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Predictive Maintenance of Industrial Equipment’s Using IOT
Chapter · January 2022
DOI: 10.1007/978-981-16-4943-1_24
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Predictive Maintenance of Industrial
Equipment’s Using IOT
S. Nithya, K. Vijayalakshmi, and M. Parimala Devi
Abstract Internet of Things (IOT) is swiftly increasing technology nowadays global
in internet world. IOT is mixture of communication system and embedded device
that is used to attach hardware devices to the community or net. IOT is used for
transmission and reception of information. These structures are used to check the
processes in industries and its applications were through implementing industry
standard protocols using IOT. In this machine small scale commercial packages like
liquid level control, power monitoring and so on can be analyzed wirelessly via Wi-Fi
gadgets, mobiles and laptops. The principle purpose is to epitomize the importance
of IOT as a way to survey small scale commercial packages.
Keywords IoT · PLC · Wi-Fi · GSM · Sensors
1 Introduction
Nowadays, business tracking has important function location to monitor and manipulate the industrial applications or appliances and apparatuses. Business tracking is
exercised for recognising the enterprising of heavy industrial appliances or apparatuses. Commercial tracking is used to perform quick processing, decrease energy
utilization and usage, to enhance quality, lessen highly-priced systems and international control of enterprise [1, 2]. Many strategies have been conducted and performed
which are to be had to reveal and manipulate industrial approaches. Nowadays, “net
of things” is the most favourable technique for commercial process tracking [3].
S. Nithya (B) · K. Vijayalakshmi
Department of Electrical and Electronics Engineering, SRM Institute of Science and Technology,
Ramapuram, Chennai, India
e-mail: nithyas@srmist.edu.in
K. Vijayalakshmi
e-mail: vijayalk1@srmist.edu.in
M. Parimala Devi
Department of Electronics and Communication Engineering, Velalar College of Engineering and
Technology, Erode, India
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022
C. Subramani et al. (eds.), Proceedings of International Conference on Power Electronics
and Renewable Energy Systems, Lecture Notes in Electrical Engineering 795,
https://doi.org/10.1007/978-981-16-4943-1_24
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IOT is aggregate of ingrained machine and verbal exchange gadget wherein business
equipments are related to internet with the assist of wireless sensor network [4] and
gadgets or commercial utility can monitor and manipulate via mobiles and laptops.
Forms of items, sensors, electrical apparatuses and items are attached to net very
easily with IOT. IOT is even employed for data transfer and accumulation of records
from electrical appliances or gadgets and connect it to the IOT dashboard via certain
communication protocols [5]. May be connected the use of Bluetooth, Ethernet,
Wi-Fi and so forth to the internet. An arrangement to raise cautions in the event
of discovery of lethal gases, fuel spillage over the safe breaking point can assist
with maintaining a strategic distance from mishaps [6, 7]. A model dependent on
ARDUINO/IOT module has been created dependent on the above idea for location
and ongoing checking of the modern floor. IOT gadgets for the most part have some
cloud administration to oversee the gadget from the web or versatile applications
[8]. The purpose of a gadget being arranged and it can get to easily from anyplace
through web association.
On applied to reveal numerous commonplace parameters utilized in industries
which include strength, liquid degree and dc motor pace manipulate [9]. On this
paper, factory and manufacturing technique tracking is finished by IOT in unique
implementation. On this paper eWON Flexy IoT module as shown in Fig. 1, CPU
315 DP PLC is used for accumulating facts from equipments and transfer it right into
Fig. 1 Concept layout
Predictive Maintenance of Industrial Equipment’s Using IOT
259
the cloud. eWON Flexy is the IoT module [10]. Business process tracking device
includes 4 application percent based coloration mixing, liquid stage manage and
tracking, dc motor velocity manipulate and electricity monitoring.
2 Methodology
The proposed solution is the vision of any organization have to be to maximize
productiveness with guaranteed employee safety and environmental obligation. A
gadget for actual time monitoring is proposed through deployment of sensors at
exclusive points of the company premises as in Fig. 2. The first rate sensors come
across the level of emissions, misalignment, temperature, frequency, current, voltage
and lots of others factors that might also send notification to the ground manager
through Google Cloud. An arrangement to raise cautions in the event of discovery
of issues and damages over the safe breaking point can assist with maintaining a
strategic distance from mishaps. A model dependent on ARDUINO/IOT module
has been created dependent on the above idea for location and ongoing checking of
the modern floor. IOT gadgets for the most part have some cloud administration to
oversee the gadget from the web or versatile applications. The purpose of a gadget
being arranged and it can get to easily from anyplace through web association. on the
web regulating of mechanical procedure have gotten most extensive angle for modern
development and benefit all things considered used to diminishes production, and
costs just like maintenance issue. Right now, forms like meter observing, load, speed
Fig. 2 Concept block diagram
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control of motors, PLC processes and analog controls are observed through android
mobiles, PCs etc. using IOT. We use the concept of Machine Management System
(MMS) to control and supervise the facilities remotely and with better efficiency.
