VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Jnana Sangama, Belagavi – 590018

A TECHNICAL SEMINAR REPORT ON

“Controlling and Monitoring of Industrial Parameters through Cloud

Computing and HMI”

A Dissertation Submitted in partial fulfillment of the requirement for the degree of

BACHELOR OF ENGINEERING
In
COMPUTER SCIENCE & ENGINEERING

Submitted by
SUSHMITHA R 1RG16CS119

Under the Guidance of

Mrs. KAVYASHREE J
Asst. Professor, Dept. of CSE
RGIT, Bengaluru-32

Department of Computer Science & Engineering

RAJIV GANDHI INSTITUTE OF TECHNOLOGY
Cholanagar, R.T. Nagar Post, Bengaluru-560032.
2019-2020
 VISVESVARAYA TECHNOLOGICAL UNIVERSITY
JNANA SANGAMA, BELAGAVI-590018

RAJIV GANDHI INSTITUTE OF TECHNOLOGY

DEPARTMENT OF COMPUTER SCIENCE &ENGINEERING

DECLARATION
I hereby declare that the project work entitled “Controlling and Monitoring of Industrial
Parameters through Cloud Computing and HMI” submitted to the Visvesvaraya
Technological University, Belagavi during the academic year 2019-2020, is record of an
original work done by me under the guidance of Mrs. Kavyashree J, Assistant Professor,
Department of Computer Science and Engineering, Rajiv Gandhi Institute of
Technology, Bengaluru and this technical seminar work is submitted in the partial fulfilment
of requirements for the award of the degree of Bachelor of Engineering in Computer Science
& Engineering. The results embodied in this this technical seminar have not been submitted
to any other University or Institute for award of any degree or diploma.

Sushmitha R 1RG16CS119
 RAJIV GANDHI INSTITUTE OF TECHNOLOGY
(Affiliated To Visvesvaraya Technological University)
Cholanagar, R.T.Nagar Post, Bangalore-560032

Department of Computer Science Engineering

CERTIFICATE
This is to certify that the Seminar Report titled “Controlling and Monitoring of Industrial
Parameters through Cloud Computing and HMI” carried out by Ms. SUSHMITHA R
(1RG16CS119), bonafide student of RAJIV GANDHI INSTITUTE OF TECHNOLOGY
in partial fulfillment for the award of Bachelor of Engineering in Computer Science
Engineering of the Visvesvaraya Technological University, Belagavi, during the year
2019-2020. It is certified that all corrections/suggestions indicated for Internal Assessment
have been incorporated in the Report deposited in the departmental library. This technical
seminar report has been approved as it satisfies the academic requirements in respect of
technical seminar work prescribed for the said degree.

Signature of Guide Signature of HOD

Mrs. Kavyashree J Mrs. Arudra A
Asst. Professor Assoc. Professor & HOD
Dept. of CSE, Dept. of CSE,
RGIT, Bengaluru RGIT, Bengaluru
 ACKNOWLEDGEMENT
I take this opportunity to thank my college Rajiv Gandhi Institute of Technology,
Bengaluru for providing me with an opportunity to carry out this technical seminar report
work.

I express my gratitude to Dr. Nagaraj A M, Principal, RGIT, Bengaluru and to

Dr. D G Anand, Rector, RGIT, Bengaluru for providing the resources and support without
which the completion of this technical seminar would have been a difficult task.

I extend my sincere thanks to Mrs. Arudra A, Associate Professor and Head,

Department of Computer Science and Engineering, RGIT, Bengaluru, for being a pillar of
support and encouraging me in the face of all adversities.

I would like to acknowledge the thorough guidance and support extended towards
me by Mrs. Kavyashree J, Assistant Professor, Dept of CSE, RGIT and technical seminar
coordinators Mrs. Geetha Pawar, Assistant Professor, Dept of CSE, RGIT and
Mrs. Sonia Komal V, Assistant Professor, Dept of CSE, RGIT, Bengaluru. Their incessant
encouragement and valuable technical support have been of immense help. Their guidance
gave me the environment to enhance my knowledge and skills and to reach the pinnacle
with sheer determination, dedication and hard work.

I also want to extend my thanks to the entire faculty and support staff of the
Department of Computer Science and Engineering, RGIT, Bengaluru, who have
encouraged me throughout the course of the Bachelor’s Degree.

