REMOTE MONITORING AND CONTROLLING OF GENERATOR COURSE EMBEDDED SYSTEMS AND DESIGN Prepared By MALIK MUHAMMAD FAIZAN 4650 MUHAMMAD ADEEL QADRI 4603 SHIREEN QURESHI 4667 Instructor: Dr Hussain Ahmed Page 1
Jul 31, 2015
REMOTE MONITORING AND CONTROLLING OF GENERATOR
COURSE
EMBEDDED SYSTEMS AND DESIGN
Prepared By
MALIK MUHAMMAD FAIZAN 4650 MUHAMMAD ADEEL QADRI 4603
SHIREEN QURESHI 4667
Instructor: Dr Hussain Ahmed
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College Of Engineering
ACKNOWLEDGEMENT
Praise to ALLAH ALMIGHTY, the most Gracious and the most Compassionate.
We wish to express our sincere gratitude to Engg. Imran Ghaffar (External Advisor from Byco)
for providing us an opportunity to work under his guidance on the Project entitled “Remote
Monitoring and Controlling of Generator”.
We are also very grateful to our course instructor Dr. Hussain and internal project advisor Asst.
Prof. Mr. M. Abdul Aleem for enlightening us with his great knowledge and vast experience
throughout the project work.
Finally our sincere thanks to our institute PAF-KIET College of Engineering, for providing us
the opportunity and to gave us the strength to undertake this project.
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Sno. Content Page No.
1 Project objective 4
2 Motivation 4
3 Objectives of project 4
4 Methodology 5
5 Test results and their analysis 6
6 Process flow 11
7 Algorithm 12
8 Block diagram 13
9 Schematic 14
10 Mechanical design 15
11 Conclusion 16
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INDEX
Project Objective:
The objective of this project is to design and construct a model for monitoring and controlling of
power generators. We have worked on three different parameters of power generators such as
fuel level, temperature and load. We have used GSM technology to communicate between
substation( where actually the generators will be installed) and the base station or a cell phone.
Motivation:
For the last few decades, technology is getting advance rapidly which has made life more
efficient and comfortable. We saw the application of this project at our Internship period to
PARCO, where they were heavily relying on the use of generators for power. From there, we get
motivated to work on this project for making the process efficient and less time consuming.
The project we are designing is an extended approach to automate and controlling different
parameters of the generator set manually as well as giving option for remote monitoring and
controlling.
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Objectives:
To design and construct a low cost industrial based monitoring system model.
Monitor different parameters of the generator; temperature, fuel and electric load.
To provide Remote and Manual options for Generator Monitoring.
Use of GSM (Global System for Mobile Communication) technology for cell phone
monitoring
METHODOLOGY :
The design and implementation of the project can be divided into following major phases:
Analysis of components, designing and selection.
Assembling of different design and testing.
Simulation development and Verification at the hardware level.
Development for future implementation.
Analysis of components, designing and selection:
The very first part to achieve our desired objectives is to analyze the components required and
selection of the best available components furthermore the hardware selection is also one of the
major part.
Assembling of different Design and testing:
Once all components were selected and all major functional parts were designed, the next step is
to assemble all of them together and then to test all the modules simultaneously.
.
Simulation development and Verification at the Hardware Level:
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Test results were simulated to achieve the desired goals and then they were verified at the
hardware level to get the desired outcome.
Market adaptability
The idea of monitoring the parameters of the generator is not new. There are systems in the
market which are used now a day in industry. There are companies having their small generators
installed at different locations they have the major issue of monitoring but they cannot afford
those costly monitoring systems available in market, this project is the solution for many small
scale industries.
TEST RESULTS & THEIR ANALYSIS
We have performed different tests for checking the working of different sensors that we are
using. Also component as well as module testing has been done before assembling the system to
the prototype. The test results and their analysis are given below.
Microcontroller (PIC16F877A)
Microcontroller PIC16F877A has been tested using different Logical Programs and its working correctly. We have also tested its working on our main control board.
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Figure 4-1 Microcontroller Module Testing
We have tested our modules of temperature, fuel and overload and all are working properly.
GSM MODULE
We are using GSM module, Siemens TC-35 which is also tested and its working properly. We
are using GSM module for communication between sub station and base station or cell phone.
Figure 4-2 GSM Module
This module has also been tested via micro-controller for sending the commands of the
conditions from sub-station to base-station.
The delay in sending the SMS is about 40 sec. to 60 sec., while it may also vary depending on
the service usage at that particular time.
ELECTRONIC OVER CURRENT RELAY (EOCR)
EOCR electronic over current relay we are using for electric load monitoring. We are using EOCR of current range from 0.5 - 6 A. this also we have tested with load and its working properly.
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Figure 4-3 EOCR Testing
S.No. Expected Delay Time (a)
Measured Delay Time
(b)
Expected Over Time (c)
Measured Over Time (d)
Current Rages
01. 0.2 sec. 01 sec. 0.2 sec. 01 sec. 0.5 – 6 A02. 05 sec. 06 sec. 02 sec. 02 sec. 0.5 – 6 A03. 10 sec. 10 sec. 05 sec. 06 sec. 0.5 – 6 A04. 20 sec. 21 sec. 08 sec. 08 sec. 0.5 – 6 A05. 30 sec. 31 sec. 10 sec. 11 sec. 0.5 – 6 A
Table 4-1 EOCR Working Analysis
EOCR has also been tested with the module and its functioning properly.
