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Abstract:
Monitoring and keeping tracking of your electricity consumption for verification is a tedious task
today since you need to go to meter reading room and take down readings. Well it is important to
know if you are charged accordingly so the need is quite certain.
Well we automate the system by allowing users to monitor energy meter readings over the
internet. Our proposed system uses energy meter with microcontroller system to monitor energy
usage using a meter. The meter is used to monitor units consumed and transmit the units as well
as cost charged over the internet using Wi-Fi connection. This allows user to easily check the
energy usage along with the cost charged online using a simple web application. Thus the energy
meter monitoring system allows user to effectively monitor electricity meter readings and check
the billing online with ease. It is a difficult job for the electricity board officials to manually take
meter readings and calculate bill as it is time consuming and requires man power. Billing
consumers for energy consumption is not uniform. It is a tedious job for the electricity board
official to manually go and take meter readings of big industrialists and reset their maximum
demand after recording it. Even the latest energy meter is not tamper proof. Hence considering
all these factors it is possible to design an energy meter that is tamper proof, supports automatic
metering and billing system, and at the same time helps in finding the fault location of
transmission lines. The same meter can be used to take the readings of industrialist which sends
these readings to a secured data location and automatically reset it after recording it.
Introduction:
The meters currently in use are only capable of recording kWh units. The kWh units used then
still have to be recorded monthly by meter readers on foot. The recorded data need to be
processed by a meter reading company for processing. The meter reading company needs to
firstly link each recorded power usage datum to an account holder and then determine the
amount owed by means of the specific tariff in use. Only then can the bills be sent to the users.
When developing a technology that might replace one which has been in use for more than thirty
years, not only the key issue needs to be addressed, but added functionality and solutions to other
obstacles presented by the previous technology need to be addressed, for example the elimination
of physical address (on site) meter reading and forcibly reducing the national load during critical
load times.
The engineering challenge is to develop a product that can serve as an “in line” replacement for
the meters currently in use, while already implementing some (if not all) of the new technology
proposed above. This entails that the meter under development has to work under the old
circumstances and perform all the previous functions (be backwards compatible) but also be able
to relay the information in a new way and perform additional functions, without the need of
replacing all the meters on the electrical grid simultaneously or the need for extensive new
infrastructure. As is always the case when developing a long term technology, besides addressing
the main problem, one needs to foresee and address other problems and shortcomings too. In
other words, the problem of making residential electricity meters compatible with variable tariffs
is only half the battle.
Energy Meter:
Energy meter or watt-hour meter is an electrical instrument that measures the amount of
electrical energy used by the consumers. Utilities is one of the electrical departments, which
install these instruments at every place like homes, industries, organizations, commercial
buildings to charge for the electricity consumption by loads such as lights, fans, refrigerators and
other home appliances. Energy meter measures the rapid voltage and currents, calculate their
product and give instantaneous power. This power is integrated over a time interval, which gives
the energy utilized over that time period.
Background:
Today, humanity can be classified as living in a “machine society” where technological tools are
predominantly at different levels, interfacing in the day–to-day activity of man. These livelihood
activities constitute and deliver economic, social and political benefits and potential risks to the
survivability of nations –especially developing nations like ours. Electricity has become one of
the basic requirements of human civilization, being widely deployed for domestic, industrial and
agricultural purposes. In spite of the very well developed sources of electricity, there are a
number of problems with distribution, metering, billing and control of consumption. Electricity
is one of the vital requirements for sustainment of comforts of life and so it should be used very
judiciously for its proper utilization. But in our country we have lot of localities where we have
surplus supply for the electricity while many areas do not even have access to it. Our policies of
its distribution are also partially responsible for this because we are still not able to correctly
estimate our exact requirements and still power theft is prevailing every home individually is
reduced. This results in considerable loss of human hours and also provides considerable details
regarding the average consumption of a locality so that power supply can be made according to
these data. This will help the officials in deciding the specifications of transformers and other
instruments required in power transmission and distribution. This idea is economically efficient
as well because the meter reading can be gotten at a very low cost.
Existing System:
In existing system an energy meter is installed at every house which records energy consumed by
user. Then a person hired by APEB(Andhra Pradesh Electricity Board) goes to each and every
house and collects the data which he gives to APEB. Then APEB calculates the bill. According to
that data bill is send to user by post to user. If a user doesn’t pay the bill then after a lot of time
period APEB sends workers to cut off that particular power supply. When that person pays the
bill then APEB sends a man to connect the power supply. This system has some major drawbacks
such as going to remote areas is not easy. The person sends APEB may or may not know the
area. While going to remote area a lot of time is wasted. That person may not take reading from
all users. There are possibilities of error in taking the reading. Then he comes back to submit data
to APEB. Then APEB is able to calculate the result. In this process a lot of time is wasted. in this
system a lot of labor work is needed. APEB have to pay these people extra money to do work. If
APEB have to cut power supply then a person goes manually cut supply. At first a power supply
is disconnected and again have to reconnect a person has to go that place and connect.
Proposed System:
In this system ARM Processor is used for selecting prepaid mode. In prepaid mode balance can
be filled by user as per requirement. This proposed system operates with high speed. For prepaid
mode it sends “Balance low” message to user when the balance is low with the help of Node
MCU module. Proposed model Almost all the meter reading systems consists of three primary
components. We divided the whole AMR system into four basic units. These are: Reading unit,
Communication unit, Data receiving and processing unit, billing system.
