing systems but can be a viable option for small-scale industries
and initial startups as it helps rapidly prototype, code and interface different types
of sensors, devices and modules and is also widely available.
Microprocessors like the ATmega 328P (present on the Arduino), can make a
number of logical control decisions by mere programming in C/C++ languages.
Arduino UNO is compatible with a number of software’s like Matrix Laboratory
(MATLAB), Parallax Data Acquisition (PLX-DAQ) tool apart from its main
software, which is the Arduino IDE. The applications of this board can be extended
even further by using compatible shields and external modules like GSM, Bluetooth,
etc. [2]. With its affordable price, it thus, becomes a feasible option for a wide range
of applications like Access Control, Data Logging and Automation [6].

2. Method and Implementation

2.1. Overview and basic block diagram
The designed system model as discussed in the introduction can be seen in Fig. 1.
Arduino UNO acts as the controller; it receives inputs from the water level sensor
and temperature sensor continuously. These monitored input variables determine if
the system should run smoothly or be stopped. The output of the system is depicted
by relays, their continuous sequential working indicating a smooth operation and
the additional relay indicating an alert.
A relay is used to power many high voltage devices, like lamp loads, motors and
pumps. In this design, regular Light Emitting Diode (LED)’s is used to demonstrate
the logical functioning of the relay, which is a real-time system can be replaced by
other actuators as required. The relay activates the loads (LED’s) in the following
sequence: relay 1- relay 2- relay 3 - relay 4 - relay 1 on a loop. Thus, the relay is an
actuator in the model, which helps produce the required output.
As discussed, the repetitive sequence of operation continues until the system
encounters any disruption in the form of increased water level in the tank or
temperature within the plant, by the sensors. These sensors are thus, the inputs
required by the system to take corresponding actions.
Once the system stops due the above-mentioned disturbances, the switching on
of the relay 5 signifies the operation of a pump to take charge of the exceeding
water level. An external power supply and a regulator is required to meet the high-
power needs of a large number of components in the circuit as shown in Fig. 1. The
status of the system is displayed continuously with the help of the LCD module.
Apart from the process above, there is continuous logging of data from the sensors
to a Data Acquisition System, which is the PLX-DAQ.

2.2. Hardware Implementation

Various blocks of the system as seen in Fig. 1 were implemented in hardware in
Fig. 2, following the circuitry in Fig. 3. The various components that make this
circuit include (1) Water and temperature sensor, (2) Arduino UNO board, (3)
Relay Module, (4) External power supply & Voltage Regulation block, (5) LCD,

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4134 A. Mir and R. Swarnalatha

Buzzers and LED’s (Loads), (6) Real Time Clock (RTC) Module and (7) PLX-
DAQ. The details of each are listed below.

Fig. 1. Basic block diagram of the system.

Fig. 2. Hardware Implementation.

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 Implementation of an Industrial Automation System Model using . . . . 4135

Fig. 3. Proposed circuit.

2.2.1. Water and temperature sensor
A Keyes Water Level Sensor as seen in Fig. 4 is used for Level Monitoring. It
comprises 3 pins, for analogue output, supply and ground. It measures the size of
the water droplets through the lines with the help of the parallel wires exposed and
determines the water level. For monitoring temperature, an LM35 temperature
sensor is used. As seen in Fig. 4 it consists of 3 pins, 2 for input voltage and ground
and the central for analogue output [4, 8]. It is used for temperature monitoring [4]
and measurement applications like Vehicle Traffic Congestion Control [9],
Automated Irrigation system [10], Automatic chicken feeder [11], greenhouse
control system [12] and fire alarm system [13]. The output voltage produced by this
sensor varies linearly with temperature in the range of -55 to 150 degree Celsius.

Fig. 4. Keyes water sensor and LM35 temperature sensor.

