Industrial Automation is a process of operating machines and other industrial equipment with the help of digital logical programming and reducing human intervention in decision making and manual command process with the help of mechanized equipment. The internet of things, or IoT, is a system of interrelated computing devices, mechanical and digital machines, objects, animals or people that are provided with unique identifiers (UIDs) and the ability to transfer data over a network without requiring human-to-human or human-to-computer interaction. A thing in the internet of things can be a person with a heart monitor implant, a farm animal with a biochip transponder, an automobile that has built-in sensors to alert the driver when tire pressure is low or any other natural or man-made object that can be assigned an Internet Protocol (IP) address and is able to transfer data over a network. Increasingly, organizations in a variety of industries are using IoT to operate more efficiently, better understand customers to deliver enhanced customer service, improve decision-making and increase the value of the business. Industrial Automation is the process of connecting various loads in different locations to a Wi-Fi (LAN) network to perform the tasks automatically and handles different processes and machineries in an industry to replace a human being. It increases the Quality and Flexibility in the Manufacturing Process. Traditionally Manpower and Bluetooth are employed in industries. In hazardous conditions there will be no production line safe for the employees and in case of the Bluetooth the coverage range is very less.
component used
Introduction:
Industrial IoT Safety Project– In this project, you will learn how to make an Industrial IoT safety project using Node MCU (ESP8266) Wifi Module, Arduino nano, DHT11 temperature and humidity sensor, MQ-2 Smoke Sensor, LM35 Sensor, and Blynk IoT platform. This project mainly focuses on the worker’s safety. This is going to be a pretty long tutorial, as in this project I have combined 4 different projects. In this project, I will practically show you the real power of Industrial IoT “iiot” by monitoring the, temperature humidity, Fire/Smoke, and industrial control system. All four sensors are monitored using the Blynk IoT platform designed for Android and iOS. With the help of this project, you will be able to monitor temperature, humidity and Fire/Smoke Sensor from anywhere around the world. Internet of Things refers to interconnected sensors, instruments, and other devices networked together with computers industrial applications or cell phone IoT platform Apps. Using the Industrial Internet of Things technology different types of industrial processes can be monitored from anywhere around the world. This connectivity allows for data collection, monitoring and analysis, potentially facilitating improvements in efficiency as well as other economic benefits. The IIoT is an evolution of a distributed control system “DCS” that allows 18 for a higher degree of automation by using clouding computing to refine and optimize the process controls. The term industrial internet of things is often encountered in the manufacturing industries, referring to the industrial subset of the IoT. Potential benefits of the industrial internet of things include improved productivity, analytics and the transformation of the workplace. The potential of growth by implementing IIoT is predicted to generate $15 trillion of global GDP by 2030. Connecting assets throughout the industrial value chain provides complete operational visibility to allow for real-time decision making and improved levels of quality and efficiency as well as new service opportunities.
• Monitoring equipment utilization
• Predictive maintenance and condition monitoring
• Industrial asset management
• Industrial smart, connected products
• Monitoring safety
Block diagram:
source code :
#include "DHTesp.h"#include<stdlib.h>/* ESP & Blynk */#include <ESP8266WiFi.h>
#include <BlynkSimpleEsp8266.h>
#define BLYNK_PRINT Serial // Comment this out to disable prints and save space#define Rl D3#define R0 D0#define BUZ D7#define R2 D5char auth[] = "jAhtdutAr_LaCCPVXPwLD1gdU-aW9XHt"; /* WiFi credentials */char ssid[] = "SSID NAME";char pass[] = "PASSWORD"; SimpleTimer timer; #define DHTpin 2 // D4 on the nodemcu ESP8266DHTesp dht; int mq135 = A0; // smoke sensor is connected with the analog pin A0 int data = 0; String mytemp; String myhum;void setup(){ pinMode(D3,OUTPUT); pinMode(D0,OUTPUT); pinMode(D5,OUTPUT); pinMode(D6,OUTPUT); pinMode(D7,OUTPUT); Serial.begin(9600); dht.setup(DHTpin, DHTesp::DHT11); Blynk.begin(auth, ssid, pass); timer.setInterval(1000L, getSendData);}void loop(){ timer.run(); // Initiates SimpleTimer Blynk.run();
} void getSendData(){ delay(dht.getMinimumSamplingPeriod()); delay(1000); float humidity = dht.getHumidity(); float temperature = dht.getTemperature(); Blynk.virtualWrite(V3, humidity); Blynk.virtualWrite(V4, temperature);
