Web based Remote Controlling and Condition Monitoring of the Heavy Machineries Akhil Deshpande1 Vinayak Kulkarni2 Gogte Institute of Technology, Udyambag, Belgaum India 1
[email protected]
2
[email protected] Anuj Deshpande3
Jain College of Engineering Machhe, Belgaum India 3
Abstract—
The
future
[email protected]
of
global
information
is
available
fingertips.
towards
heavy
components also called as condition
machineries located at different location
monitoring is currently done integrating
which run unmanned, automated, using
the electronic computational power and
artificial intelligence, and ability to
compatible
diagnose errors and self-repair.
Software like LabVIEW and MATLAB
use
of
This paper deals with the concept of building a custom WEB application for controlling
hardware.
bridge the gap between computer and the measuring hardware. With this concept remote operation
machineries by providing flexibility in
and maintenance of heavy machineries is
operation from any remote location,
possible
ensuring platform independence and low
competing with various factors like
cost
human
to
use
monitoring
measurement
machine
these
due
and
of
your
development is mandatorily directed complete
Maintenance
at
of
Open
Source
Architecture. Although this technology is
in
near
future
inaccessibility,
thereby
environmental
factors etc.
not yet mature enough for a complete exclusion
of
manual
control
and
maintenance. The Internet that we know today has become
so
advanced
that
Keywords—
Internet,
Monitoring,
Maintenance,
Condition Heavy
Machineries
every
The Thirteenth International Conference on eLearning for Knowledge-Based Society, 15-16 December 2016, Thailand
Akhil Deshpande, Vinayak Kulkarni, Anuj Deshpande
how heavy machines can be controlled
I. INTRODUCTION Machine maintenance is a very crucial work every industry needs to carry out on
unmanned
remotely
implementing
the
power of internet.
periodic basis. One man operation, control and maintenance of heavy machinery is a
II. WHAT IS CONDITION MONITORING?
tedious task. For successful and smooth
Condition monitoring is the process of
running of the machines regular servicing is
determining the condition of machinery
mandatory. Condition monitoring is one
while
such method of machine maintenance
Monitoring (CM) became well-known in
where in the fault in machines is diagnosed
the 1960’s and since then this technology
by vibration signatures.
has been rapidly developing, especially in
Vibration signature analysis is one of the significant
steps
in
in
operation
[1].
Condition
the last two decades with the advent of high
maintenance
speed computers, internet and reliable
engineering. This has been now become the
sensors [2]. Even the operating cost of all
priority task in condition based monitoring
the hardware and associated software has
of any mechanical system. Mechanical
reduced considerably.
system comprises of various moving and non-moving links which have sliding, reciprocating or rotary motions. Due to
The ways to an effective condition monitoring system incorporates: i. Recognizing
these motions among the relative machine parts
there
arises
huge
amount
of
and can hamper the productivity of any
expected
sound
pattern. ii. Step by step instructions to transform
vibrations. These vibrations if not rectified initially may lead to fatal machine failures
the
it from Analog to Digital. iii. How this knowledge can be applied. Effectively
utilizing
this
project
industry. Various tools are developed to
empowers the repair of problems of key
identify these vibrations of the machineries.
components preceding failure. Condition
It is possible that some machineries may
monitoring not just guide engineers and
be required to operate at locations where
plant personnel to diminish the likelihood
there can be extreme weather conditions
of disastrous failures, but additionally
and a human access to such locations is
permits them to request parts ahead of time,
only possible by risking his life.
and
This paper describes what is condition monitoring and illustrates the concept on
plan
downtime.
different
repairs
amid
the
Web based Remote Controlling and Condition Monitoring of the Heavy Machineries remotely monitoring machineries of any
III. CONCEPT The evolution of humans lead to many
sort over large areas.
inventions. The Stone Age saw the tools
Unlike
systems
using
traditional
being made out of stones. The problems
computer
and
dedicated
faced were mainly in the shaping of
communications
materials using stone tools. This lead to
systems combine with mobile phone and
invention of metal tools in the Bronze Age
satellite
and Iron Age. In the early days of this era
available infrastructure to provide access to
the difficulties were in production and
the machines easily, cost effectively and
shaping of complex components. With the
securely.
equipment
networks,
technology
to
web use
based publicly
working
These systems use conventional web
application of metals in structures, simple
browsers and third party communications
machines etc. increased progressively. With
infrastructure, along with all the computer
machines in hand many tasks were carried
hardware and software that are needed. Just
out
using the power of web the machines can be
improving
skill
smoothly
of
metal
without
much
effort.
Although some laborious tasks required
linked to the personal computer.
huge machines to complete them. This was
Akhil Deshpande et al [4] have described
only possible by integrating the material
how a CNC machine can be controlled and
knowledge and application knowledge with
operated remotely. Applying the similar
some simple machine components to
concept
perform the task. With the innovation of
controlled
heavy machineries there came the task of
remotely.
regular
servicing
and
maintenance.
Condition monitoring thereby evolved as one of the method of maintaining machine components by knowing the machine condition. Web based remote monitoring provides the most convenient and affordable method available today for remotely monitoring data of any sort over large areas [3]. Thus this concept can be implemented for
heavy
machineries
operated
and
can
be
maintained
The concept here is divided into two important sections namely i. Controlling of machines: Here the operation of the machines is done using a remote control system. In this the command for every operation of the machines is sent to the system located at the remote location through the internet digitally. These digital commands are the digital signals transmitted from the office network.
