VISVESVARAYA TECHNOLOGICAL UNIVERSITY

“Jnana Sangama” Belagavi -590018, Karnataka.

MINI PROJECT WORK REPORT

ON
INDUSTRIAL AUTOMATION SYSTEM USING IOT
Submitted in the partial fulfillment of the requirement for the award of degree

BACHELOR OF ENGINEERING
IN
ELECTRONICS AND COMMUNICATION ENGINEERING

Submitted by:
GANESH K (1EW22EC404)
HASAN LUTHFI (1EW22EC406)
MANOJ K (1EW22EC413)
YASHUNANDAN R (1EW22EC429)

UNDER THE GUIDANCE

OF
Dr Kavitha R J
Assoc. Professor
Dept. of ECE, EWIT

EAST WEST INSTITUTE OF TECHNOLOGY

DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING BENGALURU-560091

2023-2024
 EAST WEST INSTIUTE OF TECHNOLOGY
No.63, Off Magadi Road, Vishwaneedam Post, Bangaluru-560091
Department of Electronics and Communication Engineering

CERTIFICATE

This is to certify that the mini project work report entitled “Industrial Automation System Using
IOT” is a bonafide work carried out by GANESH K (1EW22EC404), HASAN LUTHFI
(1EW22EC406), MANOJ K (1EW22EC413), YASHUNANDAN R (1EW22EC413) in partial
fulfillment for the award of degree of Bachelor of Engineering in Electronics and Communication
of Visvesvaraya Technological University, Belagavi during the year 2023-2024. This project work
report has been approved as it satisfies the academic requirement in respect of project work
prescribed for Bachelor of Engineering Degree.

…………………….................. ………………………………………… ……………………………………………………

Signature of Guide Signature of HOD Signature of Principal
Dr. Kavitha R J Dr. S G Hiremath Dr.K Channakeshavalu
Assoc. Professor. H.O.D., Dept of ECE Principal,
Dept of ECE, EWIT, Bengaluru EWIT, Bengaluru
EWIT, Bengaluru

External Viva

Name of the Examiners Signature with Date

1.

2.
 ACKNOWLEDGEMENT

Any achievement, be it scholastic or otherwise does not depend solely on the individual efforts
but on the guidance, encouragement and cooperation of intellectuals, elders and friends. A
number of personalities, in their own capacities have helped us in carrying out this project work.
We would like to take this opportunity to thank them all.

With proud gratitude we thank God almighty for all the blessings showered on us and for being
able to complete the project work successfully.

First and foremost, we would like to thank Dr. K Channakeshavalu, Principal, EWIT,
Bengaluru, for his moral support towards completing our project work.

We would like to thank, Dr. S G Hiremath, Professor and Head of Department of ECE, EWIT,
Bengaluru, for his valuable suggestions and expert advice.

We deeply express our sincere gratitude to our guide Dr. Kavitha R J, Assoc. Professor,
Department of ECE, EWIT, Bengaluru for her valuable guidance throughout the project work
and guiding us to organize the report in a systematic manner.

We extend our thanks to the Mini Project coordinators Mr. Kotresh H M, Associate Professor,
Mrs. Manasa S, Assistant Professor, for their constant support, guidance and encouragement
for project work.

We thank our Parents, and all the faculty members of Department of Electronics and
Communication Engineering for their constant support and encouragement.

Last, but not the least, we would like to thank our peers and friends who provided us with
valuable support and suggestions.

GANESH K (1EW22EC404)

HASAN LUTHFI (1EW22EC406)

MANOJ K (1EW22EC413)

YASHUNANDAN R (1EW22EC429)

i
 DECLARATION

We GANESH K (1EW22EC404), HASAN LUTHFI (1EW22EC406), MANOJ K (1EW22EC413)

and YASHUNANDAN R (1EC22EC429), students of 6th semester Bachelor of Engineering in the
Department of Electronics & Communication Engineering of East West Institute of Technology,
Bengalore-560091, hereby declare that the project entitled “INDUSTRIAL AUTOMATION
SYSTEM USING IOT” has been carried out by us under the supervision of Internal Guide
Dr. Kavitha R J, Assoc. Professor, Department of Electronics & Communication Engineering, EWIT,
Bangalore submitted in the fulfillment of the course requirement for the award of the degree of Bachelor
of Engineering in Electronics & Communication Engineering of Visvesvaraya Technological
University during the academic year 2023-2024.

PLACE: BANGALORE

DATE:

NAME USN SIGNATURE

GANESH K 1EW22EC404
HASAN LUTHFI 1EW22EC406
MANOJ K 1EW22EC413
YASHUNANDAN R 1EW22EC429

ii
 ABSTRACT
This research presents a holistic approach to industrial monitoring and control through the
integration of Arduino-based microcontrollers, an array of environmental sensors, and advanced
communication technologies. The system is designed to provide real-time data on crucial
parameters such as temperature, humidity, fire, gas, and smoke, ensuring a safe and efficient
industrial environment. Moreover, the inclusion of infrared (IR) sensors enhances security through
person detection, while actuators like a DC Motor for door control, relays for a water pump and
DC fan, and a buzzer ensure responsive control mechanisms. To enhance the monitoring
capabilities, the system incorporates an ESP32-CAM module for live streaming. This camera
technology enables remote visual inspection of industrial processes, adding a layer of real-time
situational awareness to the overall system. The live streaming capability facilitates prompt
decision-making and intervention, particularly in critical situations. The communication aspect
of the system is fortified with the integration of a NodeMCU, allowing for seamless message
notifications via IoT protocols. This ensures that stakeholders are promptly informed of any
anomalies or emergencies. The system's user interface is enriched with an LCD display, providing
on-site personnel with immediate access to environmental conditions and live-streamed footage.
The proposed Industrial Monitoring and Control System not only emphasizes safety and efficiency
but also introduces an innovative live streaming component to enhance real-time monitoring
capabilities. This integration opens up avenues for remote inspection, troubleshooting, and
decision-making, fostering a more resilient and responsive industrial ecosystem. The utilization
of widely available and cost-effective technologies, such as Arduino and IoT modules, ensures the
scalability and applicability of this system across various industrial settings, contributing to
improved operational reliability and workplace safety.

iii
 TABLE OF CONTENTS

TITLE PAGE NO

ACKNOWLEDGEMENT i

DECLARATION ii
iii
ABSTRACT
iv-v
TABLE OF CONTENT

LIST OF FIGURES vi

CHAPTER 1: INTRODUCTION 1-3

1.1 PROBLEM STATEMENT 2

1.2 OBJECTIVES 2

1.3 MOTIVATION 3

CHAPTER-2: LITERATURE SURVEY 4-9

CHAPTER-3: METHODOLOGY 10-11

3.1 BLOCK DIAGRAM 12

CHAPTER-4: COMPONENTS REQUIREMENT 13-21

4.1 HARDWARE COMPONENTS REQUIREMENT 13-20

4.1.1 ARDUINO UNO 13-14

4.1.2 LCD DISPLAY 15

 4.1.3 HUMIDITY SENSOR 16

4.1.4 MQ-6 SENSOR 17

4.1.5 REGULATED POWER SUPPLY 18

4.1.6 SERVO MOTOR 19

4.1.7 FIRE SENSOR 20

4.2 SOFTWARE COMPONENTS REQUIREMENT 21

4.2.1 ARDUINO IDE 21

4.2.2 EMBEDDED C 21

4.2.3 TELEGRAM BOTS 21

CHAPTER-5: ADVANTAGES AND APPLICATIONS 22

5.1 ADVANTAGES 22

22
5.2 APPLICATIONS

CHAPTER-6: RESULT 23-24

CHAPTER-7: CONCLUSION AND FUTURESCOPE 25

7.1 CONCLUSION 25
7.2 FUTURE SCOPE 25
REFERENCES 26

v
 LISTS OF FIGURES

Title Page no
3.1 BLOCK DIAGRAM 12

4.1.1 ARDUINO UNO & TABLE 13

4.1.2 ARDUINO PIN CONFIGERATION 14

4.1.3 LCD DISPLAY 15
4.1.4 HUMIDITY SENSOR 16

4.1.5 MQ-6 SENSOR & TABLE 17

4.1.6 REGULATED POWER SUPPLY 18
4.1.7 SERVO MOTOR 19

4.1.8 FIRE SENSOR 20

4.2.3 TELEGRAM BOTFATHER 21
6.1 INDUSTRIAL AUTOMATION SYSTEM 23
6.3 ALERT MESSAGES TO USER MOBILE 24

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Industrial Automation System Using IoT 2023-24

CHAPTER 1
INTRODUCTION

IoT has the potential to change the world, it can create information about the connected
objects, analyze it, and make decisions; in other words, one can tell that the Internet of Things
is smarter than the Internet. It is also used widely in the industrial sector. In the industrial
sector, safety and security are given more importance, so to prevent accidental explosions due
to leakage of various gases we are developing an industrial monitoring system using IoT. It
will act as a security system also. The way this system works is that there will be an alarm
when there's a gas leak with also displaying the gas level concentration and at which it will be
in danger. Meanwhile, it will deduct all the people who all are entering the room.
In the realm of industrial operations, ensuring a safe and efficient working environment is
paramount. The advent of smart technologies has opened avenues for the development of
sophisticated Industrial Monitoring and Controlling Systems that not only enhance safety
protocols but also contribute to streamlined operations. This research introduces a
comprehensive system integrating Arduino-based microcontrollers, a diverse array of sensors,
and advanced technologies like IoT and live streaming through an ESP32-CAM module. The
core components of this system include sensors such as the Humidity Temperature Sensor for
environmental monitoring, Fire Sensor, Gas Sensor, Smoke Sensor, and IR Sensor for precise
person detection. These sensors collectively enable the system to monitor and react to critical
environmental conditions, providing a proactive approach to industrial safety. Actuation is a
key aspect of the system, with a DC Motor controlling access door, relays managing a water
pump and a DC fan, and a buzzer for immediate alerts. These components, driven by an
Arduino microcontroller, respond dynamically to sensor inputs, executing predefined actions
to mitigate potential risks. To extend the monitoring capabilities beyond sensor readings, the
system incorporates an ESP32-CAM module for live streaming. This camera technology
allows for remote visual inspection of industrial processes, empowering stakeholders with
real-time situational awareness. This live streaming feature becomes a valuable asset for
decision-makers, enabling swift responses in emergency situations and facilitating remote
troubleshooting. The communication backbone of the system is strengthened through the
integration of a NodeMCU, which enables message notifications using IoT protocols. This
ensures that stakeholders receive timely alerts regarding anomalies, allowing for rapid
response and intervention. The integration of Arduino, sensors, IoT, and live streaming
capabilities ensures a comprehensive solution that is not only adaptable but also scalable for
a wide range of industrial applications.