Problem Statement:
In Conventional metering system to measure electricity consumption the energy provider
company hire persons to visit each house and record meter reading manually which is used for
billing, the bill then sent to consumer by post or hand delivery, this is not only sluggish but
laborious, with the company having no control over these meters. There is a stark amount of
revenue loss being incurred by our country due to energy theft which is a serious problem,
people try to manipulate meter reading by adopting various corrupt practices such as current
reversal, partial earth fault condition, bypass meter, magnetic interference etc. With the aid of
this project a definite solution is proffered which allows power companies to have total control
over energy meters and have real time information of same from a remote location with little
human effort and at reduced cost as compared to conventional methods.
Formulation of a Design Problem:
performs residential electrical energy metering,
conforms to IEC 61036 Class II4specification,
generates a pulse output proportional to the energy consumed (kWh),
logs these recorded pulses to an internet based information structure at predetermined
intervals,
retrieves tariff rates and control signals from an internet based information structure at
predetermined intervals,
communicates relevant consumption estimates and tariff data to the user via an LCD,is
able to forcibly remove power to non-essential loads on behalf of the utility.
Objective:
The purpose of this project is the remote monitoring and control of the domestic energy
meter; its aims includes: to design a circuit which continuously monitors the meter reading and
sends message to electricity company, programming of the NodeMCU with AT (Attention)
command sequence, interfacing the programmable chip with the personal computer, interfacing
the programmable chip with the energy meter, interfacing of NodeMCU with the
programmable chip, sending messages from the remote phone to control device.
Functional analysis:
Software Specifications:
Arduino Compiler
MC Programming Language: C
IoT Gecko
Specifications:
The system must interface with the input power line FU1 in a similar fashion as previous
energy meters which are to be replaced.
The output power network FU2 should be able to connect to the system in a similar
fashion as was the case with previous energy meters, but should also be able to be
connected in a different (dual distribution) manner as to utilise the non-essential load
teleswitch capabilities.
The energy metering subsystem FU3 should be able to measure 220V 50Hz energy
consumption up to Class II measurement accuracy.
The computational and control unit FU5 should be able perform all of the control tasks
such as counting energy pulses, driving the display and communicating with the GPRS
module in such a manner that none of these functions are compromised (e.g., pulses are
incorrectly counted due to the display being updated).
In addition to this, FU5 should give a reasonable estimate of the calculations performed
by FU5 such as instantaneous power consumption and cost of energy per time unit.
These data do not need to be precise, as all important calculations are performed in other
parts of the system using floating point calculations.
The visual display FU6 should provide the user with the relevant tariff information and
consumption estimates as calculated by FU5 with the goal of implementing demand side
management (DSM) and incentivise users to decrease consumption at peak load times
(the tariff will be higher and thus the cost of consumption will also be greater).
The GPRS module FU7 should adequately perform communication with the database
FU10 as requested by FU5. In the event of a lost connection, it should clearly
communicate this to FU5 while re-establishing the connection.
FU8 as well as FU11 are beyond the scope of this project as discussed earlier.
FU9 should log all the data received from the energy meter correctly and provide the
meter with the requested data in a prompt and correct fashion.
FU10 should always be accessible although this is largely dependent on FU8 and should
be accessible to multiple users simultaneously without creating data handling conflicts.
FU12 must be able to connect to the database (provided FU11 is present) and perform all
data requests and control signal uploads as requested by the user in a desired fashion,
promptly and free from errors.
Literature Survey:
Economic Fallacies of fixed electrical tariffs:
An electricity meter or energy meter is a device that measures the amount of electric energy
consumed by a residence, business, or an electrically powered device. Electricity meters are
typically calibrated in billing units, the most common one being the kilowatt hour (kWh). The
electric power company which supplies the electricity installs the electric meters to measure the
amount of electricity consumed by each of its customers. Researchers have proposed different
implementation techniques for Automatic Meter Reading (AMR). According to the structure of
cost incurred on an electricity utility by selling electricity to consumers can be divided into two
parts: a fixed base cost (nodal cost) and a variable floating cost. The node cost is made up of
fixed costs that the utility experiences.
These include: maintenance of the infrastructure and generation equipment; staff salaries and
the running cost of base load generators (which is very low in countries with a lot of hydro-
generation capacity). In other words, it is the marginal cost of normal utility operation.
The floating cost represents: short term rise in fuel price and amount of peak load generation
taking place. These are costs that only start having an effect as the demand rises toward capacity.
Although there exist various tariff structures and the science of tariff design is a whole field on
its own, a main categorisation can be made between fixed tariff and variable tariff structures,
where most industrial electricity consumers (such as mines and factories) use a variable tariff and
residential consumers use a fixed tariff. The variable tariff imposed on most large consumers is
structured as follows.
Normally the tariff comprises of three separate costs between which are differentiated:
1. Fixed charges (R/month)
2. Volumetric charges (R/kWh)
3. Demand charges (R/kWpeak or R/kVAR)
The fixed charges account for invariable (slow varying) costs such as maintenance of the
infrastructure. The volumetric charge recovers the capital that would have been expended if all
the consumers constantly used all of (but not more than) the utility’s base load capacity and the
demand charge is responsible for recovering the cost of peak load generation, but also as
incentive to clients not to have a high peak demand. This kind of tariff is an example of a shaped
tariff. The foundation for a shaped tariff is its obedience towards the economic supply and
demand model. In other words, a heightened demand will end up costing proportionally more.
History of Electric Energy Meters:
Direct Current (DC):
As commercial use of electric energy spread in the 1880s, it became increasingly important that
an electric energy meter was required to properly bill customers for the cost of energy. Edison at
first worked on a DC electromechanical meter with a direct reading register, but instead
developed an electrochemical metering system, which used an electrolytic cell to totalize current
consumption. At periodic intervals the plates were removed, weighed, and the customer billed.
