Remote Generator Control Using Android Application

Remote Generator Control Using Android Application Gaby Abou Haidar

Roger Achkar

Department of Computer & Communications Engineering American University of Science and Technology, AUST Beirut, Lebanon [email protected]

Department of Computer & Communications Engineering American University of Science and Technology, AUST Beirut, Lebanon [email protected]

Ramzy Abou Dayya, Aslan Salloum, Kahtan Daoud Department of Computer and Communications Engineering American University of Science and Technology, AUST Beirut, Lebanon [email protected], [email protected], [email protected] Abstract— The traditional technique of monitoring an electric generator was through regular checks on the generator’s variables: oil, temperature, voltage, and current on a daily basis. Therefore, keeping a normal cycle of performance requires hard work and is often imprecise. The paper presents the solution for the aforementioned issues and more. The idea is to initialize an application that monitors electric generators wireless, using the famous Smart Phone operating system Android. The implemented sensors deliver analog signals that provide real time data about the generator's status. These data are converted and programmed though the Arduino micro-controller, which outputs the results in its digital state and then transforms the output into a serial signal, transmitted to the android phone, through a router. Thus a live feedback of the state of the generator is assured. In addition, this project provides a control button that can actually turn this generator on and off. This project is the first step towards the combination of systems and control because it revolutionizes the ideology of monitoring and displaying real time data which can be implemented in various fields depending on different needs. Such fields include electricity, mechanics, and communication. The main limitation faced was the lack of advanced electronics, and technology. Keywords: Wireless Monitoring, Android Application, sensor monitoring. I.

INTRODUCTION

Electric generators play an essential role in the vast majority of today’s economic fields, since they are the main element that powers up the whole system of modern life. Because the glue that holds the design of the 21st century technological dependency is extremely crucial, monitoring these generators is a major, and important issue that every factory must consider, through which each factory must have a maintenance team to check up on the vitals of the

generator in a daily, hourly, and cyclic manner which requires a lot of hard work, in addition to inaccurate data readings due to the lack of automation. To facilitate the whole process, and to resolve the aforementioned problems, the solution is presented through building an android application that can monitor the live conditions of the generator including fuel level, temperature, current, and voltage values. In addition, this application can turn the generator on and off through the android phone as needed, and finally a notification system that warns the person in charge if any of the values exceeded the standard limit. This project is a new application in the domain of embedding various systems, aiming for the advancement, and contribution to the technological world present, and finally to provide a smart and creative solution that can help and initiate a boost the field of wireless monitoring. II.

BACKGROUND INFORMATION

A. Android Android devices are powerful mobile computers with permanent internet connectivity and a rich variety of built-in sensors. More properties make the Android system very applicable for university use: Android uses the Java programming language, which our students are familiar with. Getting started with the Android API is easy; the API is open, i.e. developers can access almost every low-level function and are not sandboxed. In addition, the Android API allows easy access to the hardware components. Interesting for robotics use are the numerous communication interfaces like Wi-Fi, Bluetooth and GSM/UMTS, USB, and the integrated sensors, that is: accelerometer, gyroscope, compass and GPS. Because it’s a mass product, devices are available for already around 100$, which is much cheaper than any other ARM-based

processing unit (e.g. Beagle Board). But the Android platform currently lacks the ability to physically extend it to control more sensors and actuators. This is actually a precondition if we want to use an android device as robotic processing unit, and section VI-A will discuss various options to overcome this restriction [1]. B.

Diesel Electric Generator “A diesel electric generator is the combination of a diesel engine with an electric generator (often an alternator) to generate electrical energy. Diesel generating sets are used in places without connection to a country’s main power grid, as well as emergency power-supply devices if the grid fails, and are used also for more complex applications such as peak-lopping, grid support and export to the power grid. Sizing of a diesel generator is critical to avoid low-load or a shortage of power and is complicated by modern electronics, specifically non-linear loads”. Diesel and gaseous-fueled generators each offer advantages to consider when designing a standby power solution. By comparison, diesel-fueled generators provide access to backup power in remote areas that do not have a gaseous-fuel infrastructure. When applied to standby power applications of 150 kwe or more, a diesel-fueled generator delivers a lower capital cost per kilowatt of electricity than a gaseous-fueled generator. Attempts to lessen this disparity, such as converting industrial diesel engines to gaseous fuel, only add engineering costs to the project. as a result, diesel-fueled generators have a capital cost advantage over their sparkignited counterparts in larger standby applications, making them the traditional market norm. [2].