I want to thank my family for always being there with full support and for providing
me with a safe haven to conduct and complete my project. I am ever grateful to them for
helping me in these stressful times.

Lastly, I want to acknowledge all the helpful insights given to me by all my friends
during the course of this project.

SUSHMITHA.R (1RG16CS119)

i
 ABSTRACT
The gathering of data cause us lots of our time. Sometimes due to this delay, many
accidents occur like fire, leaking of different dangerous gases or materials, etc. This
gathering is done via the cloud, Human Machine Interface (HMI) is linked to a database so
that everyone can easily understand the working status of the plant. These data can be
controlled and monitored from everywhere and from every device which has internet
availability. Here we are using Siemens manufactured digital module of PLC s7-200.
Without any internet module of PLC, we are sending our data over cloud to be monitored
and controlled from all over the world.

ii
 CONTENTS

Acknowledgement i
Abstract ii
List of Figures iv

CHAPTER TITLE PAGE NO.

1 INTRODUCTION 1
1.1 Cloud Computing 1
1.2 Human Machine Interface 3

2 RELATED WORK 4

3 SYSTEM REQUIREMENTS 8
3.1 Hardware Requirements 8
3.2 Software Requirements 9
3.3 Hardware Requirements Specification 9
3.4 Software Requirements Specification 12

4 METHODOLOGY 14
4.1 Automatic Mode 14
4.2 Manual Mode 15
4.3 Direct Mode 16
4.4 Architecture 16
4.5 System Flow 17

5 EXPERIMENT RESULTS 18

6 ADVANTAGES AND APPLICATIONS 20

6.1 Advantages 20
6.2 Applications 21

CONCLUSION 22

REFERENCES 23

iii
 LIST OF FIGURES
FIGURE NO. NAME PAGE NO.
1.1 Cloud Computing 2

3.1 Fab Array PLC 9

3.2 Level Detector 10

3.3 Proximity Sensor 10

3.4 Temperature Sensor 11

3.5 Win CC Programming View 12

4.1 Block Diagram 16

4.2 System Flow Diagram 17

5.1 Choice wise percentage 18

5.2 HMI Screen 19

5.3 Overall percentage 19

iv
CHAPTER 1

INTRODUCTION
There are lots of automation techniques implemented and used to provide ease in work,
especially the idea of automation of the industry and its system with the exchange of data over a
secure GSM. In this study, the controlling and monitoring of industrial parameters through cloud
computing and HMI using OPC data hub software provide a solution to almost every problem.
The nature of the project is the mixture of both hardware and software; in which hardware part
contains both mechanical and electronic components. This work is not only for monitoring but
also controlling of data through a single PC. Workers do not need to visit machines again and again
to take reading to on or off the system; everything is provided on the PC. It helps in reading manual
intervention, reduce in redundancy. It helps in improving the existing service, increase in
efficiency and accuracy.

1.1 Cloud Computing

Cloud computing is the on-demand availability of computer system resources, especially data
storage (cloud storage) and computing power, without direct active management by the user. The
term is generally used to describe data centers available to many users over the Internet. Large
clouds, predominant today, often have functions distributed over multiple locations from
central servers. If the connection to the user is relatively close, it may be designated an edge server.
Clouds may be limited to a single organization, or be available to many organizations (public
cloud). Cloud computing relies on sharing of resources to achieve coherence and economies of
scale.

Advocates of public and hybrid clouds note that cloud computing allows companies to avoid or
minimize up-front IT infrastructure costs. Proponents also claim that cloud computing
allows enterprises to get their applications up and running faster, with improved manageability and
less maintenance, and that it enables IT teams to more rapidly adjust resources to meet fluctuating
and unpredictable demand, providing the burst computing capability: high computing power at
certain periods of peak demand. Cloud providers typically use a "pay-as-you-go" model, which
can lead to unexpected operating expenses if administrators are not familiarized with cloud-

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Controlling and Monitoring of Industrial Parameters using Cloud Introduction

pricing models. The availability of high-capacity networks, low-cost computers and storage
devices as well as the widespread adoption of hardware virtualization, service-oriented
architecture and autonomic and utility computing has led to growth in cloud computing.