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Industrial Automation System Using IoT 2023-24

1.1 PROBLEM STATEMENT

One of the main reasons for industrial accidents is the leakage of unwanted gases and the
depth of workers in industries. Leakage of any sort of gases will cause an immense problem
in present times whether household, industry, restaurants, etc. a need for a monitor and fault
detection is now more required than ever. The proposed system uses an MQ-6 sensor that
detects the leakage of LPG, CH4, and CO gases.

1.2 OBJECTIVES

• Environmental Monitoring: Implement a robust system for real-time monitoring of

environmental conditions, including temperature and humidity, to ensure optimal working
conditions for personnel and machinery.
• Hazard Detection and Prevention: Utilize sensors such as Fire Sensor, Gas Sensor, and
Smoke Sensor to detect potential hazards promptly. Implement automated responses to
mitigate risks and ensure the safety of personnel and assets.
• Personnel Detection and Access Control: Integrate an IR sensor for person detection to
enhance security measures. Use this information for access control and to trigger specific
actions based on personnel presence.
• Door Control and Access Management: Implement a DC Motor for door control to
regulate access to designated areas. Enable secure and automated door operations based
on sensor inputs and predefined access criteria.
• Automation of Industrial Processes: Integrate relays to control a water pump and a DC
fan, automating processes such as cooling systems and water supply. Enhance operational
efficiency by responding to environmental conditions in real-time.
• Immediate Alerting Mechanism: Integrate a Buzzer to provide immediate audible alerts
in case of critical events. Ensure that on-site personnel are promptly informed of potential
hazards or abnormal conditions.
• Remote Monitoring and Notification: Utilize NodeMCU for wireless communication
and IoT protocols to enable remote monitoring of the system. Implement a notification
system to alert relevant stakeholders via messages in case of emergencies or system
anomalies.
• Live Streaming for Visual Inspection: Integrate an ESP32-CAM module for live
streaming capabilities. Enable remote visual inspection of industrial processes, allowing
for real-time situational awareness and facilitating decision-making.

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Industrial Automation System Using IoT 2023-24

1.3 MOTIVATION

In this industrial monitor and fault detection system, we look closely into the gas leakage
detection of some variety gases such as LPG, CO, and CH4, which causes various health
problems and also has a possibility of an explosion. While taking a look at this we also detect
if there are any flames in the nearby area. There is also motion detection up to a point where
any type of movement will detect and alert during emergencies. Throughout the whole range
of the system, temperature and humidity readings are taken at infrequent intervals to also keep
them in check. Thus cover a certain range in the factory, monitoring various factors that may
lead to a threat or an emergency in automated factories that use processes that are expensive
and difficult to modify often.

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Industrial Automation System Using IoT 2023-24

CHAPTER 2
LITERATURE SURVEY
2.1 Role-based visualization of industrial IoT-based systems
The competition among manufacturers in the global markets calls for the enhancement of the
agility and performance of the production process and the quality of products. As a result, the
production systems should be designed in such a way to provide decision makers with
visibility and analytics. To fulfill these objectives, the development of information systems in
manufacturing industries has intensified in the past few years. On the other hand, the volume
of data which is being generated on the shop floor is rising. To improve the efficiency of
manufacturing processes, this amount of data should be analyzed by decision makers. To cope
with this challenge, advanced visualization is needed to assist users to gain insight into data
and make effective decisions faster. This paper describes an approach for building a role-
based visualization of industrial IoT. We propose an extendible architecture that anticipates
the future growth of data. By using the IoT platform introduced in this paper, selected Key
Performance Indicators (KPI) can be monitored by different levels of enterprise. The
prototype IoT dashboard has been implemented for a pilot production line “Festo didactic
training line” located in Seinäjoki University of Applied Sciences (SeAMK) and results have
been validated.
Published in: 2018 14th IEEE/ASME International Conference on Mechatronic and
Embedded Systems and Applications (MESA)
Date of Conference: 02-04 July 2018
Date Added to IEEE Xplore: 30 August 2018
Publisher: IEEE
Conference Location: Oulu, Finland
Authors:
Mehdi Mahmoodpour
Tampere University of Technology, Tampere, Finland
Minna Lanz
Tampere University of Technology, Tampere, Finland

2.2 Industrial Cloud Monitoring System Based on Internet of Things

Monitoring for industrial machines can get benefit from Cloud Computing and Internet of
Things capabilities. This research proposes a new approach to monitor machines based on the
low coast board (Omega2 Plus). The Omega2 Plus is an embedded system and its shape and

