Wireless Speed Control and Protection of induction motor
A factory induction motor (IM) is monitored ,controlled and protected by wireless TCP/IP protocol in order to detect and predict deviations from normal operating parameters before the occurrence of motor failure. In this way, the production process is not impeded and the required maintenan
2025-06-28 16:36:48 - Adil Khan
Wireless Speed Control and Protection of induction motor
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryA factory induction motor (IM) is monitored ,controlled and protected by wireless TCP/IP protocol in order to detect and predict deviations from normal operating parameters before the occurrence of motor failure. In this way, the production process is not impeded and the required maintenance or replacement can be performed with the least possible disruption. In this study, the motor cycle, the current drawn by the motor and the motor voltage are read by current transformer and potential transformer the required power consumption is calculated. It's Speed controlled by Variable Frequency Driver(VFD). With this aim, our purposed architecture read the accepted parameters of the motor and reported them to the central management software. The central management software operating in real time is then able to assemble these parameters and form predictive maintenance models.
Project ObjectivesThe objectives of our project to minimize the problems of industries.
•Saving of energy.
•Reduced inrush current.
•Safety of equipment.
•Easy and simple installation.
•Longer life of equipment.
•Affordable cost.
•Speed controlled smartly.
•Soft starting.
•Emergency Alert.
•Controlling and Monitoring.
•Wirelessly ON/OFF.
•Reduced jerk on system by low to high load switching.
•Switching of load at the time of disruption.
•Real Time Data Collection.
•Ability to see(current/voltage/power/RPM/short circuit) at anytime wirelessly.
Project Implementation MethodWirelessly controlling and monitoring to protect the industrial three phase induction motor simultaneously in running condition. This will be done by TCP/IP through Wi-Fi. This will provide a real time access to the parameters which are very important for the safety of induction motor. In this purposed project, two way communication procedure will be adopted for the reliability , soft starting, run time ON/OFF to overcome the problems which have to faced by industries. Soft Starting will be done by Variable Frequency Driver. It is for the control of speed of induction motor, in which a inverter and gate driver, act as frequency pulse generate used. The gate driver is attached with the Arduino which will be wirelessly controlled using Wi-Fi module. The Arduino and all the interface components will get the required supply. The sensor units will sense the corresponding motor parameters and feed to the Arduino. Arduino will read the data from various sensors and analyse according to the given instructions, Then send the sensors information to mobile network gateway through Wi-Fi. On the requirement, we will send the instruction, with the help of Mobile by using Wi-Fi protocol, to Arduino. Arduino will read the commands from internet and provides control signals to the relay via contactor, which will control the induction motor and its speed controlled by VFD. The signal which we provide, with the help of mobile using Wi-Fi to Arduino, it will generate consequent signal, which is controlled by gate driver for the generation of frequency according to our sending signal. The sensor information’s are displayed visually in server. The induction motor control will be based on the sensed parameters. The control will be done by relay and circuit breaker. The motor will also turn ON/OFF when abnormal values are detected.
Benefits of the ProjectNot only this project will save money, but also more losses can be avoided.
- Eliminate redundancy between departments.
- Less dependent on other worker.
- Easy to control the speed of motor.
- The occurrence of chances of error will be minimized by this project.
- This project will allow companies to reduce downtime when repairing machinery and ensures that productivity does not suffer.
- Saving of energy.
- Reduced inrush current.
-
Safety of equipment.
-
Easy and simple installation.
-
Soft starting.
-
Emergency Alert.
-
Controlling and Monitoring.
-
Wirelessly ON/OFF.
-
Reduced jerk on system by low to high load switching.
-
Switching of load at the time of disruption.
-
Real Time Data Collection.
Today the industry work as fast as possible to finish the product /service. In many industries, the induction motors are widely used to process the product. The drivers of these motors are mostly on motor control and the predictive maintenance schedules of the motors are not calculated. Attempts are being made to maximize efficiency by using enterprise resource planning (ERP) department, especially in 7/24 production enterprises. In this way, extra charges have to pay the employees and their shifts management is a long procedure for industrial activity. However, unexpected failures not predicted by the ERP department can cause disruptions in the production process. To ensure the reliable operation of induction motors recent advancement techniques are used. Some technology development the monitoring and controlling are done automatically. Internet of things is the recent development to control and monitor the motor from remote location. There is no system present to monitor and control the speed of three phase induction motor simultaneously. This method provides easy control and reliability. The reliability of motor is obtained by continuous monitoring of electrical and mechanical parameters. If any abnormal value of electrical and mechanical factors may be detected, the motor is controlled automatically. Motor is suddenly turn off to reduce the severe faults.
