Published July 5, 2021 © GPL3+

Automated-industrial monitoring system using BoltWifi module

A compact, automated IOT system that alerts users to malfunctions in industrial plants and helps prevent industrial accidents.

BeginnerFull instructions provided3 hours356

Automated-industrial monitoring system using BoltWifi module

Things used in this project

Hardware components

Arduino Nano R3

Bolt IoT Bolt WiFi Module

Adafruit Standard LCD - 16x2 White on Blue

Ultrasonic Sensor - HC-SR04 (Generic)

Seeed Studio Grove - 2-Channel SPDT Relay

Multi-Turn Precision Potentiometer- 10k ohms (25 Turn)

SparkFun Pushbutton switch 12mm

Breadboard (generic)

Buzzer

Jumper wires (generic)

Software apps and online services

Arduino IDE

Bolt IoT Bolt Cloud

Twilio SMS Messaging API

Story

Now-a-days, we can see lot of industrial disaster's around the world and killed lots of innocent people. Inadequate maintenance and monitoring of industrial installations is an important reason for these types of disasters. So, " what if we have a device that monitors the entire industrial plant and alert us during abnormal signatures in the process and help us to avoid industrial disasters", that sounds cool right..

To demonstrate how the project works, we will consider a straightforward scenario. A chemical industry handles tonnes of concentrated and hazardous chemicals in liquid form. They need to fill the tank's with the chemicals. Initially, the chemicals are stored in a tank, and moved to the tanks via a pump, without overflow. So, we have to build a device that stops the pump before overflowing. If a malfunction occurs in the unit and the pump continues to operate even after reaching the threshold level.

The monitoring system should alert the respective person about the malfunction and also shut down the entire plant until the malfunction is resolved. We can also monitor the tank level, each an every minute through the graphs produced by the Bolt IOT wifi module.

To make this project you will need :

1. Ardiuno nano or ATmega328p microcontroller

2. Bolt wifi module

3. 16x2 LCD display

4. Ultrasonic sensor (HC-05)

5. Relay 5V

6. BC547 Transistor

7. 1k resistor

8. Red LED's

9. Diode

10.10K Potentiometer

11. Push button

12. Bread Board

13. Buzzer (5v)

14. Pump(12)

15. Jumper wires.

Make the connection as shown in the schematics:

To make this project more compact, I have designed the entire circuit in a general purpose board:

Instead of Ardiuno I have used ATmega328p microcontroller, 16MHz Crystal oscillator and 22pF ceramic capacitors.

Create an account in twillio website and setup the settings to get alert messages from the industries, whenever there is any malfunction or abnormal signatures in the process.

to run the python code you have to install the boltiot library into your IDE with the help of command terminal.

You can also see that I have received alert about the malfunction in the industrial plants.

Code

 // include the library code:
#include<UltraDistSensor.h>
#include<LiquidCrystal.h>// initialize the library with the numbers of the interface pins
int relay_1 = 2;
int relay_2 = 3;
int button = 12;
int ult_tx =  4;
int ult_rx =  5;
int buzz   =13 ;
LiquidCrystal lcd(7, 6, 8, 9, 10, 11);
float time=0;
int distance=0,temp=0; 

void setup()

{
   Serial.begin(9600);
   lcd.begin(16, 2);
    pinMode(ult_tx,OUTPUT);
 pinMode(ult_rx,INPUT);
 pinMode(relay_1, OUTPUT);
 pinMode(relay_2, OUTPUT);
 pinMode(buzz , OUTPUT);
   lcd.setCursor(0,0);
    lcd.print("INITIALISING");
     delay(500);
      lcd.setCursor(0,1);
      lcd.print("please wait");
      delay(500);
  lcd.print(".");
  delay(500);
  lcd.print(".");  
  delay(500);
  lcd.print(".");
  delay(500);
  lcd.print(".");  
  delay(500);

  lcd.clear();
   lcd.print("PRESS START");
  


 }

void loop()

{ // set the cursor to column 0, line 1 // (note: line 1 is the second row, since counting begins with 0): lcd.setCursor(0, 0);


 
 
  
  int buttonState;
  buttonState = digitalRead(button);

if(buttonState == 1){
  lcd.clear();
  lcd.setCursor(0,0);
  lcd.print("PUMP ENGAGED");
  lcd.setCursor(0,1);
  lcd.print("system normal");
  digitalWrite(relay_2, HIGH);
  digitalWrite(relay_1,LOW);
   digitalWrite(ult_tx,LOW);
 delayMicroseconds(2);
 digitalWrite(ult_tx,HIGH);
 delayMicroseconds(10);
 digitalWrite(ult_tx,LOW);
 delayMicroseconds(2);
 time=pulseIn(ult_rx,HIGH);
  distance = time/58.2;
 Serial.println(distance);

 if(distance<5 && distance>3)
 {
     digitalWrite(relay_2, LOW);
       digitalWrite(relay_1,LOW);
     lcd.clear();
     lcd.print("Tank Filled");
     delay(5000);
     lcd.clear();
     lcd.print("Shuting Down");
     lcd.setCursor(0,1);
     lcd.print("pump");
     delay(5000);
 }

 else if(distance<3)
 {
   digitalWrite(relay_1, HIGH);
   lcd.clear();
   lcd.print("MALFUNCTION");
   digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
    lcd.print("MALFUNCTION");
    digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
    lcd.print("MALFUNCTION");
    digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
    lcd.print("MALFUNCTION");
    digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
    lcd.print("MALFUNCTION");
    digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
    lcd.print("MALFUNCTION");
    digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
    lcd.print("MALFUNCTION");
    digitalWrite(buzz,HIGH);
    delay(1000);
    digitalWrite(buzz,LOW);
  lcd.clear();
  delay(500);
   delay(3000);
   lcd.clear();
   lcd.print("EMERGENCY");
   lcd.setCursor(0,1);
   lcd.print("SHUT DOWN");
   delay(5000);
   temp=0;
 }


}

}

import conf 
from boltiot import Sms, Bolt 
import json, time

thershold_level=5

mubolt = Bolt(conf .API_KEY, conf.DEVICE_ID) 
sms = Sms(conf.SID, conf.AUTH TOKEN, conf.TO_NUMBER, conf.FROM_NUMBER)

while True:
    print("Reading sensor value")
    response = mybolt.serialRead('5') 
    data = json. loads (response) 
    j=data['value' ].rstrip() 
    print("Sensor value is: " +j) 
    try: 
        if int(j)<= thershold_level:
            print("Making request to Twilio to send a SMS") 
            response = sms.send_sms("SYSTEM MALFUCTION: Emergency Shut Down Initiated...") 
            print("Response received from Twilio is: "#str(response ))
            print("Status of SMS at Twilio is :" + str(response.status))
    except Exception as e:
        print("Error occured: Below are the details")
        print(e) 
        time.sleep(5)

Automated-industrial monitoring system using BoltWifi module

Things used in this project

Hardware components

Software apps and online services

Story

To make this project you will need :

Make the connection as shown in the schematics:

Schematics

circuit diagram of this project

Code

code for ardiuno

code for bolt python software

conf file for bolt iot code

Credits

wolverine viswa

Comments

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Automated-industrial monitoring system using BoltWifi module

Automated-industrial monitoring system using BoltWifi module

Things used in this project

Hardware components

Software apps and online services

Story

To make this project you will need :

Make the connection as shown in the schematics:

Schematics

circuit diagram of this project

Code

code for ardiuno

code for bolt python software

conf file for bolt iot code

Credits

wolverine viswa

Comments

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