Figure 1.1: Cloud Computing

Cloud computing exhibits the following key characteristics:

 Device and location independence enable users to access systems using a web browser
regardless of their location or what device they use (e.g., PC, mobile phone).
 Maintenance of cloud computing applications is easier, because they do not need to be
installed on each user's computer and can be accessed from different places
 Multitenancy enables sharing of resources and costs across a large pool of users.
 Performance is monitored by IT experts from the service provider, and consistent and
loosely coupled architectures are constructed using web services as the system interface.
 Productivity may be increased when multiple users can work on the same data
simultaneously, rather than waiting for it to be saved and emailed.
 Availability improves with the use of multiple redundant sites, which makes well-designed
cloud computing suitable for business continuity and disaster recovery.
 Security can improve due to centralization of data, increased security-focused resources,
etc.

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Controlling and Monitoring of Industrial Parameters using Cloud Introduction

1.2 Human Machine Interface (HMI)

A Human-Machine Interface (HMI) is a user interface or dashboard that connects a person to a
machine, system, or device. While the term can technically be applied to any screen that allows a
user to interact with a device, HMI is most commonly used in the context of an industrial process.
HMIs come in a variety of forms, from built-in screens on machines, to computer monitors, to
tablets, but regardless of their format or which term you use to refer to them, their purpose is to
provide insight into mechanical performance and progress. HMI technology is used by almost all
industrial organizations, as well as a wide range of other companies, to interact with their machines
and optimize their industrial processes. The most common roles that interact with HMIs are
operators, system integrators, and engineers, particularly control system engineers. HMIs are
essential resources for these professionals, who use them to review and monitor processes,
diagnose problems, and visualize data.

In industrial settings, HMIs can be used to:

 Visually display data.

 Track production time, trends, and tags.
 Oversee KPIs.
 Monitor machine inputs and outputs.

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CHAPTER 2

RELATED WORK
There are lots of automation techniques implemented and used to provide ease in our work,
especially the idea of automation of the industry and its system with the exchange of data over a
secure GSM. Mousam proposed industrial automation using 8051 microcontrollers, in which
another idea for automation of industry was presented. But still problem left, when going for
automation through micro-controller heating factor comes in our way, as 8051 chip is not built for
industrial environment. Whereas while working through GSM, the person working or controlling
industry required smart phones of high functionality so that the command of proceeding can be
sent to run the system, which is difficult for everyone to buy and keep in everywhere.
A lot of research has been done and published in the field of automation for different
parameters used in industries. In Ref. to the study, Madan and Reddy provided information that
any plant which is operated manually can be transformed into the automated plant in order to get
the highest amount of accuracy in work, in order to get the maximum amount of output or we can
say that highest efficiency and to save the precious time of user. In this work, GSM modems are
used to receive all the important data/information about working loads and about the user’s
location from any place and time. Similarly, author provides a vast study about automation level
and different types of automations used in industries using CNC, CAM, and FMS. In another
research, author presented the quantitatively verified study with the use of text mining tool also
known as a WORD Smith Tool. The study determines on how we can implement the RAS and
what the critical success factors for such implementations are. Correspondingly, Gade worked on
integration of industries and making them automate while using computer vision systems
presented topics that can help in impacts of machine vision and different types of research field’s
in industrial automations. These impacts can be direct or indirect on vision of the machine. In Ref.
to the study, Kumar and Goudar proposed a system for controlling industrial parameter using
cellular phones over GSM network. In Ref. to the study, authors worked on automation and
security offered a complete real-time monitoring and controlling system using the global system
for mobile and short messaging service for input and to take feedback of the system. In Ref. to the
study, Prasad et al. proposed the way of automating the industries and other parameters using 8051
microcontrollers.

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Controlling and Monitoring of Industrial Parameters using Cloud Related Work

The study provided by Kaur et al. gave the way of detecting different parameters of
industries like smoke, temperature, fire, explosion, and leakage of gas and many other using a
microcontroller and display the output on led screen. In Ref. to another paper, the work on
automation system with security using microcontroller gave the ideas of implementing security
and automation using a microcontroller. In Ref. to the study, the work on agenda related to cloud
computing shows how quickly we can be upgrading of industrial automation occur and what are
their efforts. In another work, Javaid et al. gave an environment for powerful computing storage
for its end user on low cost its issues and their conclusions. Another research namely industrial
environment monitoring and controlling system using android application proposed a GUI-based
system which detect and look after numbers of sensors. This system can also be used to run many
different machines of industry. It also had the feature of environment checking via manually or
automatically using android based application.