An early type of electrochemical meter used in the United Kingdom was the 'Reason' meter. This
consisted of a vertically mounted glass structure with a mercury reservoir at the top of the meter.
As current was drawn from the supply, electrochemical action transferred the mercury to the
bottom of the column. Like all other DC meters, it recorded ampere-hours. Once the mercury
pool was exhausted, the meter became an open circuit. It was therefore necessary for the
consumer to pay for a further supply of electricity. The first accurate, recording electricity
consumption meter was a DC meter by Dr Hermann Aron, who patented it in 1883.
Alternating Current (AC):
The first specimen of the AC kilowatt-hour meter produced on the basis of Hungarian Ottó
Bláthy's patent and named after him. These were the first alternating-current watt-hour meters,
known by the name of Bláthy-meters. Also around 1889, Elihu Thomson of the American
General Electric company developed a recording watt meter (watt-hour meter) based on an
ironless commutator motor. This meter overcame the disadvantages of the electrochemical type
and could operate on either alternating or direct current. In 1894 Oliver Shallenberger of the
Westinghouse Electric Corporation applied the induction principle previously used only in AC
ampere-hour meters to produce a watt-hour meter of the modern electromechanical form, using
an induction disk whose rotational speed was made proportional to the power in the circuit.
Although the induction meter would only work on alternating current, it eliminated the delicate
and troublesome commutator of the Thomson design.
UNIT of measurement:
The most common unit of measurement on the electricity meter is the kilowatt hour (kWh),
which is equal to the amount of energy used by a load of one kilowatt over a period of one hour,
or 3,600,000 joules. Demand is normally measured in watts, but averaged over a period, most
often a quarter or half hour. Reactive power is measured in "thousands of volt ampere reactive-
hours", (kvarh). By convention, a "lagging" or inductive load, such as a motor, will have positive
reactive power.
Types of meters:Electricity meters operate by continuously measuring the instantaneous voltage
(volts) and current (amperes) to give energy used (in joules, kilowatt-hours etc.). The meters fall
into two basic categories, electromechanical and electronic.
Electromechanical meters:
The electromechanical induction meter operates by counting the revolutions of a nonmagnetic,
metal disc which rotates at a speed proportional to the power passing through the meter. The
number of revolutions is thus proportional to the energy usage. The voltage coil consumes a
small and relatively constant amount of power, typically around 2 watts which is not registered
on the meter. The current coil similarly consumes a small amount of power in proportion to the
square of the current flowing through it, typically up to a couple of watts at full load, which is
registered on the meter. The disc is acted upon by two coils. One coil is connected in such a way
hat it produces a magnetic flux in proportion to the voltage and the other produces a magnetic
flux in proportion to the current. The field of the voltage coil is delayed by 90 degrees, due to the
coil's inductive nature, and calibrated using a lag coil. A permanent magnet exerts an opposing
force proportional to the speed of rotation of the disc. The equilibrium between these two
opposing forces results in the disc rotating at a speed proportional to the power or rate of energy
usage. The disc drives a register mechanism which counts revolutions. The type of meter
described above is used on a single-phase AC supply.
Electronic meters:
Electronic meters display the energy used on an LCD or LED display, and some can also
transmit readings to remote places. In addition to measuring energy used, electronic meters can
also record other parameters of the load and supply such as instantaneous and maximum rate of
usage demands, voltages, power factor and reactive power used etc. They can also support time-
of-day billing, for example, recording the amount of energy used during on-peak and off peak
hours.
Class Diagram:
Sequence diagram:
Component Diagram:
System Description:
The GSM Based Energy Meter is an electronic unit design to take real time energy usage using a
current sensing method which is then communicated to a microcontroller, who takes the
appropriate calculations and displays on an LCD. A GSM MODEM is incorporated with the unit
so as to make remote control of the meter unit by doing either of the following:
Connect the unit to power Grid.
Disconnect the unit from power Grid.
Take meter reading.
Recharge the meter unit.
Reset the meter unit.
Design alternatives
The project as a whole can be divided into fields of design. Each of these fields requires a
different approach to making design and implementation choices and should be treated
accordingly. It is very important to remember, however, that the design and implementation
choice of each of these fields will most probably affect all the other fields as well and thus it is
imperative to keep all the other design aspects of the project in mind when making these
decisions and not simply choose the optimal solution for the specific challenge at hand. The
design fields that stand out significantly for a project such as this include energy measurement,
control circuitry, communication system, data handling system and information structure.
Relay Switching
A relay is an electromagnetic switch. In other words it is activated when a current is applied to it.
Normally a relay is used in a circuit as a type of switch. The relay in this circuit is used to isolate
the consumer load from the power grid when either the loaded units are exhausted or the meter is
been tampered with.
Fig. Relay Circuit
Since the relay is transistor driven, the relay is used on the collector side. The voltage impressed
on the relay is always full rated coil voltage, and in the OFF time, the voltage is completely zero
for avoidance of trouble in use. The NPN transistor is used for the switching of the relay. The BC
547 NPN transistor is selected based on current, voltage and power handling capabilities. The
transistor is driven into saturation (turned ON) when a LOGIC 1 is written on the PORT PIN thus
turning ON the relay. The relay is turned OFF by writing LOGIC 0 on the port pin. A diode
1N4007 is connected across the relay coil; this is done so as to protect the transistor from
damage due to the ‘BACK EMF’ generated in the relay's inductive coil when the transistor is
turned OFF. When the transistor is switched OFF the energy stored in the inductor is dissipated
through the diode & the internal resistance of the relay coil. This diode is also called as free-
wheeling diode. Resistor R10 is used as a Series Base Resistor to set the base current. This is
calculated thus:
LED Indicators:
A “Light Emitting Diode” or LED as it is more commonly called, is basically a specialised type
of PN junction diode, made from a very thin layer of fairly heavily doped semiconductor
material. When the diode is forward biased, electrons from the semiconductors conduction band
recombine with holes from the valence band releasing sufficient energy to produce photons
which emit a monochromatic (single colour) of light. Three LED’S are visible in the design as
indicators.
