International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

MONITORING AND CONTROL OF PLC BASED AUTOMATION SYSTEM

PARAMETERS USING IoT
Somesh Bakshi1, Gaurav Khairmode2, Nilesh Varkhede3, Swapnil Ayane4
1,2,3students, Dept. of Electronics and Telecommunication Engineering, Pimpri Chinchwad College of Engineering,
Pune, Maharashtra, India
4Assistant Professor, Dept. of Electronics and Telecommunication Engineering, Pimpri Chinchwad College of

Engineering, Pune, Maharashtra, India

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Abstract - Industrial process machines mainly work on PLC information with each other and with users. Manufacturing
and SCADA based system. PLC are equipped with many sensor, is a mature industry with machines and assembly lines that
electronic safety guard, connectors. PLC is an industrial digital run with a high degree of automation. Supervisory Control &
computer adapted for the control of manufacturing process Data Acquisition Systems (SCADA) and Distributed Control
such as assembly lines, or robotic devices. All the information Systems (DCS) are prevalent industry standards.
gathered from sensors is accepted as digital signals to PLCs.
This information is made available on Supervisory control and IoT is complementary to SCADA and DCS. Information
data acquisition (SCADA) through RS485 protocol. Internet of generated from SCADA systems acts as one of the data
Things (IoT) is rapidly increasing technology. IoT is the sources for IoT. SCADA’s focus is on monitoring and control.
network of physical objects or things embedded with IoT’s focus is firmly on analyzing machine data to improve
electronics, software, sensors, and network connectivity, which your productivity and impact your top line. Internet and
enables these objects to collect and exchange data. In this wireless technologies, as well as increase in computational
project, we are developing a system which will automatically and storage capability of computers.
monitor the industrial applications and generate
Alerts/Alarms or take intelligent decisions using concept of 1.1 Objective
IoT. IoT has given us a promising way to build powerful
industrial systems and applications by using wireless devices  To take the input parametric value.
and sensors. It designs and implements a web based real time
programmable logic controllers (PLC) data monitoring  To monitor the parameter value.
system. A main contribution of this project is that it
summarizes uses of IoT in industries with Artificial Intelligence  To implement IoT gateway.
to monitor and control the Industry.
 To generate report and alerts.
Key Words: PLC, IoT, Sensors, RS485, Energy meter,
CCW software, Modbus communication.
 To take remote monitoring and controlling actions.
1. INTRODUCTION
1.2 Problem Statement
In existing systems there is no ways to detect un-even
condition in industry. Manual intervention required for To build the system which can monitor the sensor data and
monitoring. Where need to use CCTV which only monitor but upload it over internet and also provides facility to take
no Alert generation. Alert and their appropriate actions not controlling action from remote location using IoT.
present. The process of monitoring and control is time
consuming to detect and generate Alert Manually. Industry 2. LITERATURE SURVEY
alert are based on manual intervention. Notification for any
circumstances in Industry not provided. The Internet of Ashwini Deshpande, Prajakta Pitale and Sangita Sanap[1]
Things (IoT) is a term, referring to the trend of enabling
connectivity for all devices, to allow more information Introduces Internet of Things (IoT) is rapidly increasing
provided for optimization of device operation, whereas technology. IoT is the network of physical objects or things
Industry 4.0 specifically applies the IoT trend to industrial embedded with electronics, software, sensors, and network
scenarios and use cases. connectivity, which enables these objects to collect and
exchange data. In this paper, they are developing a system
Industry 4.0 vision that outlines the next generation Smart which will automatically monitor the industrial applications
Connected Factory. The second is Internet of Things (IoT) and generate Alerts/Alarms or take intelligent decisions
which is a big shift towards smart, connected ‘things’. using concept of IoT. IoT has given us a promising way to
Everyday objects are getting connected and exchanging build powerful industrial systems and applications by using

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 650
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

wireless devices, Android, and sensors. A main contribution According to controlling parameters, instructions are
of this review paper is that it summarizes uses of IoT in written in rungs, Blocks as well as in statement format. In
industries with Artificial Intelligence to monitor and control this control programming input/output switch symbols,
the industry timers, & counter blocks are used.

Putta Sindhuja and M. S. Balamurugan[2] introduced In this blocks we can set an appropriate parametric values
machine to machine interaction. This work has been according to requirements. It is necessary to configure
designed to implement smart power monitoring and control Ethernet IP driver for communication. To configure PLC
system through IoT using cloud data storage. Findings: module to CCW Ethernet address MAC ID should be set
Power consumed by various appliances is monitored through BOOTP DHCP Ethernet/IP commissioning Tool. The
through an ARM based controller interfaced to Hall Effect loading of these code takes place through Ethernet cable.
current sensors and stored in a cloud data base known as Now, data received on PLC is transmitted to distant location
Xively. Power control of home appliances is achieved to observe machine performance and for predictive
through actuators such as relays which can be controlled by maintenance through Ethernet TCP/IP protocol.
client with the help of a web server. The web server is
designed using Hyper Text Transfer Protocol for It is possible to see graphical representation of control
communication between client and server by establishing system on SCADA platform and also able to perform
Remote Procedure Calls between client and server. controlling action from distant location in industrial plant.
Conclusion/Improvements: The designed system enables
client to monitor and control the appliances at home from IoT gateway is established through internet based Ethernet
anywhere availing the IoT features protocol for data and command transmission and reception.

3. PROPOSED METHOD Program can be created on web server which allow for a web
based SCADA system by using .NET languages like C#,
3.1 Block diagram VB.net, C++.

There are many features can be implement through IoT

platform such as mail alerts, daily reports formation for
analysis of machine health. Data also get stored locally as
well as on cloud.

4. CONCLUSION
In industries to reduce manual overhead we planned to
implement Internet of Things (IoT) in Industry to monitor as
well as to inform the responsible person to take appropriate
measures, but this will partially fulfill our requirement. As
sometimes it will be late in this process So, We are
developing an industrial application using internet of things
technology. We aim to provide an application for monitoring
Fig -1: Block Diagram industrial appliance. We aim to serve as an efficient
backbone for achieving a network of sensors and actuators
3.2 Working which can help for improving the performances of the day to
In this IoT based PLC automation initially controlling and day gadgets/activities for industry use.
data acquisition takes place through a PLC for various
parameters like flow, pressures, phase voltage via their
ACKNOWLEDGEMENTS
appropriate sensors. An instantaneous real time data display Sincere thanks to Instron Technologies and their project
takes place on energy meter and it has eight segment LED manager Mr. Shailesh Bangale for making the resources
display and contains three rows of alphanumeric displays, available at right time and providing valuable insights
according to that one can adjust parameters through leading to the successful completion of this paper and also all
potentiometer knob. This energy meter having feature to the anonymous researchers for providing such a useful and
convert to Kilo, Mega, Giga values by indicators. helpful opinion, findings, conclusions and recommendations.
Also gives immense pleasure to thanks HOD Dr. N.B.
Appropriate power supply is given by SMPS to PLC. Input
Chopade, Principal Dr. A.M. Fulambarkar and friends for
given to SMPS is ranging from 100-240v and current
their kind support and guidance.
approximately ranging from 1.5A. The output voltage of the
power supply that we used typically is 24V and current
approximately at 2.5A.

© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 651
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

REFERENCES
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2. Putta Sindhuja and M. S. Balamurugan, “Smart

Power Monitoring and Control System through
Internet of things using Cloud Data Storage” Indian
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