The Thirteenth International Conference on eLearning for Knowledge-Based Society, 15-16 December 2016, Thailand
Akhil Deshpande, Vinayak Kulkarni, Anuj Deshpande
At the remote locations these signals
user at the other end can analyse these
are processed and converted into
signals using either MATLAB or
analog signals in the control unit
LabVIEW software and can thereby
using Analog to Digital Converter
maintain
(ADC). These analog signals then
remotely.
actuate
the
machines
mechanisms thereby
in
making
the the
machines work. ii. Maintenance
using
Condition
Monitoring: When machines operate they produce tremendous vibrations due to various moving parts within it like gears, rotors, sliders etc. These parts
have
frequency.
their
own
natural
When
the
natural
frequency of these parts match with the frequency of the overall machine causes the machine to vibrate. Faulty
the
machines
sitting
IV. HOW INTERNET AIDS IN REMOTE CONTROL AND MAINTENANCE OF MACHINES? Today the most prevalent and most basic method for conveying is the web. It permits clients to hunt, search, recover, spread and offer
data
remotely.
It
really
gives
worldwide availability and the capacity to effectively remotely control from any point on Earth. The idea of establishment of Web based
tele-control
is
in
light
of
straightforwardness and has minimal effort of advancement and sending.
components create high amplitude vibrations in the machine. These vibrations are analysed using the technique of Condition Monitoring. Here accelerometers are mounted at
Fig. 1. Schematic diagram of remote control
key locations on the machine which
of machines.
sense the vibrations. Vibrations are analog
signals
in
nature.
The
accelerometers are connected to a Data
Acquisition
System
(DAS)
which convert them to digital signals. These digital signals are transmitted through
internet
from
remote
locations which are received at the user end through office network. The
Fig. 2 Schematic representation of WEB control of machine [5]
Web based Remote Controlling and Condition Monitoring of the Heavy Machineries Figure 1 and 2 demonstrates a chart of
Conceptual Framework
the created idea of web control. The idea
Web pages installed with Java applets
comprises of the created Web application
give an interface for remote operation of the
that is gotten to from the PC that is joined
machine as a feature of the proposed
with the web by means of a TCP/IP
Internet based control and operation of
convention. Constant correspondence with
heavy machines as shown in figure 3. As
the server is given utilizing attachment
Java is web and user friendly, all that a
programming. Server advances solicitations
remote client requires is a Java-empowered
to the EMC2 control unit [6] that is
web program and Internet association to
physically joined with the machine device.
utilize the framework. Utilizing the web
The
the
interface, the approved remote customers
unit's
give machining parameters which are
capacities are accessible remotely for usage
transferred to the web server utilizing the
in a Web application, it is conceivable to
CGI.
use
of
adaptability.
open Since
source the
gives
control
straightforwardly control the control unit as compared to controlling the local PC on which the control unit is introduced. Design Considerations Taking into account the research work of Lee et al. [7], preparatory examinations concerning the remote control of the machine
were
undertaken
utilizing
commercial off-the-shelve (COTS) remote control programs, for example, NetOp,
Fig. 3 Conceptual framework outlining the various components (subsystems) and their interaction in the proposed web-based manufacturing system [8].
VNC and Telnet. There were a few
The machining parameters after coming
shortcomings with respect to the remote
to the server (center level) constitute a
control programming in its present setup to
sections program which is put away in work
completely control the machine operation.
record booked for execution of task by the
These shortcomings lead to recognizable
heavy machine say ground boring machine.
proof of the accompanying key necessities
The ground penetrating machine is a
which were considered into the last outline
machining's representation process, which
of the remote control setup.
is controlled by the server by means of the upgraded parallel port.
The Thirteenth International Conference on eLearning for Knowledge-Based Society, 15-16 December 2016, Thailand
Akhil Deshpande, Vinayak Kulkarni, Anuj Deshpande
The machining procedure is checked by the system camera, which is a center's piece level giving continuous criticism to the remote clients. Clients can further work together on item plan on the other hand
Advantages of remote controlling and maintenance of heavy machines The following are the few advantages of having remotely located heavy machines
Remote operation is advantageous
different issues by method for a visit room
for operations required at locations
facilitated by the web server.
inaccessible to humans
In tending to security issues relating to
The
technique
can
prove
cost
the online assembling framework, the
effective as the cost incurred in
firewall is the primary line of safeguard in
deputing a person every time to
limiting unapproved access to the server
remote location is very high.
and the heavy machine. Notwithstanding
The World Wide Web is one of the
this, the web server confirms clients before
readily
allowing consent to submit employments,
accessing anything anywhere so
screen the machining process or take an
controlling a heavy machine at
interest in virtual exchange. At last all
remote locations becomes easier.
available
channel
for
contact based correspondence between the
Multiple inputs from n number of
customers and the server is extended TLS
clients can be given to any machine
in this way guaranteeing classification,
from
information
productivity rate.
trustworthiness
and
server
anywhere
thus
increasing
verification. The Server for Internet-based Secured
Limitations of remote controlling and
Manufacturing (Sisman) which has the
maintenance of heavy machines
online manufacturing framework has been
The following are the few limitations of
arranged to run the Red Hat Linux working
having remotely located heavy machines
framework, Apache web server and Iptables
Up-front investment required for a
firewall. Sisman has additionally been
solution of setting up of remote
enlisted on USP's space name server.
machinery is larger due to development
Moreover
costs.
associations
beginning from
outside USPNet foreordained to port 80
Cultural acceptance is an issue as all the
(HTTP) and port 443 (HTTPS) on Sisman
countries around the globe have their
were permitted to go through USPNet's
own national standards and very few of
firewall.
them follow international standards.
Web based Remote Controlling and Condition Monitoring of the Heavy Machineries Due
to
a
very small
REFERENCES
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in
Chemical
Science,
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Tallinn, Estonia
The Thirteenth International Conference on eLearning for Knowledge-Based Society, 15-16 December 2016, Thailand
Akhil Deshpande, Vinayak Kulkarni, Anuj Deshpande
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