ii. 412 Arduino Current “412 Arduino current sensors provide a capability of sensing current in a compact, easy to install package. The 412 Arduino current sensor is compatible with virtually any electric device because of its ability to sense the current draw of whatever is plugged into it, and in a very flexible manner” [4]. iii. 412 Arduino Level “The sensor surface metal processing, can extend its service life. Insert it into any liquid container, and then read it using the AD convertor. It helps in all liquid mixtures through sending analog signals providing information to the sensor’s current status. In addition, it maintains a steady output for long periods of time” [5]. iv. Voltage Self-Made There is no need for a physical voltage sensor, through which a simple placement of a transformer followed by a bridge and a filter can transform the high voltage of the electric generator, to a small, scalable voltage that can be sensed by the Arduino. Upon simple calculations, a reading can be set due to scaling facts (Figure 1).

Figure 1:Self-Made Voltage Sensor

D. C.

Sensors i. Arduino LM 35 For the measurement of temperature, an LM35 temperature sensor is being used. LM35, an integrated circuit sensor to measure temperature with an electrical output proportional to the temperature (in ᵒC) is used in this paper. It operates for biasing voltage of +4 volts to +40 volts and has sensitivity of 10 mV/°C. Characteristics of LM35 Sensor: i. An output voltage which is proportional to the Celsius temperature is obtained. ii. Sensitivity factor is .01V/ᵒC iii. The sensor does not require any external calibration or trimming and maintains an accuracy of +/-0.4 ᵒC at room temperature and +/- 0.8 ᵒC over a range of 0ᵒC to +100 ᵒC. iv. LM35 sensor draws only 60 micro amps from its supply and possesses a low self-heating capability. v. Its self-heating cause’s less than 0.1 ᵒC temperature rise in still air. Uses of LM35 Sensor: i. Temperature can be measured more accurately using this sensor than with any thermistor. ii. The LM35 generates a higher output voltage when compared with that of thermocouples and may not require the amplification of the output voltage [3].

Arduino UNO Microcontroller

The Arduino Uno is a microcontroller board based on the ATmega328.. It has 14 digital input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz ceramic resonator, a USB connection, a power jack, an ICSP header, and a reset button. It contains everything needed to support the microcontroller; simply connect it to a computer with a USB cable or power it with an AC-to-DC adapter or battery to get started. The Uno differs from all preceding boards in that it does not use the FTDI USB-to-serial driver chip. Instead, it features the Atmega16U2 (Atmega8U2 up to version R2) programmed as a USB-to-serial converter. (Figure 2) [6].

Figure 2: Arduino Uno Datasheet

E. Nano Router (TP-LINK) “Measuring 2.2 inches by 0.7 inch by 2.2 inches and weighing just 8 ounces, the square TP-Link 150Mbps Wireless N Nano Router is about the size of a candy bar. And it looks like one, too, with a sleek two-tone plastic cover that comes in white and a mild blue. On one side, the router has an Ethernet port and a standard Micro-USB 2.0 port for charging. The included USB charger, which is relatively compact in its own right, is in fact bulkier than the router itself. The router also comes with a flat network cable neatly curled, ready to be carried when you're on the go. The router's Ethernet port works either as a LAN port (to connect to a client) or a WAN port (to connect to an Internet source). The only time it works as a WAN port is when the TL-WR702N is being used as a router. When it's used as an access point, range extender, or media bridge, this port acts as a LAN port” [7]. III.

