Control and monitoring system design for single phase AC generator

Project Title

Control and monitoring system design for single phase AC generator

Project Area of Specialization Internet of ThingsProject Summary

Generators are needed almost everywhere because of its better performance and portability. Due to the break/cut off of the grid power supply, for various reasons like faults or blackouts, industries and institutions face problems like discontinuity in the flow of work, loss of data and damaging equipment. Simple designed generators provide electric power in such emergency cases of power break that may result in loss of capital and time. These generators as emergency power suppliers are needed to be checked properly and maintained periodically. This is necessary to have efficient use of the generators and save it from damaging. There are various parameters of generators that are to be checked regularly. It may face the problem of fuel leveling, temperature leveling, over/under voltage conditions or may require certain repairing. In this project we are installing various sensors and we are using driver circuit for each sensor. Our sensors will be connected to our smart system that will have access to smartphone through mobile application. Temperature sensor will help to detect the body temperature of generator. Fuel sensor will help in determining the level of the fuel as well the other sensors used will help to completely gather the monitoring data from the generator. This data will be monitored through the android app. Generator will be able to sustain voltage. And also we could control load using the app.

Project Objectives

1. Real time monitoring of various parameters of a generator that are fuel level, oil level, temperature, energy generated, running hours and on/off status using mobile application.
2. voltage sustainability (over/under voltage condition) and suggesting maintenance
3. Load control through user interface.

Project Implementation Method

Overall system’s design is split into two parts:

1. Hardware design and implementation
2. ) Software coding

The system will work in flowing manner: 

1. Collect sensor-based data
2. Deploy data to cloud and data visualization
3. Monitoring and Alerting System (android app)

Algorithm will be able to analyse the data, and the resulting information is delivered to the user. The system will be able to;

1. turning generator on/off using app
2. alerts for the conditions
3. fuel level
4. body temp
5. power generated
6. notifications in case of any deviations
7. voltage generated
8. load connected
9. current
10. on/off status (history/ log)
11. generator scheduling
12. self-voltage sustainability
13. automatic power supply changing
14. predictive maintenance
15. increasing / decreasing connected loads using app

Maintenance

Oil change in generators are big problems, the operator doesn’t know when to renew the oil of the generator. Therefore, we proposed a scheduling algorithm which will suggest to change the oil.

The steps of the algorithm are as follows.

Step 1`:

Define threshold time for changing oil in hours

Step 2:

Convert Hours in to Seconds

Step 3: Condition if Counting Seconds reached the threshold notify

Step 4: If oil changed jump to Step 1 Else Step 5

Step 5: After quarter day if the oil is not changed warn of damage

If oil is changed move to Step 1 Else

Step 6: After a day if the oil is not changed shut down the generator

Else Move to Step 1.

Load Control

The generator will have the ability to control the load. Semi- automation algorithm. If the load of the generator is moved from is threshold the user will be notified to turn off the load through a user application. If the user didn’t take action the app will automatically shut down the load to equate with generator.

Benefits of the Project

• Monitoring of  the generator
• Reducing Labor Efforts and Cost
• Avoid Catastrophe of the Generator
• Proper check on fuel level.
• Scheduling algorithm to remind change of oil
• Load Control and Load Catastrophe avoidance
• Over Voltage and Under Voltage Control

Technical Details of Final Deliverable

Workflow of system is completed in following steps:

1. Collect sensor-based data
2. Deploy data to cloud.
3. Application dashboard
4. Monitoring and Alerting System

Sensors are connected to Arduino along with NodMcu Wifi module to sense the data and pass it to the cloud namely Firebase. The Firebase is the Bridge between Arduino and Android Application. The Android Application Receive the data from Firebase Send by the Arduino to Firebase and vice versa.

Final Deliverable of the Project HW/SW integrated systemCore Industry Energy Other IndustriesCore Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	69820
AC current sensor	Equipment	1	350	350
soldering iron	Miscellaneous	1	850	850
NODmcu WiFi ESP8266	Equipment	1	600	600
PCB pin connector	Equipment	12	20	240
current wire	Equipment	8	100	800
Temprature sensor	Equipment	1	300	300
soldering stand	Miscellaneous	1	350	350
AC voltage sensor	Equipment	1	350	350
Arduino nano	Equipment	1	1250	1250
veroboard	Equipment	4	100	400
Power bank	Miscellaneous	1	3500	3500
soldering wire	Miscellaneous	1	4800	4800
1.3inch display module	Equipment	1	1000	1000
solder flux paste	Miscellaneous	1	480	480
jumper wire	Equipment	5	500	2500
4KW generator	Equipment	1	40000	40000
fuel sensor	Equipment	1	12050	12050