2013 IEEE International Conference on Emerging Trends in Computing, Communication and Nanotechnology (ICECCN 2013)

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Automatic speed and torque monitoring in induction motors using ZigBee and SMS
Arun Nadh M.E (Communication Systems), Electronics & Communication Department, Dhanalakshmi Srinivasan Engg. College, Perambalur, Tamil Nadu, India, Email Id: arunnadh@yahoo.co.in
Abstract- This project is for monitoring the speed and torque in induction motors in real time by employing ZigBee based wireless sensor network. An embedded system is used for acquiring electrical signals from the motors in a noninvasive manner. The processing for speed and torque estimation is done locally. Embedded system is used to control the speed of the motor. The values calculated by the embedded system are transmitted to a monitoring unit through ZigBee based wireless sensor network. The real time monitoring of various motors can be done at the base unit. Speed of deployment, maintenance, low cost, security, reliability and throughput are the main advantages of using ZigBee. From simulation, plot for output voltage, output current, speed and torque can be obtained by applying different load values. Keywords-Induction motors, embedded systems, torque measurement, speed estimation, ZigBee based wireless sensor networks (WSNs).

Lakshmi Praba N. Research Scholar, Anna University, Chennai, Electronics & Communication Department, Dhanalakshmi Srinivasan Engg. College, Perambalur, Tamil Nadu, India, Email Id: laksh_abi@rediffmail.com quadrant DC drives. This drive application allows vector control of the AC induction motor. Torque is one of the main parameters for production machines. Torque measurements [8] can identify equipment failures in oil and gas, mining, sugar and alcohol industries. There are mainly two types of torque estimation. 1) Direct torque measurement on the shaft 2) Estimated torque measurement from motor electrical signals Measuring directly the rotor speed can be impractical in some cases. Several methods of sensorless rotor speed estimation have been proposed. Embedded system is used for determining speed and torque in industrial electric motors by employing WSNs [5], [13] technology. For a set of electric motors, current and voltage measures are gathered for later processing into an embedded system. Speed and Torque results of the induction motor [15] are then sent to a base unit for real-time monitoring. Wireless sensor networks [14] presents a number of advantages compared to wired networks. In addition to that, wireless sensor networks (WSNs) [9], [11], [12] provide self-organization and local processing capability. Therefore, these appear as a flexible and inexpensive solution for building industrial monitoring and control systems. ZigBee based wireless sensor network is used here. ZigBee allows the formation of a large network of sensors, in various industrial segments. . This standard has been employed also in the mechatronics field. In comparison with other standards such as IEEE 802.11 (Wi-Fi) [16], [18] and IEEE 802.15.1 (Bluetooth), the ZigBee standard has advantages related to energy consumption, scalability, reduced time for node inclusion, and low cost. II. RELATED WORK An induction or asynchronous motor [6] is an inherently self-starting AC motor in which energy is transferred by electromagnetic induction from a primary winding to a secondary winding. The two windings being separated by an air gap and such

I.INTRODUCTION This system aims at monitoring the speed and torque in induction motors. An embedded system is used for acquiring electrical signals from the motors in a noninvasive manner. It performs local processing for speed and torque estimation. The values calculated by the embedded system are transmitted to a monitoring unit through a ZigBee based wireless sensor network. Local processing capability is essential for this type of application. Motor systems use nearly 70% [1] of the total electric energy consumed by industry in the U.S. Among industrial motor systems, three-phase induction motors are dominant because of their simple design, rugged performance, and easy maintenance. AC induction motors, [2] which contain a cage, are very popular in variable-speed drives. They are simple, rugged, inexpensive and available at all power ratings. Progress in the field of power electronics and microelectronics enables the application of induction motors for high-performance drives, where traditionally only DC motors were applied. AC induction [3], [4] drives offer the same control capabilities as high performance four-