Fig. Led schematic symbol and I-V characteristics curves showing the different colours
available
Energy measurement alternatives
One of the biggest choices presented when implementing a project such as this, is which energy
measurement technique to utilise. As was discussed, the prevalent technique for residential
energy measurement was by means of electro-mechanical Ferraris disc meters. These meters
proved a great success for an era that had not yet seen solid state (electronic) energy
measurement methods. Thirty years later, there exist numerous electronic methods to measure
energy that are not only usually lower in cost but also more accurate and less prone to failure (no
moving parts) than their electro-mechanical predecessors. In the field of solid state energy
measurement, again there exists a vast variety of different implementations to effectively
measure energy. The basic principle on which most of these methods function is the
measurement of instantaneous voltage and current that exists on the line, multiplying these
signals to produce the instantaneous power and averaging (or integrating) this over time to end
up with the amount of energy consumed. The mathematics behind this principle is as follow:
Where P is power in watts, V is voltage, I is current in ampere and E is energy in joules. The
most basic electronic implementation of this mathematical function would be to multiply the
voltage and current signals with an analogue multiplier such as the AD5346 and then sampling
this instantaneous power signal for the purposes of integrating and processing. Another method
of discretely implementing the power calculation would be to sample both the voltage and
current signals and multiply them digitally on the device (DSP or microcontroller) that will be
used for the integration and processing. A third fully electronic method relies on the principle of
determining the maximum values of the voltage and current signals, but also the phase difference
between them and then by trigonometric methods, the power as well as the power factor can be
determined. This method adds unnecessary complexity to the energy measurement as residential
electrical consumption is only billed according to real power consumption. A fourth category can
be assigned to off-the-shelf products and IC’s that perform the whole energy measurement
function and communicates only the power consumption to other circuitry. There exist numerous
IC’s from various large microelectronic and semiconductor companies that perform this function,
with variations in factors such as the amount of phases it can monitor or which kind of voltage
and current transducer to be used but one commonplace that the energy measurement industry
seems to be heading towards, is the manner in which this consumption data is communicated
back, namely energy pulsing. This method relies on pulses acting as integration markers, for
example, if the specific device is designed to deliver 31000 pulses/kWh then each pulse can be
viewed as a 1/31000th of a kWh energy unit.
Design alternatives for data handling
Because most of the value adding that this approach to residential energy metering holds is the
revolutionary way in which it accepts data in the form of tariffs and control signals from the
utility and returns logged energy usage data, great consideration must be given to the manner in
which the data handling will take place such as the platform to be used for data handling. Again
it is necessary to envision the system as a whole (as if the system were already commissioned
and is working). The first aspect worth mentioning is that there could potentially be millions of
users. All these users need to receive the same data nationally, or at least regionally (i.e. the tariff
in effect and possibly load control signals), but all the users have unique data to communicate
back to the utility (namely consumption). This then needs to be a deciding factor in choosing a
data handling platform. In engineering practice it is often acceptable to set up a data logging pc
or server for the purposes of recording, field acquired data. In this case the sheer number of users
that must be able to communicate data back to the utility would render this traditional
configuration as insufficient. It is thus proposed to investigate a solution such as used by most
data handling companies, namely a relational database of some sort. Where a relational database
really comes into its own is when multiple users (thousands, even millions) are connected to this
data structure. Where a data logging server might experience conflicts if a user is trying to
modify data that is being accessed by another user, a relational database enforces a FIFO (first in
first out) structure.
Information structure alternatives
When using a data logging server configuration as discussed earlier, information structure is not
really the key to the result of the experiment, as long as all the relevant data are logged and the
process is even more useful if it is time-stamped. When using a relational database, however, it is
imperative to have a good information structure in place that guarantees mapable identifier fields
between tables and no conflicts between primary keys. The information structure involves issues
such as the breakdown of the database structure and the way in which different components of
the system (energy meters, control room and billing authority) interface with the database and
what privileges each of these agents possess. Another design alternative concerned with the
information structure is whether each meter will access the database via a unique user account.
Although each meter will be uniquely identified in the database, they do not need to possess a
unique user account with unique administrative rights.
Implementation:
When considering thoroughly the concept of energy measurement as the time integral of
instantaneous power, many interesting issues arise. As is the case with any digital circuitry,
continuous time integration is impossible and will have to be substituted with discrete time
summation. The next challenge then is to determine an adequately small time interval over which
to integrate the instantaneous power. When considering previously used electromechanical
energy measurement devices, these are subject to some extent to mechanical inertia, effectively
acting on a low pass filter for changes in the instantaneous power. In other words, if the speed at
which the counter turns is proportional to the amount of instantaneous power consumed and the
maximum load is suddenly connected, the counter would not be able to accelerate to its
maximum speed immediately.
Software Description
Arduino IDE:
Arduino is an open-source prototyping platform based on easy-to-use hardware and software.