PROPOSED SOLUTION

Condition monitoring is the process of monitoring a parameter of condition in machinery (fuel level, temperature etc), in order to identify a significant change which is indicative of a developing fault. It is a major component of predictive maintenance. The use of conditional monitoring allows maintenance to be scheduled, or other actions to be taken to prevent failure and avoid its consequences. Condition monitoring techniques are normally used on important equipments and other machinery (pumps, electric motors, internal combustion engines, presses). A wireless sensor network of spatially distributed autonomous sensors to monitor physical or environmental conditions, such as temperature, current, fuel level, etc. and to cooperatively pass their data through the network to a main location. The more modern networks are bidirectional, also enabling control of sensor activity. Today such networks are used in many industrial and consumer applications, such as industrial process monitoring and control, machine health monitoring, and so on.

Android is the new revolution of operating systems, developed in 2003 based on an open source platform, through which the programming world has included everything needed in order to build an interface with every electronic, or apparatus system, therefore the Android combination makes wireless systems and logic programs valid for control purposes . Using Android, controlling from a distance or abroad has became possible, this project is an example that shows how technology makes life easier. Its aim is to build a system based on a generator, with implemented sensors and an Arduino microcontroller that receives the sensor’s analog signal and convey them to a router that emits Wi-Fi signals. These signals get captured by an android phone, which then displays details of the generator’s status. The application also includes a control button that can turn the generator on and off. This apparatus is a new theory in the world of building embedded systems based on programming, communication and control, for the aim of advancing, and creating a one of kind project, in addition to solving the exhausting problem of monitoring generators. Therefore not only are the main problems solved, they are replaced with a better, simpler and more practical processes. IV.

MATERIALS AND METHODS

This project fundamentally consists of two parts, the control part, and the monitoring part; describing how the application controls the electrical generator, and offers a range of monitors to help keep the user up to date with the significant aspects that affect the functionality of the generator. The control that this project offers to the user is the ability to start and turn off the generator in case of malfunction or when being present in a remote location without the need to be near the generator allowing the user easy access to generator and providing more security. The monitoring part allows the user to keep in touch with the major components that the generator acquires to operate properly, the fuel level, its temperature, in addition to keeping the user on a minute to minute basis A. Design The four sensors are directly connected to the Arduino microcontroller, in addition to pins from the digital side of the Arduino connected to relays implemented in the generator, making it possible to initiate the generator once the start button is pushed, a signal will be sent from the phone to the router all the way to the Arduino’s control digital pins where it will be switched from 0V to 5V which will turn the relay on allowing the battery of the generator to close the circuit thus turning the generator on.

After this step is complete, the 4 sensors will be connected to the application by sending real time values to the Arduino, and the latter will transmit them, after turning them into digital values, to the router which in turn will emit them through wifi to the phone insuring live feedback of the generator’s vital signs. Moreover, if any sign gets out of the normal range the phone will receive a notification, warning the user to check up on the generator. Afterwards, if the user wants to turn off the generator, all what is necessary to be done is to press the STOP button where a control signal will be transmitted from the phone to the Arduino, following the same concept as the START button and a normally close relay will open allowing the generator to turn off (see Figure 3).

sensor includes a 9V transformer followed by a bridge, and a filter in the end which transforms the 220v output from the generator to a 9V stable dc outcome and was scaled in order for the data to be read and accepted by the Arduino, which made the scaling process enormously essential for the success of the operation. Afterwards, the router was programmed to be able to transmit and emit signals from 2 sides, the phone side, and the Arduino side. The Arduino microcontroller was only programmed to take analog input from all the sensors, scale them and send them to the router as digital values; the digital pins were programmed to get control signals from phone in order to be able to turn the motor on and off.

V.

RESULTS AND DISCUSSIONS

A. Results After fixing the encountered problems, and they were many, the project functioned completely just as planned in the earlier periods of design without any exclusions. First of all, the Android phone should have the application installed and the phone should be connected wirelessly to the router that is connected to the Arduino (see Figure 4).