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4136 A. Mir and R. Swarnalatha

2.2.2. Arduino UNO

Arduino UNO board comprises of the ATmega 328P microcontroller and supports
digital/analogue inputs and outputs as shown in Fig. 5. According to Priya et al. [14],
it consists of 14 digital I/O pins, out of which, 6 can be used as Pulse Width
Modulation (PWM), 6 analogue pins, a reset button, in-circuit serial programming
(ICSP) header and a power jack. When connected through the USB port it
communicates through Serial and loads the program into the microcontroller. As
explained by Darandale and Gunjal [6], in addition to this, it has an inbuilt voltage
regulation circuitry, which makes it ideal for use in such applications.

Fig. 5. Arduino UNO.

2.2.3. Relay module
Based on a study by Mashilkar et al. [15], the relay is an electrically operated
switch. It uses an electromagnet to mechanically operate a switch using a low power
signal. Relay board with 4 relays has been used for carrying out the repetitive
sequential action and an additional relay to drive the pump in case the water level
exceeds as in Fig. 6.

Fig. 6. Relay module and an additional relay.

2.2.4. External power supply and voltage regulation block
Since a large number of components are connected to the Arduino board and they
derive a lot of power, an additional battery is needed to drive the components. This
voltage must be regulated to 5V for smooth operation and thus, a voltage regulator
IC LM7805 is used in addition to a few capacitors to get the required voltage. The
circuit diagram can be seen in Fig. 7 [16].

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 Implementation of an Industrial Automation System Model using . . . . 4137

Fig. 7. Voltage regulation circuit (hardware and circuit).

2.2.5. LCD, buzzers and LED’s

A 16X2 Liquid Crystal Display always provides the status of the operation [15].
The LCD works on 5V and 1mA current and requires a total of 11 connections
comprising of 8 data and 3 control pins [10]. In addition to the LCD, a buzzer rings
in case the water level or temperature exceeds the operating range. LED’s are used
to indicate the relay switching on/off as shown in Figs. 8 and 9.

Fig. 8. Liquid crystal display.

(a) Process start status. (b) Process in operation.

(c) Process disturbance alert.

Fig. 9. LCD statuses.

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4138 A. Mir and R. Swarnalatha

2.2.6. RTC clock module

The DS1302 in the RTC clock module functions as a real-time clock and calendar
as shown in Fig. 10. It has 31 bytes of Static Random-Access Memory (SRAM)
and communicates with the processor using serial communication. According to
Zeebaree and Yasin [2], it makes automatic adjustments based on the number of
months and also handles leap years. In this design, it helps to keep an accurate
record of data for the PLX-DAQ.

Fig. 10. RTC clock module.

2.2.7. PLX-DAQ
The PLX-DAQ or the Parallax Data Acquisition System is an add-on to excel,
which helps us acquire data from any microcontroller from up to 26 channels. It
puts the incoming data into separate columns. This available data can be used for
analysis, monitoring and control [17] as in Fig 11.

Fig. 11. PLX-DAQ.

2.3. Software implementation

Arduino IDE 1.0 and PLX-DAQ were the two major software’s used for the
implementation of this design. Apart from this, 2 libraries for the LCD and clock
module were incorporated into Arduino IDE. These are the ‘LiquidCrystal.h’ and
‘DS1302.h’ for the LCD and the RTC module respectively. The logic can be seen
in Fig. 12 in the form of a flowchart.

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 Implementation of an Industrial Automation System Model using . . . . 4139

As depicted in this chart, the relay sequence continues unless and until it
experiences a disturbance in the form of a water level or temperature hike. The
Arduino code is composed of 2 modules, namely setup and loop [6]. The setup
function initializes input/output pins, variables and serial ports for serial
communication. The loop function performs the repetitive action of monitoring the
water level and temperature, controlling the relay sequence accordingly and
recording the readings in the PLX-DAQ system. An additional set of code is
required to initialize the date and time on the RTC module, which can be then be
commented after its first use. The Arduino IDE interface can be seen in Fig. 13.

Program code
The code is composed of 2 modules, namely setup and loop [6]. The setup function
initializes input/output pins, variables and serial ports for serial communication.
The loop function performs the repetitive action of monitoring the water level and
temperature, controlling the relay sequence accordingly and recording the readings
in the PLX-DAQ system. An additional set of code is required to initialize the date
and time on the RTC module, which can be then be commented after its first use.
The code is outlined in Appendix A.

