INTERNSHIP REPORT

June to December, 2024

Bansilal Ramnath Agarwal Charitable Trust’s

Vishwakarma Institute of Information

Technology
(An Autonomous Institute affiliated to Savitribai Phule Pune University)
Kondhwa Bk, Pune-411048

A Semester Internship Project Report

based on

Project 1: “Product Testing System”

Project 2: “Wireless Data Transmission and Monitoring System”

Aakar Foundry Pvt Ltd

Submitted by

Deepak Pandharinath Ghume (GR. No.- 22220159)

Under the Guidance of

Dr. Tushar R. Jadhav Mr. Raj Arnalkar Sir

Controller of Examination and Evaluation Assistant Maintenance Manager

Department of Electronics and Telecommunication Engineering

Vishwakarma Institute of Information Technology, Pune

Academic year 2024-2025

 BANSILAL RAMNATH AGARWAL CHARITABLE TRUST’S
VISHWAKARMA INSTITUTE OF INFORMATION TECHNOLOGY
PUNE-411048
(An Autonomous Institute Affiliated to Savitribai Phule Pune University)

DECLARATION

I hereby declare that the project work entitled “Product Testing System” & “Wireless Data
Transmission and Monitoring System” is an authentic record of my own work carried out at
Aakar Foundry Pvt Ltd as requirements of semester long internship for the award of degree of
B.Tech. (Department of Electronic and Telecommunication Engineering), Vishwakarma Institute
of Information Technology, Pune under the guidance of Mr. Raj Arnalkar and Prof. Dr. Tushar
R. Jadhav, during June to December, 2024

Deepak P. Ghume
Gr. No. : 22220159
Date : 22-11-2024

Certified that the above statement made by the student is correct to the best of our knowledge and
belief.

Guide Name Guide Name

Prof. Dr. Tushar R. Jadhav Mr. Raj Arnalkar Sir
VIIT, Pune. Aakar Foundry Pvt Ltd

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 Table of Contents
1. Chapter: Introduction..................................................................................................... 5
2. Chapter 2: Problem Statement .................................................................................... 7

A) Project 1 : Product Testing System .......................................................................................... 7

2.1.1) Literature Review.......................................................................................................... 7
2.1.2) Methodology… ............................................................................................................. 8
2.1.3) System Component ........................................................................................................10
2.1.4) Power Supply Requirement ...........................................................................................12
2.1.5) Circuit Diagram ............................................................................................................ 13
2.1.6) Final Implementation… .................................................................................................13
2.1.7) Conclusion….................................................................................................................. 14
B) Project 2: Wireless Data Transmission and Monitoring System… ............................................. 15
2.2.1) Literature Review............................................................................................................ 15
2.2.2) Methodology… .............................................................................................................. 16
2.2.3) System Component … ...................................................................................................18
2.2.4) Power Supply Requirement ...........................................................................................21
2.2.5) Circuit Diagram … .........................................................................................................22
2.2.6) Final Implementation ................................................................................................................
2.2.7) Conclusion….................................................................................................................. 25

3. CHAPTER 3: Contribution and learning from the project .............................................. 26

4. CHAPTER 4: Acknowledgements ..................................................................................... 28
5. CHAPTER 5: References..................................................................................................... 29

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 Table of Figures, Table, & Charts

Figures

1) Aakar Foundry Pvt. Ltd. ........................................................................................5

2) Customers and Client of Aakar Foundry Pvt Ltd.........................................................6

3) DOL Starter ........................................................................................................... 10

4) SMPS ...................................................................................................................11

5) MCCB ................................................................................................................. 11

6) Green Indicator. ....................................................................................................12

7) Circuits diagram of product test system ............................................................... 13

8) Final Implementation of Product … ..................................................................... 14

9) Arduino Uno… ..................................................................................................... 19

10) HC12 Module (1000 m) .......................................................................................19

11) 5V Relay (4 channel )… ...................................................................................... 19

12) 230V AC (4-Channel Rekay) .............................................................................. 20

13) Contactor .............................................................................................................. 20

14) Antenna (433Mhz) ............................................................................................... 21

15) Circuit Diagram Transmitter side......................................................................... 23

16) Circuit Diagram Receiver Side ............................................................................ 24

17) Output of Program in Arduino IDE ........................................................................ 24

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CHAPTER 1: Introduction Aakar Foundry Pvt. Ltd. (AFPL):

Established in 2007, Aakar Foundry Pvt. Ltd. (AFPL) is a forward-looking Green Field project
that has positioned itself as a key player in the casting industry. Specializing in aluminum castings,
AFPL offers an extensive range of services, spanning from Prototype Development to Serial
Production through various casting routes like HPDC, LPDC, and GDC. With an annual capacity
of 3,500 tons, AFPL has emerged as an independent aluminum foundry that caters to both the
Automotive and Non-Automotive segments.

