Dissertation

ON

Machine Monitoring System on Cloud

using Raspberry Pi and IOT,
Devgiri Forgings Pvt Ltd

Guided By Submitted By
Dr. A.S. Bhalchandra Amit R. Rana
 Machine Monitoring on Cloud using Raspberry
pi and IoT
sponsored by
Devgiri Forgings Pvt Ltd
Wireless Production Line Counter
Machine Intelligence System
st using Rpi
Commissioned on 1 March 2016

 Internal Guide  External Guide

 Dr A. S. Bhalchandra  Mrs Aditi M.
Someshwar
Title: Machine Monitoring System
• CNC Machine Monitoring System

• Production Counter Monitoring System

 Introduction: Internet of Things
• Connected Infrastructure for centralized
monitoring
• Connect small devices to entire plant
machinery to internet based server (CLOUD)
• Monitor and Control sitting anywhere in the
world
• Increased productivity, efficiency and
monitoring
• Assets located anywhere in world can be
monitored
Introduction: Machine Monitoring
• Production Companies use CNC machines for
various operations
• One operator at per machine
• Different types of jobs to perform
• Operator Productivity is vital
• Machine Parameters Monitoring is required
• Machine parameter monitoring requires very
costly equipments
 Objective: Machine Monitoring
• Develop a Machine Intelligence System to
monitor performance of CNC machine
• Accept Inputs from CNC machine and log on
Server
• Labor efficiency monitoring
• Remote analysis of daily production and down
times with reasons
 Objective Machine Monitoring
• IoT Based Machine Monitoring
• Machine Runtime Log on web server using
single board system including
– Name of Machine
– Operator Name
– Job in progress
– Target/actual achieved count
– Real Time status/downtime intimation
– Machine performance, inputs from CNC log onto
server
– Provide a terminal to operator to login/logout
 Need of Project: Machine
Monitoring
• CNC Machine is operated by a Technician
• Evaluation of total work produced by the
machine is important
• Intentional faults created by labor many times
• Automation of Total Job produced record
• Online monitoring enables complete remote
access
• Plant owner needs to analyze daily production
data without being present at plant in real
time
 Proposed System: Machine
Monitoring
• ARM based system
• Raspberry Pi Board
• Opto-coupled Input Data Card
• Optional Device Control
• VGA Display Interfacing
• Internet Connectivity through wifi
• Data Sensing to Server using HTTP requests
• Data posting on Cloud every 30 seconds
• Web based User Interface
 Proposed System

Wifi
Raspberry Pi Dongle

VGA
Raspberry Pi GPIO MOnitor

Opto-coupled
Keyboard Mouse Wifi-Dongle
Input Card

Sensor 1 Sensor 2 ... Sensor 8

User End

User Can Open a website

To Monitor the Real Time
Video as well as the
Security system and
Device Control
Simply Through a web
browser
 System Workflow
• User enters an IP address on browser
• A website opens
• User has to log-in using ID and Password
• There in the Cloud platform, we’ll have
different fields for different parameters
• All the parameters coming from our system
will be shown at this place
Introduction: Production Counter
• Production line counters are required in
manufacturing assembly
• MASO automotives manufactures Raw Metal
Parts
• Daily production report is formulated at the
end of day manually
• Weekly/monthly reports are made manually
• Commercial production counters are available
Introduction: Production Counter
• Currently Selec made Production Counters are
used
• 6 Digits, 7 segment LED totalizer
• NPN/PNP Inputs
• Max Count 999999 count
• Cheap Option
• No automation
Objective: Production Monitoring
• IoT Based Production Monitoring
• 4-inch 4-digit Counter with
– Wireless Connectivity
– Memory backup
– 8-additional Logical Optocoupled Inputs
– Rugged performance in harsh environment
– Software on Local computer to feed data to the
web server
 Need : IoT based Production
Counter
• Client is having 2 different production units
and needs single automation system
• Production Line Counter needs internet
connectivity
• If data sent directly to cloud, management
person can monitor it from anywhere
• There are 10 Production line counter from
which data is to be sent to Internet
 Proposed System:
Production Counter Monitoring
• PIC18 based Production Counter
• 4-Inch 4-Digit Display
• EEPROM Memory Backup
• 8-Optocoupled Inputs
• Zigbee Interfaced to central Computer
• PC based GUI for Local Monitoring
• Data Sensing to Server using HTTP requests
• Web based User Interface
 Proposed System
Production Monitoring
Count
Sensor Xbee
PIC18F452 Transceiver

