DEPARTMENT OF ELECTRICAL AND COMPUTER ENGINEERING

STREAM:- INDUSTRIAL CONTROL ENGINEERING

PROPOSAL OF THE PROJECT TITLE

GSM BASED INDUSTRIAL FAULT CONTROL AND DETECTION SYSTEM

NAME OF GROUP MAMBERS

1. MASTEWAL ABEGAZ

2. YOHANNENS MESELE

3. SAMRAWIT BELAY

4. LEUL TILAHUN

Submitted to:-MR. AMARE

Submission date: -26 jan 2018

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 ACKNOWELEDGMENT

We wants to express our deep gratitude to AASTU and ASTU and DIRE DAWA University’s institute
of technology departments of Electrical and computer Engineering for their commitment and behave good
for us to take part in these internship and vital event. Since it brings what the real world and the working
environment looks like beyond many other experiences that we archives from our relatives from our
company.

Yekatit paper converting private limited company, as a stake holder accepts us and tries much to
properly manage and monitor us. We would like to offer a hundreds of thanks to our host company.
Particularly Mr. Amare Kassa who is the corporate service director of Yekatit Paper Converting PLC is
also among the great share holder of our acknowledgment for his internal passion and faith on us to
participate and insists us to stamp what we can for the company.

Finally we are glad to acknowledge all those who are beyond us.

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 ABSTRACT

The purpose of this project is to develop GSM technology in this company is to automatically
detect and monitor faults caused by overheat (temperature), smoke or LPG leakage. We can send
SMS from these projects. Various actions can be performed after receiving a SMS. With the
help of these projects we can perform various actions like, remote monitoring through SMS or
performing any desired action or controlling devices. GSM modem interfacing with
microcontroller is done in these projects. These are engineering projects with GSM modem. We
have to insert GSM simcard into the GSM module.

SMS based Fire detection system using Smoke and Temperature sensor has application in
many areas like Industries, Companies, Offices, Shopping malls and even at our home. This
project has a Smoke sensor and a Temperature sensor to detect the fire. Fire detection system
sends SMS to user when anyone this sensor crosses threshold value. We have provided a Buzzer
which turns on when SMS is sent to user

SMS based LPG gas leakage detection system using GSM has application in various areas like
home, industries, hotels, hospitals. This project has a gas leakage detector implemented by using
an LPG Gas sensor. The user can get remote indication through SMS sent from the project. This
SMS is sent from GSM modem which is connected to the microcontroller. A buzzer is turned on
after LPG gas leakage so it acts as a gas leakage alarm.

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1. INTRODUCTON

Automation or numerical control is the use of control systems such as computers to control
industrial machinery and processes, reducing the need for human intervention. In the scope of
industrialization, automation is a step beyond mechanization. Whereas mechanization provided
human operators with machinery to assist them with the physical requirements of work,
automation greatly reduces the need for human sensory and mental requirements as well.
Processes and systems can also be automated. Automation plays an increasingly important role
in the global economy and in daily experience. Engineers strive to combine automated devices
with mathematical and organizational tools to create complex systems for a rapidly expanding
range of applications and human activities. Many roles for humans in industrial processes
presently lie beyond the scope of automation. Human-level pattern recognition, language
recognition, and language production ability are well beyond the capabilities of modern
mechanical and computer systems. Tasks requiring subjective assessment or synthesis of
complex sensory data, such as scents and sounds, as well as high-level tasks such as strategic
planning, currently require human expertise. In many cases, the use of humans is more cost-
effective than mechanical approaches even where automation of industrial tasks is possible.
Specialized hardened computers, referred to as programmable logic controllers (PLCs), are
frequently used to synchronize the flow of inputs from (physical) sensors and events with the
flow of outputs to actuators and events. This leads to precisely controlled actions that permit a
tight control of almost any industrial process.