Steenbruggen et al. gave a comparative approach for home security from remote location
through wireless network system and by using GSM also. This system is using low power and is
developed by using WSN and GSM technologies. It contains microcontroller based wireless
sensors for different parameters or machineries used in home. For security purpose, an alarm
system is made using ZIGBEE chip. In Ref. to, Dillon et al. worked on controlling power proposed
a smart grid for monitoring and controlling of power utilization. It covers the area for
communication of low data rate having minimum power consumption. It controls most of the user
friendly home appliances and their power on/off using internet. In Ref. to another study by Foster
et al. gave the idea of home automation using smart GSM. In it, the focus was on the functionality
and working of the GSM protocol that authorized the user to monitor and control system far away
from the bandwidth used in home. In this system, user or controller can easily get response or the
status from the home appliances attached to the protocols, that weather they are on or power off.
This research proposed an idea of intelligent home. In which she showed about home security
system having instant response. In this, she proposed a password based security for home. In it,
the controller of the house had access to switch on or off the lights and other parameters of the
house. In it, the feature of alert SMS is also given, that is in case of emergencies like fire, gas
leakage, robbery or other issues related to home a SMS is initiated to the owner or the user of the
service.

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Controlling and Monitoring of Industrial Parameters using Cloud Related Work

Birman et al. reviewed the application that gives versatile phone knowledge from GSM
network for traffic parameters and metropolitan and geographical sketch evolution. This work gave
organized rundown of the project working on the use of the data taken from the cell phone network
to get coordinates and to know traffic approximation of the single user. Also shows remote working
of industrial parameters over cloud using voice activation. In this, he gives the idea of controlling
of industry and converting of natural spoken language into the codes that control or process the
working of the industry. In Ref. to the study, Maiti and Sivanesan provided a case study, in which
the working on end to end automation and transferring of data through cloud is discussed. Also
proposed the security system and burglary prevention stratagems through ad-hoc wireless home
automation system with suite intrusion system. Fog provides focal points for the improve
competence, better protection and carrying of information in an organized manner from one place
to another. It also shows that fog is better to use instead of transferring the all of our information
on the cloud.

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CHAPTER 3

SYSTEM REQUIREMENTS
The nature of the project is the mixture of both hardware and software. System
requirements are the configuration that a system must have in order for a hardware or software
application to run smoothly and efficiently. Failure to meet these requirements can result in
installation problems or performance problems. The former may prevent a device or
application from getting installed, whereas the latter may cause a product to malfunction or
perform below expectation or even to hang or crash. System requirements are also known as
minimum system requirements. System requirements only tell what system must have and
what it must allow users to do. The system requirements are of two types:

 Hardware Requirements
 Software Requirements

3.1 Hardware Requirements

The most common set of requirements defined by any operating system or software
application is the physical computer resources, also known as hardware. The hardware part
contains both mechanical and electronic components.

 Solenoid valve
 Level detector
 Conveyor belt
 Driving motor
 Fab array PLC
 Microcontroller
 Power supply
 Proximity sensor
 Temperature sensor

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Controlling and Monitoring of Industrial Parameters using Cloud Requirements

3.2 Software Requirements

Software requirements deal with defining software resource requirements prerequisites
that need to be installed on a computer to provide optimal functioning of an application.

 Micro win PLC S7-200 Siemens PLC software

 PC-Access (OPC)
 Cogent Hub SCADA & HMI
 Orcad 9.0

3.3 Hardware Requirement’s Specification

Fab array PLC:

A programmable logic controller (PLC) or programmable controller is an industrial digital

computer which has been ruggedized and adapted for the control of manufacturing processes, such
as assembly lines, or robotic devices, or any activity that requires high reliability, ease of
programming and process fault diagnosis.

PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a housing
integral with the processor, to large rack-mounted modular devices with a count of thousands of
I/O, and which are often networked to other PLC and SCADA systems.

They can be designed for many arrangements of digital and analog I/O, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile memory.

