INTRODUCTION

In the scope of industrialisation, automation and digitalization is a step beyond

mechanization. Whereas mechanization provided human operators with
machinery to assist them with the muscular requirement of work, automation
digitalization greatly decreases the need for human sensory and mental
requirements as well. Automation plays an increasingly important role in the
world economy and in daily experience. Automatic systems are being preferred
over manual system. Through this we have tried to control some industrial
equipment’s as a result power is saved to some extent.
Generally, the preceptors are sensors mounted on the controller, processing is
done by the on-board processor, and the task (action) is performed using relay.
Industrial production is nowadays driven by global competition and the need for
fast adaptation of production to the ever-changing market requests. These
requirements can be met only by radical advances in current manufacturing
technology. Industry 4.0 is a promising approach based on integration of the
business and manufacturing processes, as well as integration of all actors in the
company’s value chain (suppliers and customers). Technical aspects of these
requirements are addressed by the application of the generic concepts of Cyber-
Physical Systems (CPS) and industrial Internet of Things (IoT) to the industrial
production systems. The Industry 4.0 ‘execution system’ is therefore based on
the connections of CPS building blocks. These blocks are embedded systems
with decentralized control and advanced connectivity that are collecting and
exchanging real-time information with the goal of identifying, locating, tracking,
monitoring and optimizing the production processes by digitalization of data.
Related work

Power-generating technology such as robotization and automation has

long existed. The Internet, however, revolutionizes process organization
by networking robotic and automated devices. The development of the
Internet and technology creates a continuous network of people,
machines and companies, and through the continuous sharing of value-
creating processes, it is now possible to produce a competitive, fully-
customized product for the buyer.
By Industry 4.0, In 2013, the Fraunhofer Institute reviewed the
productivity and growth potential of companies using by digitalization
and connected industrial technologies. Its main impact comes from five
technology areas: Embedded systems, smart factories, strong networks,
cloud computing and IT (Information Technology) security
Today, in an Industry 4.0 factory, machines are connected as a
collaborative community. Such evolution requires the use of advance
prediction tools, so that data can be systematically processed into
information to explain uncertainties and thus make more informed
decisions . It can be concluded that the term digitalization and
connected industrial technologies describes different—primarily
Information Technology (IT) driven—changes in manufacturing systems.
These developments not only have technological but also versatile
organizational implications
The perception of the productivity of new technologies is influenced, on
the one hand, by company-level calculations that have shown that
Industry 4.0 investments have clearly increased investor productivity. It
is worth considering the possibility that the timing of the studies may
distort the conclusions drawn from the results.
Design of case study

Determine your digitization objectives

Digitization is all about transforming manufacturing operations using the latest
technology—and it often starts with connecting factory floor equipment. Over
the past few years, the cost of components that support connectivity has fallen
dramatically. Consumables like RFID tags now cost very little to include in
products. Sensors are becoming more affordable, increasing the amount of new
equipment sold with sensor capabilities built in, while older equipment can be
retrofitted, or IoT-enabled, at lower price points. At the same time, it is now
possible to collect and analyze massive quantities of sensor and device-
generated data, thanks to technologies like the cloud and advanced analytics.
Digital transformation means harnessing capabilities like these to gain insights
that you can use to make your manufacturing operation faster, more efficient,
and more flexible.

Experiment with simulated data

Experimenting with a solution that allows for simulation gives you a no-risk way
to see what digitization can accomplish. Simulations don’t require connecting
any of your actual equipment and won’t impact your operations.
simulated interfaces and dashboards, we can get a sense of how equipment all
over the world can be viewed holistically, including both an overall view of
performance and detailed insight into the status of individual machines. Even if
connecting operations around the globe is a much later step, seeing the results
of a simulation firsthand can help us refine your objectives and get a better
sense of what’s possible.
Connect equipment without disruption
Digitization doesn’t have to be accomplished all at once. Connecting a specific
set of equipment enables you to experiment on a small scale and at your own
pace—all without disrupting operations.

Contextualize and visualize manufacturing performance

With connected equipment comes greater visibility into operational status,
anomalies, trends, and other performance insights. This visibility is the
foundation for making a wide array of operational improvements.
Data from connected equipment is also the foundation for uncovering trends
and patterns. For example, collecting and analyzing historical data enables you
to establish your own performance benchmarks across similar equipment and
across plants. By comparing real-time data against benchmarks, you can
constantly monitor whether a piece of equipment is operating within normal
ranges, and identify subtle anomalies that emerge over time. A digital approach
to operational visibility offers tremendous potential value. A recent Automation
World survey found that nearly three-quarters of respondents use plantfloor
data at the corporate level, but a spreadsheet was cited as the most common
reporting tool.1 With a connected factory solution, operational intelligence is
available automatically and immediately, enabling better, faster decisions at the
plant and at the corporate level.