if(temperature<34) { digitalWrite(D3, LOW); digitalWrite(D5, HIGH); } else { digitalWrite(D3, HIGH); digitalWrite(D5, LOW); } data = analogRead(mq135); Blynk.virtualWrite(V2, data); //virtual pin V2 if (data > 600 ) { Blynk.notify("Smoke Detected !!!"); } }
FOR ARDUINO NANO:
Arduino nano39//this project is made by Manish Kumar Yadavint motorpin=9;int sensorpin= A0; int sensorval;int ledpin1=13;int ledpin2=12;void setup() { pinMode(motorpin,OUTPUT); pinMode(sensorpin,INPUT); pinMode(ledpin1,OUTPUT); pinMode(ledpin2,OUTPUT); // put your setup code here, to run once:}void loop() { sensorval=analogRead(sensorpin); sensorval=sensorval/2.0741; if(sensorval>50) { digitalWrite(motorpin,HIGH); digitalWrite(ledpin1,HIGH); digitalWrite(ledpin2,LOW); delay(500); } else { digitalWrite(motorpin,LOW); digitalWrite(ledpin1,LOW); digitalWrite(ledpin2,HIGH); delay(500); }}
Advantages:
1. Reduces Cost : One of the top advantages of automation is reduction in manufacturing costs. Instead of having a floor full of workers, you can now have just a few supervisors and have robots do the job. The initial investment will be a little high, but then the operation costs will reduce, which will be beneficial in the long run. Your expenses will only include maintenance, repairs, and energy. AI and data analytics have also helped reduce production costs by providing insights and information to make the right production decisions. Automation helps improve productivity, quality and system performance, which in turn reduces your operating expenses (OPEX). At the same time, automated preventive maintenance can improve the life and performance of the machines. It enhances the value of your assets and in turn decreases your capital expenses (CapEx).2. Monitoring & Predictive Maintenance: A huge benefit of industrial automation is that it helps in monitoring and predictive maintenance. Production lines and production floor can be continuously monitored using sensors. These sensors track temperature, acoustics, time, frequency, oil pressure and other parameters related to the production process. If the sensors detect any change in these parameters, they will immediately send an alert. When the alert is received, the technicians can immediately identify the cause for the change. If it is noted that the changes in parameters may cause equipment problems or issues in the production process, then immediate service or 45 repairs can be done. Automation can therefore help identify possible issues before they blow up into huge problems that can result in production downtime.3. Enhances Quality Industrial automation: also helps increase and maintain consistent quality of the output.In manual processes, the error rate is around 1 to 1.15%. On the other hand, automated machines in the manufacturing industry have an error rate that is as low as 0.00001%. Adaptive control and monitoring help check every level of the manufacturing process tom reduce the margin of errors.4. Industrial Safety: A huge benefit of automation is improved safety at the workplace. Using robots for loading and unloading materials or transferring huge machine parts reduce risks of accidents. Industrial automation also keeps workers from going too close to the assembly lines, thereby improving safety. Thermal sensors continually check the temperatures in the production area. In case, they identify any spike in temperature, the sensors will send an alert. Immediately, precautions can be taken to ensure the safety of everyone on the production floor.5. Accurate Results :Data automation is based on accurate data integration and connectivity. When accurate information is used in the production process, you can be assured of precise results. AI and ML solutions help you get detailed data that can be analyzed using data analytics tools to get accurate information. Deep learning algorithms are used to build self-healing digital grids that use data analytics and intelligent energy forecasts to manage energy generation. Machine Learning apps have been used to build self-learning quality control system for assembly line. ML and AI solutions are scalable and self-learning. Both these features ensure that the automated systems deliver accurate results every time, without fail.
Disadvantages:1. Technical Limitation: Current technology is unable to automate all the desired tasks. 2. Security Threats/Vulnerability: An automated system may have limited level of intelligence; hence it is most likely susceptible to commit error. 3. Unpredictable development costs: The research and development cost of automating a process may exceed the cost saved by the automation itself. 4. High initial cost: The automation of a new product or plant requires a huge initial investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches .5. Unemployment: Unemployment rate increases due to machines replacing humans and putting those humans out of their jobs.
Result:
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