Human-machine interfaces (HMI) or computer human interfaces (CHI), formerly known as

man-machine interfaces, are usually employed to communicate with PLCs and other computers,
such as entering and monitoring temperatures or pressures for further automated control or
emergency response. Service personnel who monitor and control these interfaces are often
referred to as stationary engineers. Industrial automation is the process of controlling and guiding
the industrial equipment, i.e. process and systems with less of the human intervention. The
operation and control of the modern industrial equipment and process needs lot of sensors to
monitor various parameters of the systems.

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1.1. Statement of Problem

During a missed operation of machineries ,the way of their maintenance our company follows
is a much delayed and anon- cost fitting mode .after the nominated operator for a machine
approceced that there is a fault, on his machine, based on the rules of the company he/she have to
notify for the maintenance planner ,even if the maintenance planner has a specified office, due to
the regulation of the company he/she is dynamic ,hence sometimes it is impossible for operators
to announce the fault . This is a unit problem. Beyond this, the maintenance planner also will
spend a time to search out where the electrical/mechanical technicians are. This problem leads to
wastage and time directly as well as non-profitable and costly in direct direction. This is how
machines are maintained in Yekatit Paper Converting PLC. This project will eliminate all the
stated problems and directly notify the technician through the SMS technology,

1.2. Objectives of project

The aim of this project is to reduce the maintenance costs and to optimize critical monitoring
system GSM Based Industrial Automation Technology is used. . In this project a GSM server is
implemented with PSOC mixed signal chip, sensors and relays. The GSM Modem can provide
the necessary data related to industry to a maintenance officer located anywhere at any time.
According to data received officer will take some action by sending some commands to PSOC
chip through mobile unit to GSM modem. PSOC chip decodes the commands and controls the
industrial devices through relays.

1.2.1. General objective

• designing an automatic fault detection and monitoring system.

• implementing consumption of time properly after detection of a fault in the machineries.

 Designing a system that will reduce the need of a human power.

1.2.2. Specific objective

• Reducing the need for manpower.

• To implement a cost compatible system

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 1.3. SCOPE OF THE PROJECT

The scope includes connecting the different control systems to relays for controlling the
environment. The PSOC microcontroller can be used for implementation of more complex
systems for complex tasks like controlling different systems like nuclear plants and reactors in
the industry. It can also be used in the system where there is a need of instrumentation, inverting
and non-inverting amplifiers.

2. METHDOLOGY

LCD
LPG sensor

Relay
Temperature sensor
ADC Micro-controller (Buzzer)

Smoke sensor GSM modem

2.1. Required tools

1. Arduino Uno microcontroller

2. Temperature sensor

3. Smoke sensor

4. LPG gas sensor

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5. Analogue to digital converter ADC

6. Liquid Crystal Display LCD

7. Relay (buzzer)

8. GSM modem

2.1.1. Description of the required tools

1. Smoke sensor: it detects smoke from fire.

2. LPG Gas sensor: : these acts as LPG gas leakage detector with SMS alert.

3. Temperature sensor: It is used to detect if there is overheat due to fire.

4. Microcontroller: This is the CPU (central processing unit) of our project. We are going to use a

The arduino microcontroller of the various functions of microcontroller is like

I. Reading the digital input from infrared receivers and sensors.

II. Sending this data to LCD so that the person operating this project should read the status of sensors.

III. Sending SMS through GSM modem

5. LCD: We are going to use 16x2 alphanumeric Liquid Crystal Display (LCD) which means it can
display

Alphabets along with numbers on 2 lines each containing 16 characters.

6. GSM Modem: We are going to use SIM as a GSM modem. The values of number of LPG Gas

Leakage status and the status of temperature sensor and IR sensor will be sent to GSM modem.

7. Analog to digital converter (ADC): ADC is required because output of all sensors is in analog format.
And 8051 Microcontroller cannot read analog input.