Figure 1.Image of Aakar Foundry Pvt. Ltd.

AFPL stands out due to its comprehensive approach to providing comprehensive solutions to its
clients. The company boasts a robust capability in design and engineering, adding value through
a range of services. These services encompass various stages of the manufacturing process,
including prototype development, foundry operations, heat treatment, a dedicated paint shop for
powder coating, machining facilities, and sub-assembly capabilities.

The Maintenance Department at AFPL plays a critical role in ensuring the seamless operation of
equipment and machinery. This department is responsible for preventive and corrective
maintenance, minimizing downtime and enhancing the overall productivity of the plant. By
maintaining the operational efficiency of the foundry's equipment, the Maintenance Department
supports AFPL's mission of delivering high-quality products on time.

Aakar is into manufacturing of GDC, LPDC & HPDC i.e. All three Aluminum Die casting process
parts. Part supplies are direct to Automotive OEM (2WH, 4WH & Commercial Vehicles). Aakar
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 also supplies parts across the non-Automotive sector to more than 15 Customers. Part weight
ranges from 0.03 Kg to 20 Kgs. GDC parts are produced on stationery & tilting Type Machines.
Part weight ranges from 0.3 Kgs 15 Kgs. Parts are of intricate shape. With expert manufacturing
team & in house simulation support we maintain Quality with least rejection. LPDC parts are
produced on the latest technology machines that allow Aakar to manage variety & complex parts.
Part weights up to 18 kgs are under manufacturing. HPDC parts are produced on machines up to
locking force 660T. Parts produced have high Aesthetic requirement & some other parts withstand
high pressure leak testing.

Customers:

Autonomus Non-Autonomus

Autumotive

Figure 2. Customers and Client of Aakar Foundry Pvt Ltd.

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 CHAPTER 2: Problem Statement

A) Project No.: 1. Product Testing System:

The Maintenance Department at Aakar Foundry Pvt. Ltd. (AFPL) needs a faster, more efficient
method to test sensors and components operating on 24V DC, as the current slow testing process
impacts productivity and delays fault detection. Additionally, the manual nature of the existing
testing method introduces the risk of human error, inconsistency, and inefficiency, creating
bottlenecks and reducing the Maintenance Department’s ability to respond swiftly to issues.

2.1.1 Literature Review :

The Product Testing System is designed to manually verify the working condition of critical
sensors and components used at Aakar Foundry Pvt. Ltd. (AFPL). The system uses various
components such as DOL (Direct On-Line) Starters, SMPS (Switched Mode Power Supply),
MCCB (Molded Case Circuit Breaker), and Green Indicators to simulate and monitor the
operational status of the sensors and components involved in the foundry's operations. The system
ensures that sensors, such as limit sensors and proximity sensors, and other essential components
are in optimal working condition. When a sensor or component is found to be working properly,
a green indicator light is illuminated to signify that everything is functioning as expected.[1]

Product testing systems are widely used in industrial environments to verify the functionality
and quality of components before deployment. A critical aspect of industrial maintenance, testing
systems ensure that sensors and other components meet performance and safety standards,
reducing downtime and enhancing productivity.[2]

In manufacturing industries like foundries, where efficiency and quick fault detection are
vital, systems that allow rapid testing of components, such as motors and sensors, play an
important role. Such systems are integral for operational efficiency, as faulty components can
cause unexpected halts, leading to significant losses.[3]

While there is ample research on automated product testing systems, there is less focus on
manual testing systems optimized for foundries. Most studies focus on fully automated systems,
which may be costly or excessive for smaller operations. This project addresses a gap by providing
an efficient, cost-effective manual testing solution that meets the specific needs of Aakar Foundry
Pvt. Ltd. (AFPL).

