Published August 6, 2024 © LGPL

Basic Andon System using Arduino Uno R3 and Python

Your First step to learn Industrial visualizations!

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Basic Andon System using Arduino Uno R3 and Python

Things used in this project

Hardware components

Arduino UNO

Solderless Breadboard Full Size

Adafruit Standard LCD - 16x2 White on Blue

Jumper wires (generic)

Resistor 220 ohm

Resistor 10k ohm

Single Turn Potentiometer- 10k ohms

LED (generic)

SparkFun Pushbutton switch 12mm

Buzzer

Digilent 6-pin Header & Gender Changer (5-pack)

Software apps and online services

Arduino IDE

Microsoft Visual Studio Code

Hand tools and fabrication machines

Soldering iron (generic)

Solder Wire, Lead Free

Solder Flux, Soldering

Story

Project Overview:

This project is a simple application for real-time monitoring and alerting in industrial or workshop settings. This project utilizes an Arduino Uno R3 board with a Python-based GUI to manage and display system status through both hardware indicators (LEDs, buttons, and a buzzer).

Safety Warning:

Caution: When working with electronic components and soldering irons, always prioritize safety. Ensure that the soldering iron is used in a well-ventilated area, and avoid direct contact with the hot tip to prevent burns. Use appropriate safety gear and follow best practices for handling electronic components to prevent damage and ensure a safe working environment.

Project Description:

This project features a basic Andon system designed to display and signal different operational statuses. The system is controlled through an Arduino Uno and provides feedback through LEDs, an LCD, and a buzzer. The statuses include:

Normal : Indicated by a green LED and displayed on the LCD.
Attention Needed : Triggered by pressing the corresponding button, turning the LED blue, and displaying the alert on both the LCD and the GUI.
Critical Error : Triggered by pressing the critical error button, activating the red LED, and showing the critical message on the LCD and GUI.

The Python GUI application is developed using Tkinter and communicates with the Arduino via serial communication. It displays the current status of the system and updates dynamically based on the Arduino's inputs.

Steps to Complete the Project:

1- Connect the Components:

Connect the Arduino Uno to the breadboard and wire up the components as shown in the attached photo. Ensure all connections for LEDs, buttons, the LCD, and the buzzer are correctly made.

2- Upload the Arduino Code:

Open the Arduino IDE, copy and paste the provided Arduino code into a new sketch, and upload it to the Arduino Uno. This code will manage the input from buttons, control the LEDs, and handle the buzzer.

3- Run the Python Code:

Ensure you have Python installed on your computer along with the serial and tkinter libraries. Save and run the provided Python script. This code will create a GUI communicating with the Arduino via serial communication and displaying the system status.

4- Done:

Your Andon system should now be operational. The LCD and Python GUI will display the current status based on the button presses, with corresponding visual and audible alerts.

Now... What is an Andon System?

In the industrial field, an Andon system is a visual and/or audible signaling system used to communicate the status of production processes and alert operators or managers to any issues or abnormalities that need attention. Originating from Toyota's lean manufacturing principles, Andon systems are crucial in maintaining efficiency, quality, and rapid response to problems on the production line. They typically include:

Visual Indicators : Such as lights or displays, to show the current status or highlight problems.
Audible Alerts : Such as alarms to draw attention to critical issues.
Feedback Mechanisms : Allowing operators to report problems or status changes directly.

By providing immediate feedback and visibility into production processes, Andon systems help ensure timely resolution of issues, reduce downtime, and enhance overall production efficiency and quality.

Conclusion:

This project demonstrates a practical application of Arduino and Python for creating a responsive and informative Andon system. It provides a solid foundation for understanding real-time monitoring and alert systems, with clear visual and audible feedback mechanisms.

Feel free to adapt and expand on this project to suit specific needs or to integrate additional features for more complex implementations.