Figure 3.1: Fab array PLC

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Controlling and Monitoring of Industrial Parameters using Cloud Requirements

Solenoid valve:

A solenoid valve is an electromechanically operated valve. Solenoid valves differ in the

characteristics of the electric current they use, the strength of the magnetic field they generate, the
mechanism they use to regulate the fluid, and the type and characteristics of fluid they control. The
mechanism varies from linear action, plunger-type actuators to pivoted-armature actuators and
rocker actuators. The valve can use a two-port design to regulate a flow or use a three or more port
design to switch flows between ports. Multiple solenoid valves can be placed together on
a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut
off, release, dose, distribute or mix fluids. They are found in many application areas. Solenoids
offer fast and safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.

Level detector:

Level sensors detect the level of liquids and other fluids and fluidized solids,
including slurries, granular materials, and powders that exhibit an upper free surface. Substances
that flow become essentially horizontal in their containers because of gravity whereas most bulk
solids pile at an angle of repose to a peak. The substance to be measured can be inside a container
or can be in its natural form. The level measurement can be either continuous or point values.
Continuous level sensors measure level within a specified range and determine the exact amount
of substance in a certain place, while point-level sensors only indicate whether the substance is
above or below the sensing point.

Figure 3.2: Level detector

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Controlling and Monitoring of Industrial Parameters using Cloud Requirements

Proximity sensor:

A proximity sensor is a sensor able to detect the presence of nearby objects without any
physical contact. A proximity sensor often emits an electromagnetic field or a beam
of electromagnetic radiation and looks for changes in the field or return signal. The object being
sensed is often referred to as the proximity sensor's target. Different proximity sensor targets
demand different sensors. Proximity sensors can have a high reliability and long functional life
because of the absence of mechanical parts and lack of physical contact between the sensor and
the sensed object. Proximity sensors are also used in machine vibration monitoring to measure the
variation in distance between a shaft and its support bearing.

Figure 3.3: Proximity sensor

Temperature sensor:

A Temperature Sensor is the instrumentation equipment which is used to measure

temperature or heat on the operating machine part. Temperature sensing is performed by
equipment called Thermocouple. A thermocouple is a temperature-measuring device consisting of
two dissimilar conductors that contact each other at one or more points. It produces a voltage when
the temperature of one of the points differs from the reference temperature at other parts of the
circuit.

Figure 3.4: Temperature sensor

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Controlling and Monitoring of Industrial Parameters using Cloud Requirements

3.4 Software Requirement’s Specification

Micro Win PLC:
STEP7-Micro/Win is helping us in saving our most valuable time, money and energy if we
program our data on it. This tool is simple in used like any other normal windows-based
application. In it, we have all the required tools that can be helpful in proper and suitable
programming. It is the newest version which is appropriate to work on different level or versions
of windows like WIN2000, version of XP, and much other upper level of operating systems. It
provides us other things to work on as well like segmented data memory, etc. It also helps in
diagnosing function as well as a user specific LED, history of error, editing in run time and facility
of online downloads.
This programming wizard gives simple graphical assistance to complex tasks as well as automatic
testing services to all the memory operations exists. It creates commented programming blocks
and others. STEP 7-Micro/WIN helps us in getting the right wizard for any type of complex
automation solution.

Figure 3.5: Win CC software programming view

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Controlling and Monitoring of Industrial Parameters using Cloud Requirements

PC Access (OPC):
Open Platform Communications (OPC) is a series of standards and specifications for
industrial telecommunication. OPC specifies the communication of real-time plant data between
control devices from different manufacturers. It is a cheap OPC server, which gives connectivity
to the Siemen- micro PLC over any version of S7-200 PLC protocols i.e. MPI, DP, ETHERNET,
PPI, and modem.

In OPC also known as ole for process control, we have the following things:
 It can possibly provide connectivity up to 8 coexistent connection.
 It has ability to use symbols directly from the STEP 7-Micro/WIN project.
 It has a full backup of all the sets of S7-200 data types.
 It also allows dead band parameters such as Engineering Units.
 In it, a “TEST CLIENT” is also provided in order to have a quick and easy way to test any
link live.
 It has ability to work in almost six different languages such as Spanish, Chinese, German,
English, Italian, and French.
 It also includes samples work projects with popular clients.
 In its helps system documentation is also given which can be used as hard or soft copy as
manual.
 Available as an OEM license version for OEM convenience.