Opto
coupler
8-Inputs
Display Driver using Shift
register and Current Diving UC

4 – Digit Seven
Segment DIsplay
Literature Review
 Literature Review
Machine Monitoring
• Video Surveillance System
• SCADA System
• Human Machine Interface System
• Proprietary Cloud platforms by Allen
Bradley and SIEMENS
• Commercial IoT platform e.g. ALTIZON
DATONIS[1]
• Goodyear tyres, Aurangabad uses AB
secure server for production monitoring,
 CCTV / Video Survilliance
• By far the most preferred solution for video
Surveillance
• Standard Wired Installation with a recording
Unit
• Costs a Minimum of 10000 Rupee with 7000
extra for each camera
• Heavy installation
• Large Power Consumption
• Regular Maintenance
• Production can’t be
 SCADA System
• For the desired results use of SCADA systems
is an option
• Requires use of at least one Master Computer
• Can analyze large data through industry
standard protocol and secure communication
• Suitable for substantially large setup
• Costly Solution
• Not suitable for 1-5 machine
• Internet connectivity is further costly [3]
 HMI Systems
• Using an HMI with Every machine to send data
to internet is an option
• HMI is a general purpose Large Screen Based
Device
• Inputs and outputs can be
programmed
• Uses standard industry protocols
• Cheaper, but not suitable for current
requirements [4]
 ALTIZON
• Pune based startup Company ALTIZON has
made a product DATONIS
• This is Raspberry Pi based System
• Can be used to connect anything to cloud
• Suitable for any kind of machine and almost
every industrial protocol
• Priced moderately at around 30000/- rupee
for single installation with monthly 3000/- for
cloud platform [5]
 Literature Survey
ThingWorx IoT & Machine
Learning
• USA based ThingWorx have developed an IoT
software platform
• Can be used with Raspberry pi and galileo
boards
• Open C-Language SDK available
• Online Compose, things and
business process management[7]
 Allen-Bradley
• The Connected Enterprise product line by
Rockwell Automation
• Proprietary Products
• Secure Cloud Server
• Facilities like remote programming/debuging
• Remote Installations
• Very Costly [6]
Literature Review: Production Line
Counters
AUTONICS
• Autonics D1SC Units
• 7-Segment Display
• 12-24v Operation
• Memory Retention
• Various Options in Display No
• Input via Sensor and RS232[9]
 Comparison of Wifi 802.11
standards
Feature 802.11 b 802.11 g 802.11 n

Range 35 m 38 m 70 m

Maximum Data 11 MBPS 54 MBPS Up to 600 MBPS

Rate

Freq Band 2.4 GHz 2.4 GHz 2.4 GHz / 5 GHz

Bandwidth 22 MHz 20 MHz 20 / 40 MHz

Encryption TKIP TKIP AES

 RADIX
• Autonics RCT404 [10]
• Absolute Accuracy
• Up to 2 user programmable setpoints/relays
• Programmable scale factor and relay modes
• Totalizer, RPM, Meters/Minute, Mains
Frequency and more
• Measures up to 5 KHz
• 4 Counting Modes
 Drawbacks of Commercial
Counters
• No wireless Connectivity
• No additional Inputs
• No Customizations possible
• No Internet / wireless connectivity
System Development

IoT Based Production Counter

 System Hardware Production
Counter
• PIC18F452 Microcontroller
• 4-Digit 4-Inch Seven Segment Display CA
• 74HC164 Shift Register
• ULN2803 High Current Driver
• LVT 847 8-bit Optocoupler
• PC817 Optocoupler
 System Hardware Production
Counter (cont)
LVT847 Opto ULN2803 Currrent Driver
74HC164 Shift
and 4-Inch Seven
coupler Register Segment
4 Inputs
ULN2803 Currrent Driver
74HC164 Shift
and 4-Inch Seven
LVT847 Opto Register Segment
MICROCONTROLLER
coupler 4 PIC18F452 ULN2803 Currrent Driver
Inputs 74HC164 Shift
and 4-Inch Seven
Register Segment
PC817
ULN2803 Currrent Driver
Opeocouper x 74HC164 Shift
and 4-Inch Seven
2 Register Segment