IoT gadgets, motors and equipment in industries are prone to wear and tear over
a period of usage. Industrial motors are used for heavy machinery equipments and
use a lot of load and stress to do the required job properly. Hence in this paper we
will talk about the prevention of wear and damage and reduce the downtime and also
increase the up time. The motors in industries are equipped with a smart sensor. The
sensors we will be:
• Vibration sensor
• Temperature sensor.
The sensors are attached on to the motor or any industrial equipment that we
need to monitor. The vibration sensor that is used is a accelerometer sensor. When
the motor undergoes a slight misalignment or a spike in temperature that causes it
to work vigorously, the sensors senses the change in frequency of its rotation in
its radial or axial position in the form of analog waves. The same is applied to the
temperature sensors. The frequency read is sent into the A/D converter that converts
the input signals from analog to digital signals. The Variable frequency drive (VFD)
is kept attached to the motor for controlling the frequency of the motor speed as per
the needs of the industrial needs. The VFD can also show the current and voltage at
which the motor is running.
After the conversion of the signals into digital format, the signals are sent from
the sensors and VFD to the PLC for processing. The signals received are analysed in the PLC. The signals are compared with the ladder program that is build
with the help of SIMATIC manager. PLC framework has the fundamental practical
section of processor, memory, power gracefully, input/yield interface, interchanges,
and industrial equipment devices. The PLC framework works only if the user inputs
the required instructions and algorithms of work into the program that helps it perform
the needed process executions and atomization. These instructions are input into the
PLC by the user or officials during handling. The info/yield channels give disengagement and sign molding capacities so sensors and actuators can frequently be
straightforwardly associated with them without the requirement for other hardware.
Yields are indicated as being of hand-off sort, transistor type, or triac type. The
interchanges interface is utilized to get and transmit information on correspondences
systems from or to other remote PLCs.
2.1 Ladder Logic
LCs frequently use “Ladder Logic Programming” a short-sighted programming
language that is appropriate for modern applications. Ladder logic is similar to
stacking up relay circuits. The program involves the use of relay circuits to form
connection to various sensors in the system linking to the motors or any industrial
Predictive Maintenance of Industrial Equipment’s Using IOT
261
equipment. Presently in our case the ladder logic uses bit logic operation. The LD is
the standardized PLC programming operation. The program uses different graphical
elements in contrast to other coding softwares. Ladder logic symbols look like electric
symbols that gives better user interface that will help the engineers to assign different
symbols. The lines in the PLC ladder logic programme are called rungs. These rungs
can be as many in relation to the number of equipments that is connected to the rungs.
During execution the ladder logic rungs are read and executed one rung at a time,
the PLC executes one symbol at a time. There are many symbols like normally open,
normally closed, output coil etc. as in Fig. 3. The normally open contact specifies
the switched off state, normally closed consists of the closed contact through which
the current flows and the output coil consists of the motor or any equipment. When
the programme is running, it reads the states of these symbols then convert it into
binary values of 0’s and 1’s also considered as low and high respectively.
The program build is used for analysing the values that the PLC receives. The
program has functions known as counter and comparators. The counter will count
the input signal value and the then sends it to the comparator. The comparator is
another function that compares the values of the input digital signals with the safe
running values inputed by the industrial user with the help of SIMATIC manager. If
the values analysed by the PLC from the sensors are found to be abnormally high or
low compared to the values set by the user then the PLC send the processed data to
the IOT. The signals are sent to the IOT which triggers a prompt to send a message
to the GSM module. A software called eBuddy is used for generating the message
that is needed to be sent to the maintenance officials or any other higher authority
manager.
2.2 Vibration Monitoring
Speed and quickening are the two generally normal parameters that are checked
with vibration sensors to distinguish issues on turning hardware. Speed is the speed
estimated a solitary way. It is estimated in ‘mm/sec’. Speeding up is the pace of
progress of speed.
Vibration sensors shown in Fig. 4 are devices or apparatus that measures a wide
range of readings and values that include speed, frequency, velocity, strain, etc.