You Can check the simulation here: https://www.tinkercad.com/things/ltKT4azhb2s-basic-andon-system

Code

import tkinter as tk
from tkinter import messagebox
import serial
import threading

# Serial communication setup
ser = serial.Serial('COM5', 9600)  # Update with your COM port
ser.flushInput()

# GUI setup
root = tk.Tk()
root.title("Andon System")

# Colors
NORMAL_COLOR = "green"
ATTENTION_COLOR = "blue"
CRITICAL_COLOR = "red"

# Create labels for status display
status_label = tk.Label(root, text="System Status", font=("Arial", 100))
status_label.pack(pady=20)

status_message = tk.Label(root, text="Normal", font=("Arial", 70), fg=NORMAL_COLOR)
status_message.pack(pady=20)

# Function to update the GUI based on serial data
def update_gui():
    while True:
        if ser.in_waiting > 0:
            line = ser.readline().decode('utf-8').strip()
            if line == "ATTENTION":
                status_message.config(text="Attention Needed", fg=ATTENTION_COLOR)
            elif line == "CRITICAL":
                status_message.config(text="Critical Error", fg=CRITICAL_COLOR)
            elif line == "NORMAL":
                status_message.config(text="Normal", fg=NORMAL_COLOR)
            else:
                status_message.config(text="Unknown Status", fg="gray")
        root.update_idletasks()
        root.update()

# Run the update_gui function in a separate thread
thread = threading.Thread(target=update_gui, daemon=True)
thread.start()

# Start the GUI loop
root.mainloop()

#include <LiquidCrystal.h>

// Initialize the LCD with the pin numbers
LiquidCrystal lcd(12, 11, 10, 9, 8, 7);  // RS, E, D4, D5, D6, D7

const int buttonAttentionPin = 2;  // Button for Attention Needed
const int buttonCriticalPin = 3;   // Button for Critical Error
const int buzzerPin = 4;           // Buzzer connected to digital pin 4

const int ledNormalPin = 13;       // LED for Normal status
const int ledAttentionPin = 5;     // LED for Attention Needed status
const int ledCriticalPin = 6;      // LED for Critical Error status

// State variables
bool attentionState = false;
bool criticalState = false;
unsigned long lastBeepTime = 0;
bool beepOn = false;

void setup() {
  Serial.begin(9600); // Start serial communication at 9600 baud
  pinMode(buttonAttentionPin, INPUT_PULLUP);
  pinMode(buttonCriticalPin, INPUT_PULLUP);
  pinMode(buzzerPin, OUTPUT);
  
  pinMode(ledNormalPin, OUTPUT);
  pinMode(ledAttentionPin, OUTPUT);
  pinMode(ledCriticalPin, OUTPUT);

  lcd.begin(16, 2);  // Initialize the LCD with 16 columns and 2 rows
  lcd.setCursor(0, 0);
  lcd.print("  System Status  ");
  lcd.setCursor(0, 1);
  lcd.print("     Normal     ");

  noTone(buzzerPin); // Ensure buzzer is off initially
  digitalWrite(ledNormalPin, HIGH); // Turn on Normal LED
  digitalWrite(ledAttentionPin, LOW); // Turn off Attention LED
  digitalWrite(ledCriticalPin, LOW); // Turn off Critical LED
}

void loop() {
  static bool lastAttentionButtonState = HIGH;
  static bool lastCriticalButtonState = HIGH;

  bool currentAttentionButtonState = digitalRead(buttonAttentionPin);
  bool currentCriticalButtonState = digitalRead(buttonCriticalPin);

  // Handle Attention Needed Button
  if (currentAttentionButtonState == LOW && lastAttentionButtonState == HIGH) {
    // Button was pressed
    if (!attentionState) {
      attentionState = true;
      criticalState = false;
      lcd.setCursor(0, 0);
      lcd.print("Attention Needed");
      lcd.setCursor(0, 1);
      lcd.print(" Press button 2 ");