Arduino boards are able to read inputs - light on a sensor, a finger on a button, or a Twitter
message - and turn it into an output - activating a motor, turning on an LED, publishing
something online. You can tell your board what to do by sending a set of instructions to the
microcontroller on the board. To do so you use the Arduino programming language (based on
Wiring), and the Arduino Software (IDE), based on Processing. Over the years Arduino has been
the brain of thousands of projects, from everyday objects to complex scientific instruments. A
worldwide community of makers - students, hobbyists, artists, programmers, and professionals -
has gathered around this open-source platform, their contributions have added up to an
incredible amount of accessible knowledge that can be of great help to novices and experts alike.
NodeMCU Firmware:
NodeMCU is an open source IoT platform. It uses the Lua scripting language. It is based on the
eLua project, and built on the ESP8266 SDK 0.9.5. It uses many open source projects, such as
lua-cjson, and spiffs. It includes firmware which runs on the ESP8266 Wi-Fi SoC, and hardware
which is based on the ESP-12 module. NodeMCU was created shortly after the ESP8266 came
out. In December 30, 2013, Espressif systems began production of the ESP8266.The ESP8266 is
a Wi-Fi SoC integrated with a Tensilica Xtensa LX106 core, widely used in IoT applications.
NodeMCU started in 13 Oct 2014, when Hong committed the first file of NodeMCU - firmware
to GitHub. Two months later, the project expanded to include an open-hardware platform when
developer Huang R committed the gerber file of an ESP8266 board, named devkit 1.0. Later that
month, Tuan PM ported MQTT client library from Contiki to the ESP8266 SoC platform, and
committed to NodeMCU project, then NodeMCU was able to support the MQTT IoT protocol,
using Lua to access the MQTT IoT protocol, using Lua to access the MQTT broker. Another
important update was made on 30 Jan 2015, when Devsaurus ported the u8glib to NodeMCU
project, enabling NodeMCU to easily drive LCD, Screen, OLED, even VGA displays.
Blynk App:
Blynk is a Platform with iOS and Android apps to control Arduino, Raspberry Pi and the likes
over the Internet. It’s a digital dashboard where you can build a graphic interface for your project
by simply dragging and dropping widgets. It’s really simple to set everything up and you'll start
tinkering in less than 5 mins. Blynk is not tied to some specific board or shield. Instead, it's
supporting hardware of your choice. Whether your Arduino or Raspberry Pi is linked to the
Internet over Wi-Fi, Ethernet or this new ESP8266 chip, Blynk will get you online and ready for
the Internet of Your Things.
Software Integration Proprietary process software, analytical applications and standard databases
can be run separately from the direct factory process control, using both-real time and stored
information. Controllers required software programming to run specific applications and transmit
data from relays and sensors to other edge devices and/or the control centre for future analysis.
There are many software solutions for factory automation use: some are off-the-shelf and some
are proprietary, used at different levels in a distributed control system. These software solutions
have become more advanced and have been created to work with the Internet of Things concept.
Factory management will often prefer to run applications on standard platforms with standard
software. Integrating these computers into the overall IoT factory automation concept via a
shared network, common information storage locally and in the cloud, and shared access to all
important process data through the IP addresses increases flexibility and computing capabilities –
while leaving the direct automated process management to the embedded controllers.
IoT Applications:
The IoT concept lends itself to solutions of specific problems in manufacturing. Process
efficiency challenges, scheduling, logistics and quality control are all issues that could benefit
from better, more timely and more accurate information. The IoT can deliver the information that
is required in real time with high accuracy. Companies are using these capabilities to improve
their operations. Medical device manufacturers are trying to reduce costs while complying with
regulations and delivering consistent quality. An IoT approach lets them identify bottlenecks in
production, unnecessarily high costs and quality issues easily and precisely. They can see from
production line data where inventory or material on hand is piling up due to lack of capacity at a
given production point. They can track costs to make sure high-cost parts and processes deliver
corresponding benefits. When products fail, they can track the serial number back to the
production line and see exactly how that product was manufactured and where the failure
originated. Solutions are often software based and can be implemented without major production
disruptions. The information containing the problems and the tools for implementing solutions
are both online.
The Internet of Things is coming and in some industries is already here but is in its infancy.
Industrial Automation is ahead of most other industries in the readiness for the Internet of Things
(IoT) and more specifically for the Industrial Internet of Things(IIoT). When one looks at the
deployment of the sensors, actuators, and low-level devices that are needed to enable IoT or IIoT,
Industrial Automation has an advantage.
Most industries are waiting on the deployment of the low-level connected devices to enable IoT
in that industry. Industrial Automation on the other hand already has over a billion connected
devices deployed. By connected device I mean an end node that is Internet Protocol (IP) enabled
or is directly controlled by a proxy device that is IP enabled. On a curve of connected devices
needed to make IoT effective, Industrial Automation is much higher up the curve than other
industries. That is not to say Industrial Automation is done growing with respect to IoT far from
it. There will be many more devices deployed at an increasing rate. The rate of growth will be
lower with respect to some of the other industries and especially in regards to commodity device
industries. The Industrial Automation rate of growth will still be impressive.
Where Industrial Automation may be lagging other industries is in the gathering of useful data
and the use of this data. Much of the information that resides on the end device that could be
useful is not gathered. Data that is not consumed at the field or process levels in the traditional
Industrial Automation hierarchy is not gathered. If it is gathered, the data is not being sent up the
network in most cases. The value of this data is increasing and Industrial Automation networks
are starting to collect the data and communicate this data farther up the hierarchy. Energy usage
and concerns are the first initiative spurring the change in the data transmission strategy.