LIMIT XBEE 12V 2 Ampere SMPS and +5V

Reset
SWITCH WIRELESS regulated Supply
 System Hardware Production
Counter (cont)
• Microcontroller PIC18F452
• ULN2803 High Current Driver
• 4-Inch RED seven segment display
• 74HC164 Shift Register
• LVT847 4-input Optocoupler
• PC817 Single Input Opto-coupler
• Xbee 2.4Ghz Zigbee Transceiver
 PIC18F452 Microcontroller
• High Performance 8-bit RISC Controller
• 32KB Flash, 1536 Bytes RAM, 256 B EEPROM
• Up to 40MHz clock with max 10 MIPS
• C Compiler Optimized Instruction set
• 10-bit A-D Converter
• On-Chip I2C and SPI protocol support
• 2v – 5.5v wide operational Voltage
• 40-Pin DIP Package with 33 Programmable IO
[11]
 LVT847
• Multiplexed 4-Input Optocoupler
• High Input Isolation Voltage (5000V)
• Used for 8-bit Input on Counter coming from
machine
 PC817
• Single Input, Small package HIGH Speed
Optocoupler
• Used for Accepting Sensor Input and Reset
Input [12]
 ULN2803
• High Current Sink Driver
• 8-Channel Darlington Pair
• Current Sink Capacity 500mA per Channel
• Used for driving Common Anode Seven
Segment Display
• Low Cost
• Internal Clamp Diodes
 74164
• Serial In, Parallel Out Shift Registers
• Used for sending 8-bit data to Seven Segment
Display Driver through 2 lines
 Seven Segment Display
• 4-Inch Common Anode Display
• 12V operation max 70mA Current
Consumption per segment
• 9V typical forward Voltage
• 630nmeter Peak wavelength
• Comfortable Viewing Distance up to 100 feet
 Xbee
• 2.4GHz ISM Band Wireless Transceiver with
Networking Capabilites
• Implements IEEE 802.15.4 protocol
• Indoor Range upto 40m, up to 120 m LOS
• DSSS, with QPSK modulation
• Can securely perform PAN
• Low Power (45mA/1uA)
• 128-bit AES encryption
• CSMA with CA [13]
 A Read Sensor Input
Flow Chart
Yes
START Sensor Increment Count
INPUT Send Wireless Word
HIGH?

Initialize All I/O No

Ports
Read Reset Input
Initialize UART with
9600 Baud Rate
Yes
Reset
Reset Count, Send
Input Wireless Word
Initialize Xbee HIGH?

Read EEPROM Inputs No

REPEAT Read 8-bit Input
NO
Is Display
Value Yes
Count Any 8-
zero?
bit Send Wireless Word
Input
Yes
HIGH?
No
Display 0
Update Display and
EEPROM
A
System Development

IoT Based Machine Monitoring

System
System Hardware Machine Monitoring
• Linux Based Computer
• Raspberry pi, being the cheapest among all
Linux systems
• ARM11 Core Running at 700MHz with 512MB
RAM
• 26 GPIO
• LVT847 Optocouplers
• VGA Monitors, Keyboard and Mouse
• Wifi Connectivity
 System Hardware Machine
Monitoring(cont)
LVT847 Opto
coupler USB Keyboard
4 Inputs

USB Mouse
Output from Raspberry Pi
CNC Computer System
VGA Monitor
LVT847 Opto
coupler 4 Wifi
Inputs Transceiver

LIMIT
Sensors SD Card +5V Power Supply
SWITCH
Raspberry Pi
 System Hardware
• 8-Optocoupled Inputs
• Inputs Coming from CNC and Sensors
• Active Internet Connection through Wifi
• Color VGA Monitors
• Keyboard and Mouse
• Fully operational at only 5V 1A power supply
 System Software
• Raspberry pi running Raspbian Operating
system
• Python Development Environment
• GPIO libraries for Python Installed
• HTTP Lib for Python
• SMTP lib for Python
• Midori / Opera / Epiphany for Frontend
• Python programming language
System Flow Chart
A

Read Input GPIO

START

Import Required YES

Libraries Chang Formulate HTTP String and
e
SEND GET REQUEST
Detect
Initialize All GPIO Pins ed?
NO

YES
Make All GPIO inputs any
excepti Throw Exception Message
on??
Start Infinite Loop
NO

Sleep 5 Sec
Machine Monitoring Software Use
Flow
• User of CNC Machine Logs onto the Cloud
Panel using browser
• Operator Selects Machine
• Operator Selects Parts
• Enters the details of job
• If operator wishes to take any break, he has to
enter it in DOWNTIMEs
• While stopping work, operator has to enter
the total no of rejections
 Wi-fi
• We are using Wifi for taking advantage of the
existing wifi infrastructure.
• There are many vendors manufacturing wi-fi
USB dongles
• We are using 150 Mbps TL-WN721N Wireless
N USB adapter
• 802.11 n compatible router and adapter gives
maximum range
• Further Range depends upon the Router
Transmit Power [14]
 Specifications
• Operating Voltages
– Raspberry Pi +5v
– Motion sensor +5v
– Camera Module +3.3v
– Wi-fi Router +9v
– Relay Coil Voltage +12v
• Overall Current less than 1 A
• Relay Coil Current 100mA
• Wi-fi Normal Range: 50-70 feet
• Motion sensor detection Range 20-30 feet
Performance Analysis

