GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
CHAPTER 1
INTRODUCTION
The use of Generators has become a very common in almost using every infrastructure
companies, Industries, hospitals, Townships etc. as the application of generators has
become common the problems occurred in using them have also become very common
such as low fuel, High temperature and these problems can be solved by continuous
monitoring of generator, a system which can remotely monitoring generator and provide
you all the information through mobile
The GSM a monitor the power generator placed at the remote areas and increases its
efficiency by monitoring the various parameters of generator, Reporting critical Problems
minimizes downtime and maximizes availability by sending if any failure in generator
through messages instantly to diagnosis and emergency service dispatch if required and
the GSM is used in standby, prime and rental power applications. This system provides
ideal solution to the problems caused in situations when a wired connection between a
remote appliance/device and the control unit might not be feasible. The project is aimed
to analyzing and testing the use of mobile phones to remotely monitor an appliance
control system through GSM based wireless communication. The Microcontroller would
then control a device based on the information given to it.
1.1 Literature Survey: Amit sachen et al have discussed the user can send
commands in the form of SMS messages to read the remote electrical parameters. This
system also can automatically send the real time electrical parameters periodically (based
on time settings) in the form of SMS. This system can be designed to send SMS alerts
whenever the Circuit Breaker trips or whenever the Voltage or Current exceeds the
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
predefined limits. This project makes use of an onboard computer which is commonly
termed as microcontroller
Mallikarjun et al proposed this system is a specially designed computer system that is
completely encapsulated by the device it controls. The embedded system has specific
requirements and performs pre-defined tasks. The diesel generator is used when
electricity is not readily available, or when power failures occur due to natural disasters
such as typhoons or floods, or during other unexpected crises. Generally, the diesel
generator operates in analog. The analog type controller cannot be processed precisely
due to the distortions and noises coming from the data. In order to increase data accuracy,
the controller needs to be digitalized
Vimalraj et al have described a distribution transformers have a long service life if they
are operated under good and rated conditions. However, their life is significantly reduced
if they are overloaded, resulting in unexpected failures and loss of supply to a large
number of customers thus effecting system reliability. This system provides flexible
control of load parameters accurately and also provides effective means for rectification
of faults if any abnormality occurs in power lines using SMS through GSM network
Andriy Palamar et al proposed the system the Cellular phone containing SIM
(Subscriber’s Identifying Module) card has a specific number through which
communication takes place. The mode of communication is wireless and mechanism
works on the GSM (Global System for Mobile communication) technology. Here, the
communication is made bi- directional where the user transmits and also receives
instructions to and from the system in the form of SMS
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
CHAPTER 2
Block Diagram
Description of Proposed Method
The Real-time point-to-point data reporting architecture is useful for remote surveillance
and control, if communication network can be convenient to access. In the new age of
technology, mobile phone redefines communication. The worldwide trend for wireless
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
communication has elevated into wide band data instead of voice only. Sending written
text messages is very popular among mobile phone users. We have used the embedded
based control the generator plant from a remote area. Remotely the user can establish
effective monitor and control via the mobile phone set by sending commands in the form
of SMS. This system provides ideal solution to the problems caused in situations when a
wired connection between a remote appliance/device and the control unit might not be
feasible. The generator monitoring system is useful because of the following reasons;
It gives awareness of the power stability and the behavior of power supply thus
one can be able to deal with the problem of constant power outage by looking for
Alternative means of power supply
It records the time of the duration and in the process letting someone know in
advance the effect of the damage caused by the power outage
If one is far-away from the microcontroller based monitoring unit, with the
facilities of reporting the failures to a central control via GSM module, one can be
able to respond to the situation as soon as possible
The subject matter disclosed herein relates to a fault detection system system , and more
specifically to a fault detection system including a generator and a power converter that is
selectively connected to the generator.
Wind turbines are one alternative to conventional sources of energy. A wind turbine
includes multiple blades that are connected to a rotor, where spinning of the blades by
wind spins a shaft of the rotor. The rotor is connected to a generator that generates
electricity. Some wind turbines include a gearbox that couples the rotor to the generator.
Various types of generators are employed in wind turbines such as, for example,
induction machines and separately excited synchronous machines. Specifically, one type
of generator that may be employed is a permanent magnet generator. The permanent
magnet generator allows for higher efficiency but, because the permanent magnet
generator is excited by permanent magnets, the permanent magnet generator is almost
always capable of producing voltage when spinning Thus, as long as the permanent
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
magnet generator is spinning, voltage will typically be produced. However, a fault may
occur on the output of the permanent magnet generator while voltage is being produced.