These sensors utilize the piezoelectric impact by changing over them to an electrical
charge these sensors can also help in finding out the cracks, wears and tears that the
machines undergo if it has any faulty motors. These sensors can be used in many
industries and facilities. There are two types of vibrations axial vibration and radial
vibration. Notwithstanding the sensor qualities, you should think about the necessary equipment and programming to appropriately condition, procure, and imagine
accelerometer estimations. For instance, you have to perform signal handling on
crude vibration signs to show the information in a progressively significant arrangement, for example, the recurrence range. To all the more likely acquaint yourself with
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Fig. 3 Ladder Logic
the estimation equipment and programming handling essential for accelerometer
estimations, download the Engineer’s guide to accurate sensor measurements.
With speeding up we can screen a lot higher frequencies. We use speeding up
estimations to identify issues that apply a power, for example, little stuns and effects
Predictive Maintenance of Industrial Equipment’s Using IOT
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Fig. 4 Vibration sensors
that happen at the beginning of bearing harm, gearbox shortcomings, and siphon
cavitation and so on.
2.2.1
i.
ii.
iii.
Different Levels of Monitoring
Machinery Protection sensor
Basic apparatus assurance sensors offer checking of the general vibration levels,
estimated in speed (mm/sec). These are regularly applied to the ISO 10816
norm. This degree of checking won’t analyze a particular machine issue, yet
will distinguish an adjustment in the general vibration level brought about by
deficiencies, for example, unbalanced, misalignment, looseness, belt drives.
Intelligent Vibration Sensor
Smart vibration sensors encourage checking of both the speed levels (mm/sec)
also, increasing speed levels (g). This degree of observing won’t ordinarily
analyze a explicit machine shortcoming. In any case, by observing both speed
and increasing speed it is conceivable to recognize vibration increments brought
about by a more extensive scope of issues, for example, Unbalance, Misalignment, looseness, belt drives, Bearing defects, Rubbing, Gears, Fluid noise,
Impact detection.
Fault analysis
Flaw examination frameworks can be customized to distinguish explicit hardware
issues by checking the individual deficiency frequencies that identify with these
different vibration issues. When distinguished, the client would then be able to be
advised which flaw is beginning to create on the machine. This degree of point by
point examination takes into consideration progressively proficient support systems
to happen. These frameworks can be modified to analyze explicit machine blames,
for example, Unbalance Misalignment, Looseness, Belt drives, bearing defects,
Rubbing, Gears, Fluid noise, Impact detection (Fig. 5).
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Fig. 5 Screenshot of conveyor status screen
2.3 Wireless Monitoring
An IOT module is a device that is installed in various devices and appliances in today’s
technological world. It helps in interconnecting and linking different machinery in
industries or factories with each other that when combined forms a cyber physical
system. The IOT helps in sending receiving and transferring information with all of
these devices or machinery. In general it helps in the autonomous communication
between each of these devices without human intervention. The IOTs always depend
on the internet for the transfer of information consistently on network. This is on
the grounds that IOT applications need to send information naturally, progressively
without any sort of user interface with the devices in order to transfer data. These
devices have good reliability, cost effectiveness, and rigidness. Not at all like customer
gadgets that are ordinarily conveyed by the end-client and utilized in controlled
conditions, IOT gadgets are regularly sent in extraordinary situations and remote
like transportation holders or under seawater in harbor the executives arrangements.
IOT situations can be immensely requesting with outrageous temperatures, vibration,
and mugginess.
A GSM module shown in Fig. 6 is a chip or circuit that can provide a connection between the module and the remote operator or overseer who has established
the connections. The connections can be between any portable devices like tablets,
phones, laptops, chrome books, etc. for interactions between the module and GSM
framework. The modem is a basic part here. A GSM includes a GSM module alongside some different parts like correspondence interface power gracefully and a few
markers. The Ethernet cables and wireless connection based on wifi and internet
Predictive Maintenance of Industrial Equipment’s Using IOT
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Fig. 6 GSM/GPRS module
we can link these devices together without much issues as it has a wide range of
compatibility. GSM Modules permit remote correspondence with different gadgets
and instruments. Since this technology allows us to remotely and securely connect to
various devices and monitor the company activities it is easier to perform the security monitoring, hoe automation, automotive GPS tracker, online and e commerce
transactions. GSM module associates with the network utilizing a SIM cards from
any companies like airtel Vodafone, etc. The basic radio frequencies where a run of
the mill GSM Module works are 900 and 1800 MHz.