Cogent Hub SCADA:

Cogent Hub SCADA facilitates our system with connecting, storing, integrating of data
and displaying of data in real time scenario. We are able to build a complete system, or argument
installed or existing systems. Supervisory control and data acquisition (SCADA) is a control
system architecture comprising computers, networked data communications and graphical user
interfaces for high-level process supervisory management, while also comprising other peripheral
devices like programmable logic controllers and discrete proportional-integral derivative (PID)
controllers to interface with process plant or machinery.

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CHAPTER 4

METHODOLOGY
The nature of the project is the mixture of both hardware and software; in which hardware
part contains both mechanical and electronic components. Viewing the mechanical part of this
research depends upon the table structure having four containers: solenoid valve, level detector for
level maintain and conveyor belt with its driving motor. This setup is aligned in order to meet all
aspects of practically real industrial requirements. In it, the electronic part consists of fab array
PLC, microcontroller, power supply, different types of sensors and many other components which
can be placed in as a secondary component list. PLC logic diagram and HMI screen are part of
software as these are required to process the software side function.
This autonomous project has two modes of operation; one is the automatic and the other mode of
operation is manual. The PLC takes input from HMI and gives the signal to PLC via
communication port (serial communication port) to perform the whole process either automatic or
manual mode. When the input signal is received by PLC, it starts the process using the logic
diagram file which is uploaded in PLC register. The HMI and PLC are communicating which each
other using a communication card or dongle.

The methodology of our system defines the three mode of operation. The automation
project has three modes of operation.

 Automatic mode of operation

 Manual mode of operation.
 Direct mode of operation.

4.1 Automatic Mode

When using the first mode of operation, the automatic one. The procedure or sequence of
the project is when plugging the PLC plug on the electric board and make them on and then move
the selector switch onto the position of automatic mode. As a fab array, PLC starts it first check
its loop test and then using comm. Check button on HMI screen the communication between HMI
and PLC will be tested. As soon as the automatic start button is press on the HMI screen, the whole

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Controlling and Monitoring of Industrial Parameters using Cloud Methodology

process start, it contains three transparent plastic containers that contain three any different liquid.
Solenoid valve is attached to these three containers. Solenoid valve will operate through
programming via PLC. First solenoid will come in operating condition and remain open until the
given specified time is completed. Then the second solenoid will operate when the first solenoid
is off and it will remain on until its specified time is not completed; now the third solenoid will
operate and repeat the same procedure. These solenoid valves are time based are used to fill the
center container. The center container is milky white plastic. After solenoid operation mixing
motor will start its operation to mix the liquid in the center milky container. The center container
contains a heater to achieve a specific temperature so it became on and raise the temperature of the
liquid. A level sensor is also attached to maintain a liquid at particular level. After that, the
conveyor belt will start to move. When the empty beaker is placed on the rotating conveyor belt,
the beaker starts moving with belt. When the beaker comes in front of position Sensor or proximity
sensor, a signal goes to the PLC, which causes the motor to stop & after some delay fourth solenoid
valve opens & filling starts. After some delay, the Solenoid valve stops causing stop to fill the
beaker & after few more seconds’ conveyor starts. This process continues in a loop & filling
purpose is accomplished.

4.2 Manual Mode

When using the second mode of operation, the manual mode. The procedure or sequence
of the project is when plugging the PLC plug on the electric board and make them on and then
move the selector switch onto the position of manual mode. As fab array PLC start it first check
its loop test and then using comm. Check button on HMI screen the communication between HMI
and PLC will be tested. In this mode, you can activate each and every component of the project by
pressing its button on the HMI screen. For example, if we want to open the third solenoid all we
have to do is just press the button on HMI indicating third solenoid and third solenoid came in
working condition and by pressing one more time it will stop the operation of third solenoid. Each
and every device can be manually on and off using the same above procedure.

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Controlling and Monitoring of Industrial Parameters using Cloud Methodology

4.3 Direct Mode

The direct mode of operation is only an automatic mode. The direct mode of operation is a
mode in which the whole project will run without personal computer or HMI or any input from
any input device. In this mode just plug the fab PLC pluck into the electric board and move the
selector switch onto the position of automatic mode. So, the PLC will start following his automatic
operation. No communication cable or communication circuit or dongle is required to run in direct
mode.