However if the data is not used then there is no reason to collect it.
With all these enabled connected devices in Industrial Automation and the desire to communicate
more data there is a concern for cyber security. Stuxnet taught us this. Cyber security is being
addressed. Even in resource constrained devices there are solutions to support encryption and
other cyber security requirements. The Scalable Encryption Algorithm (SEA) is an example.
The Industrial Internet of Things will change how Industrial Automation networks are designed
and used, both now and in the future. IIoT will increase the productivity of the Industrial
Automation network. With the large number of currently deployed connected end devices, the
understanding of the value of new data that is available at the end device, the deployment of
cyber security practices, Industrial Automation is already part of the Internet of Things. There are
more changes to come for Industrial Automation and IIoT. Industrial Automation is ready for
these changes as well.
Operating systems & SOFTWARE with the support for real-time operating systems
Use of ESP32-WROVER compute module adds the support for real-time operating
systems (compared to most Raspberry Pi based Linux and Windows OS versions), and openness
of the Espressif’s platform to Moduino industrial automation controller. Thanks to enormous
community of ESP32 and Arduino users and developers, the Moduinocan now adapt existing
software solutions, tools and programming environments, for example:
ESP-IDF (Espressif IoT Development Framework)
Zephyr Project (scalable RTOS)
Arduino (C++)
MicroPython
Mongoose OS, etc.
Algorithms:
Algorithms or mathematics plays the most essential role in machine learning, for this is the tool
to deal with the data. Have a look at them may be not vital, but useful to understand the
application to it afterwards.
Bayesian Statistics
Bayesian methods adapt probability distribution to efficiently learn uncertain concepts (e.g. θ)
without over-fitting. The crux of the matter is to use the current knowledge (e.g., collected data
abbreviated as D) to update prior beliefs into posterior beliefs p(θ|D) α Q p(θ)p(D|θ), where p(θ|
D) is the posterior probability of the parameter given the observation D, and p(D|θ) is the
likelihood of the observation D given the parameter θ.
k-Nearest Neighbors(k-NN)
This supervised learning algorithm classifies a data sample (called a query point) based on the
labels (i.e., the output values) of the near data samples. Basically, the algorithm classifies k kinds
of cluster that the distance inside is minimum. This is a general classify algorithm.
Neural Network
For example, sensor node localization problem (i.e., determining node's geographical position).
Node localization can be based on propagating angle and distance measurements of the received
signals from anchor nodes [Dargie10]. Such measurements may include received signal strength
indicator (RSSI), time of arrival (TOA), and time difference of arrival (TDOA) as illustrated in
Figure 2 [Safavian91]. After several training, the neurons can computed the location of the node.
An SVM algorithm, which includes optimizing a quadratic function with linear constraints (that
is, the problem of constructing a set of hyperplanes), provides an alternative method to the multi-
layer neural network with nonconvex and unconstrained optimization problem
k-Means Algorithms
This is widely used for node clustering problem due to its linear complexity and simple
implementation. The k-means steps to resolve such node clustering problem are
(a) randomly choose k nodes to be the initial centroids for different clusters;
(b) label each node with the closest centroid using a distance function;
(c) re- compute the centroids using the current node memberships
(d) stop if the convergence condition is valid (e.g., a predefined threshold for the sum of
distances between nodes and their perspective centroids), otherwise go back to step (b)
Power supply
The power supply design will be implemented very flexibly, to allow for flexibility in the
installation options of the project. What is meant by this is that the input to the power supply
should be able to accept a wide range of input voltage (e.g. 10V-20V) AC or DC. The supply
definitely needs to be regulated to a specific voltage(s) and because of the low cost of linear
regulators, compared to buck switching regulators and the expected low power consumption of
the system, the higher efficiency of a buck switching regulator is not justified.
Instantaneous power approximation
The circuit responsible for the approximation of the instantaneous power consumption, was
originally also responsible for the energy measurement, by means of discrete time integration
and was also implemented with an analogue multiplier. This previous implementation also
uses only one ADC channel, where the new implementation uses two ADC channels.
This will entail, sampling the voltage and current from the respective voltage and current
transducers and then determining the appropriate instantaneous power approximation, either
from multiplication on the microcontroller or by lookup table within the microcontroller
software.
NodeMCU:
The NodeMCU is an open-source firmware and development kit that helps you to Prototype your
IOT product within a few Lua script lines.
Features:
Open-source
Interactive
Programmable
Low cost
Simple
Smart
WI-FI enabled
Arduino-like hardware IO
Advanced API for hardware IO, which can dramatically reduce the redundant work for
configuring and manipulating hardware. Code like arduino, but interactively in Lua
script.
Nodejs style network API Event-driven
API for network applicaitons, which faciliates developers writing code running on a
5mm*5mm sized MCU in Nodejs style. Greatly speed up your IOT application
developing process.
Specification: The Development Kit based on ESP8266, integates GPIO, PWM, IIC, 1-Wire and
ADC all in one board. Power your development in the fastest way combination with NodeMCU
Firmware! USB-TTL included, plug&play 10 GPIO, every GPIO can be PWM, I2C, 1-wire
FCC CERTIFIED WI-FI module
PCB antenna
Communication method
A basic decision tree is shown for different communication media.
Decision tree for communication medium
Although power line communication [18] seems like an appealing option, due to the fact that
the infrastructure already exists, this media would entail the successful implementation of a
technology that has only really succeeded under laboratory conditions. In addition to this,
issues such as cable theft could mean a break in the communication infrastructure serving
areas that are not necessarily without power.