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Industrial Automation System Using IoT 2023-24

size like a credit card work as a computer. It's can transmit data to the cloud server directly.
In any industrial factory there are multiple types of machines, this approach coupled machines
logical outputs to Omega2 Plus GPIO and send data to web-based server to be monetarized.
The Cloud Monitoring System (CMS) gives a real-time information about production data,
current work, the employee ID working on a given machine, the production rate, and
downtime. All machines monitored by supervisors or specialists sitting in a remote place
virtually any part of the world. Additionally, the Cloud Monitoring System is simple and run
by an untrained worker employed on the basic level.
Published in: 2018 Second World Conference on Smart Trends in Systems, Security and
Sustainability (WorldS4)
Date of Conference: 30-31 October 2018
Date Added to IEEE Xplore: 17 January 2019
Publisher: IEEE
Conference Location: London, UK
Author:
Ibtesam R. K. Al-Saedi
Communication Eng. Dept., University of Technology (UoT), Baghdad, Iraq

2.3 A framework for rapid integration of IoT Systems with industrial environments
An IoT-based system running in industrial environments. The aim is to minimize development
and testing time while abiding with standards and needs. We take the view that efficient
adoption of IoT in industrial environments should be treated as a multidisciplinary issue and
should be carried out in relatively small steps to minimize risks and disruption. Our method
approaches this problem with a holistic end-to- end point of view stretching from sensor
devices to interfacing with the final user where all software and hardware elements of the
system are being considered and addressed.
Published in: 2019 IEEE 5th World Forum on Internet of Things (WF-IoT)
Date of Conference: 15-18 April 2019
Date Added to IEEE Xplore: 22 July 2019
Publisher: IEEE
Conference Location: Limerick, Ireland
Author:
Alex Vakaloudis
TEC Gateway, Cork Institute of Technology, Cork, Ireland

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Industrial Automation System Using IoT 2023-24

2.4 Bluetooth based Sensor Monitoring in Industrial IoT Plants

Internet of Things adoption in traditional and slow changing industrial plants such as power,
water, oil-gas and chemical has proven to be beneficial in providing business value by
transforming the way data is utilized in decision-making and visualization. Typical industrial
IoT use cases involve acquiring data from sensor devices in plant and communicating the
same to internet for local or remote monitoring and control. The sensor data acquisition in an
industrial plant thus becomes paramount as the same acquired data is used for bringing out
the underlying knowledge of system. IoT typically requires a local, low power wireless
communication to acquire data from sensor devices and local gateway that is connected to
internet for local or remote monitoring and control. This paper describes how Bluetooth low
energy (BLE) technology can be used to connect sensor nodes to Internet-based services and
applications using gateway in an industrial plant. It also investigates the performance of BLE
technology as a local communication for sensor device monitoring.
Published in: 2019 International Conference on Data Science and Communication
(IconDSC)
Date of Conference: 01-02 March 2019
Date Added to IEEE Xplore: 29 August 2019
Publisher: IEEE
Conference Location: Bangalore, India
Authors:
Rahul N. Gore
ABB Corporate Research, Bangalore, India
Himashri Kour
ABB Corporate Research, Bangalore, India

2.5 Cloud-Based Asset Monitoring and Predictive Maintenance in an Industrial IoT

System
Industrial production is pushed on by the constantly changing market requests and global
competition. To keep up with these demands and thrive in a furiously competitive market,
rapid advances in current manufacturing technologies are required. Automation is the
trendsetter among the technologies currently in operation. To aid in the development of
production methods, the idea proposed is predictive maintenance and asset tracking.
Predictive maintenance is a revolution in the way machines that are in continuous operation
can be constantly monitored to detect an anomaly before it blows up into a full-fledged

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Industrial Automation System Using IoT 2023-24

problem. The device is kept under constant monitoring and readings of different parameters,
for example, temperature and vibrations are tabbed. Any reading that strays from the regular
pattern could indicate a flaw in the device. By predicting this, downtime for maintenance can
be reduced. Asset tracking is another revolutionary method to speed up efficiency in the
industrial sector. Using different technologies like Wireless Sensor Networks (WSNs), the
assets and their locations can be viewed using a remote device. The benefit of the same lies in
the fact that often an asset whose location is unknown, wastes production time of the team by
unnecessarily having to look for it. Ultimately, the idea is to implement these technologies
using the modern concepts of Machine Learning, Data Visualization, Cloud Computing and
the Internet of Things. This paper provides a brief introduction to the architecture of such a
system followed by a detailed rundown of the above methodologies for real-time applications.
Published in: 2020 International Conference for Emerging Technology (INCET)
Date of Conference: 05-07 June 2020
Date Added to IEEE Xplore: 03 August 2020
Publisher: IEEE
Conference Location: Belgaum, India
Authors:
Sarthak Gagdani
Department of Information Technology, MIT College of Engineering, Pune, India
Akash Butala
Department of Information Technology, MIT College of Engineering, Pune, India

2.6 Design of an Industrial IoT-Based Monitoring System for Power Substations

The Internet of Things (IoT) concept allows objects to share data through wired or wireless
connections for communication purposes. The Industrial Internet of Things (IIoT) is an
extended concept of IoT that refers to an integration of data acquisition, communication, and
processing on a real-time network. Currently, IIoT has been involved with the development
of smart grids in many applications. As the operation of power systems is extremely time-
critical, low-latency communication needs to be considered for most control and monitoring
applications. Real-time capability of IoT is considered as a key feature for monitoring and
control applications of power systems. Therefore, system operators can use the real-time
monitoring system to provide better decisions for both technical and financial-related matters.
In this paper, a high-speed IIoT-based monitoring system with recording functions is
developed and implemented for a power system substation. Due to the high reliability and
processing speed of FPGAs, an FPGA-embedded controller is adopted in this system. The IoT