Fig. 12. Program logic.

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4140 A. Mir and R. Swarnalatha

Fig. 13. Arduino IDE interface.

3. Results and Discussions

As witnessed, the designed hardware helps replicate a sequential logical operation
on a small scale using a micro-controller based system. This design can be
implemented in an industrial environment, with appropriate measures taken.
Continuous monitoring of data is done through the LCD display as seen in section
2.2.7. With PLX-DAQ this data is compiled for analysis and record purposes.
Experimental data from PLX-DAQ is shown in Table 1 and Fig. 14.
Based on an analysis by Reneker [18] with the current designed system on
implementation of flow control using an Arduino and PLC independently, the
results can be summarised as follows:
 Conventional controllers prove to be expensive for small industries due to the
high initial cost of setup compared to a basic microcontroller system. An
Arduino thus, with its minimal cost proves to be a feasible option
 Arduino being an open source platform, can perform any control function and
replicate any industrial process by mere C/C++ programming language
eliminating the need of wiring and technical expertise.
 In addition to the initial setup cost, the added cost of assembly, manufacturing
and maintenance activities is also minimised.
 The use of Arduino can be extended further, by incorporating compatible
shields, external modules, sensors and actuators like Humidity sensor,
Bluetooth module, motors, etc.
 The Arduino platform is also compatible with many software’s like MATLAB,
PLX-DAQ, etc., through the Arduino IDE further increasing its applications.
 An Arduino provides flexibility, helps rapidly prototype and rectify errors
with ease.
Despite the above-mentioned advantages, the existing industrial systems like
DCS, SCADA, etc., are still irreplaceable in a number of domains. Where an
Arduino can perform similar functions, its use is still limited to certain
applications and industrial environments due to industry standard and
certification requirements. In rugged environment conditions like high
temperatures, the use of an external protection shield becomes essential. Since

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 Implementation of an Industrial Automation System Model using . . . . 4141

PLC’s and conventional industrial systems are built for the purpose, they have
built-in protocols and provide extensive resources to aid set-up and operation. An
Arduino in comparison would require additional hardware, programming skills
and technical support.

Table 1. Data from PLX-DAQ.

Current Time Water
Date Day Temperature
time (in operation) level
12/4/2018 Monday 18:48:51 25 28.75 100
12/4/2018 Monday 18:49:11 45 28.27 115
12/4/2018 Monday 18:49:31 65 28.88 117
12/4/2018 Monday 18:49:51 85 28.51 118
12/4/2018 Monday 18:50:11 105 27.41 118
12/4/2018 Monday 18:50:31 135 26.31 121
12/4/2018 Monday 18:50:51 155 26.56 124
12/4/2018 Monday 18:51:11 175 26.43 124

Fig. 14. Temperature and water level profile.

4. Conclusion
In this paper, a simple industrial system was implemented on a small scale. This
design can be modified as per needs and utilized in many small applications. It
depicts how simple control functions can be carried out using just a microcontroller
and a few sensors and actuators. This design could perform repetitive sequential
actions with great ease and could also take corrective actions in case of water level
or temperature disturbances. The LCD, Buzzer depicts the status of the process and
the PLX-DAQ helps with data logging.

Acknowledgement
The authors would sincerely like to thank Prof. R. N. Saha, Director, BITS Pilani,
Dubai Campus for his constant encouragement and support.