      Serial.println("ATTENTION");
      digitalWrite(ledNormalPin, LOW); // Turn off Normal LED
      digitalWrite(ledAttentionPin, HIGH); // Turn on Attention LED
      digitalWrite(ledCriticalPin, LOW); // Turn off Critical LED
    } else {
      attentionState = false;
      lcd.setCursor(0, 0);
      lcd.clear();
      lcd.print("  System Status  ");
      lcd.setCursor(0, 1);
      lcd.print("     Normal     ");

      Serial.println("NORMAL");
      noTone(buzzerPin); // Turn off buzzer
      digitalWrite(ledNormalPin, HIGH); // Turn on Normal LED
      digitalWrite(ledAttentionPin, LOW); // Turn off Attention LED
      digitalWrite(ledCriticalPin, LOW); // Turn off Critical LED
    }
    delay(500); // Debounce delay
  }

  // Handle Critical Error Button
  if (currentCriticalButtonState == LOW && lastCriticalButtonState == HIGH) {
    // Button was pressed
    if (!criticalState) {
      criticalState = true;
      attentionState = false;
      lcd.setCursor(0, 0);
      lcd.clear();
      lcd.print(" Critical Error ");
      lcd.setCursor(0, 1);
      lcd.print(" Press Button 1 ");

      Serial.println("CRITICAL");
      digitalWrite(ledNormalPin, LOW); // Turn off Normal LED
      digitalWrite(ledAttentionPin, LOW); // Turn off Attention LED
      digitalWrite(ledCriticalPin, HIGH); // Turn on Critical LED
    } else {
      criticalState = false;
      lcd.setCursor(0, 0);
      lcd.clear();
      lcd.print("  System Status  ");
      lcd.setCursor(0, 1);
      lcd.print("     Normal     ");

      Serial.println("NORMAL");
      noTone(buzzerPin); // Turn off buzzer
      digitalWrite(ledNormalPin, HIGH); // Turn on Normal LED
      digitalWrite(ledAttentionPin, LOW); // Turn off Attention LED
      digitalWrite(ledCriticalPin, LOW); // Turn off Critical LED
    }
    delay(500); // Debounce delay
  }

  lastAttentionButtonState = currentAttentionButtonState;
  lastCriticalButtonState = currentCriticalButtonState;

  // Handle Buzzer for Attention and Critical States
  if (attentionState || criticalState) {
    unsigned long currentTime = millis();
    if (currentTime - lastBeepTime >= 1000) { // Change interval for beep
      lastBeepTime = currentTime;
      beepOn = !beepOn;
      if (beepOn) {
        tone(buzzerPin, attentionState ? 1000 : 2000); // Lower frequency for Attention, higher for Critical
      } else {
        noTone(buzzerPin);
      }
    }
  } else {
    noTone(buzzerPin);
  }
}

Credits

Ibrahim M. Abdelsalam

1 project • 0 followers

Using my knowledge and experience to guide the new generations in making meaningful changes in the world.

Contact

Comments

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Basic Andon System using Arduino Uno R3 and Python

Things used in this project

Hardware components

Software apps and online services

Hand tools and fabrication machines

Story

Project Overview:

Safety Warning:

Project Description:

Steps to Complete the Project:

Now... What is an Andon System?

Conclusion:

Schematics

Diagram

Schematics

Code

GUI

Arduino System

Credits

Ibrahim M. Abdelsalam

Comments

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Basic Andon System using Arduino Uno R3 and Python

Basic Andon System using Arduino Uno R3 and Python

Things used in this project

Hardware components

Software apps and online services

Hand tools and fabrication machines

Story

Project Overview:

Safety Warning:

Project Description:

Steps to Complete the Project:

Now... What is an Andon System?

Conclusion:

Schematics

Diagram

Schematics

Code

GUI

Arduino System

Credits

Ibrahim M. Abdelsalam

Comments

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