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Industrial Automation System Using IoT 2023-24

platform also provides remote visualization for system operators in real time. This paper
mainly aims to provide a practical application that was implemented and tested in a real power
substation. The system incorporates the features of an IoT platform with the needs of high-
speed real-time applications while using a single high-resolution time source as the reference
for both steady-state and transient conditions.
Published in: 2019 IEEE/IAS 55th Industrial and Commercial Power Systems Technical
Conference (I&CPS)
Date of Conference: 05-08 May 2019
Date Added to IEEE Xplore: 10 June 2019
ISBN Information:
Publisher: IEEE
Conference Location: Calgary, AB, Canada
Authors
Long Zhao
University of Texas at Arlington, Arlington, TX, USA

2.7 Securing Industrial Control Systems Using Physical Device Fingerprinting

The advent of the Internet-of-Things (IoT) has introduced new connectivity modalities,
communication protocols, and optimized architectures to coordinate Things on a network.
BACnet MS/TP is a protocol that has the potential to deliver a reliable IoT back-end for
industrial systems. However, conventional security threats can severely affect trust between
the nodes in the network, leading to critical infrastructure failures. Hence, we analyze the
opportunities and challenges for hardware solutions in securing BACnet controllers in this
work. First, we look into the security threats and develop practical attack models. Then, we
demonstrate how we model clocks in the network for fingerprinting. Next, we propose a
distributed security monitor for deployment across the BACnet MS/TP nodes. We also
illustrate how clock fingerprinting data can enable the security monitor to prevent intrusion
and tampering. Finally, we experimentally verify our attacker model, attack scenarios, and the
effectiveness of hardware-oriented security solutions for intrusion prevention and tampering
on an industrial standard BACnet MS/TP network.
Published in: 2020 7th International Conference on Internet of Things: Systems,
Management and Security (IOTSMS)
Date of Conference: 14-16 December 2020
Date Added to IEEE Xplore: 02 February 2021
Publisher: IEEE

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Conference Location: Paris, France

Author:
Md Tanvir Arafin
ECE Department, Morgan State University, Baltimore, Maryland

2.8 IoT Based Industrial Air Quality Monitoring System

In the past two decades, researchers have accelerated a number of different methods to monitor
and reduce air contamination leading to the development of efficient and effective air quality
measuring systems using air purifiers. Although, recent technological advancements such as
IoT (Internet of Things) with Cloud Computing have allowed researchers to obtain and
monitor real-time data. In this report, an IoT-enabled industrial air quality monitoring device
is proposed. This device is enabled with an MQ-135 gas sensor for precisely monitoring the
air quality and detecting the presence of foreign contaminants such as alcohol. The proposed
device also uses a Node MCU ESP S266 Wi-Fi module to efficiently transmit real time data
to a smart device (E.g. Smartphone) using an IoT platform.
Published in: 2022 Second International Conference on Computer Science, Engineering and
Applications (ICCSEA)
Date of Conference: 08-08 September 2022
Date Added to IEEE Xplore: 07 November 2022
Publisher: IEEE
Conference Location: Gunupur, India
Authors:
Dipanjan Jana
AEIE, RCCIIT, Kolkata, India
Rahul Nandy
AEIE, RCCIIT, Kolkata, India

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Industrial Automation System Using IoT 2023-24

CHAPTER 3
METHODOLOGY

The project's design process is based on data, which is collected through several sorts of
sensors like, flame sensors, gas sensors, and temperature and humidity sensors. These sensors
are installed in the required locations, such as where the gas has leaked. The temperature and
humidity sensors are used to display the readings, the flame sensor is used to detect fire, and
the is used to notify unauthorized entry. These sensors gather data continuously and
communicate it to the microcontroller (Arduino UNO). Arduino UNO is programmed with a
specific threshold value. If the value is less than the threshold, the situation is normal. If it
exceeds the threshold value, the Arduino UNO sends a signal to the corresponding output. If
the gas is leaking, a buzzer sound is produced when the sense is very low. When the perception
of smell is strong, the exhauster fan is activated. If a fire is detected by the flame sensor, the
Arduino UNO is triggered, and the water sprayer is used to extinguish it if the fire is bright.
Anyone who enters the industry without being allowed is tracked. On the LCD panel, all data
is shown 24*7. Over IoT, data is sent and shared utilizing a Wi-Fi module. From our Wi-Fi
network, we can control the Wi-Fi module. The WiFi module allows microcontrollers to
connect to wireless networks. The Thing speak website is used to provide graphical
representations of all types of data from sensors including gas, flame, humidity, and
temperature sensors. We have developed a fully autonomous IoT wireless sensor-actuator
network for the monitoring of the environment.

