SYNCHRONIZATION AND MONITORING OF MULTIPLE MOTORS WIRELESSLY
In various industries speed synchronisation of the motor plays a major role. Mainly, in textile industries the differential speed error leads to much consumption of power. The aim of this project is synchronization of multiple motors using wireless technology. In textile mills where multiple m
2025-06-28 16:36:13 - Adil Khan
SYNCHRONIZATION AND MONITORING OF MULTIPLE MOTORS WIRELESSLY
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryIn various industries speed synchronisation of the motor plays a major role. Mainly, in textile industries the differential speed error leads to much consumption of power. The aim of this project is synchronization of multiple motors using wireless technology. In textile mills where multiple motors work simultaneously on a conveyor belt to draw clothes, it is essential that all the motors there should run at same speed, so that balanced tension is achieved to avoid clothes getting damaged. In this work motors are wirelessly synchronized to reduce the differential speed error among multiple motors. One motor acts as transmitter and the rest as receivers. Brush Less Direct Current Motors (BLDC) used operate on the basis of Pulse Width Modulation (PWM) control. The pulse width output from the microcontroller would be automatically adjusted to maintain the DC power to the motor such that the entered speed percentage matches the running Rotation Per Minute. The above operation is carried out by using electronic speed controller for driving the BLDC motor duly interfaced from the microcontroller.
There are so many other different techniques for the solution this problem. But those are not that reliable. In order to reduce man intervention and save the labour cost and time both can use microcontroller to control, operate and synchronize this task. As compared to conveyor belt method is compatible as it involves hardware as well as software in this module. The microcontroller can be programmed to control its speed and also can set the required speed through potentiometer to get our work done. Synchronization has been done here using wireless method. RF communication technology has been used here for wireless communication. Motors are synchronized with the master slave method. The motor speed is transmitted using the RF Module from the transmitter and using PWM Technique the speed is received in the receiver side and the motors will run at synchronized speed.
Project ObjectivesThe main objective of the project is to control the speed and synchronization of DC motors using wireless module with higher efficiency and less maintenance.
- Counting RPM of the master and slave motors
- Wirelessly transmitting the speed from master to slave
- Synching the speed of the slave motors to the master motor
- Displaying the speed of motors in real time
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To overcome hazardous for operator and also for cloth production
- Monitoring the power consumption and remotely controlling motors speed and on and off system in industries
- we are monitoring and controlling it remotely
- We choose Android app because its easy to use and almost everybody has it
In this project, wireless technology is used to synchronize the motors without any differential error speed. Among all the motors one motor acts as transmitter
and all other motor as receivers, therefore the speed set in the transmitter side of the motor, the same speed is applied to all the receivers side of the motors . This operation can be possible by using universal asynchronous receiver transmitter (UART) device. Generally the loads applied on the motors is variable, due to that the speed of the motor affect and satisfactory operation not achieve. For minimizing that problems, the speed control is necessary. PWM technique is used for controlling the speed of the motors . For PWM generation PIC18F4520 is used. In this method, the regulation of motor’s speed is achieved by changing the voltage of the motor which is adjusted by the duty cycle of PWM. Instead of using transformer and rectifier for giving supply, we used Adapter to give 12V supply to the DC motor. IC7805 is used to convert 12V into 5V supply. 12V DC motor is used for speed control and synchronization purpose. Driver circuit consists of BJT, MOSFET for interfacing between DC motor and PIC, because direct dc motor can’t connect to the PIC. Manpower and time is saved in this arrangement. Satisfactory operation obtaine
The motors are synchronized in a master-slave combination. In this project we use Arduino UNO board as a microcontroller. The Arduino perform processing such as computing the speed of a master motor. The motor used driver to integrate it with Arduino to drive. The IR sensor connecting to the motor give us the speed after every rotation it came across the black label or dot. After computing the speed of motor by Arduino on master side it displays the speed on crystal display screen. Then the same speed transferred to other microcontrollers through RF transmitter which having the frequency of 433 MHZ. The other receiver side receive the speed of master motor and the Arduino read the speed of the master motor, then the slave motor synch its speed with master motor accordingly, also it displays its own speed. In this project we have only one master transmitter motor. While more three receiver used to synch its speed with master motor. The transmitter broadcast its message to all other receiver in range. The receiver than automatically synch its speed with master motor. The block diagram shows the detail of the project working. Receiver end will synch its speed with master and also send its status of precaution and energy consumption to master transceiver. The master transceiver send data to firebase and android. The user will see all the activities through android app.
Master Block Diagram:
Slave Block Diagram:
Some of the benefits of this projects are:
- They are fairly inexpensive.
- Greater Efficiency and the ability to remove signal variations and noise.
- Human friendly reduce the chances of injuries and death
- Easy to maintain and manage
- Extending motors required no efforts
- Reduce time and effort consumption
- Having flexibility to make changes in future
- Has no effect on products, such as cloth or steels.