4.4 Architecture
The PC which is working as a server for data to store and process. the Wi-Fi module is
connected to the PLC to ensure wireless communication between PLC and PC. Then on the next,
the PLC is connected to the server and all the industrial parameters attached to it. Here S1, S2, S3
shows the three switches whereas M1 and M2 show the connection of the motor to the PLC and
H1 shows the heater or mixture, depend on the instrument used in the main tank to mix the
material/data. In it, we show that the PLC is taken its input from different types of sensor such as
temperature sensor, flow sensor, level detector, and proximity sensor. Also we show that we can
display output and can take input from any place and from any device that have internet facility in
it.

Figure 4.1: Block Diagram

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Controlling and Monitoring of Industrial Parameters using Cloud Methodology

4.5 System Flow

The flow diagram shows the working or we can say the flow of data from the start of the
project to the end. In this, the first step is to fill the main tank up to the required level. This level
is checked and collected data through the level sensor. The material comes from the sub tank with
the help of solenoid valves. In the main tank, we mix the material comes from different sub tanks
via heating or mixer. After checking that the mixing or heating reached the required level, we
allow them to be filled in bottles or containers which are moving on the conveyor belt. A motorized
valve is installed so that the exact amount, level or quantity or material is filled in the bottle. There
is a proximity sensor installed to stop the bottle exactly under the motorized valve. After filling
we check the level of the main tank and do it till the required number of product is produced or we
reached the lowest level of material in the main tank.

LIQUIDE FROM
SUB TANK MAIN TANK
X

CHECK
FAN TEMPERATURE HEATER

OVERHEATED NOT DESIRED

TEMPERATURE
DESIRED
TEMPERATURE

RUN
CONVEYOR

NO METAL SENSE

PROXIMITY
OUTPUT

METAL SENSE

STOP
FLOW SENSOR OPEN VALVE
CONVEYOR

NOT
DESIRE
DESIRE
STOP VALVE CHECK LEVEL
VALUE
X LEVEL

Figure 4.2: System Flow Diagram

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CHAPTER 5

EXPERIMENT RESULTS
For assessment of the suggested design, we select five different water bottles filling
companies with names as Ali and Son, Refiller, Water, Ahsan, and OZ2 Water. Table 1 shows the
total number of users and choice of their users.
Table 1 shows the interest of the workers, working in above-mentioned companies, according to
the three choices location, website and phone.

Method of use/ Total number User on Using website Using phone

company name of users location
Ali Son 44 17 15 12
Refiller 20 11 8 1
Water 33 1 28 4
Ahsan 15 0 7 8
OZ2 Water 10 6 4 0
Table 1: Different Company’s User Choice

In Figure 5.1, we get the idea that more people are interested in using the website than working on
location and less people want to use the phone for such purpose.

Figure 5.1: Choice Wise Percentage

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Controlling and Monitoring of Industrial Parameters using Cloud Result

A simple HMI view after programming is shown in Figure 5.2. We can easily link from any virtual
source to or live data while using individual, modular component. All the data which are visible
to the user can be integrated into a common data set. After that, we can create web pages to see
and make a bridge with live process. We can store data for analyzing or archives as well as we can
send notifications.

Figure 5.2: HMI Screen

Figure 5.3 shows the overall and separately percentage of three choices likeness by the worker of
the companies.

Figure 5.3: Overall Percentage

Dept. of CSE, RGIT 2019-2020 Page 19

CHAPTER 6

ADAVANTAGES AND APPLICATIONS

6.1 Advantages
 Safety: Many workers required in different places of the plant to monitor, analyze, and
gather data and to perform specific function accordingly. Sometimes due to this delay,
many accidents occur like fire, leaking of different dangerous gases or materials, etc. hence
monitoring from PC helps in reduce of these accidents and ensure safety to the workers.
 Time: Gathering of data cause us our precious time. Workers do not need to visit machines
again and again to take reading to on or off the system; everything is provided on the PC.
Hence saving the valuable time of the workers.
 Automation and control: Due to physical objects getting connected and controlled
digitally and centrally with wireless infrastructure, there is a large amount of automation
and control in the workings. Without human intervention, the machines are able to
communicate with each other leading to faster and timely output.
 Monitor: The gathering of information is done through cloud and helps in easy monitoring
of parameters. The work is not only restricted for monitoring but also controlling of data
through a single PC.
 Communication: Communication is provided through any Wi-Fi module which makes
the information to be available at any time. Communication can be provided to multiple
devices at a time.
 Efficiency and accuracy: The machine-to-machine interaction provides better efficiency,
hence; accurate results can be obtained fast. This results in saving valuable time. It helps
in reading manual intervention, reduce in redundancy. It helps in improving the existing
service, hence increasing in efficiency and accuracy.
 Real time output: All the outputs are provided in real time.
 Security: Security is ensured through a password. All the safeguards that are important are
actualized within the system.