IoT based
Production Counter
 Work Flow
• Developed 2 Different Systems Connected to
Cloud
• Production Line Counter
– Microcontroller based system
– Production counter as well as data posting
• Machine Monitoring System
– Raspberry Pi Computer based system
– Data posting to cloud from various machine parts
 Performance Analysis
Production Counter
• Display Features
• Wireless Features
• General Purpose Input Features
• Memory Backup Features
• Count Reset
• Overall Stability of System
 Production Counter Software
Algorithm
• Power On, make all the required ports go
output/input as required
• Check for EEPROM, if some non-zero data is
present, read in variables
• Shift Data according to display to print this
value
• Continuously Check for Inputs
i. If sensor input is detected, increment count, send
wireless WORD, save count to EEPROM
ii.If one of 8-bit input is detected, send wireless
WORD
 Performance Analysis
Production Counter (cont)
• LED Display Current Vs Series Resistor
• Vf = 6.3volts – 4.8v
• Forward Current If = 20mA
• Supply Voltage : 12v
• Ideal Resistor Value :
(Vs – Vf) / If = (12-6.4) / 20 = 285 Ohm
Selected Value : 220 Ohm
 Performance Analysis
Production Counter (cont)
• Wireless Communication
• Secure Wireless Communication
• Immune to Industrial Noise and Harsh Environment
• No interference caused due to external supplies in
xbee
• Very Low wireless Latency as good as wire
replacement
• Covers Wide Area
 Performance Analysis
Production Counter (cont)
Zigbee Compared to Other technologies
LOW ENERGY Zigbee NFC WIFI LOW
Bluetooth POWER
Frequency in 2402-2482 868-0.8,902- 13.56 2400-5400
MHz 928, 2402-
2482
Channels 3 16 1 3
Modulation GFSK QPSK ASK 64QAM
Max Data Rate 1 MBPS 250kbps 424kpbs 54 MBPS
Range 10 meter 100+ meters 10 CM 30 meters
Power Profile Days Months Months Hours
Complexity Complex Simple Simple Complex
Nodes/Master 7 65000 1+1 Variable 100
Extendibility No Yes No Yes
 Performance Analysis
Production Counter (cont)
• MICROCONTROLLER
8051 AVR atmega32 PIC18F452
AT89S51
Architecture 8-bit CISC 8-bit RISC 8-bit-RISC
On Chip 4KB / 128 bytes 32KB / 2Kb 32KB/1.5KB
Flash/RAM
Speed Up o 33MHz Up to 16 MHz 1-T Upto 40MHz 4-T
12-T States States states
EEPROM NO YES 1KB YES 256 Bytes
On-Chip I2C No Yes Yes
Full Duplex UART No Yes Yes
ISP Facility YES YES YES
On-Chip ADC No YES YES
 Performance Analysis
Production Counter (cont)
• MICROCONTROLLERs
• Comparison shows Both Atmega32 and
PIC18F452 are suitable for requirement
• Previous Attempt on atmega32 resulted in
Noisy performance
• Shift to PIC18F452 provided smoother
performance as compared to Atmega
 Performance Analysis
Production Counter (cont)
• MICROCONTROLLER Performance Comparison
With Atmega32 With PIC18F452
Frequency of Accidental Several Times in a day Close to zero
Resets
Interference Loss of Frequent Rare
Wireless Word
Display Flickering Display flickers with Heavy Smoother Performance
units switchin
Falls Counting Up By 100’s of counts, Zero
frequent
EEPROM Corruption Within 3 Months No problems for 2 Years
EEPROM Write Cycles 100,000 Write Cycles 10,00,000 Write Cycles
Allowed
Over all System Stability Non Acceptable Acceptable
Possible Reason Bad Quality Semiconductor -
 Performance Analysis
Production Counter (cont)
• Seven Segment Display Interfacing
Using Multiplexed Using Shift Registers
Complexity of Design More Complex Relatively Simple
Complexity in More Complex Relatively Simple
programming
Stability in Harsh Frequency Reset Smooth Operation
Environment, Furnaces, Causes Issues, Display throughout
Vibrations and High Flickering Many times
Temperatures
Power Consumption Low Relatively High
Display brightness / Less More
viewing clarity
 Performance Analysis
Production Counter (cont)
• Zigbee Comparison
• We’use used xbee
Parameter Xbee Xbee Pro
Line of Sight Range 100 meter 1.6 KM
Out of site range 30 meter 300 meter
Transmit current 45mA 250mA
Addressing and SAME SAME
network features
Footprint Small Large
Price per unit 1100/- INR 2500/- INR
 Performance Analysis
Production Counter (cont)
• Input Comparison
Sensor Type Allowed Voltage Actuation Denounce Response
Time
Limit Switch 12v Automatic HIGH 1 sec
Snitcher 24v Automatic HIGH 1 sec
Paddle Switch 24v Manual HIGH 2 sec
Pusher 24v Automatic Medium 1 sec
Sensor 24v Automatic LOW 500 ms
 Performance Analysis
Production Counter (cont)
• Different Voltage Levels