8. Relay: It acts as output device. We can turn on any AC or DC device using relay.

9. Buzzer: It gives alert indication for the employees working in industry.

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2.2. Analytical description of the block diagram

Up on the occurrence of a failure on the machines to operate properly, the cause behind the fault
can be easily detected by the sensors. It is immediately converted into an Electrical signal by
those sensors. The ADC will digitalize what has been detected by the sensor and transfers the
message to the ARDUINO UNO Microcontroller, after processing it will send an alert SMS for
the employed technicians using the GSM modem.

The liquid crystal display (LCD) helps to show the status of the GSM modem. In some cases
the GSM modem will not send the alert text message even under faulty conditions. During this
the LCD is vital to show as there is a missed operation on the installed system. Beyond texting a
message we have used a relay or buzzer to emit an emergency sound in the company for
operators around machineries.

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3. Simulation

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4. Arduino sketch(programming code) for the simulation
#include<SoftwareSerial.h>

String Message;

SoftwareSerial mySerial(7,8);

#define PINNUMBER ""

#include<LiquidCrystal.h>

LiquidCrystal lcd(12,11,10,9,6,5);

int Tempmotor=2;

int Tempheater=A2;

float Temp;

int setpoint=35;

#define relaymotor 8

# define relayheater 9

int LPGpin=5;

float gas_value;

int SmokeA0=A5;

float Smoke;

int Sensorthresh=400;

int redled=11;

int greenled=12;

int buzzer=13;

void setup() {

Serial.begin(9600);

mySerial.begin(9600);

lcd.begin(20,0);

lcd.setCursor(0,0);

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 SendMessage();

Serial.println("Temperature has crossed the limit please take action immediately");

Serial.println(Temp);

Serial.println("=Temp*c");

Serial.println("LPG has crossed the limit please take action immediately");

Serial.println(gas_value);

Serial.println("=gas_valueppm");

Serial.println("Smoke has crossed the limit please take action immediately");

Serial.println("SmokeA0");

Serial.println("=Smokeppm");

lcd.print("Status of the GSM MODEM is under abnormal condition!");

lcd.print("no Message has been sent! ");

lcd.print("temperature has crossed the limit please take action immediately");

lcd.print(Temp);

lcd.print("=Temp*c");

lcd.print("LPG has crossed the limit please take action immediatey");

lcd.print(gas_value);

lcd.print("=gas_valueppm");

lcd.print("Smoke has crossed the limit please take action immediately");

lcd.print(Smoke);

lcd.print("=Smokeppm");

lcd.print("Sent Message:");

lcd.print("delivery report!");

lcd.print("is the delivered Message.");

pinMode(Tempmotor,INPUT);

pinMode(Tempheater,INPUT);

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pinMode(relayheater,INPUT);

pinMode(relaymotor,INPUT);

pinMode(LPGpin,INPUT);

pinMode(SmokeA0,INPUT);

pinMode(greenled,OUTPUT);

pinMode(redled,OUTPUT);

pinMode(buzzer,OUTPUT);

void loop(){

if(Serial.available()>0)

switch(Serial.read()){

case's':

SendMessage();

break;

case'r':

ReceiveMessage();

break;

if(mySerial.available()>0){

mySerial.write(mySerial.read());

Message=mySerial.read();

lcd.write("sent Message:");

lcd.write(mySerial.read());

Serial.print(mySerial.read());

else if(mySerial.available()<0){

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lcd.write("Status of the GSM MODEM is under abnormal condition! ");

lcd.write("no Messagge has been sent!");

int Temp=analogRead(Tempheater);