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Controlling and Monitoring of Industrial Parameters using Cloud Applications

6.2 Applications
Glass Industries: Glass manufacturing sector is one such artistic industry that has evolved a lot
since its inception in the prehistoric times. From manual glass fusion to using modern technologies
for producing glass containers, the industry has come a long way. Piramal Glass is one prominent
industry that has used an army of IoT sensors and advanced data analytics in the cloud to improve
their manufacturing operations and speed up their decision making.

Power Plants: Many power plants which has to be monitored continuously cloud-Based condition
monitoring data centers are designed, applied and controlled in many areas. Critical facilities like
Electrical Power plants have been taken to apply a remote condition monitoring system for the
critical assets using cloud based condition monitoring system for industrial machinery in order to
determine the condition of equipment and predict potential problems remotely.

Chemical Industries: All segments of the chemical industry-including basic and intermediate
chemicals, polymers, fibers and elastomers, agricultural chemicals, paints and coatings, industrial
gases and others- are well-positioned to leverage advantages from emerging technologies, such as
industrial Internet of Things and cloud computing. To simplify operations, chemical companies
are integrating innovative cloud platforms to connect their workforces with operational data.

Real-time Monitoring Industries: Useful to industries which requires monitoring real time
output. The cloud-based industrial system controlling and monitoring application is designed not
only to help in gathering data but also in controlling of different parameters of industry in a single
application. System can be installed by the industries where workers are especially employed in a
dangerous vicinity of operating machines. Also the system is useful for upgrading the security
system and reducing time lose and health issues etc.

Dept. of CSE, RGIT 2019-2020 Page 21

 CONCLUSION
Installing this system can be very easy, after modification on to different industrial needs.
Anyone link to this system can view its live input or data status, or control it via using any simple
PC or smart phone. This process is monitored and controlled over cloud using Wi-Fi device. HMI
provide, convincing the operator to get the visual view. The basic purpose is to resolve the problem
which is faced by the operator during controlling. The system can manually as well as
automatically operate all the parameters such as flow, pressure, temperature & level, beneficial for
the operator. This system can be used as vast technology in the industries.

Future Enhancement:
• The next step of this system will be receiving notifications via email or SMS whenever a
parameter is changed.

• It can also be implemented for remote working of industrial parameters over cloud using
voice activation.

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 BIBLIOGRAPHY

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[3] Madan V, Reddy SR. GSM-bluetooth based remote monitoring and control system with
automatic light controller. International Journal of Computer Applications, 2012.
[4] Meenu JT. Automation and integration of industries through computer vision systems.
International Journal of Information and Computation Technology, 2013.
[5] Gade AH. A survey paper on cloud computing and its effective utilization with
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[6] Kumar S, Goudar RH. Cloud computing-research issues, challenges, architecture,
platforms and applications: a survey. International Journal of Future Computer and
Communication, 2017.
[7] Prasad MR, Naik RL, Bapuji V. Cloud computing: research issues and implications.
International Journal of Cloud Computing and Services Science, 2018.
[8] Kaur N, More S, Revanwar K, Kolapkar S. Industrial environment monitoring and
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Research (IJIR), 2016.

Reference websites:

 https://www.researchgate.net/publication/325335307_ROLE_OF_AUTOMATION_IN_
MANUFACTURING_ INDUSTRIES
 https://repository.lboro.ac.uk/articles/Influencing_factors_for_implementing_automation
_in_manufacturing_businesses_a_literature_review/9554552
 https://www.controleng.com/articles/cloud-h/how-cloud-computing-works-for-industrial-
processes/

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