IMPLEMENTATION OF INDUSTRIAL WIRELESS SENSOR NETWORK

IMPLEMENTATION OF INDUSTRIAL WIRELESS SENSOR NETWORK

1Mrs.P.Alagumathi, 2Mrs.R.Saratha

1,2Assistant Professor, Department of Science and Humanities

Sri Bharathi Engineering College for Women, Kaikurichi, Pudukkottai 622 303

Abstract- Primary objective of this paper is Industrial parameter monitoring through serial communication and to develop an embedded system which will monitor all the devices through Zigbee enabled wireless technologies. Since the monitoring application have been developed in medicine, agriculture, military, building, motion tracking and many other fields which involves the measurement of voltage, current, temperature, etc., These can be done by using sensor which are configured to measure internal temperature, remote temperature, remote current, remote voltage.

Keywords: Zigbee, Automation, Sensors, Wireless Sensor Networks, Monitoring & Control

1. INTRODUCTION

   Industrial Automation Networks involves Programmable Logic Controller (PLC) or Distributed control system (DCS) that communicate with the sensors to collect the data related to the process. To provide the control PLC or DCS act on the physical variables measured by issuing the commands or signals that activate relays, solenoid, motors and actuators. Developments in Wireless Sensor Network domain plays an important role in the implementation of an Industrial monitoring and Controlling Network, which contains number of sensor nodes that measures the value of physical parameters such as Temperature, Pressure, Flow, level, Density etc., and transmit them to the centralized control room through intermediate nodes or remote control panels present in field.

   Generally this can be achieved through wired networks by involving standard 4-20mA Electrical System. Wired Industrial monitoring and Controlling Network increase the implementation cost because the cost of cabling and structural support arrangement may be sometimes higher than the cost of Transmitter itself and also leads to increase the maintenance cost.

   Wireless Sensor Technology has been effectively is an open standard. This paper proposes an Intelligent Industrial Automation system based on Wireless Sensor Network which may be implemented in Home Automation, Environmental monitoring, Health monitoring and so on. Bluetooth, X-10, Wi-Fi and Zigbee are the suitable wireless technologies to be employed in above mentioned areas. The wireless technology like Wi-Fi and X-10 are not suitable for Industrial automation applications because Wi-Fi is most suitable for high data rate application and X-10 is most suitable for very low data rate applications only.Hence Bluetooth and Zigbee may be the suitable wireless technologies for low data rate application like monitoring and control.Zigbee is capable of establishing two way communications between multiple devices over a simple networks using low power and with low cost. It uses license free 2.4 GHz band and IEEE defined 802.15.4 standard.

   CONTROL	ACTUATOR
   ROOM HEATER TEMPERATURE LIGHT SENSOR SENSOR

   Fig 1. Traditional Industrial Monitoring System

2. TRADITIONAL METHOD

   In wired Industrial Automation Network (Fig 1) closed and open loop control is achieved by passing the values of physical variables measured in the process to the base station through signal cables. The control action performed by the controller present in the control Room.

   As a result the controllers will send signal to the final control element, which in turn cause the changes in the process to maintain the physical parameters at desired value to perform closed loop control. In the above method in case of melting of cable it may

   either leads to shut down or reinstallation it may further leads to production loss as well as large reconfiguration cost.

3. PROPOSED METHOD

   Wireless sensor networks (WSNs) provide one potential solution to tackle the above listed challenges. Compared with a wired system,WSNs have many inherent advantages, such as relatively low cost, convenience of installation, and ease of relocation. These merits make a low-cost condition monitoring system for noncritical equipment possible.

   Fig2. Proposed Monitoring Method

   However, industrial processes and devices have unique characteristics that make further demands on industrial WSNs (IWSNs), such as processing heterogeneous sensor signals, higher sampling rates, faster data transmission rates, and higher reliability.In our proposed method radio module is either electrically powered or battery powered data transmission or reception must occur through wireless.

   1. Sensor Network Architecture

      Wireless sensor network (Figure 2)is thenetwork of tiny low power devices capable of performing Sensing,Processing,

      and Communication within the single chip. Wireless sensor network [6] classified into two types. First one consists of hundreds or thousands of node operate in large geographical areas. This network used in communication, military, and environmental monitoring. Second one consists of ten of sensors which used in remote measurement applications.

      1. Sensor node consists of following components Sensing sub system (Sensor which consists of Signal conditioning & A/D convertor)

      2. Processing subsystem (Microcontroller with Small amount of data storage)

      3. Communication subsystem (Radio module)

      4. Power supply

   2. Monitoring & Data logging

      In particular, the following two functionalities are of great significance [1].

      Fig 3. Typical Sensor Node

      1. Graphic interface. The graphic interface allows representing the whole system display the status of all or part of the field. This allows the human operator to evaluate how the system is working and to recover quickly from critical conditions.

      2. Historian module. The historian module Allows to record all significant parameters and to display them as suitable graphs. This can be useful to discover the reasons of some problems which occurred in the field.

      Several IWSNs for industrial device monitoring have been developed. Most of these applications only use WSNs for data acquisition and transmission and complete the feature extraction and fault diagnosis functions on a central computer. On- sensor feature extraction and fault diagnosis is a promising alternative approach to raw data transmission, which can reduce the quantity of transmitted data, save node energy, and prolong node lifetime.

   3. Communication Technologies Commercially available wireless protocols (Table

      1. for WSNs, including IEEE802.15.4,IEEE802.11(Wi-Fi), and IEEE802.15.1 Bluetooth). IEEE 802.15.4 was demonstrated IWSNs. Three protocols based on the IEEE802.15.4 physical layer, ZigBee, Wireless HART, and ISA 100.11a, will be explored.