The sensors make up the detecting section: IR motion sensor, a DHT11 digital temperature
and humidity sensor, a MQ-2 smoke sensor, and a MQ-5 gas sensor. These specialist modules
are in charge of identifying and measuring particular environmental changes, then transmitting
the measured data to the microcontroller for additional processing. The LCD display's main
purpose is to show the system's current condition. As the system carries out monitoring tasks,
it displays a variety of notifications, including alarms for gas leaks, smoke, temperature, and
intruder detection, as well as any actions made by the microcontroller. A buzzer is used to
execute the alarm portion. The buzzer uses a quick electric makeand-break mechanism that
generates fast vibration to produce signals. Every time the microcontroller detects an
abnormality in the physical circumstances of the surroundings, the buzzer is programmed to
sound in accordance with the program's instructions.

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System Design: Identify and define the specific requirements of the industrial environment.
Design the architecture of the monitoring and controlling system, considering the placement
of sensors, actuators, and communication modules.
Hardware Integration: Connect the Arduino microcontroller to the various sensors
(Humidity Temperature Sensor, Fire Sensor, Gas Sensor, Smoke Sensor, IR Sensor) using
appropriate wiring. Integrate the DC Motor, relays for the water pump and DC fan, and the
buzzer into the system. Connect the ESP32-CAM module for live streaming capabilities.
Programming the Arduino: Develop Arduino code to read data from sensors, process the
information, and control actuators based on predefined logic. Implement error handling and
safety features in the code. Create functions for efficient and modular code structure.
User Interface Development: Program the LCD display to show real-time data such as
temperature, humidity, and status of various sensors and actuators. Ensure that the user
interface is intuitive and provides relevant information for on-site personnel.
Communication Setup with NodeMCU: Program the NodeMCU to establish a connection
with the Arduino via serial communication. Develop code for sending and receiving messages
using IoT protocols to enable remote monitoring and notifications.
Integration of ESP32-CAM for Live Streaming: Configure the ESP32-CAM module to
capture and stream live video. Integrate the live streaming functionality into the Arduino code
to provide remote visual inspection capabilities.

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3.1 BLOCK DIAGRAM

Fig.: 3.1 Block diagram

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CHAPTER 4
4
HARDWARE AND SOFTWARE REQUIREMENTS

4.1 HARDWARE COMPONENTS REQUIREMENT

4.1.1 ARDUINO UNO

Arduino Uno is a microcontroller board based on the ATmega328P. It has 14 digital input/output pins
(of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz quartz crystal, a USB
connection, a power jack, an ICSP header and a reset button. It contains everything needed to support
the microcontroller, simply connect it to a computer with a USB cable or power it with an AC-to-DC
adapter or battery to get started. You can tinker with your UNO without worrying too much about
doing something wrong, worst case scenario you can replace the chip for a few dollars and start over
again. "Uno" means one in Italian and was chosen to mark the release of Arduino Software (IDE) 1.0.
The Uno board and version 1.0 of Arduino Software (IDE) were the reference versions of Arduino,
now evolved to newer releases. The Uno board is the first in a series of USB Arduino boards, and
the reference model for the Arduino platform; for an extensive list of current, past or outdated boards
see the Arduino index of boards.

Fig 4.1.1 Arduino Uno

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Microcontroller ATmega328P
Operating Voltage 5V
Input voltage 7-12V
Input voltage limit 6-20V
Digital I/O Pins 6
Analogue input Pins 6
DC current per I/O pins 20 mA
DC current for 3.3v Pin 50 mA
Flash Memory Of which 0.5KB is used
SRAM 2 KB
EEPROM 1KB
Clock Speed 16MHz
Length 68.6mm
Width 53.4nm
Weight 25g
Table 4.1.1

Fig 4.1.2 Pin Configerations

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Communications
Arduino Uno has a number of facilities for communicating with a computer, another Arduino uno
board, or other microcontrollers. The ATmega328 provides UART TTL (5V) serial
communication, which is available on digital pins 0 (RX) and 1 (TX). An ATmega16U2 on the
board channels this serial communication over USB and appears as a virtual com port to software
on the computer. The 16U2 firmware uses the standard USB COM drivers, and no external driver
is needed. However, on Windows, an inf file is required. The Arduino Software (IDE) includes a
serial monitor which allows simple textual data to be sent to and from the board. The RX and
TX LEDs on the board will flash when data is being transmitted via the USB-to-serial chip and
USB connection to the computer (but not for serial communication on pins 0 and1).

4.1.3 LCD DISPLAY

Fig:4.1.3. 16*2 LCD display

A liquid-crystal display (LCD) is a flat-panel display or other electronically modulated
optical device that uses the light-modulating properties of liquid crystals. Liquid crystals do
not emit light directly, instead using a backlight or reflector to produce images in color
or monochrome. LCDs are available to display arbitrary images (as in a general-purpose
computer display) or fixed images with low information content, which can be displayed or
hidden, such as preset words, digits, and 7-segment displays, as in a digital clock. They use
the same basic technology, except that arbitrary images are made up of a large number of
small pixels, while other displays have larger elements.

LCD is used in wide range application including computer monitors, televisions, instrument
panels, aircraft cockpit displays, and indoor and outdoor signage. Small LCD screens are
common in portable consumer devices such as digital cameras, watches, calculators,
and mobile telephones, including smart phones. LCD screens have replaced heavy, bulky
cathode ray tube (CRT) displays in nearly all applications. LCD screens are available in a
wider range of screen sizes than CRT and plasma displays, with LCD screens available in
sizes ranging from tiny digital watches to huge, big- screen television sets.