Temp = analogRead(Tempheater);

if (Temp <= 35) {

lcd.write("Tempheater=");

lcd.write(Temp= ' ');

lcd.write("°c");

digitalWrite(relayheater, HIGH);

else if (Temp > 35||Temp>=100) {

lcd.write("Tempheater=");

lcd.write(Temp);

lcd.write("°c");

digitalWrite(relayheater, LOW);

int TempM=analogRead(Tempmotor);

if (TempM>=100){

lcd.write("Temp=");

lcd.write(Temp);

lcd.write("°c");

digitalWrite(relaymotor, LOW);

int Smoke = analogRead(SmokeA0);

if(Smoke<=400){

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lcd.write("Smoke=");

lcd.write(Smoke);

lcd.write("ppm");

digitalWrite(greenled,HIGH);

delay(1000);

digitalWrite(redled,LOW);

noTone(buzzer);

else if(Smoke>400){

lcd.write("Smoke=");

lcd.write(Smoke);

lcd.write("ppm");

digitalWrite(redled,HIGH);

digitalWrite(greenled,LOW);

tone(buzzer, 1000, 200);

int gas_value=digitalRead(LPGpin);

void SendMessage(){

Temp=analogRead(Tempmotor);

for(Temp=100;Temp>=100;Temp++){

mySerial.println("AT+CMGS=1");

mySerial.println("AT+CMGS=\"+251910183609\"\r");

lcd.write("Temperature has crossed the limit please take action immediately");

lcd.rightToLeft();

delay(1000);

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Serial.println("sent Message:");

Serial.println("Alerttttttt!");

Serial.println("Temperature has crossed the limit please take action immediately ");

delay(100);

lcd.rightToLeft();

break;

lcd.write("sent Message:");

lcd.write("Temp=");

delay(100);

mySerial.println(char(26));

delay(100);

for(gas_value=250;gas_value>=250;gas_value++){

mySerial.println("AT+CMGS=1");

mySerial.println("AT+CMGS=\"+251910183609\"\r");

mySerial.println("Message Send");

lcd.rightToLeft();

lcd.write("LPG has crossed the limit please take action immediately");

lcd.rightToLeft();

delay(100);

mySerial.println("LPG has crossed the limit please take action immediately");

Serial.println("sent Message:");

Serial.println("LPG has crossed the limit please take action immediately ");

delay(1000);

lcd.write("sent Message:");

lcd.write(mySerial.println());

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lcd.write(gas_value);

lcd.write("=gas_valueppm");

delay(100);

mySerial.println(char(26));

delay(100);

for(Smoke=400;Smoke>400;Smoke++){

mySerial.println("AT+CMGGS=1");

mySerial.println("AT+CMGS=\"+251910183609\"\r");

mySerial.println("Messege Send:");

mySerial.println("Smoke has crossed the limit please take immediate action");

lcd.rightToLeft();

Serial.println("sent Message:");

Serial.println("Smoke has crossed the limit please take immediate action");

delay(1000);

lcd.write("sent Message:");

lcd.write(mySerial.println());

lcd.write(Smoke);

lcd.write("=Smokeppm");

delay(100);

mySerial.println(char(26));

delay(100);

void ReceiveMessage(){

mySerial.println("AT+CNMI=2,2,0,0,0");

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delay(100);

5. Result of the simulation

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6. Recommendation for our project

1. We can modify our project by controlling other parameters like using other types of sensors.

2. Beyond our finding the project can be reformed to control many other tasks like vibration and
Interfacing GPS system.

7. CONCLUSION

From the beginning 0ur aim was designing automatic fault detection and monitoring system,
implementing consumption of time properly after detection of a fault in the machineries and
Designing a system that will reduce the need of a human power. It is already a done deal.
Additional beyond designing an industrial fault monitoring we have also able to reduce the need
for manpower as well as implementing a cost compatible system.

As it is shown in the result of the simulation we can control, automate and bring a stable system
for the industrial sector. This means we can prevent the failures of machines before it’s too late.
And also this project facilitates the repairing of machines in the scope of minimizing the time
which is required for repairing and maintenance.

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References
-www.projects of 8051.com

-T. Heverhagen, R. Tracht, "Integrating UML-Real Time and IEC 61131-3 with Function Block
Adapters", International Symposium on Object-oriented Real-time Computing (ISORC), 2001.

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