The industrial production may be impeded and disrupt due to the electrical and mechanical faults. The electrical faults may occur due to the following factors such as unbalanced 3phase supply, over voltage, over loading. The mechanical fault may occur due to rotor bar broken, air gap eccentricity, damage in bearing, rotor and stator winding failure.. So the continues monitoring of induction motor is needed for safe and reliable operation of industrial induction motors. The electrical and environmental parameters such as voltage, current, temperature and earth fault(short circuit) of the motor, affects the good performance of motor. And also the mechanical factors such as vibration and abnormal speed affect the good performance of the motor. Some electrical and mechanical factors cause the severe damage to the health of induction motor and also cause severe problem to application where the induction motors are used.
At the end this project provide real time access to the system and not only speed controlled but also protect the induction motor automatically and simultaneously in running condition wirelessly.
Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Agriculture , Food , Energy Core Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 28272 | |||
| resistor | Equipment | 5 | 10 | 50 |
| OPTOCOUPLER | Equipment | 8 | 150 | 1200 |
| DIODE 4007 | Equipment | 8 | 3 | 24 |
| CONNECTOR(G) | Equipment | 10 | 35 | 350 |
| 680 micorfarad (35V) | Equipment | 5 | 40 | 200 |
| 10 ohm resistor | Equipment | 8 | 12 | 96 |
| 4.7 megaohm | Equipment | 8 | 12 | 96 |
| 4.7 Kohm | Equipment | 6 | 12 | 72 |
| black connectors | Equipment | 5 | 80 | 400 |
| 20N 60 (FET) | Equipment | 6 | 450 | 2700 |
| heat sink | Equipment | 6 | 260 | 1560 |
| PCB Chemical | Equipment | 1 | 500 | 500 |
| Motor | Equipment | 1 | 5000 | 5000 |
| Big resistor | Equipment | 1 | 1700 | 1700 |
| adaptor(12 V) | Equipment | 1 | 400 | 400 |
| 2pin/3pin black connectors | Equipment | 2 | 21 | 42 |
| LCD | Equipment | 1 | 650 | 650 |
| Fuse | Equipment | 2 | 35 | 70 |
| 22 kOhm5W | Equipment | 1 | 25 | 25 |
| Fuse body | Equipment | 2 | 30 | 60 |
| LED | Equipment | 4 | 5 | 20 |
| 390 microfarad (400V) | Equipment | 1 | 650 | 650 |
| 1N5404 | Equipment | 4 | 18 | 72 |
| Arduino(UNO) | Equipment | 1 | 800 | 800 |
| male header | Equipment | 30 | 1 | 30 |
| female header | Equipment | 30 | 1 | 30 |
| 100 microfarad capacitor | Equipment | 2 | 65 | 130 |
| 7805 voltage regulator | Equipment | 2 | 35 | 70 |
| heat sink(small) | Equipment | 2 | 80 | 160 |
| 10k voltage regulator | Equipment | 2 | 25 | 50 |
| 3.3 kohm.5W | Equipment | 2 | 5 | 10 |
| 220 kohm.5W | Equipment | 2 | 5 | 10 |
| CT+connector | Equipment | 1 | 550 | 550 |
| PT+connector | Equipment | 1 | 300 | 300 |
| 1N4007 | Equipment | 1 | 10 | 10 |
| 3.3kohm.5W | Equipment | 1 | 5 | 5 |
| 1kohm.5W | Equipment | 1 | 5 | 5 |
| 100 nanofarad | Equipment | 10 | 5 | 50 |
| 680 micro farad 35v | Equipment | 8 | 65 | 520 |
| 3 pin green connectot | Equipment | 3 | 15 | 45 |
| 470R.5W | Equipment | 2 | 5 | 10 |
| Vero boards+solder | Equipment | 1 | 600 | 600 |
| 220 cables | Equipment | 1 | 850 | 850 |
| wooden board | Miscellaneous | 1 | 1500 | 1500 |
| documentation | Miscellaneous | 4 | 900 | 3600 |
| design cost | Miscellaneous | 1 | 3000 | 3000 |