Thus, a breaker may be provided to the output of the generator to generally prevent the
current flow in the event of a fault.
A power converter system may also be employed to convert the variable frequency
electrical output power of the generator to an AC electrical power that matches the
frequency of an electrical grid. Sometimes the power converter is not activated. For
example, the power converter may not be activated if there is not adequate wind,
maintenance work is being performed on the wind turbine, or in the event the wind
turbine is nonoperational.
A fault may occur between the cables that connect the generator to the power converter.
For example, the fault may be a short or an open circuit. In the event the power converter
is activated, detection of a fault between the generator and the power converter is
typically relatively simple to detect. While operating, both the power converter and the
breakers an internal trip relay will detect the fault. The power converter will shut down
and the breaker will open. However, in the event the power converter is not activated, this
fault may go undetected. When a generator breaker is in a closed position, the power
converter may or may not be activated. One approach for detecting a fault between the
generator and the power converter when the power converter is not activated but the
breaker is closed involves employing an internal trip relay in the generator main circuit
breaker. However, the internal trip relay may not always be reliable at lower frequencies,
and may also be prone to overheating while the power converter is activated due to the
current harmonics produced by the power converter.
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Microcontroller
89c52: The AT89C52 is a low-power, high-performance CMOS 8-bit microcontroller
with 8K bytes of in-system programmable Flash memory. The device is manufactured
using Atmel’s high-density non-volatile memory technology and is compatible with the
industry standard 80C51 instruction set and pin out. The on-chip Flash allows the
program memory to be reprogrammed in-system or by a conventional non-volatile
memory programmer. By combining a versatile 8-bit CPU with in system programmable
Flash on a monolithic chip, the Atmel AT89C52 is a powerful microcontroller, which
provides a highly flexible and cost-effective solution to many, embedded control
applications. The AT89C52 provides the following standard features: 8K bytes of Flash,
256 bytes of RAM, 32 I/O lines, Watchdog timer, two data pointers, three 16-bit
timer/counters, a six10 vector two-level interrupt architecture, a full duplex serial port,
on-chip oscillator, and clock circuitry. In addition, the AT89C52 is designed with static
logic for operation down to zero frequency and supports two software selectable power
saving modes. The Idle Mode stops the CPU while allowing the RAM, timer/counters,
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serial port, and interrupt system to continue functioning. The Power-down mode saves the
RAM con-tents but freezes the oscillator, disabling all other chip functions until the next
interrupt
PIN DESCRIPTION
Although 8051 family members come in different packages, such as DIP (dual in-
line package), QFP (quad flat package), and LLC (leadless chip carrier), they all have 40
pins that are dedicated for various functions such as I/O, RD, WR, address, data, and
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
interrupts. It must be noted that some companies provide a 20-pin version of the 8051
with a reduced number of I/O ports for less demanding applications. However, since the
vast majority of developers use the 40-pin DIP package chip, we will concentrate on that.
Examining Figure 4-1, note that of the 40 pins, a total of 32 pins are set aside for
the four ports P0, P1, P2, and P3, where each port takes 8 pins. The rest of the pins are
designated as VCC, GND, XTAL1, XTAL2, ALE/PROG, RST, EA, PSEN. Of these 8
pins, six of them (VCC, GND, XTAL1, XTAL2, RST, and EA) are used by all members
of the 8051 and 8031 families.
In other words, they must be connected in order for the system to work, regardless
of whether the microcontroller is of the 8051 family. The other two pins, PSEN and
ALE, are used mainly in 8031-based systems. We first describe the function of each pin.
Ports are discussed separately.
VCC
Pin 40 provides supply voltage to the chip. The voltage source is +5V.
GND
Pin 20 is the ground.
Fig. 4-2 (a). XTAL Connection to 8051 Fig. 4-2 (b). XTAL Connection to
an External Clock Source
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
XTAL1 and XTAL2
The 8051 has an on-chip oscillator but requires an external clock to run it. Most
often a quartz crystal oscillator connected to inputs XTAL1(pin 19) and XTAL2 (pin 18).
The quartz crystal oscillator connected to XTAL1 and XTAL2 also needs two capacitors
of 30 pF value. One side of each capacitor is connected to the ground as shown in Figure
4-2 (a).