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4142 A. Mir and R. Swarnalatha

Abbreviations
DAS Data Acquisition System
DCS Distributed Control System
GSM Global System for Mobile Communications
ICSP In Circuit Serial Programming
LCD Liquid Crystal Display
LED Light Emitting Diode
MATLAB Matrix Laboratory
PI Proportional-Integral
PID Proportional-Integral-Derivative
PLC Programmable Logic Controller
PLX-DAQ Parallax Data Acquisition Tool
PWM Pulse Width Modulation
RTC Real Time Clock
SCADA Supervisory Control and Data Acquisition
SRAM Static Random-Access Memory

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Appendix A

Program Code
//Initilaising header files and variables required.
#include <LiquidCrystal.h>
#include <DS1302.h>
LiquidCrystal lcd(A5, A4, 8, 9, 10, 11); DS1302 rtc(A3, 3, 6);
#define RELAY1 4
#define RELAY2 7
#define RELAY3 12
#define RELAY4 13
#define RELAY5 5
int level = A0; int buzzer = 2; int tempPin = A1; int t=0;
int val; float temp; float voltage;
void setup()
{ //Initilaising input and output pins.
pinMode(level, INPUT);
pinMode(RELAY1, OUTPUT); pinMode(RELAY2, OUTPUT);
pinMode(RELAY3, OUTPUT); pinMode(RELAY4, OUTPUT);
pinMode(RELAY5, OUTPUT);
digitalWrite(RELAY5,LOW); digitalWrite(RELAY1,LOW);
digitalWrite(RELAY2,LOW); digitalWrite(RELAY3,LOW);
digitalWrite(RELAY4,LOW);
//Initialising the LCD
lcd.clear(); lcd.begin(16, 2); lcd.setCursor(0, 0);
lcd.print(" Setup running! "); delay(5000);
//Setting up the DAS - PLX-DAQ
Serial.begin(128000); Serial.println("CLEARDATA"); Serial.println("CLEARLABEL");

Serial.println("LABEL,Date,Day,Current Time,Time(in operation)(s),Temperature,Water Level");

//Setting up the RTC-clock module
rtc.halt(false); rtc.writeProtect(false);}
void loop()
{ int w=0; int flag1=1;
w = analogRead(level); //Taking input from the water sensor
//Taking input from the temperature sensor
val = analogRead(tempPin);
voltage = 5 * val / 4095.0; temp = (0.5-voltage) * 100;
if(w>250) //Checking the water level
{ flag1=0;
lcd.clear(); lcd.setCursor(0, 0); lcd.print("Water ALERT!!!");
lcd.setCursor(0, 1); lcd.print(flag1);
digitalWrite(RELAY5,HIGH);
tone(buzzer, 1000); //Buzzer Alert
delay(1000); noTone(buzzer); delay(2000); }
else if(temp>35) //Checking the temperature
{ flag1=0; lcd.clear(); lcd.setCursor(0, 0); lcd.print("Temperature ALERT");
lcd.setCursor(0, 1); lcd.print(flag1);
tone(buzzer, 1000); //Buzzer Alert
delay(1000); noTone(buzzer);
delay(2000); }
else
{ //Operation in normal operating conditions
lcd.clear(); lcd.setCursor(0, 0); lcd.print("Plant Operating!");
lcd.setCursor(0, 1); lcd.print(flag1);
//RELAY sequence
digitalWrite(RELAY1,HIGH); delay(5000);
digitalWrite(RELAY1,LOW);
digitalWrite(RELAY2,HIGH); delay(5000);
digitalWrite(RELAY2,LOW);
digitalWrite(RELAY3,HIGH); delay(5000);
digitalWrite(RELAY3,LOW);
digitalWrite(RELAY4,HIGH); delay(5000);
digitalWrite(RELAY4,LOW); }
long int milli_time = millis(); //Calculating the time since the start of operation
t=milli_time/1000;
//The following code is used to initialise the RTC module
//Commented once used
/*Serial.println(rtc.getTimeStr()); Serial.println(rtc.getDOWStr());
Serial.println(rtc.getDateStr());
Serial.println("LABEL,Date,Day,Current Time,Time(in operation),Temperature,Water Level"); */
//Printing into the Data Aquistion System
Serial.print("DATA,DATE,"); Serial.print(rtc.getDOWStr());
Serial.print(","); Serial.print(rtc.getTimeStr());
Serial.print(","); Serial.print(t);
Serial.print(","); Serial.print(temp);
Serial.print(","); Serial.print(w);
Serial.println(); }

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