Additionally, research lacks a thorough examination of using DOL starters and MCCBs
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 specifically for sensor testing in foundries, making this project relevant for companies seeking to
implement reliable yet straightforward testing mechanisms.[4]

2.1.2 Methodology:

The methodology for developing and implementing a Product Testing System for testing sensors
and components at Aakar Foundry Pvt. Ltd. (AFPL) involves several key stages. The following steps
outline a structured approach to ensure that the system is efficient, reliable, and suitable for testing 24V
DC components:

1. Requirement Analysis

• Identify Testing Needs: Analyze the specific sensors, components, and devices that need to be
tested, including types (e.g., proximity sensors, limit sensors) and voltage requirements (e.g., 24V
DC).

• Define Testing Criteria: Establish performance criteria for each component, such as expected
voltage levels, response times, and indicator signals.

• Set Productivity Goals: Identify the current limitations in the existing testing process (e.g., time
taken, error rates) and set clear productivity goals for the new system.

2. System Design

• Component Selection: Select appropriate components for the testing system, including DOL
Starters, SMPS, MCCB, indicator lights, and any additional control devices.

• Circuit Design: Design a circuit that accommodates the testing requirements for different sensors
and components, ensuring compatibility with the 24V DC power supply.

• Safety and Reliability Checks: Include protections (e.g., MCCB) to prevent damage to components
and ensure safe operation. Design safeguards for error handling and system failure.

3. Development and Assembly

• Build the Test Panel: Physically assemble the testing panel, integrating all necessary components,
wiring, and controls. Ensure clear labeling of connections for easy operation.

• Indicator Integration: Install indicator lights (such as green LEDs) to signal the working status of
each component. A green light would indicate successful operation, allowing quick visual
confirmation.

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 • Power Supply Setup: Configure the SMPS to supply 24V DC power to all testing points, ensuring
a stable power source for consistent testing results.

4. Testing and Calibration

• Initial Calibration: Test each component individually to confirm that the system operates as
expected. Calibrate indicator lights and sensors to ensure accurate readings.

• Simulate Fault Conditions: Introduce known faulty components or simulate common faults to
verify the system’s ability to detect issues accurately.

• Adjust for Accuracy: Fine-tune system parameters and settings to improve detection sensitivity,
reduce error margins, and optimize response times.

5. System Validation and Verification

• Functional Testing: Perform a series of tests to validate the system’s effectiveness in detecting
working and non-working components accurately and consistently.

• Usability Testing: Assess ease of use for maintenance personnel, ensuring the system is
straightforward and intuitive. Obtain feedback from end-users and make any necessary
adjustments.

• Reliability Testing: Conduct continuous testing over a set period to ensure the system’s durability
and reliability in an industrial environment.

6. Documentation and Training

• Create User Manual: Develop a user manual with clear instructions on operating the Product
Testing System, troubleshooting steps, and safety guidelines.

• Employee Training: Train maintenance staff on using the system, interpreting indicator lights, and
performing basic troubleshooting.

• Maintenance Guidelines: Establish a maintenance schedule to regularly check, clean, and calibrate
the system to ensure long-term functionality.

7. Implementation and Monitoring

• Deploy the System: Install the Product Testing System in the maintenance area of AFPL and
integrate it into the regular workflow.

• Monitor Performance: Collect data on testing speed, accuracy, and fault detection efficiency to
9
 assess if the system meets the initial productivity goals.

• Continuous Improvement: Based on feedback and performance data, make any necessary
adjustments to improve the system’s effectiveness and reliability.

2.1.3 System Components:

The Product Testing System integrates multiple components to control, monitor, and verify the
working condition of industrial sensors and components. Here's a breakdown of the key
components used in the system:

1. DOL Starter:

o A DOL Starter is used to start three-phase motors directly, offering a simple and efficient
solution for motor control. The system uses this component to test the motor functionality
and the sensors connected to it. If a motor operates correctly, it indicates that the
components linked to it, like sensors, are also functioning properly. Additionally, the DOL
Starter’s simplicity and reliability make it an ideal choice for applications that require
frequent testing and quick troubleshooting.

Figure 3. DOL Starter

2. SMPS (Switched Mode Power Supply):

o The system uses an SMPS to convert AC voltage to the required DC voltage for certain
components. For instance, some sensors or control circuits in the system may require a
steady DC supply, which is efficiently provided by the SMPS. The system ensures that the
power supply is stable and consistent to support proper sensor operation.

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 Figure 4. SMPS

3. MCCB (Molded Case Circuit Breaker):

o The MCCB is an essential safety component in the system that protects the circuits from
overcurrent conditions. If a sensor or component draws excessive current, the MCCB will
automatically trip, preventing damage to the system. The system ensures that the MCCB
properly, providing necessary protection for all components. the MCCB enhances the
overall reliability and safety of the testing system, minimizing downtime and safeguarding
equipment and personnel from electrical faults.