Make operational changes based on data

Connected equipment is ultimately useful when it drives changes. Anomalies
can be quickly detected and fixed. Maintenance schedules can be optimized to
minimize disruption.
detecting anomalies through real-time insights gives you the ability to intervene
more quickly. monitoring against benchmarks enables an even more proactive
approach. ability to identify under-performers and outperformers, and make
corresponding improvements. optimizing production processes to reduce waste
and bottlenecks, adding or replacing equipment, and adjusting staffing or
training procedures.
Scale and enable new scenarios
Scale from a single assembly line to an aggregated view across your operations.
Add new equipment and capabilities at your own pace. Use your solution as a
starting point for expanding to scenarios like predictive maintenance.
Beyond scaling to more equipment and factories, you can also choose to expand
the capabilities and scope of your digitization efforts. Visibility into current
performance and historical data are a powerful foundation for other digital
changes, such as predictive maintenance programs and an optimized energy
management approach.
Digital transformation can take many forms and mean many things for your
operation. As you enable new scenarios and scale, the key is to continue
experimentation using a phased approach, and to continue fine-tuning as your
needs and environment evolve.

Sensors and Microcontrollers that can be used

in this system

1. DHT 22
The DHT 22 sensor is a low-cost basic temperature and humidity sensor
with a digital as well as analog pin for reading the temperature and humidity
readings. The readings can be read at intervals of two seconds. The suitable
temperature range within which the sensor can work reliably is -40 to +80
degree Celsius. The humidity reading can be from 0 to 100 % with an error
of up to 2%. The module is very compact in form and lightweight. The current
consumption of the device is not more than 2.5mA and this makes it
especially suitable for systems which might need to run on battery power.

2. Gas Sensor
The MQ2 gas sensor is a sensor used typically in the detection of gases
making it suitable for use across a variety of industries to detect any faults.
The sensor can detect alcohol, propane, Methane, LPG, CNG, and Hydrogen.
The sensor in our test setup was used to detect any fumes that might arise in
case the circuitry begins to melt caused by any short circuits. The sensor has
a fast response stable and long lifetime and a wide detecting scope.

3. PIR Sensor
The passive infrared sensor works by detecting infrared rays emitted by all
warm bodied living animals. The sensor has a single output pin which goes
high or low depending upon whether anything has been detected or not. There
are two adjustable potentiometers that can be adjusted to adjust trigger range
and time interval for which the output pin remains high after any movement
is detected.

4. IR Sensor
The IR sensors used on the conveyors use active sensing an IR emitting
diode and a black colored photo-diode work together to detect obstacles in
their range which is adjustable by using a potentiometer. IR sensor module
used in the test setup had a digital as well as an analog pin that can be used
to read the output.

5. Load Cells
The load cells consist of a physical element that can generate an
electrical signal in response to any deformation. Commonly used
strain gauge load cell was used in the setup for detecting the
workpiece on the CNC laser engraver. The signal produced by the
load cell is too weak to be detected by the microcontroller and be
converted into any useful information. Therefore a level shifter in
the form of load cell shield is used.

6. Stepper Motors

A stepper motor also referred to as a step motor or stepping motor is a type

of brushless DC electric motor that divides a full rotation into a large number
of equal steps. The position of the motor can then be ordered to move and
hold for feedback at one of these steps without any position sensor as long as
the torque and speed of the motor are carefully sized to the application.

7. Arduino

Arduino is an open-source hardware and software company, project and user

community that designs and manufactures single-board microcontrollers and
microcontroller kits for building digital devices.

8. Raspberry pi

Raspberry Pi is a low-cost, credit card-sized computer that connects to a

computer monitor or TV using HDMI, and uses a standard keyboard and
mouse. It can run a host of operating systems, such as Raspbian (Debian
Linux), Android, Windows 10, IoT Core, etc.

9. ESP8266

The ESP8266 is a low-cost Wi-Fi microchip with full TCP/IP stack and
microcontroller capability produced by manufacturer Espressif Systems.
Algorithm

There are several approaches to solve multiparametric tasks of designing the

mechanical
assembly production, the major part of which are based on the mathematical
apparatus of the additive criteria. Those criteria became very popular to optimize
the indications of object designing quality with some values of the different
vector. In case if the designing object is a system which includes some
qualifying characteristics as well (for example, some purpose properties or
compatibility properties), then the mathematical convolution should include
some logical operations (conjunction, disjunction) and Hamming criterion.
The review of designing methods of mechanical assembly production reveals that
engineering calculation methods, proposed by specialists, are based on designing
the iterative procedure section By section with some special quality criteria which
correspond to the manufacturing technological operations for item designing
components. The popularity of that scalarization approach for designing project
procedures of the Industry 4.0 company production seems to be pointless because
that approach supposes a probability that a conflict of interests may appear during
the project task solution between subsystems (technological sections) and the
entire system in general (mechanical assembly production) at the level where
some quality private and general criteria of the project are not in agreement.

