Cellular Based Automated Industrial Control and Monitoring System

Advanced Computational Intelligence: An International Journal (ACII), Vol.2, No.4, October 2015
DOI:10.5121/acii.2015.2402 11
CELLULAR BASED AUTOMATED INDUSTRIAL
CONTROL AND MONITORING SYSTEM
Farzana Sultana Dristy1
and Sadeque Reza Khan2
1
Department of Computer Science and Engineering, Varendra Universty, Bangladesh
2
Department of Information and Communication Engineering, Chosun University, Korea
ABSTRACT
Graphical User Interface (GUI) based systems are flourishing their popularity in the industrial area in
present days. If it is possible to integrate the GUI based systems with a Global System for Mobile (GSM)
modem for controlling and monitoring, it will be magnificently acceptable communication system. In this
paper a method is presented on a distant machine and motor control system monitoring and controlling,
using a GSM modem and GUI. PIC microcontroller is used to bridge and synchronize the operation of GUI
and GSM systems.
KEYWORDS
GUI, GSM, PWM, SMS, AT Command.
1. INTRODUCTION
The starting of GUI based systems are exposed out from the conception of Human Computer
Interaction in the early 60s [1].Now a days the use of GUI has achieved the position that makes
our life easier by expecting some graphical windows. GUI’s are very much reliable in the
industrial control and monitoring [2]. The uses of GUIs are not only limited to industrial purposes
but also available in general office communication purposes [3]. Advanced level GUI based
system is also available for the purpose of monitoring water reactor properties [4].
In contrast with the mentioned systems, an updated control system is proposed here which is
wireless and can maintain any industry using a modern GUI software. In this project a GSM
modem is used to control machines on motor belt using Short Message Service (SMS). USB
based communication is established with the PC or laptop to control machines as well as motor
speed and its direction. Motor speed is also monitored through the USB. As a central controller
PIC 18F2550 is used and advanced graphical compiler and simulator Flowcode is used. Visual
Basic 2010 is the developer software for GUI.
2. PROPOSED SYSTEM
PIC 18F2550 is used in the proposed system as central controller. Two modes are used in the
designed system, one is user interface (GUI) and another is wireless (GSM) which is shown in
figure 1. Both modes are used to control the industrial machines as well as motor speed and
rotating direction. The speed is also monitored through GUI and it is measured by using an
autonics sensor (proximity sensor).

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Fig:1: System overview
3. USER INTERFACE DEVELOPMENT
The Graphical User Interface (GUI) is designed with visual basic 2010 and showed in figure 2.
Fig:2: Designed GUI
Although other graphical software’s (Java, C#, Python, Perl etc) are available but visual basic is a
drag and drop type software. Another reason to choose visual basic is its serial port integration
property. The designed GUI for this project contains four sections. USB Panel section is used to
select and connect the target Universal Serial Bus (USB) port. One section is dedicated for motor
speed monitoring in rotation per minute (RPM) unit. Next section (Control Panel) is for industrial
machine on and off. Although in this particular paper one machine is controller but any number of
machines can be controlled through this section. Last is the Motor section is used to control the
speed of the motor as well as the speed.

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4. GSM INTERFACE
For the purpose of wireless communication GSM (Global System of Mobile) modem SIM900 is
used. The GSM modem operation is controlled by AT command. Basic AT command format is
provided bellow:
Table 1: Basic AT command set
Command Description
AT Check if serial interface
and GSM modem is
working.
AT$AREG=0 AT command to turn off
the automated GSM
registration feature.
AT+CFUN=1 Turn the radio on.
AT+COPS=0 Select network operator
for registration.
AT+CGATT=1 AT command to start the
ATTACH sequence.
ATD<number> Dial to a number
ATA Answer
AT+CMGF=1 Set message format to
TEXT mode.
AT+CMGS="number" Send a message to the
telephone number.
General format of SMS is described below:
GSM modem is connected with the PIC microcontroller through level converter MAX232 [5, 6].
To control the machines and motor speed, rotation the received SMS through the central
controller will be compared with the previously stored string set and generate the control signal.
5. MOTOR SPEED CONTROL
One simple and easy way to control the speed of a motor is to regulate the amount of voltage
across its terminals and this can be achieved using “Pulse Width Modulation” or PWM. The pulse
width modulation speed control works by driving the motor with a series of “ON-OFF” pulses
and varying the duty cycle, the fraction of time that the output voltage is “ON” compared to when
it is “OFF”, of the pulses while keeping the frequency constant.