- Major drawback of the existing system is the speed cannot be synchronized at the particular range. Many research papers have been proposed to synchronize the motors at particular speed but everything leads to failure approach. Old method of speed synchronization that is by means of conveyer belt has a speed variation of above 1000 RPM and the wired technique of speed synchronization had over the somewhat and gave the results of speed variation up to 600 RPM to 900 RPM. Above proposed system of speed synchronization has overcame all the drawbacks and speed of the motor can be synced at maximum set point given in the transmitter side. Now the variation has been reduced up to 100 RPM to 150 RPM.
Speed Control And Synchronization:
a. Initially, the 220v AC supply is fed to the adapter which converts 220 into 12v supply. After this 12v supply is given to the positive terminal of 12v dc motor. By using regulator IC7805, 12V is converted into fixed 5V DC supply and it is given to the PIC18F4520.
b. The required speed is entered using a switches (Sw1, Sw2, and Sw3) which is connect with the PIC. Where switch Sw1 is use to START/STOP the motor, switch Sw2 is use to increase the speed of motor and switch Sw3 is use to decrease the speed of the motor.
c. The DC motor is interfaced with the PIC through BJT and a MOSFET together forms a driver circuit and drive the motor. The block diagram of transmitter and the receiver set of DC motors are shown above. The entire arrangement consists of a single transmitter circuit and two receiver circuits. The block diagram of the receiver side which is exactly same as the transmitter block diagram the only difference is that the arrangement of switches is not present in the receiver side because the slave motors will going to operate at the speed which is set by the master motor and is done by the switches as we have discussed above. Thus, the switches are replaced by wireless module. These block diagram consists of main parts such as power supply, PIC18F4520, LCD, DC motor, wireless module, driver circuit. Driver circuit:
Driver circuit consists of BJT and MOSFET which is essential for driving DC motor. BJT is current driven while Power MOSFETs, with their insulated gates, are voltage driven. A basic knowledge of the principles of driving the gates of these devices will allow the designer to speed up or slow down the switching speeds according to the requirements of the application. Power MOSFETs can be used to control the movement of DC motors directly by using pulse-width modulation (PWM) type controllers. As a DC motor offers high starting torque and which is also proportional to the armature current, MOSFET switches along with a PWM can be used as a very good speed controller that would provide smooth and quiet motor operation. NPN type BJT is used here which is made from silicon semiconductor material. If the transistor’s base emitter is open (Ib=0) the device is in off state.
- . Pluse Width Modulator (Pwm) :
Pulse-width modulation (PWM) or duty-cycle variation methods are commonly used in speed control of DC motors. The duty cycle is defined as the percentage of digital ‘high’ to digital ‘low’ plus digital ‘high’ pulse-width during a PWM period. The average DC voltage value for 0% duty cycle is zero; with 25% duty cycle the average value is 1.25V (25% of 5V). With 50% duty cycle the average value is 2.5V, and if the duty cycle is 75%, the average voltage is 3.75V and so on. The maximum duty cycle can be 100%, which is equivalent to a DC waveform. Thus by varying the pulse-width, we can vary the average voltage across a DC motor and hence its speed.
we are using Proteus software for simulation purpose
Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Manufacturing Core Technology Internet of Things (IoT)Other Technologies Wearables and ImplantablesSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 45005 | |||
| Brushless motors | Equipment | 4 | 900 | 3600 |
| Motor driver | Equipment | 4 | 1199 | 4796 |
| Lcd display | Equipment | 4 | 420 | 1680 |
| Arduino uno | Equipment | 4 | 980 | 3920 |
| USART | Equipment | 4 | 575 | 2300 |
| button | Equipment | 4 | 450 | 1800 |
| male header | Equipment | 10 | 70 | 700 |
| female header | Equipment | 10 | 70 | 700 |
| IR module | Equipment | 4 | 95 | 380 |
| connecting cable | Equipment | 4 | 350 | 1400 |
| connector | Equipment | 8 | 30 | 240 |
| motor mounting | Equipment | 2 | 150 | 300 |
| base | Equipment | 1 | 2199 | 2199 |
| invertors | Equipment | 4 | 1600 | 6400 |
| testing | Equipment | 1 | 2000 | 2000 |
| fire sensor | Equipment | 4 | 245 | 980 |
| temperature sensor | Equipment | 4 | 270 | 1080 |
| speed sensor | Equipment | 4 | 265 | 1060 |
| wifi module | Equipment | 1 | 330 | 330 |
| other | Equipment | 1 | 1000 | 1000 |
| Thesis+binding | Miscellaneous | 2940 | 1 | 2940 |
| stationary, printing etc | Miscellaneous | 2000 | 1 | 2000 |
| FYP Banner | Miscellaneous | 3000 | 1 | 3000 |
| Other | Miscellaneous | 200 | 1 | 200 |