Create:
The create step encompasses outfitting the physical process with myriad sensors
that measure critical inputs from the physical process and its surroundings. The
measurements by the sensors can be broadly classified into two categories: (1)
operational measurements pertaining to the physical performance criteria of the
productive asset (including multiple works in progress), such as tensile strength,
displacement, torque, and color uniformity; (2) environmental or external data
affecting the operations of a physical asset, such as ambient temperature,
barometric pressure, and moisture level. The measurements can be transformed
into secured digital messages using encoders and then transmitted to the digitally
connected factor.
The signals from the sensors may be augmented with process-based information
from systems such as the manufacturing execution systems, enterprise resource
planning systems, CAD models, and supply chains systems. This would provide
the digitally connected factory with a wide range of continually updating data to
be used as input for its analysis.

Communicate:
The communicate step helps the seamless, real-time, bidirectional
integration/connectivity between the physical process and the digital platform.
Network communication is one of the radical changes that have enabled the
digitally connected factory; it comprises three primary components:
Edge processing: The edge interface connects sensors and process historians,
processes signals and data from them near the source, and passes data along to
the platform. This serves to translate proprietary protocols to more easily
understood data formats as well as reduce network communication. Major
advances in this area have eliminated many bottlenecks that have limited the
viability of a digitally connected factory in the past.
Communication interfaces: Communication interfaces help transfer information
from the sensor function to the integration function. Many options are needed in
this area, given that the sensor producing the insight can, in theory, be placed at
almost any location, depending on the digitally connected factory configuration
under consideration: inside a factory, in a home, in a mining operation, or in a
parking lot, among myriad other locations.
Edge security: New sensor and communication capabilities have created new
security issues, which are still developing. The most common security approaches
are to use firewalls, application keys, encryption, and device certificates. The
need for new solutions to safely enable digitally connected factory’s will likely
become more pressing as more and more assets become IP enabled.

Aggregate:
The aggregate step can support data ingestion into a data repository, processed
and prepared for analytics. The data aggregation and processing may be done
either on the premises or in the cloud. The technology domains that power data
aggregation and processing have evolved tremendously over the last few years in
ways that allow designers to create massively scalable architectures with greater
agility and at a fraction of the cost in the past.

Analyze:
In the analyze step, data is analyzed and visualized. Data scientists and analysts
can utilize advanced analytics platforms and technologies to develop iterative
models that generate insights and recommendations and guide decision making.
Insight: In the insight step, insights from the analytics are presented through
dashboards with visualizations, highlighting unacceptable differences in the
performance of the digital connected factory model and the physical world
analogue in one or more dimensions, indicating areas that potentially need
investigation and change.

Act:
The act step is where actionable insights from the previous steps can be fed back
to the physical asset and digital process to achieve the impact of the digitally
connected factory. Insights pass through decoders and are then fed into the
actuators on the asset process, which are responsible for movement or control
mechanisms, or are updated in back-end systems that control supply chains and
ordering behavior—all subject to human intervention. This interaction completes
the closed loop connection between the physical world and the digitally
connected factory.

Conclusion

For a smart factory to function, assets—defined as plant equipment

such as material handling systems, tooling, pumps, and valves—
should be able to communicate with each other and with a central
control system. These types of control systems can take the form of a
manufacturing execution system or a digital supply network stack. The
latter is an integrated, layered hub that functions as a single point of
entry for data from across the smart factory and the broader digital
supply network, aggregating and combining information to drive
decisions. However, organizations will need to consider other
technologies as well, including transaction and enterprise resource
planning systems, IoT and analytics platforms, and requirements for
edge processing and cloud storage, among others. This could require
implementing the various digital and physical technologies inherent
in digital connected plant including analytics, additive manufacturing,
robotics, high-performance computing, AI and cognitive technologies,
advanced materials, and augmented reality—to connect assets and
facilities, make sense of data, and digitize business operations.
 IOT Assignment on Digital/Connected Factory

Submitted by: -
Name: - Mallikarjun T
USN: - 1MS17ME413
Dept: - Mechanical Engineering
 IOT Assignment on Inventory Management

Submitted by: -
Name: - PS. Kaustubh
USN: - 1MS16ME108
Dept: - Mechanical Engineering