From the remaining alternatives (i.e. wireless communication), if a radio link using frequency
shift keying (or similar) in some commercial radio band is chosen another crucial issue arises.
If one uses a high frequency (say 433MHz) half-duplex link, the link distance is limited to less
than a kilometre. This means that there will have to be a base station of some kind
(utilising different long distance communication such as ADSL8 or microwave link) for
approximately each 3.14 square kilometre9 of power grid, to relay the data over greater
distances. On the other hand, if a low frequency (say 1KHz) link is utilised such as that in the
UK , this will limit the communication to simplex, where the meters will not be able to
communicate any data back to the utility.
Detailed Design and Implementation
Theory:
This section is a detailed case (situation) study of different scenarios that the system will
encounter and the logical generic operational algorithms to deal with each of these instances. In
view of total the operating time of the system, downtime should represent an insignificant small
fraction of the total operating time. The start-up and initialisation of the system will therefore be
discussed along with prolonged power outages and maintenance routines. The first case that will
be discussed should then be the state in which the system will operate for the greater part of up-
time. Although there exists no real norm for residential energy usage, all metering systems have a
nominal current rating (relating to maximum and calibration currents), which is usually taken to
be 25A (or 220V*25A=5500W) which roughly translates to the equivalent of a geyser, a fridge,
and a few lights.
2.2.1.1 Normal off-peak tariff operation case
The case under discussion deals with the system operating with an off-peak tariff and a combined
cycle of energy usage. This case should be analogous to the current operation of residential
energy meters as there currently exists only one fixed tariff (assumed to be offpeak). The sole
duty of the energy meters currently in use is to measure the amount of energy consumed by the
consumer. The duties of the smart metering system, however, will be as
follows:
Measure all energy consumed by the consumer (up to Class II accuracy).
Connect to the internet to verify assumption that off-peak tariff is in effect, as well as
check for control signal status changes and log the consumption data since the last
connection to the MySQL database.
Calculate the approximate instantaneous power consumed.
Calculate the cost per time (R/h) of current energy usage.
Display the tariff, approximate instantaneous power consumption and approximate cost
per time to the user via the visual LCD display.
Peak tariff operation case:
This case pertains to situations where the utility decide, may it be at a fixed daily period or at the
discretion of the utility, to have a higher tariff than the normal (off- peak) tariff. For this case to
be active, two conditions have to be met. Firstly, the utility should have loaded the tariff change
onto the MySQL database with the control software and secondly, the energy metering system
would have to have connected to the MySQL database and retrieved the new tariff in effect.
When these two conditions are met and the peak tariff case is in effect the duties of the energy
metering system are almost identical than to the off-peak case except for the higher tariff that is
displayed on the LCD and used in the cost per time (R/h) calculation.
Load control (non-essential load switching) case
The Load control case is concerned with conditions where the utility decide (usually under
critically high load conditions) to forcibly remove power to some of the non- essential loads in
residences such as geysers or pool pumps for a period of time, until the national load is at a safer
level. To achieve this case, two conditions are again in place. As before, the utility should have
logged the change in control signal (controlling the non-essential load relays).
Initial start-up and service routine case
This particular case is concerned with the conditions encountered when the system is first
commissioned after installation, when it is started up after a service routine or an extended
power outage that the back-up battery could not sustain the system through. The main concern
faced with this scenario is not to lose energy consumption data due to power outages. This
should either be achieved by keeping the system operational for the full power outage by means
of back-up battery, or to store the energy consumption data on flash or EEPROM technology and
reload the stored value at start up.
Hardware Design
This section of the design and implementation of the system gives the details of the design and
implementation of the hardware used in the prototype of the project.
Implementation of the power supply
A bi-voltage, bi-regulator power supply configuration was implemented on the control circuitry
board. The main reason (and advantage) of this kind of implementation is the inclusion of a
back-up battery (to sustain the system during short power outages). Unregulated AC (or DC) of
up to 20V is connected to the system via the screw clamp input. This input power (AC or DC)
then passes through a rectifier bridge (to rectify AC and assure correct DC polarity). The
unregulated DC passes through a LM317T linear voltage regulator and additional decoupling
capacitor. This regulated DC can be adjusted from 6V to 14V (assuming that the input voltage is
at least 2V higher than this) lending flexibility to the backup battery used. This regulated output
serves as the connection point for the back-up battery as well as for the GPRS module’s power
input.
Input Design:The input design is the link between the information system and the user. It
comprises the developing specification and procedures for data preparation and those steps are
necessary to put transaction data in to a usable form for processing can be achieved by inspecting
the computer to read data from a written or printed document or it can occur by having people
keying the data directly into the system. The design of input focuses on controlling the amount of
input required, controlling the errors, avoiding delay, avoiding extra steps and keeping the
process simple. The input is designed in such a way so that it provides security and ease of use
with retaining the privacy. Input Design considered the following things:
Objectives:
1.Input Design is the process of converting a user-oriented description of the input into a
computer-based system. This design is important to avoid errors in the data input process and
show the correct direction to the management for getting correct information from the
computerized system.
2. It is achieved by creating user-friendly screens for the data entry to handle large volume of
data. The goal of designing input is to make data entry easier and to be free from errors. The data
entry screen is designed in such a way that all the data manipulates can be performed. It also
provides record viewing facilities.