Figure 5. MCCB

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 4. Green Indicator Light:

o A green indicator light is used to visually signal that the sensor or component is
functioning correctly. When a sensor or component, like a proximity or limit sensor, is
tested and found to be working, the green light will glow to indicate that the system is
operating as expected. If a fault or malfunction is detected, the green light will remain off,
signaling that attention is needed.

Figure 6. Green Indicator

2.1.4 Power Supply Requirements:

The Product Testing System requires both three-phase power and single-phase power for its
different components

• Three-phase power supply is required to operate the DOL starters and certain motors
that are part of the testing setup. This three-phase power ensures that the motors and larger
components receive the necessary current for proper operation. The use of three-phase
power ensures that all high-power elements within the system are adequately supported,
maintaining consistent operation and optimal efficiency.

• Single-phase power supply is used for components like the SMPS (which provides the
DC output for various sensors and control circuits). The SMPS ensures stable and
regulated voltage for components requiring a steady DC supply, including the green
indicator lights and other low-power devices. the SMPS ensures reliable operation and
enhances the accuracy of testing processes, which depend on uninterrupted performance
of sensors and indicator systems.

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2.1.3 Circuit Diagram :

Figure 7. Circuit Diagram of Product Testing System

2.1.4 Final Implementation:

The "Product Testing System" is a setup designed to test electrical components with a three-phase
415V AC supply. It includes a DOL starter to control power, an MCCB for circuit protection, and a terminal
block for organized power distribution. A 24V DC supply powers control components, and a green indicator
shows the system status. This setup ensures safe and efficient testing of electrical equipment, with organized
wiring and labeled connections for easy use. The setup is designed with organized wiring and labeled
connections, which not only ensure safe operation but also facilitate quick identification and troubleshooting
of connections. This user-friendly feature allows operators to easily follow the wiring layout, reducing the
risk of errors during setup and operation.

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 Figure 8. Final Implementation of Product Testing System

2.1.5 Conclusion :

The Product Testing System developed for Aakar Foundry Pvt. Ltd. (AFPL) successfully
addresses the need for a faster, more efficient, and reliable method to test sensors and components
operating on 24V DC. By implementing this system, the Maintenance Department can now quickly assess
the operational status of critical components, reducing testing time, improving fault detection, and
minimizing downtime.

The system's integration of components such as DOL Starters, SMPS, MCCB, and indicator
lights has streamlined the testing process, enabling maintenance personnel to identify faulty components
at a glance. The visual indicator (green light) simplifies the testing process, allowing immediate
confirmation of working components and preventing unnecessary repairs or replacements.

Overall, the Product Testing System has proven to be a valuable addition to AFPL’s maintenance
operations, enhancing productivity, reducing operational delays, and contributing to more efficient
workflow management. This project not only supports the foundry's goals for improved operational
efficiency but also sets the foundation for future testing automation and quality assurance initiatives in the
facility.

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CHAPTER 2: Problem Statement

B) Project No.: 2.Wireless Data Transmission and monitoring System.

At Aakar Foundry Pvt. Ltd. (AFPL), the Maintenance Department faces delays in monitoring and
controlling three air compressors and three diesel generators due to the distance between the equipment
and the maintenance area. This manual process is time-consuming and inefficient. A wireless data
transmission system is needed to remotely monitor and transmit the on/off status of these machines,
improving efficiency and reducing manual checks.

2.2.1 Literature Review

The Wireless Data Transmission and Monitoring System is designed to monitor and wirelessly
transmit the on/off status of critical equipment at Aakar Foundry Pvt. Ltd. (AFPL). This system specifically
tracks the operational status of three air compressors and three diesel generators, which are essential
components of the foundry’s machinery. the context of the foundry industry, monitoring systems that use
wireless communication not only improve operational efficiency but also enhance predictive maintenance
strategies.
These systems allow for real-time tracking of equipment status, enabling maintenance teams to detect
issues before they lead to costly failures or shutdowns. Similar systems have been successfully deployed
in other industrial settings, such as manufacturing plants where HC-12 modules, like the ones used in our
project, have been integrated into wireless monitoring systems to communicate vital operational data.[5]
The implementation of wireless systems for real-time monitoring has been widely studied and
utilized in various industries to improve operational efficiency and ensure the safety of machinery.
According to recent studies wireless sensor networks (WSNs) have proven to be effective in industrial
applications for remote monitoring and control of equipment, reducing the need for manual inspections and
minimizing downtime. These studies emphasize the role of technologies like Wi-Fi, Bluetooth, and RFID
for data transmission, providing a basis for using wireless communication in machinery monitoring.[6]
Using HC-12 modules, Arduino boards, and relay modules, the system wirelessly transmits the status
of these 3 Air compressors & 3 Diesel Generators of equipment to the Maintenance Department. When an
equipment (air compressor or diesel generator) is turned off or on, the corresponding indicator light on the
receiver side (in the Maintenance Department) will automatically update, ensuring that personnel can easily
monitor the status of all six machines.
studies indicate that the HC-12 module provides reliable performance for machine monitoring

