REMOTE MONITORING AND CONTROL
Department of Electrical and Electronics
Engineering
Submitted by
NAME REGISTER
NUMBER
JANARDHANAN.S 110821105308
Guided by
Mr. M. Deepakkumar [Link]
TRAINER
Jaya Engineering College
TABLE OF CONTENTS:
1. ABSTRACT
2. INTRODUCTION
3. PROBLEM STATEMENT
4. PROPOSED SYSTEM
5. COMPONENTS REQUIRED
6. SOFTWARE
7. BLOCK DIAGRAM
8. PIN DIAGRAM & OUTPUT
9. WORKING
10. CONCLUSION
1. ABSRACT
These paper presents an implementation of a human machine
interface (HMI) for a programmable logic controller (PLC) based
automated packaging process that can be remotely controlled and
monitored using mobile application. A conveyor belt does the moving of
products to a destined place for packaging, is controlled by Siemens
LOGO! 230 RCE PLC. Microcontroller (arduino uno) operates the relays
according to the output of IR sensors, which are used to sense the
products. States of relays are taken as the input of the PLC. An HMI is
designed with an android application and the microcontroller (as the
processor) that establish a communication path between the operators
and PLC based plant. The interface provides remote controlling and
monitoring feature. The proposed design minimized the overall cost by
replacing the widely used supervisory control and data acquisition
(SCADA) system with normal sensors and mobile application based
control. The performance of the implemented prototype is evaluated
through several real-time operations, which shows satisfactory results
2. INTRODUCTION
Industrial automation is one of the most global trends that enhances
the quality of production, safety and proper utilization of plant and
resources. From the economic view, mass production is the main goal of
any industry to stay ahead in the recent competitive market. The mass
production can be eased through the process automation. In any kind of
industry, packaging is a widely used process. Packaging is done for
providing protection and safety of products from dust, moistures and
other objects that are harmful to the products. The packaging also
provides better handling, transporting and, stable storage capability,
company branding and many more. The manual packaging process is
toilsome work and costly, as a large number of workers is required for it.
Therefore, many companies switching to industrial automation for cost-
effective and uninterrupted production. Automation of the packaging
process with remote control and monitoring system will provide more
reliable and developed packaging with less error and less probability of
hazards. In industry, an essential equipment of product processing is the
conveyor belt. Conveyor belt performs the functions include rotation,
accumulation, flipping, stacking, and diversion of products depending
upon the application. There are several conveyor belt systems are used
in industries.
3. PROBLEM STATEMENT:
In the area of industrial automation, programmable logic controller
(PLC) found greater interest for its robustness and low-cost
implementation. PLC is a kind of small computer specially designed for
industrial purpose, performs several functions including logical
operations, counting and arithmetic functions to control various process
or machinery through digital or analog modules. Various automation of
packaging using PLC and supervisory control has been proposed and
implemented by numerous researchers around the world. Each
automation has its own pros and cons. A brief discussion has been made
on the various automation of packaging processes in Section II.
4. PROPOSED SYSTEM:
In this paper, a prototype of two conveyor belts is considered, one for
products carrying to the destined box and another for carrying filled and
unfilled boxes. PLC is designed as the controller for a constant speed
geared DC motor, which rolls the conveyor belt. An interface is designed
based on android platform, arduino uno and bluetooth module to control
and monitor the packaging process. The novelty of the proposed system
is that it has been found suitable and cost-effective for small industries
where capital is small. This work can also be implemented for large
industries considering the requirements of robustness and application
field.
5. COMPONENTS REQUIRED
5.1 LOGO! 230 RCE PLC Module
LOGO! 230 RCE is a small PLC module that is made for home
appliances. It provides higher system stability and performance
rather than a microprocessor. It comes with easy programming
features i.e. ladder diagram that can be programmed using the
installation software LOGO! Soft V8. The inputs (220V AC pulse) are
provided by a four-array relay switch to the PLC according to the
command of arduino uno and the outputs (relay switch) that are
connected with the conveyor motor circuits.
5.2 Arduino, Bluetooth Module and Android phone
Arduino uno is used to communicate between mobile phone and
PLC (LOGO! 230 RCE) via bluetooth module. Moreover, IR sensors
are directly connected to the arduino uno to generate respective
logical input of the PLC module. Data strings provided by arduino
uno.
6. S0FTWARE COMPONENT
Software implementation includes implementation of PLC ladder
diagram, developing an android application and configuring necessary
programs (remote control and monitoring system) for arduino.
A. PLC Ladder Diagram
For programming and operation of the presented prototype, a PLC
ladder diagram is applied by using LOGO! Soft V8. For a faster,
uncomplicated and space-saving solution, LOGO! is a perfect choice.
LOGO! Soft Comfort makes possible of easier installation with a minimum
wiring effort [14]. This ladder diagram, as shown in Fig. 2 provides two
stages of the packaging operation. The input, output, relay switch and
counter configuration
7. BLOCK DIAGRAM
8. PIN DIAGRAM & OUTPUT
9. WORKING
9.1 OBJECT DETECTION BY USING ESP32-CAM
A. Start Packaging System
Tapping the “Start” button on android application, a specific data
(e.g. “a”) sent from mobile. Bluetooth module (HC-05) receives the
transmitted data, which are processed by a microcontroller (arduino
uno). Arduino uno makes a particular pin as logical “High” for one
second, which will control the switching of relay switch (four-array relay
switch 5v DC). This will make arduino uno to send a string e.g.,
“packaging starts” through bluetooth module to the mobile. This relay
switch provides logical information to the respective PLC input. PLC
module then operates its logical operations to close or open respective
output relay. Electrical dc motor can be used as an output actuator to
move box or sample conveyor belt.
10. CONCLUSION
An automated packaging process with remote control and
monitoring capability has been implemented. The main purpose of
this design implementation is the reduction in the cost of
automation. For lower capital industry or small industries, large
automation or high-configured devices are not economical. A
reduction of almost 1700 USD become possible using the proposed
design. The proposed design provides low-cost HMI to interact with
the machine from remote places using the mobile. A notification or
alert system and communication path have been developed that
monitoring and control of plant can be done from a distant place
from the plant. This ensures the reliability and errorless process of
the plant. The proposed design has successfully tested using
numerous trial and get a satisfactory result with greater
performance of reliability, robustness, and less-error in packaging.
This design is feasible for low-capital industries as well as can be
implemented for large industries.