3.When the data is entered it will check for its validity. Data can be entered with the help of
screens. Appropriate messages are provided as when needed so that the user will not be in maize
of instant. Thus the objective of input design is to create an input layout that is easy to follow
Output Design:
A quality output is one, which meets the requirements of the end user and presents the
information clearly. In any system results of processing are communicated to the users and to
other system through outputs. In output design it is determined how the information is to be
displaced for immediate need and also the hard copy output. It is the most important and direct
source information to the user. Efficient and intelligent output design improves the system’s
relationship to help user decision-making.
1. Designing computer output should proceed in an organized, well thought out manner; the right
output must be developed while ensuring that each output element is designed so that people will
find the system can use easily and effectively. When analysis design computer output, they
should Identify the specific output that is needed to meet the requirements.
3.Create document, report, or other formats that contain information produced by the system.
The output form of an information system should accomplish one or more of the following
objectives.
A 7805 linear 5V regulator further regulates the voltage down to 5V from where the control
circuitry is powered. All the power stages were fitted with decoupling capacitors as indicated on
the schematic and all voltage regulators were fitted with heat sinks. The LF347 operational
amplifier used in the analogue part of the control circuitry requires a split (dual polarity) voltage
supply, albeit at a very low current (<3mA). This was supplied from the on-board dual (+10V,
-10V) charge pump power supply that the MAX232 uses for the differential voltages associated
with the RS232 standard. Although this is an unusual implementation (exploitation) of the
MAX232, it might be viewed as innovative, seeing that an available resource is uniquely applied
without placing strain on it and eliminating the need for a dual voltage rectification decoupling
and regulation, not to mention the elimination of the second step-down transformer.
Software design
Been an embedded system, the programme was written in C# using the Microsoft Visual Studio
Integrated Development Environment (IDE). This section describes the design of the general
building blocks used in various sections of the project. These blocks include the amplifier design
for the system output, the output impedance matching network, buffers and phase shifting
layouts for the system. The current reference generator used in the biasing of all the above
systems is also shown here.
For any software
design the following steps are considered:
Understand the problem
Plan the logic
Code the program
Translate the program to machine language
Test the program
Put the program to production
First the system initializes each module, and then reads the meter reading regularly and stores
them. When the receiving the command, meter send the current status along with the energy
consumption.
Summary:
Man is on the way to ultimately derive the benefits in remote automation and control of electrical
system. With this design fully implemented the cost associated with metering is reduced. Power
theft at minimum, proper documentation and even distribution of power to consumers is found to
be more effective. Therefore it avoids human intervention, provides efficient meter reading,
avoid the billing error and reduce the maintenance cost. It displays the corresponding
information on LCD for user notification.
Testing:
System Testing
The purpose of testing is to discover errors. Testing is the process of trying to discover
every conceivable fault or weakness in a work product. It provides a way to check the
functionality of components, sub assemblies, assemblies and/or a finished product It is the
process of exercising software with the intent of ensuring that the
Software system meets its requirements and user expectations and does not fail in an
unacceptable manner. There are various types of test. Each test type addresses a specific testing
requirement.
Types of Tests:
Unit testing
Unit testing involves the design of test cases that validate that the internal program logic is
functioning properly, and that program inputs produce valid outputs. All decision branches and
internal code flow should be validated. It is the testing of individual software units of the
application .it is done after the completion of an individual unit before integration. This is a
structural testing, that relies on knowledge of its construction and is invasive. Unit tests perform
basic tests at component level and test a specific business process, application, and/or system
configuration. Unit tests ensure that each unique path of a business process performs accurately
to the documented specifications and contains clearly defined inputs and expected results.
Integration testing
Integration tests are designed to test integrated software components to determine if they
actually run as one program. Testing is event driven and is more concerned with the basic
outcome of screens or fields. Integration tests demonstrate that although the components were
individually satisfaction, as shown by successfully unit testing, the combination of components is
correct and consistent. Integration testing is specifically aimed at exposing the problems that
arise from the combination of components.
Functional test
Functional tests provide systematic demonstrations that functions tested are available as
specified by the business and technical requirements, system documentation, and user manuals.
System Test
System testing ensures that the entire integrated software system meets requirements. It tests a
configuration to ensure known and predictable results. An example of system testing is the
configuration oriented system integration test. System testing is based on process descriptions
and flows, emphasizing pre-driven process links and integration points.
Unit Testing:
Unit testing is usually conducted as part of a combined code and unit test phase of the
software lifecycle, although it is not uncommon for coding and unit testing to be conducted as
two distinct phases.
Test objectives
The task of the integration test is to check that components or software applications, e.g.
components in a software system or – one step up – software applications at the company level –
interact without error.
Test Results: All the test cases mentioned above passed successfully. No defects encountered.
Acceptance Testing
User Acceptance Testing is a critical phase of any project and requires significant
participation by the end user. It also ensures that the system meets the functional requirements.
Test Results: All the test cases mentioned above passed successfully. No defects encountered.
Sample Screen:
References:
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IEEE Trans. Power Appar. Syst., 1983, PAS- 102, pp. 2455–2460
[2] Ferrero, A., and Muscas, C.: ‘On the selection of the ‘‘Best’’ test waveform for calibrating
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IEEE Trans. Power Syst., 2000, 15, pp. 1142–1147
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VedanthamSystem Engineer Smart Grid Solutions team Texas Instruments Incorporated (TI),
Implementing PRIME for Robust and Reliable Power Line Communication (PLC)
[12] Printed circuit Processes & Instructions, Comprehensive Datak Instructions for Printed
Circuit Prototyping
[13] 2W005G 2.0A Glass Passivated Bridge Rectifier, Diodes Incorporated.
[14] 1N5221B - 1N5263B Zener Diodes, Fairchild Semiconductor Corporation
www.fairchildsemi.com
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