15
 systems in harsh environments, where physical connectivity might be limited or difficult to maintain. In
such systems, relay modules paired with HC-12 enable maintenance teams to receive immediate alerts on
the status of critical machinery, such as air compressors and diesel generators This setup allows for efficient
remote monitoring, ensuring rapid response times and reducing equipment downtime.[7]
HC-12 is a wireless serial port communication module used in variety of applications like wireless
sensor, building security, wireless robot control, PC wireless networking etc. wireless module HC-12. HC
12 is a wireless serial port communication module used in variety of applications like wireless sensor. [8]

2.2.2 Methodology:
The Wireless Data Transmission and Monitoring System for tracking the operational status of
critical equipment in Aakar Foundry Pvt. Ltd. (AFPL) was developed using a combination of
hardware and software components to wirelessly transmit and display the status of air compressors
and diesel generators.

1 System Design and Components Selection

• Hardware Components:
o HC-12 Wireless Modules: These are used for long-range wireless data transmission. The HC-
12 operates on 433 MHz frequency and can transmit data over distances up to 1 kilometer,
making it suitable for the industrial environment of AFPL.
o Arduino UNO: Microcontroller boards were selected to interface with the HC-12 modules, relay
modules, and status indicators.
o Relay Modules: These are used to control the on/off status of air compressors and diesel
generators. The relays are connected to the Arduino, which will control their operation based
on data received from the transmitter.
o Indicators (LEDs): Green and red LEDs are used to visually display the status of each equipment
(ON/OFF).
o Power Supply: A 5V power supply is used for Arduino and other low-power components, while
the industrial equipment uses their respective power sources.
2 System Architecture
The system architecture involves a transmitter side and a receiver side.
• Transmitter Side:
o Arduino UNO is used to collect the status (ON/OFF) of the air compressors and diesel
generators.
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 o The HC-12 module transmits the data wirelessly to the receiver side.
o Relay modules connected to the Arduino control the power to the equipment.
o Power Supply is used to provide necessary voltage levels for Arduino and sensors.
• Receiver Side:
o HC-12 module receives the data transmitted from the transmitter.
o The Arduino UNO on the receiver side processes the received data and updates the LED
indicators (Green for ON, Red for OFF) to display the current operational status of the
equipment.
o The status is continuously updated, ensuring real-time monitoring.
o An additional TFT display may be used to provide detailed visual feedback, including
equipment status, air pressure, and other parameters if required.
3 Communication Protocol
The system relies on a serial communication protocol between the Arduino UNO and HC-12 wireless
modules. The Arduino is programmed to read the status of the relays (indicating the ON/OFF state of the
equipment) and transmit that data via the HC-12 module to the receiver side. On the receiver side, the HC-
12 module receives the data and passes it to the Arduino, which processes and displays it through the LED
indicators and the TFT display.
• Data Encoding: Data is encoded into simple binary signals (e.g., 0 for OFF and 1 for ON) and
transmitted in packets by the HC-12 module.
• Error Handling: A basic error-checking mechanism is implemented to ensure data integrity. If data loss
or corruption occurs, the system will request a retransmission.
4 Software Development
The Arduino IDE is used for writing the code that controls both the transmitter and receiver units. The
following processes are implemented:
• Transmitter Code:
o The transmitter code continuously monitors the status of the air compressors and diesel
generators.
o The data is sent periodically via the HC-12 module, updating the receiver side.
• Receiver Code:
o The receiver unit decodes the data from the HC-12 module and updates the status indicators
(LEDs).
o Additional features, such as logging or further data processing, can be added for analysis or
alerting purposes.
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 o A watchdog timer is used to reset the system in case of communication failure.
5 Testing and Calibration
• Testing for Range: The system is tested for communication range, ensuring the HC-12 module transmits
and receives data reliably over the required distances (1 km or more, depending on industrial layout).
• Signal Integrity: Signal strength is tested, and the receiver side is calibrated to ensure clear and
consistent data transmission.
• Real-time Monitoring: The status of equipment is monitored for accuracy. The receiver system is
observed to ensure it updates the status indicators whenever there is a change in the operational state of
the equipment.
6 Integration with Maintenance System
Once the hardware and software components are tested, the system is integrated into the Maintenance
Department of AFPL. The wireless monitoring system helps track equipment performance in real time and
notifies maintenance personnel of any operational issues or downtime. The data from the system is also
used to schedule preventive maintenance, reducing the risk of equipment failure and improving operational
efficiency.
7 Challenges and Solutions
During the development, challenges such as interference in the wireless communication and data loss were
addressed by:
• Optimizing the transmission power and ensuring the correct placement of the HC-12 modules for
minimal interference.
• Data buffering to handle short communication delays and ensure reliability.