It must be noted that there are various speeds of the 8051 family. Speeds refers to
the maximum oscillator frequency connected to XTAL. For example, a 12-MHz chip
must be conneted to a crystal with 12 MHz frequency or less. Likewise, a 20-MHz
microcontroller requires a crystal frequency of no more than 20 MHz. When the 8051 is
connected to a crystal oscillator and is powered up, we can observe the frequency on the
XTAL2 pin using the oscilloscope.
If you decide to use a frequency source other than a crystal oscillator, such as a
TTL oscillator, it will be connected to XTAL1; XTAL2 is left unconnected, as shown in
Figure 4-2 (b).
RST
Pin 9 is the RESET pin. It is an input and is active high (normally low). Upon
applying a high pulse to this pin, the microcontroller will reset and terminate all activities.
This is often referred to as a power-on reset. Activating a power-on reset will cause all
values in the registers to be lost.
RESET Value of Some 8051 Register
Register Reset Value
PC 0000
ACC 0000
B 0000
PSW 0000
SP 0007
DPTR 0000
(Fig. 4-1: RESET Value of Some 8051 Registers)
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Table 4-1 provides a partial list of 8051 registers and their values after power-on
reset.
Notice that the value of the PC (program counter) is 0 upon reset, forcing the CPU to
fetch the first opcode from ROM memory location 0000. This means that we must place
the first line of source code in ROM location 0 because that is where the CPU wakes up
and expects to find the first instruction. Figure 4-3 shows two ways of connecting the
RST pin to the power-on reset circuitry.
In order for the RESET input to be effective, it must have a minimum duration of
2 machine cycles. In other words, the high pulse must be high for a minimum of 2
machine cycles before it is allowed to go low.
EA
The 8051 family members, such as the 8751, 89C51, or DS5000, all come with
on-chip ROM to store programs. In such cases, the EA pin is connected to V CC. For
family members such as the 8031 and 8032 in which there is no on-chip ROM, code is
stored on an external ROM and is fetched by the 8031/32. Therefore, for the 8031 the EA
pin must be connected to GND to indicate that the code is stored externally. EA, which
stands for “external access,” is pin number 31 in the DIP packages. It is an input pin and
must be connected to either VCC or GND. In other words, it cannot be left unconnected.
In 8051 chips with on-chip ROM, such as the 8751, 89C51, EA is connected to VCC.
PSEN
This is an output pin. PSEN stands for “program store enable”. In an 8031-based
system in which an external ROM holds the program. code, this pin is connected to the
OE pin of the ROM.
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
ALE
ALE (address latch enabel) is an output pin and is active high. When connecting
an 8031 to external memory, port 0 provides both address and data. In other words, the
8031 multiplexes address and data through port 0 to save pins. The ALE pin is used for
demultiplexing the address and data by connecting to the G pin of the 74LS373 chip.
I/O port pins and their functions
The four ports P0, P1, P2, and P3 each use 8 pins, making them 8-bit ports. All
the ports upon RESET are configured as output, ready to be used as output ports. To use
any of these ports as an input port, it must be programmed.
Oil Level Sensor: The Rxl oil level sensor are best suited to oil level
measurement and the oil mainly used in generator for purpose of using cooling of
generator .When temperature of generator goes high, oil level in generator tank decreases
due to heating effect .For normal operation of generator oil level should maintain at
required level. If oil level decrease beyond required level, it affect cooling generator.
Temperature Sensor The Thermocouples are best suited to very low and
very high temperature measurements. The typical measuring range is from −270 ◦C to
+2600 ◦C. In addition, thermocouples are low-cost, very robust. The temperature sensor
which is used to monitoring the generator temperature and when the generator
temperature exceeds predefined limits it is known through temperature sensor. The choice
of a sensor depends on the accuracy, the temperature range, speed of response, thermal
coupling, the environment (Chemical, electrical, or physical) and the cost.
Fuel Level Sensor PH606 liquid level sensor measures different kinds of liquid
level by utilizing capacitive technology. The fuel level sensor using to monitoring the fuel
level of generator. The generator to maintain the level of fuel and an abnormal decrease in
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content could indicate fuel is being stolen. With a remote monitoring system that supports
alarms, a notification is sent immediately when the theft occurs. Even if it’s difficult to
catch the thieves, you’re at least aware of the situation and can schedule a refill to ensure
the gene rators have the fuel needed to operate. In cases where organized theft is
common, awareness of the tank’s fuel level might help you detect patterns and take
action.