There has been an error of approx. 10% in over-time and delay time, which is acceptable in our
circumstances.
PT-100
PT-100, temperature sensor is also being tested and it’s working properly. It is also interfaced with microcontroller for verification of temperature sensing.
TemperatureDeg. oC
Expected Resistance (a)
Measured Resistance (b)
Measured Temperature
Error (a-b/a)*100
0 oC 100.00 Ω 98.58 Ω 0 oC 1.42 %10 oC 103.90 Ω 103.20 Ω 9.5 oC 0.67 %20 oC 107.79 Ω 107.15 Ω 19.0 oC 0.59 %30 oC 111.67 Ω 110.50 Ω 29.0 oC 1.05 %40 oC 115.54 Ω 114.93 Ω 41.0 oC 0.53 %
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60 oC 123.24Ω 122.20 Ω 61.0 oC 0.84 %80 oC 130.90 Ω 129.89 Ω 79.0 oC 0.77 %100 oC 138.51 Ω 138.10 Ω 99.0 oC 0.30 %110 oC 142.29 Ω 141.98 Ω 108.0 oC 0.22 %
Table 4-2 PT-100 Resistance Table Analysis
0 10 20 30 40 60 80 100 1100
0.2
0.4
0.6
0.8
1
1.2
1.4
1.61.42
0.6700000000000020.59
1.05
0.53
0.8400000000000010.770000000000
002
0.30.22
Error Analysis
Error Analysis
Temperature (deg Cent.)
%ag
e er
ror
Graph 4-1 b/w Temperature Measured and Tabled (PT-100)
From these test results, we have analyzed that the error will get minimum as the temperature gets nearer to the 100 mark.
FLOATING BALL BASED FUEL SENSOR
Since ultrasonic sensors are too much expensive, therefore, we have worked on floating ball
based fuel sensor for our model displaying. The sensor is tested and its working properly.
S. No. Expected Resistance (a)
Measured Resistance (b)
State Error (a-b/a)*100
Slow Movement of Arm
1 (0 – 2.6) KΩ (0 – 2.7) KΩ Low 3.852 (2.6 – 5.2) KΩ (2.7 – 5.5) KΩ Moderate 7.693 Above 5.2 KΩ Above 5.5 KΩ Full 6.25
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Fast Movement of Arm
4 (0 – 2.6) KΩ (0 – 2.9) KΩ Low 11.545 (2.6 – 5.2) KΩ (2.9 – 6.1) KΩ Moderate 23.086 Above 5.2 KΩ Above 6.1 KΩ Full 18.75
Table 4-3 Fuel Sensor Analysis
1 2 3 4 5 60
5
10
15
20
25
3.85
7.696.25
11.54
23.08
18.75
Error Analysis
Error Analysis
No. of Reading
%ag
e er
ror
Graph 4-2 for errors b/w fast and smooth movement of sensor.
From these test results, we have analyzed that the error will get maximum if the arm of the sensor is moved fast. But in our case it will move slowly, so no danger to use it.
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PROCESS FLOW
ALGORITHM
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1. Initialize all the circuit.2. Initialize GSM modem.3. Send status SMS to the cell phone.4. Get temperature reading from PT100 and display on LCD and send it to the cell phone
through GSM.5. If temperature in range, go to step 10 if higher than normal range go to step 6.6. Turn ON the buzzer and send an SMS to cell phone through GSM if temperature goes
down go to step 5 else continue.7. If temperature exceeds from the maximum limit turn OFF the Generator and send an
SMS to cell phone.8. Go to step 18.9. Get Load reading from Overload relay and display on LCD and send SMS to cell
phone.10. If load is in range go to step 15 if higher than normal continue to next step.11. Turn ON the buzzer and send an SMS to cell phone, if load decreases go to step 10
else continue.12. If load exceeded from the maximum limit Turn OFF the generator and send SMS to
cell phone. 13. Go to step 18.14. Get Fuel reading from Fuel sensor and display on LCD also send SMS to cell phone15. If fuel is enough go to step 5, if lower than defined range continue to next step.16. Send an SMS of low fuel status to base station 17. If fuel gets lower than the 2nd defined range Turn OFF the generator and send an SMS
to cell phone.18. Wait for SMS from base station or manual restart.19. If manual restart go to step 1.20. If restarted from cell phone go to step 3.21. END
BLOCK DIAGRAM
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PIC(Peripheral Interface
Controller)
Sub-StationO/P
Operational Panel
RS232(Serial
Interfacing)
GSM Module
SUB - STATION MODEL
Generator
PT-100 Temperature
Sensor
EOCR Electric Load Monitoring
PT-100 Temperature
Sensor
SCHEMATIC
CELL PHONE
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MECHANICAL DESIGN
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CONCLUSION
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Initially, it was considered by us a very difficult task to measure different parameters of the
generator and then display them on the panel as well as send those indications via GSM to the
base station, but Alhamdulillah with hard work and good support from our teachers, we have
successfully achieved our aim and all the objectives for the project.
Following are the expected results and the results which we have obtained.
Results Expected
Following results are desired and expected for successfully running a project:
Parameters must be read correctly from the sensors that are placed.
Microcontroller must get the readings from sensors timely and make the indication
decisions according to the programmed values.
GSM module must be interfaced with micro controller for cell phone monitoring.
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