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4.1.4 Humidity Sensor (DHT11):

Fig 4.1.4 Humidity Sensor

Humidity sensor is used for sensing the vapours in the air. The change in RH (Relative
Humidity) of the surroundings would result in display of values. Humidity Sensor is one of
the most important devices that has been widely in consumer, industrial, biomedical, and
environmental etc. applications for measuring and monitoring Humidity. Humidity is defined as
the amount of water present in the surrounding air. This water content in the air is a key factor in
the wellness of mankind. For example, we will feel comfortable even if the temperature is 00C with
less humidity i.e. the air is dry. But if the temperature is 100C and the humidity is high i.e.
the water content of air is high, then we will feel quite uncomfortable. Humidity is also a
major factor for operating sensitive equipment like electronics, industrial equipment,
electrostatic sensitive devices and high voltage devices etc. Such sensitive equipment must
be operated in a humidity environment that is suitable for the device.

DHT11 Specifications

• Operating Voltage: 3.5V to 5.5V

• Operating current: 0.3mA (measuring) 60uA (standby)
• Output: Serial data
• Temperature Range: 0°C to 50°C
• Humidity Range: 20% to 90%
• Resolution: Temperature and Humidity both are 16-bit
• Accuracy: ±1°C and ±1%

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4.1.5 MQ-6 SENSOR

Fig:4.1.5 MQ-6 Sensor

MQ-6 module is suitable for detecting Alcohol, Benzine, CH4, Hexane, LPG, CO. Sensitive
material of MQ-6 gas sensor is SnO2, which with lower conductivity in clean air. When the
target alcohol gas exist the sensor’s conductivity is more along with the gas concentration
rising. MQ-6 gas sensor has high sensitivity to Alcohol, and has good resistance to disturb
of gasoline, smoke and vapor. This sensor provides an analog resistive output based on
alcohol concentration. When the alcohol gas has exist, the sensor’s conductivity gets higher
along with the gas concentration rising. There is a resistance across an A and B inside the
sensor which varies on detection of alcohol. More the alcohol, the lower the resistance. The
alcohol is measured by measuring this resistance. The sensor and load resistor form a
voltage divider, and the lower the sensor resistance, the higher the voltage reading will be.

Fig 4.1.5 Table 4.1.5

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Structure and configuration of MQ-6 gas sensor is shown in the figure above for Configuration
A or B, sensor composed by micro AL2O3 ceramic tube, Tin Dioxide (SnO2) sensitive layer,
measuring electrode and heater are fixed into a crust made by plastic and stainless steel net.
The heater provides necessary work conditions for work of sensitive components. The
enveloped MQ-6 have 6 pin, 4 of them are used to fetch signals, and other 2 are used for
providing heating current.

4.1.6 Regulated power supply:

Fig 4.1.6 Regulated Power Supply

Transformer:
A transformer is a device that transfers electrical energy from one circuit to another through
inductively coupled conductors without changing its frequency. A varying current in the first
or primary winding creates a varying magnetic flux in the transformer's core, and thus a
varying magnetic field through the secondary winding. This varying magnetic field induces
a varying electromotive force (EMF) or "voltage" in the secondary winding. This effect is
called mutual induction. If a load is connected to the secondary, an electric current will flow
in the secondary winding and electrical energy will be transferred from the primary circuit
through the transformer to the load. This field is made up from lines of force and has the
same shape as a bar magnet.
Rectifier:
A rectifier is an electrical device that converts alternating current (AC) to direct current (DC),
a process known as rectification. Rectifiers have many uses including as components of
power supplies and as detectors of radio signals. Rectifiers may be made of solid-state diodes,
vacuum tube diodes, mercury arc valves, and other components. A device that it can perform
the opposite function (converting DC to AC) is known as an inverter. When only one diode

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is used to rectify AC (by blocking the negative or positive portion of the waveform), the
difference between the term diode and the term rectifier is merely one of usage, i.e., the term
rectifier describes a diode that is being used to convert AC to DC.
Filter:
The process of converting a pulsating direct current to a pure direct current using filters is
called as filtration. Electronic filters are electronic circuits, which perform signal-processing
functions, specifically to remove unwanted frequency components from the signal, to enhance
wanted ones.
Regulator:
A voltage regulator (also called a regulator) with only three terminals appears to be a simple
device, but it is in fact a very complex integrated circuit. It converts a varying input voltage
into a constant regulated output voltage. Voltage Regulators are available in a variety of
outputs like 5V, 6V, 9V, 12V and 15V. The LM78XX series of voltage regulators are
designed for positive input. For applications requiring negative input, the LM79XX series is
used. Using a pair of voltage-divider resistors can increase the output voltage of a regulator
circuit. It is not possible to obtain a voltage lower than the stated rating. You cannot use a
12V regulator to make a 5V power supply. Voltage regulators are very robust. These can
withstand over-current draw due to short circuits and also over-heating. In both cases, the
regulator will cut off before any damage occurs. The only way to destroy a regulator is to
apply reverse voltage to its input. Reverse polarity destroys the regulator almost instantly.