GSM Modem: The SIM300 is a complete Tri-band GSM solution in a compact
plug-in module. The Featuring an industry-standard interface, the SIM300 delivers
GSM/GPRS900/1800/1900Mhz performance for voice, SMS, data and Fax in a small
form factor and with low power consumption. The leading features of SIM300 make it
deal fir virtually unlimited application, such as WLL applications (Fixed Cellular
Terminal), M2M application, handheld devices and much more .This GSM Modem can
accept any GSM network operator SIM card and act just like a mobile phone with its own
unique phone number. Advantage of using this modem will be that you can use its RS232
port to communicate and develop embedded applications. Applications like SMS Control,
data transfer, remote control and logging can be developed easily. The modem can either
be connected to PC serial port directly or to any microcontroller. It can be used to send
and receive SMS or make/receive voice calls. It can also be used in GPRS mode to
connect to internet and do many applications for data logging and control. In GPRS mode
you can also connect to any remote FTP server and upload files for data logging. This
GSM modem is a highly flexible plug and play quad band GSM modem for direct and
easy integration to RS232 applications. Supports features like Voice, SMS, Data/Fax,
GPRS and integrated TCP/IP stack.
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Software Implementation The proposed system has implemented
LabVIEW which stands for Laboratory Virtual Instrumentation Engineering Workbench,
is a graphical computing environment for instrumentation, system design, and signal
processing. In my project using Lab view is very easiest and more powerful tools for
acquiring, analyzing and presenting real word date. By using LabVIEW to prototype,
design, test, and implement our instrument systems, it can reduce system development
time and increase productivity using LabVIEW, can create 8-bit compiled applications
that give you the fast execution speeds needed for custom data acquisition, test,
Measurement, and control solutions and also can create stand-alone executable mode of
function
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Flow Chart
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Working
The use of Generators has become a very common in almost using every infrastructure
companies, Industries, hospitals, Townships etc. as the application of generators has
become common the problems occurred in using them have also become very common
such as low fuel, High temperature and these problems can be solved by continuous
monitoring of generator, a system which can remotely monitoring generator and provide
you all the information through mobile. The GSM a monitor the power generator placed
at the remote areas and increasesits efficiency by monitoring the various parameters of
generator, Reporting critical Problems minimizes downtime and maximizes availability
by sending if any failure in generator through messages instantly to diagnosis and
emergency service dispatch if required and the GSM is used in standby, prime and rental
power applications. Thissystem provides ideal solution to the problems caused in
situations when a wired connection between a remote appliance/device and the control
unit might not be feasible. The project is aimed to analyzing and testing the use of mobile
phones to remotely monitor an appliance control system through GSM based wireless
communication. The Microcontroller would then control a device based on the
information given to it.
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Algorithm
Step 1: Start the program
Step 2: To initialize the system
Step 3: Get Hardware Software for relevant application.
Step 4: To monitoring the generator status and parameter and if any abnormal conditions occur
it is automatically intimated to authorized person.
Step 5: If new SMS received on mobile and go to step3 else, go to step1
Step 6: Receive SMS
Step 7: Check SMS pattern
Step 8: Control the device based on status and operator can making a decision.
Step 9: Notify end user Step 10: Go to step1
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Result
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GSM Based Generator Monitoring System for Steel Melting Shop 2019-2020
Conclusion
As steel manufacturing extends from ore handling to tracking wagon movement carrying
finished steel, operations are complex and there is no single control system deployed to
control the entire integrated plant. In particular the suggested system will be a powerful,
flexible and secure tool that will offer this service at any time, and from anywhere with
the constraints of the technologies being applied. However, the GSM system poses some
potential threats. But the suggested system can be used as a reference or as a base for
realizing a scheme to be implemented in other projects of greater level. Further it is hoped
that it will serve as a basis for further study of industrial power management strategies
and The GSM based monitoring of generator is quite useful as compared to manual
monitoring and also it is reliable as it is not possible to monitor always the oil level,
temperature rise, manually.
After receiving of message of any abnormality we can take
action immediately to prevent any catastrophic failures of generator. We need not have to
check generator status and thus we can recover the system in less time. The time for
receiving messages may vary due to the public GSM network traffic but still then it is
effective than manual monitoring..
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BIBILIOGRAPHY
1. Electronic Communication Systems
George Kennedy.
2. Radio Engineering
G. K. Mithal.
3. Principles of Electronics
V. K. Mehta.
4. Programming & Customizing the 8051
Microcontroller
Myke Predko.
5. Emdeded System Design using 8051 Microcontroller
Prof. Satish Shah
6. Analog Circuits
D. V. Kamat & Sudha Kamat.
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