         	Zigbee	Blueto oth	Wibree	Wi- Fi
         Frequenc yband (GHZ)	2.4	2.4	2.4	2.4
         Range (ft.)	-11.6	30300	Up to 10	100 150
         Data rate (Mbps)	250 kbps	1	1	11-54
         Power	Low	Mediu m	Low	High
         Cst	Low	Low	Low	High
         Modulati on/proto col	DSSS, CSMA /CA	FHSS	FHSS	DSS S

         (RF) communications standard based on IEEE 802.15.4.

         The Zigbee coordinator is responsible for creating and maintaining the network. Each electronic device (i.e. Washing Machine,Television, Lamp etc.) in the system is a Zigbee device managed by the coordinator. All communication between devices propagates through the coordinator to the destination

         device.

         The ZigBee standard theoretically provides 250kbps data rate, and as 40kbps can meet the requirements of most control systems, it is sufficient for controlling most industrial automation whereas Wi-Fi provides 54 Mbps. Soit only suitable for high data rate applications.

         Table 1. Comparison of Communication Technologies

   4. ZigBEE

      Fig 4:ZigbeeNetwork

      Nowadays, Zigbee [4] a de facto standard for WSNs has become one of the most promising protocols for wireless home networking and automation due to its low power consumption, low cost, and support for various ad hoc network configurations. ZigBee is a radio frequency

   5. ZIGBEE BASED MONITORING SYSTEM

   The Zigbee network [5]Fig.5depicts the monitoring networks by a ZigBee network system. The networks include a master node connected with a server PC and a series of client nodes, which are classified into master, sensor, gatherer, actuator and, controller. The main functions of each element are described as follows.

   Fig 5.Zigbee Based Monitoring System Server: Issues commands to the networks and collects responding information from the sensor network. Database: Logs the system configuration data and monitoring data. Master Node:Collects original monitoring data and reports to management software; connects with the Server via a USB or a RS232 port. Gathering Node (Reader): Composes the backbone of data collecting and status monitoring network. Equipment Controller: Controls the actuator action to start or close the connected equipment/machine. Checking Node (controller):Acts as a checker a client PC can connect with a checking node used to display the real-time message of the system and issue control commands to the network when a specified event occurs. Alarm device:Functions as an emergency reporter used to notify the production controller.

4. IMPLEMENTATION:

   Fig 6 shows the typical transmitter diagram. It consists of Sensor, Communication module, Processor& Power supply. Sensor usually deployed in the field, from where the sensed phenomenon is transferred via transmitter to the control station which has receiver from that received information controller will initiate corrective action to establish control.The above implementation setup capable to cover up to 30 meters in order to address the large area relay concept may be applied

   LIGHT SENSOR RF MODULE

   POWER

   DISPLY PROCESSOR SUPPLY

   Fig 6.Typical Transmitter

   Fig7. shows typical receiver diagram. It also has the same components as above.

   RF MODULE DISPLAY

   Fig 7. Typical Receiver

   Fig 6 & 7 Shows the experimental setup for the data transmission and reception.

5. RESULTS & CONCLUSION

   The experiment conducted for 15 minutes by keeping TX and RX at the distance of 30mand observe the results. The table 5.1& 5.2 given below summarizes the TX and RX values at time distant.

   85

   80

   75

   70

   65

   1. Graph of Light Sensor

      TIM E	TX TEM P	RX TEM P	TX LIGH T	RX LIGH T
      3.10	30	30	82	82
      3.11	34	34	83	83
      3.12	39	39	82	82
      3.13	41	42	74	73
      3.14	42	42	74	74
      3.15	42	43	72	71
      3.16	42	40	79	78
      3.17	43	41	82	83
      3.18	32	32	44	40
      3.19	44	42	70	70
      3.20	32	31	81	81

      TX Value, RX Value

      Table 5.1.Tx& RX from temperature sensor& Light Sensor

      The following graphs(a,b) depicts the

      relationships between TX & RX value.

      50

      40

      30

      20

      10

      3:10:00 PM

      3:11:00 PM

      3:12:00 PM

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      3:17:00 PM

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      3:21:00 PM

      3:22:01 PM

      0

      1. Graph of Temperature Sensor

6. REFERENCES

1. A Hybrid Wired/Wireless Networking Infrastructure for Greenhouse ManagementOrazio Mirabella, Senior Member, IEEE, and Michele Brischetto, IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT, VOL. 60, NO. 2, FEBRUARY 2011.

2. Novel Industrial Wireless Sensor Networks for Machine Condition Monitoring and Fault DiagnosisLiqunHou and Neil W. Bergmann,IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT.

3. Wireless HART: Applying Wireless Technology In Real-Time Industrial Process Control Jianping Song, Song Han, Aloysius K. Mok, IEEE Real-Time and Embedded Technology and Applications Symposium.

4. A ZigBee-Based Home Automation SystemKhusvinder Gill, Shuang-Hua Yang, Fang Yao, and Xin Lu,IEEE Transactions on Consumer Electronics, Vol. 55, No. 2, MAY 2009.

5. A plug-and-play data gathering system using ZigBee-basedsensor network sensor network

   Kun-Yung Lu,Department of Electronics Engineering, National United University,Lienda, Kungching Li, Miaoli 36003, Taiwan, ROC.

6. A review of wireless sensors and networks applications in agriculture Aqeel-ur-Rehman , Abu ZafarAbbasi , Noman Islam, Zubair Ahmed Shaikh.

7. Recent and Emerging Topics in Wireless Industrial Communications: A Selection Andreas Willig, Member, IEEE, IEEE TRANSACTIONS ON INDUSTRIAL INFORMATICS, VOL. 4, NO. 2, MAY 2008.

8. Wired and Wireless Reliable Real-Time Communication in Industrial SystemsMagnus Jonsson and Kristina Kunert Halmstad University Sweden.