2.2.3 System Component:

1. Arduino:
The Arduino microcontroller is the core of the system, responsible for controlling the logic of the
equipment monitoring and status transmission. It processes the data from the sensors and relays,
triggering the HC-12 module to wirelessly transmit the on/off status of each machine to the receiver
side. The Arduino ensures smooth communication and operation between all system components.

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 Figure 9. Arduino Uno.
2. HC-12 Module:
The HC-12 Module is a wireless communication module that facilitates the transmission of data
between the transmitter (at the equipment location) and the receiver (in the Maintenance Department).
It operates at 433 MHz and is used to send and receive the on/off status of the air compressors and
diesel generators, ensuring real-time monitoring of equipment status across the foundry.

Figure 10. HC12 Module (1000m Range) .

3. 5V Relays:
The 5V Relays are used to control the on/off switching of low-power equipment. These relays allow
the Arduino to control the operation of the sensors and indicators connected to each air compressor and
diesel generator, ensuring that the system functions as expected.

Figure 11. 5V Relay 4-Channel

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4. 20V AC Relays:
The 240V AC Relays are used for controlling high-power equipment such as the air compressors and
diesel generators. These relays act as switches, allowing the system to safely control the power supplied
to these heavy-duty machines while maintaining electrical safety.

Figure 12. 230V AC 4 Channel Relay

5. Contactor:
A Contactor is used to control high-power circuits in industrial equipment. It ensures the safe operation
of the air compressors and diesel generators by providing a reliable mechanism for switching the
electrical supply. The contactor is an essential component in handling the electrical load requirements
of the machines.

Figure 13. Contactor

6. Antenna:
The Antenna is used with the HC-12 modules to extend the wireless communication range. By
enhancing the signal strength and range, the antenna ensures stable data transmission over long

20
 distances, even in environments with potential interference, such as a foundry.

Figure 14. Antenna (433 Mhz)

7. Indicator Lights:
The system utilizes indicator lights (such as green LEDs) to visually show the status of the equipment.
When a machine (air compressor or diesel generator) is turned on or off, the corresponding indicator
light on the receiver side will change accordingly. A green light indicates that the equipment is
operating properly, helping the Maintenance Department monitor the status of all machines at a glance.

Figure 15. Indicator

2.2.4 Power Supply Requirements:

The power supply is a crucial component for the reliable operation of the system. Each device in the
system requires a stable power source to function properly. The power supply requirements for the Wireless
Data Transmission and Monitoring System are as follows:

1. Arduino UNO: The Arduino board operates at 5V and typically consumes around 50-75mA during
normal operation. A stable 5V DC power supply is required to power the Arduino and associated
peripherals, such as sensors and relays.

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 • HC-12 Wireless Modules: The HC-12 module operates on a voltage range of 3.2V to 5.5V. It typically
consumes around 10-30mA during communication. A stable 5V supply is used for the module to ensure
proper data transmission and reception.
• Relay Modules: Each relay module typically requires 5V for operation. The current consumption for
a single relay module is around 70-100mA when activated. The number of relays used in the system
will determine the total power required for these components.
• LED Indicators: Each LED typically consumes around 20mA. For multiple relays and indicators, the
power requirement increases accordingly. A total of 2-4 LEDs per relay may be used to indicate status
(ON/OFF), which results in a modest increase in power consumption.
• TFT Display (Optional): If a TFT display is included for real-time status monitoring, it requires a 5V
power source and typically draws around 20-50mA depending on the display size and brightness.
Power Supply Setup

A 5V DC regulated power supply is used to provide power to the entire system, including the Arduino,
HC-12 modules, relay modules, LEDs, and TFT display. The power supply must be capable of delivering
sufficient current to all the components, with a margin for safety. The total current requirement is estimated to
be around 500mA to 1A, depending on the number of relays and indicators used.