Figure 3: Block Diagram representing project

B. Construction Procedure The Construction started after making a sharp check up on the generator’s vital conditions, taking in consideration that the generator is a bit old; it was revised in a way to be able to use it with no worries. Afterwards, the work started on the application, which represents the fundamental block of the project and design that will control all variables. Making sure the software part is secured and functional; the first major step is complete. After making sure the application is reacting with the Arduino microcontroller, testing using real sensors, one at a time has began, and the results were acceptable after experiencing some errors which were diagnosed and fixed eventually. The level sensor is planted in the fuel reservoir in addition to the temperature sensor also planted were monitoring of the generators heat is plausible. The current sensor was planted near the generator, in the electronics box, and this sensor plays a huge role in sensing the current consumed from the motor on every electronic product consuming electricity. The final sensor which is the voltage sensor is not actually an electronic product sensor because it was self-made. The process of building this

Figure 4: Software's Final Look

The current, the voltage, the temperature, and the level sensors are all connected to the Arduino microcontroller, and the Arduino is connected from its digital output extremities to two relays that control the electric generator to turn on and off. This is considered to be the initial configuration in order for this project to function properly. After pressing the “Start” button on the application, the generator turned on, and it was possible to read the values of the four sensors successfully on the phone. If the

temperature sensor exceeds 35 degrees which represents the red line, a notification is sent on the phone to warn the user monitoring the generator to take precautions. Also, if the fuel level decreased below 1 cm it also sends a notification to refill the generator. Finally if the user decided to turn the generator off, all what should be done is to press the stop button and the motor will directly turn off. Results were fascinating and we were amazed by the outcome especially because it was our first time dealing with huge projects. B. Discussion This project opens a huge discussion due to its simplicity, yet beneficial outcome; it assembled a mixture of systems, and dedicated them to a real issue were people related to the industry are facing; the idea isn’t widespread in the world, and it will ensure more productivity, and make human’s life easier and more precise especially that this project’s concept of embedding various systems can be implemented in many fields, industrial wide scale projects or for personal usage; so it is considered as a simple drag and drop modules system. Not forgetting to mention that this project has emerged huge learning outcomes as students dealing with practical equipment for the first time, grasping various main concepts in a vivid manner related to electricity, and how current physically gets divided, the concept of voltage, and current, and android programming in addition to Arduino programming and implementation. VI.

monitoring, and control system, as it can be produced in other forms to reflect different needs. For example, this project can have the same idea but could be combined with an industrial control, with higher standards operating under the same concept. As a personal conclusion this project was reflected on us as engineering students with a lot of learning outcomes, and especially technical learning, because for the past three or four years, all what we did is study the world of signals, and communications in theory, but we never had the real chance to build a system with multiple theories involved, and see it function properly, so after working with our hands, and performing the construction work of this project we learned a lot of new information and technique which made us happy in addition to the large number of mistakes we did, because each mistake made us think of a way to fix it, and sometimes we returned to some books that we have studied to solve the problem, so we were able to build this link between the theory and the real world implementation which we will definitely benefit from it in the after work life. Finally, this project was done in order to fulfill the bachelor’s requirements. We learned a lot from this experience because we were directly involved in every step of the process. We developed good knowledge in all aspects related to the functioning and monitoring of an electric generator which increased our experience in the real world of technology.

CONCLUSION AND FUTURE WORK

Due to the limitations as students living in third world countries, and with insufficient materials to work with, it is considered as an important thing for us as engineering students to build a system with such affordable resources, a system that is really needed, especially in the world of generators. Plus this application comes handy wherever monitoring or control is essential. In addition, this experience benefited us on the academic level, since we learned a lot about how electronics function and it helped us understand the link between theory and real world implementation. This endeavor is considered to be the best experience we had as engineering students in this field. A. Conclusion This project is built on a new idea. It is simple yet advanced. It offers a mixture of formulas that finally got tested for validation. It offered us a chance to nurture our curiosity towards our courses in communication, signals, programming, and electrical circuits (figure 5). The importance of this project isn’t the project itself; it’s the contribution of the project to the world as an advanced

Figure 5: Control Box

B. Future Work The project opens up a whole new dimension related to future work in the market, especially since it is highly requested by managers in fields concerned with controlling, and monitoring machines from a distance. In addition, this project is still in need for several types of updates: Our future work as students in such a project is has wide scale because we plan on continuously advancing this project and updating it. In addition, we plan on altering the project to fit the needs of fields that are somewhat far away from regular industry. For instance an idea is to switch the task of monitoring electric generators to monitoring and controlling

medical equipment in hospitals because the whole communications system works with the same concept. REFERENCES [1]

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