14
Fig:3: PWM for Clockwise Rotation at 20 MHz Crystal
Fig:4: PWM for Anti-Clockwise Rotation at 20 MHz
Crystal
The power applied to the motor can be controlled by varying the width of these applied pulses
and thereby varying the average DC voltage applied to the motors terminals. By changing or
modulating the timing of these pulses the speed of the motor can be controlled, ie, the longer the
pulse is “ON”, the faster the motor will rotate and likewise, the shorter the pulse is “ON” the
slower the motor will rotate. In other words, the wider the pulse width, the more average voltage

15
applied to the motor terminals, the stronger the magnetic flux inside the armature windings and
the faster the motor will rotate.
The rotational direction of the motor is controlled by L293D IC. Figure 3 and 4 are showing the
clock and anti-clockwise rotation PWM signal simulation in Flowcode simulator for forward and
reverse rotation of motor respectively.
6. RESULT AND DISCUSSION
The PIC series 8 bit microcontroller PIC18F2550 is used as a central controller in this
implemented system. The major purpose to select this microcontroller is its direct USB interface
feature. Figure 5 shows the overall schematic diagram of the proposed system. The external
interrupt (RB0) is used as motor speed measurement pin and a proximity sensor is connected to
this pin which is used to count the number of revolution of the motor. RC0 pin is representing the
output machine controlling. It can be accomplished by using an opto-coupler and a power relay.
Any GPIO pin can be used for this purpose. The dedicated PWM pins (RC1 and RC2) are used to
control the industrial motor. RC6 and RC7 are used for Universal Asynchronous Receiver
Transmitter (UART) and GSM modem is controlled through those particular pins. MAX 232 IC
is used as a level converter along with the GSM modem [5, 6].
Fig: 5: Schematic Diagram of Implemented Circuit
Figure 6 shows the flowchart of the designed system. If the system is not connected with any
COM port of the computer then the system will be controlled using the GSM network, else the
system will be controlled by using the designed GUI. Figure 7 shows the implemented circuit

16
which is tested in real time environment.
Fig: 6: Schematic Diagram of Implemented Circuit
Fig: 7: Implemented and Tested Circuit

17
7. CONCLUSION
Proposed system is a modern era setup for the controlling and monitoring of Industrial
environment. Multiple machines can be controlled using the designed prototype. Motor torque
monitoring in RPM unit and its speed controlling is a unique feature. Both the GUI and GSM
controlling make the system more versatile and robust. This low cost system can be a promising
device to fulfil the industrial monitoring and controlling setup.
REFERENCES
[1] Jorgensen, A. H. and Myers, B. A. "User interface history". Proceeding CHi '08 extended abstracts on
Human factors in computing systems, 2008, pp. 2415-2418.
[2] Sadeque Reza Khan and Dr. M.S. Bhat, "GUI Based Industrial Monitoring and Control System",
IEEE Power and Energy Systems Conference: Towards Sustainable Energy, 2014, pp: 1-4.
[3] Sadeque Reza Khan, Archis Banerjee, Dr. M. S. Bhat and Aritra Banerjee, "Wireless and GUI Based
Smart Office Communication System", Digital Signal and Image Processing, Elsevier Science and
Technology Publications, International Conference on Communication and Computing (ICC-2014),
pp 44-51.
[4] Yu-Chen Chen, Yuan-Hsiang Chang, Te-Chuan Wang, "A Real Time Computer Graphical User
Interface for Advanced Boiling Water Reactor Case Comparison Using MAAP Software", Computer
Symposium (ICS), 2010 International IEEE conference, pp. 274 - 278.
[5] Archis Banerjee, Sadeque Reza Khan and Dr. M. S. Bhat, "Modern Home Automation System for
Energy Conservation",Digital Signal and Image Processing, Elsevier Science and Technology
Publications, International Conference on Communication and Computing (ICC-2014), pp 98-105.
[6] Sadeque Reza Khan, Archis Banerjee, Dr. M. S. Bhat and Aritra Banerjee, "Advanced GSM Based
Harvesting and Cultivation System", Digital Signal and Image Processing, Elsevier Science and
Technology Publications, International Conference on Communication and Computing (ICC-2014),
pp 1-8.
Authors
Farzana Sultana Dristy
Farzana Sultana Dristy is currently continuing her B.Sc. degree in Computer Science
and Engineering at Varendra University, Bangladesh. She is involved in the research
fields of Embedded System Designing and Robotics.
Sadeque Reza Khan
Sadeque Reza Khan received B.Sc. degree in Electronics and Telecommunication
Engineering from University of Liberal Arts Bangladesh and He complered his M.Tech
in VLSI Design from National Institute of Technology Kernataka (NITK), India.
Currently he is doing Ph.D at SoC Design laboratory, Chosun University, Korea. His
research interest includes VLSI, Microelectronics, Control System Designing and
Embedded System Designing.

Cellular Based Automated Industrial Control and Monitoring System

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