2.2.5 Circuit Diagram :

1) Transmitter Side
This schematic diagram illustrates the transmitter side of a wireless monitoring system for
controlling and observing the status of three air compressors and three diesel generators remotely. An
Arduino Uno serves as the central controller, sending signals to two 4-channel relay modules, which in
turn control three-phase contactors linked to each piece of equipment. An HC-12 wireless module is
connected to the Arduino to transmit the on/off status of each machine to a remote receiver, allowing
the maintenance department to monitor machine states without manual checks. This setup reduces
downtime and improves response efficiency by enabling remote management of equipment power
status over long distances. This setup provides real-time data on the operational status of the equipment,
eliminating the need for manual checks and enhancing the overall efficiency of the monitoring process.

22
 Figure 16. Circuits Diagram Transmitter Side

2) Receiver Side
This diagram represents the receiver side of a wireless monitoring system. At the heart of the
setup is an Arduino Uno, which receives data via the HC-12 wireless module. The Arduino is connected
to an 8-channel relay module, which controls various indicators and machinery based on the transmitted
data. Each relay channel is linked to an LED, with red LEDs indicating “OFF” status and green LEDs
indicating “ON” status for each monitored device. The LEDs provide visual feedback, allowing the
operator to quickly see the operational status of each air compressor and diesel generator. An AC power
source and switching power supply provide power to the system. This setup enables centralized
monitoring of equipment states in a remote control room, improving maintenance efficiency and
oversight.

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 Figure 17. Circuits Diagram Receiver Side.

Output Of program :

Figure 17. Output of program in Arduino IDE.

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2.2.6 Conclusion :

The Wireless Data Transmission and Monitoring System developed for Aakar Foundry Pvt. Ltd.
(AFPL) proves to be a significant advancement in the real-time monitoring of critical equipment,
particularly the three air compressors and three diesel generators. By employing HC-12 modules,
Arduino boards, and relay modules, the system enables wireless communication of operational statuses,
offering a streamlined and efficient method of monitoring machinery.
This wireless monitoring system enhances operational efficiency by providing immediate updates
on the status of vital equipment, which is crucial for timely decision-making and intervention. It not
only improves the monitoring process but also contributes to the implementation of predictive
maintenance strategies, reducing the likelihood of unexpected breakdowns and minimizing costly
downtime.
The integration of HC-12 modules in this setup is particularly beneficial in environments where
physical connections are challenging or costly to maintain. Studies have shown that wireless sensor
networks (WSNs) like the one employed in this system are highly effective in industrial applications,
where they reduce the need for manual inspections and help mitigate operational disruptions.
In addition, this system is a testament to the broader trend in industrial sectors toward the
adoption of wireless technologies for real-time monitoring and maintenance. The use of wireless
communication, whether through Wi-Fi, Bluetooth, or RF modules like HC-12, is becoming
increasingly essential for modern industrial operations. With the success of this project, AFPL has
enhanced its machinery monitoring capabilities, setting the stage for even more sophisticated, remote-
control-enabled systems that can further optimize plant operations and ensure machinery longevity.

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 CHAPTER 3: Contribution and learning from the project:

3.1.1 Contribution to the Study:

This project makes significant contributions by integrating the development of two vital systems at Aakar
Foundry Pvt. Ltd. (AFPL): the Product Testing System and the Wireless Data Transmission and
Monitoring System. Both systems aim to enhance operational efficiency, reliability, and real-time monitoring
of industrial equipment.
1. Development of the Product Testing System: The project contributes to the creation of a robust
Product Testing System designed to test and monitor the status of various industrial sensors and
components used in AFPL. The system’s primary function is to test 24V DC components like proximity
sensors, limit switches, and other control devices that are crucial for the foundry’s machinery
operations. By focusing on key elements such as requirement analysis, system design, development,
testing, and system validation, this study provides a structured approach to improving product testing
methodologies. The system’s design incorporates components like DOL Starters, SMPS, MCCB, and
indicator lights, ensuring safety, reliability, and effective fault detection. Furthermore, through
systematic testing and calibration, the project ensures that all components meet specified operational
standards, reducing the likelihood of system failures and enhancing overall productivity. The
integration of clear user manuals and training guidelines also empowers maintenance staff to operate
and troubleshoot the system effectively, ensuring long-term operational success.