Sr Voltage Limit Power 7805 Opto SMPS

No logic Switch Supply Output coupler Input
Output Input

1 Logic HIGH 12V 12V 5v 24v 230v

2 Logic LOW 0V 0V 0 0v 110v

 Performance Analysis
Production Counter (cont)
• Different Voltage Levels

Sr No Logic Level PIC18F452 Xbee Seven Optocoupler

Voltages Module Segment Input
Display

1 Logic Low 0V 0V 0v 2.5v

2 Logic High 5V 3.3V 12 5v- 24v (Max)

 Performance Analysis
Production Counter (cont)
• Timing Details
Sr No Delay Parameter Required Value Actual delay

1 System start and Memory 1 seconds Approx 2 seconds

Backup Display

2 Sensor Count Increment 200 ms 1 second

3 Reset upon switch press 2 seconds Approx 3 seconds

4 Wireless Data Send and 3 seconds 5 seconds

Reception at Receiver upon
sensor

5 One of 8 Input Sense and 1 seconds 2 seconds

data send

6 Count Reset After 9999 0 seconds 2 Seconds

 Machine Monitoring Software
Algorithm
• Power On, make all the required ports go
output/input as required
• Connect to the internet using pre-set settings
• Python Code will run in background using
CRON
• Program Continuously Check for Inputs
– Change GPIO Status
– If any of the 8-input is changed, python script will
compute an HTTP String and send GET Request
– If there is no change in inputs, do nothing
– Repeat
Future Scope
 Future Scope
• Integration of Entire Plant can be done using
IoT
• Connection of All the CNC Machines on Shop
Floor Including the production line of raw
materials
• Output Control in Raspberry Pi system can
also be implemented
• Output Control in Counter unit is possible
• Solution may be made applicable to other
Companies/Units
 Advantages: Counter
• Overall System cost is very low
• No error, system can run for 24 hours without
any software issue
• Easy to use and replace components
• Long life
• Capable to be run on battery
• Lower Power Consumption as compared to
similar systems
• More Inputs
Advantages: Machine Monitoring
• Low Cost replacement to available IoT
application
• No error, system can run for 24 hours without
any software issue
• Availability
• User Friendly
• Web browser based system
 Conclusion
• A system is built in low budget (around INR
7000) to work as IoT Station using Rpi
• Wireless Counting is connected to IoT for
production monitoring
• Same system is reconfigured to be used in
different application areas
• There is virtually infinite number of IoT units
which can be monitored using Web Server
• Improves the production monitoring of CNC
• Improves the labor monitoring and downtimes
 Conclusion
• Production Line Counter is connected to Cloud
platform
• Counting system is automated for local and
online report generation
• Improves Productivity
• Provides Low Cost solution
• Possible to add more inputs as well as outputs
 References
• [1] www.3aia.com
• [2] www.amazon.in, www.wikipedia.org (CCTV)
• [3] www.schneider-electric.co.in , literature.rockwellautomation.com
• [4] HMI Systems, www.renuelectronics.com, pune
• [5] DATONIS, www.altizon.com
• [6] allen bradley connected enterprise www.rockwellautomation.com
• [7]IoT Application Platform www.thingworkx.com
• [8]Microsoft Azure Iot www.microsoft.com/azure
• [9] www.autonics.co.in
• [10] www.radix.co.in
• [11]Microchip PIC18 www.microchip.com
• [12] www.sharp.com
• [13] www.digi.com
• [14] www.electronicdesign.com
 Thank you!!!

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