Previously mentioned errands, cultivated with the assistance of AT Commands.
AT Commands are pieces of Command Set, which are characterized initially for a
modem. GSM Network likewise actualizes a comparable AT like orders for its GSM
Modules. The processor or controller to which the GSM/GPRS Module is associated
with, is answerable for sending the AT Commands to the module. Accordingly, the
GSM Module performs order explicit errands like noting a call, send a SMS Message,
etc. Even through the AT Commands may appear to be nonexclusive, it is fitting to
allude with the information gave by the maker of the GSM Module for right and
complete rundown of AT Commands.
2.4 Wireless Communication
Nowadays, The eBuddy software must be installed in every official’s phones or tables
to receive the messages. The message is sent to the GSM module that sends it to the
cloud or user. The user receives the messages through the eBuddy app. The messages
sent depends on the gravity of the situation i.e. if the problem faced by the motor or
equipment is low then the messages are only sent to the lower maintenance officials
and if the problem persists for a longer time or if it’s more grave and precarious
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then the messages are sent even to the higher officials who can get the details of
the matter and tend to it as soon as possible which prevents any further troubles and
circumstances. The user gets the message in the form of Email or SMS. The received
data is stored in the cloud in the form of spreadsheet. The database of every ongoing
or previous operations of the equipments are stored in the cloud and the officials or
managers can get a monthly or yearly data report on the equipments and its values. A
vitality observing dependent on IoT is utilized to improve the vitality the executives
framework.
3 Results and Discussion
The proposed framework can screen and measure the situations and state progressively inside the plant. By determination of exact and precise sensors, a test arrangement to measure the gases was created. The information from the sensors were
gathered progressively and transferred in Google spread sheet shown in Fig. 7.
The communication between PLC and VFD is done with the help of a STARTER
software through an IP gateway. The gateway is a device for controlling and translating CIP protocol to SEIMENS profibus protocols. Then we configure the VFD to
the SEIMENS starter software in the form of a profibus slave. We have to enter the
motor or equipment details like the power rating, current ratings and voltage ratings
and the type of motor (Figs. 8 and 9).
This product particularly intended for administrator control and observing in
SIMATIC. Procedure perception framework is a standard administrator Interface
with all the significant administrator control and observing capacities which can be
utilized in any part any innovation. SIMATIC software is present day devices for
Fig. 7 Google spread sample
Predictive Maintenance of Industrial Equipment’s Using IOT
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Fig. 8 Light and harmful gases
Fig. 9 Temp and humidity graph
arranging SIMATIC administrator board’s conservative gadgets. Programming that
secures data on the area and reason for mistakes in plants and apparatus and along
these lines offers quick and pointed procedure diagnostics.
The proposed structure can assist with forestalling industry related mishaps
because of gas and fuel spillage by legitimate recognizable proof and cautioning
the individuals around. The proposed configuration can likewise be made appropriate for recognizing the contamination level from vehicles and to keep a mind the
smoke outlet from processing plants. The plan can be altered to identify the level of
gases inside pit openings with the goal that valuable lives can be spared. Utilization of
IOT in relationship with ARDUINO/IOT module makes the framework modest and
moderate. The light weight framework can be installed in Jacket, Helmet and Wrist
observes which can be worn by labourers to investigate the highlights of Wearable
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Technology [11]. The framework likewise empowers basic man to screen the nature
of air in their region by means of cell phone application.
4 Conclusion and Future Work
In this paper an Intelligent Industry Monitoring framework in light of IOT is
proposed which can successfully screen the Mechanical floor. A model dependent on
ARDUINO/IOT module was created which could detect the centralization of current,
vibrations and temperature. The continuous information acquired from the various
sensors has been transferred to Google cloud. Notwithstanding this other parameters
like temperature, dampness and light force were estimated. For simplicity of investigation the above information got were plotted. Arrangements were likewise made
to alarm the labourers if there should be an occurrence of any crisis. The framework gives solid, precise investigation to forestall any instance of mishaps. This
framework utilizes ARDUINO/IOT module giving modest arrangements for security. Slight adjustment of the model empowers the client to adjust it to any condition.
Prescient support is an up and coming modern need, for which the proposed model
can be ad libbed. If there should arise an occurrence of misalignment and damage
we need to access the issues from point to point which must be broke down further.
Also, the gases diffusing out during spillage may likewise join among themselves
delivering different results which must be managed in detail. These cases can open
an eye for the sprouting analysts.
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