4.1.7 Servo Motor:

Fig 4.1.7 Servo Motor

The MG90 servo motor is a versatile and widely used micro servo motor, particularly
suitable for various robotic and automation projects. Here are some key specifications and
features of the MG90 servo motor:

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Key Specifications:

• Weight: Approximately 13.4 grams

• Dimensions: 22.8mm x 12.2mm x 28.5mm

• Operating Speed:

- 0.11 seconds per 60° (at 4.8V)

- 0.09 seconds per 60° (at 6V)

• Operating Voltage: 4.8V to 6V

• Control System: PWM (Pulse Width Modulation)

• Dead Band Width: 5 µs

• Servo Wire Length: Approximately 25 cm

• Connector Type: 3-pin JR type (compatible with most servo controllers and Arduino
boards)

4.1.8 Fire Sensor:

Fig 4.1.8 Fire Sensor

A fire sensor is used to detect the presence of fire around its range. A fire emits heat waves
which are also called infrared rays. So, it consists of an IR receiver, a comparator LM393,
resistors, capacitors and a potentiometer to adjust its sensitivity. The infrared waves of
700nm to 1000nm wavelength can be readily detected by this sensor. The IR receiver
converts the wave intensity to corresponding current value. It can give analog as well as
digital outputs. The sensor has a detection angle of 60 degrees in the forward direction. A
voltage of 3.3V to 5.2V can be used to power the sensor.

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4.2 SOFTWARE REQUIREMENTS

4.2.1 Arduino IDE: The Arduino IDE (Integrated Development Environment) is a software
platform used to write and upload code to Arduino boards. It provides a user-friendly interface
to write, compile, and upload code, making it easier for beginners and experienced developers
to work with Arduino hardware.

4.2.2 Embedded C: Embedded C refers to a variant of the C programming language

specifically tailored for programming embedded systems, which are small-scale computer
systems typically designed to perform dedicated functions within a larger mechanical or
electrical system. Embedded C accounts for the limitations and requirements of embedded
systems, such as limited memory, specific hardware constraints, and real-time operation,
allowing developers to write efficient code for these devices.

4.2.3 Telegram Bots

Bots are third-party applications that run inside Telegram. Users can interact with bots by
sending them messages, commands and inline requests. You control your bots using HTTPS
requests to our Bot API. At the core, Telegram Bots are special accounts that do not require an
additional phone number to set up. Users can interact with bots in two ways: Send messages and
commands to bots by opening a chat with them or by adding them to groups. This is useful for
chat bots or news bots like the official TechCrunch bot. Send requests directly from the input
field by typing the bot's @username and a query. This allows sending content from inline bots
directly into any chat, group or channel. Messages, commands and requests sent by users are
passed to the software running on your servers. Our intermediary server handles all encryption
and communication with the Telegram API for you. You communicate with this server via a
simple HTTPS-interface that offers a simplified version of the Telegram API. We call that
interface our Bot API.

Fig 4.2.3 Telegram Botfather

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CHAPTER 5
ADAVNATGES AND APPLICATIONS

5.1 ADVANTAGES

• The probability of human error is greatly reduced.

• This system provides time and financial savings for the business.
• Constant monitoring also allows for consistent and dependable data from anywhere
around the world.
• Major accidents can be prevented without any huge damages.

5.2 APPLICATIONS

• Laboratories contain many chemicals, in that many are retractable to high

temperatures or heat. So, every lab must contain this detecting of smoke so that
vigorous reaction of chemicals with fire can be avoided.
• Refrigeration plants use CFC gases which highly react able with fire, so it is
necessary to have this system in the plants.
• It is also used in various other industries like beverage manufacturing, biogas
industry.
• Nowadays vehicles also use this system to prevent fire accidents.

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CHAPTER 6
RESULTS

Fig 6.1 Industrial Automation System

Fig 6.2 Alert Messages in LCD

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Fig 6.3 Alert Message to User Mobile

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CHAPTER 7

CONCLUSION AND FUTURE SCOPE

7.1 CONCLUSION
By working on this project, we aim to gain in-depth knowledge in the technical aspects of
the internet of things and digital electronics systems. The core objective of our industrial
monitoring system is achieved with digital integration of sensors with optimum value
precision and micro-controllers. We have incorporated sensors for detection of
environmental parameters which when reaches undesired condition observed data is
communicated to the head center. Arduino UNO is used for processing and allocation of
the data received and the processed data is communicated to the internet applications via
the internet. Therefore, we have included MQ6 gas sensor, flame sensor, PIR sensor,
temperature sensors for receiving data and Arduino for inter-device communications and
proposing desired commands. We have also used an internet-based for the collection of
data. The significance for preventing undesired hazards and activities in the management's
absence is the key novelty of our project and we believe it would help industries reduce
these accident rates efficiently if deployed. With the ongoing industrial modernization,
these days the demand for digital and automation systems to perform functions especially
in the information technology and algorithmic sectors has risen exponentially and the
application of IoT in their operational mechanisms paves way for development and feasible
innovation.

7.2 FUTURESCOPE

• Right now we have designed the project for control of two devices but it can be
designed for more number of devices.
• It can be further expanded with a voice interactive system facility.
• A feedback system can also be included which provides the state of a device
(whether it is on/off) to the remote user.

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