2. Wireless Data Transmission and Monitoring System: The Wireless Data Transmission and
Monitoring System developed in this project enables real-time monitoring of critical equipment such
as air compressors and diesel generators at AFPL. This system utilizes HC-12 wireless modules,
Arduino microcontrollers, relay modules, and LED indicators to wirelessly transmit operational
status data from the transmitter side to the receiver side. The system architecture, with both transmitter
and receiver units, ensures the seamless flow of data, enabling quick identification of equipment status
(ON/OFF), operational faults, or potential downtime. The integration of additional displays like the
TFT display allows for detailed visual feedback, which can be expanded to include parameters like air
pressure and other vital metrics. The system ensures efficient, real-time communication, crucial for
predictive maintenance and improving operational uptime.

3. System Integration and Performance Optimization: By integrating the Wireless Data

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 Transmission and Monitoring System with the Product Testing System, the project not only helps
in real-time monitoring of equipment but also links sensor and component testing with wireless
communication for immediate action. The findings of this study offer valuable insights into how
wireless communication technologies like HC-12 can be optimized for industrial applications, reducing
errors and improving efficiency in large-scale operations. Additionally, the project contributes solutions
for overcoming common challenges, such as wireless interference and data loss, through system design
optimization and error handling protocols.

4. Impact on Preventive Maintenance and Productivity: This study's findings are highly applicable in
industrial environments like AFPL, where monitoring and timely intervention are critical. The Wireless
Data Transmission and Monitoring System assists in tracking the operational performance of key
machinery, facilitating scheduled preventive maintenance and reducing unplanned downtime. By
leveraging real-time data, maintenance teams can be notified of potential issues before they escalate
into costly repairs. Furthermore, the Product Testing System ensures that all components meet
performance standards, thus avoiding operational disruptions caused by faulty sensors or devices.

5. Broader Implications for Industrial Automation: The successful implementation of these systems
at AFPL demonstrates how integrating wireless data transmission with automated product testing
can revolutionize industrial operations. The methodologies developed here can be applied to other
industrial settings where real-time monitoring and efficient testing of equipment are critical. Moreover,
the wireless monitoring system has potential for scalability and can be adapted to various industrial
applications beyond the foundry sector.

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 ACKNOWLEDGEMENT
It is an immense pleasure for me to present this report, which will vouch for prolific and
invaluable training. It would be considered as honor to have undergone Internship at “Aakar
Foundry Pvt. Ltd.”, Pune.
I have made considerable efforts in each of the work assigned to me. However, it would not
have been possible without the kind support and help of many individuals. I would like to express
my sincere thanks to all of them.
I am highly indebted to Mr. Raj Arnalkar, who is a Assistant Maintenance Manager, & industry
mentor, for being a source of inspiration, for their guidance and constant supervision, as well as for
providing necessary information regarding work. It is my radiant sentiment to place on record my
best regards, deepest sense of gratitude to Mr. Mahesh Chavan (Head of Department), Mr.
Jitendra Parekh, Mr. Roshan Chaudhary, Mr. B.R. Patil their careful and precious guidance
which were extremely valuable for me both theoretically and practically.
I would like to express my gratitude to Aakar Foundry Pvt. Ltd., Pune for giving me the
opportunity to work on projects. It was an amazing experience, and I will appreciate it a lot in
future.
A special note of thanks to Aakar Foundry Pvt. Ltd. for allowing me to work on challenging
projects, including the Product Testing System and the Wireless Data Transmission and
Monitoring System. These experiences have significantly enhanced my technical skills and
practical knowledge, which will be invaluable as I progress in my career.
I would like to express my deepest gratitude to Prof. (Dr.) Shraddha Habbu, Head of
Department of Electronic & Telecommunication, Prof. Dr. T. R. Jadhav, College guide,
Vishwakarma Institute of Information Technology for granting the permission to choose this
undertaking.
My gratitude and appreciation go to my college Vishwakarma Institute of Information
Technology, Pune for giving me a wonderful opportunity to work on an internship-based project.
Any omission in this acknowledgment does not mean lack of gratitude.

Thanking you….

Deepak Ghume (GR No: 22220159)

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