978-1-4673-5036-5/13/$31.00 2013 IEEE

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Fig.1. Transmitter side

transfer usually from the stator to either a wound rotor or a short-circuited squirrel cage rotor. It is the existing system. Induction motor [19] is used here. Induction motor used is three phase induction motor. It is advanced than single phase induction motor. Three phase induction motor is self-starting. It is an asynchronous motor. Speed can be controlled by varying the voltage. A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. The process is known as rectification. Physically, rectifiers take a number of forms, including vacuum tube diodes, mercury-arc valves, solid-state diodes, silicon-controlled rectifiers and other silicon-based semiconductor switches. A 3 phase inverter is an electrical power converter that changes direct current (DC) to alternating current (AC). The inverter performs the opposite function of a rectifier. The electrical inverter is a high-power electronic oscillator. Three-phase inverters are used for variable-frequency drive applications and for high power applications such as HVDC power transmission. A basic three-phase inverter consists of three single-phase inverter switches each connected to one of the three load terminals. For the most basic control scheme, the operation of the three switches is coordinated so that one switch operates at each 60 degree point of the fundamental output waveform. This creates a line-to-line output waveform that has six steps. The six-step waveform has a zero-voltage step between the positive and negative sections of the

square-wave such that the harmonics that are multiples of three are eliminated as described above.

Fig. 2. Three Phase inverter

The embedded system used here consists of peripheral interface controller, PIC16F877A. Microchip the second largest 8-bit microcontroller supplier in the world is the manufacturer of the PIC microcontroller and a number of other embedded control solutions. PIC16F877A is an open loop peripheral controller. Program to find out the speed and torque are written in this microcontroller. It is an 8 bit controller. It is having 40 pins. The operating frequency is 20MHz. Flash memory is 14.3 kb. Data SRAM is 386 bytes. The PIC16F877A CMOS FLASH-based 8-bit microcontroller is upward compatible with the PIC16C5x, PIC12Cxxx and PIC16C7x devices. It features 200 ns instruction execution, 256 bytes of EEPROM data memory, selfprogramming, an ICD, 2 Comparators, 8 channels of 10-bit Analog-to-Digital (A/D) converter, 2 capture/compare/PWM functions, a synchronous serial port that can be configured as either 3-wire SPI

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or 2-wire I2C bus, a USART, and a Parallel Slave Port.

ZigBee specifies operation [17] in the unlicensed 2.4 GHz (worldwide), 915 MH Hz (Americas and Australia) and 868 MHz (Eu urope) ISM bands. Sixteen channels are allocated in n the 2.4 GHz band, with each channel requiring 5 MHz M of bandwidth. The 2.4 GHz band provides up to 250 kbit/s, k and 868 MHz 915 MHz provides up to 40 kbit/s provides a data rate up to 20 kbit/s. k Binary phaseshift keying (BPSK) is used in th he 868 and 915 MHz bands, and offset quadrature phase-shift keying s per symbol is used (OQPSK) that transmits two bits in the 2.4 GHz band. The raw, over-the-air o data rate is 250 kbit/s per channel in the e 2.4 GHz band, 40 kbit/s per channel in the 915 MHz z band, and 20 kbit/s in the 868 MHz band. Transmissi ion range is between 10 and 75 meters (33 and 246 feet) f and up to 1500 meters for ZigBee PRO, altho ough it is heavily dependent on the particular enviro onment. ZigBee is not intended to support power line networking but to interface with it at least for smart metering and smart appliance purposes. Because s to active mode ZigBee [20] nodes can go from sleep in 30 ms or less, the latency can n be low and devices can be responsive, particula arly compared to Bluetooth wake-up delays, which w are typically around three seconds. 250 kbi it/s, best suited for periodic or intermittent data or a single signal transmission from a sensor or input device. Applications include wireless light switches, me-displays, traffic electrical meters with in-hom management systems, and oth her consumer and industrial equipment that re equires short-range wireless transfer of data at relati ively low rates. The technology defined by the ZigB Bee specification is intended to be simpler and less expensive e than other WPANs, such as Bluetooth.

Fig.3. Embedded unit

RS-232 is the traditional name for a series of nded data and standards for serial binary single-en control signals connecting between a DTE (Data (Data CircuitTerminal Equipment) and a DCE ( terminating Equipment). It is comm monly used in computer serial

Fig.4. RS 232 port

ports. The standard defines th the electrical characteristics and timing of signals, t the meaning of nd Pinout of signals, and the physical size an connectors. An RS-232 serial port is a standard for connections feature of a personal computer, used fo to modems, printers, mice, d data storage, uninterruptible power supplies, and ot ther peripheral devices. e of high level ZigBee is a specification for a suite communication on protocols using sm mall, low-power 2 standard for digital radios based on an IEEE 802 personal area networks. ZigBee [10 0] devices are often used in mesh network form to transmit data over longer distances, passing data through tant ones. This intermediate devices to reach more dist allows ZigBee [16] networks to be fo formed ad-hoc, with no centralized control or r high-power transmitter/receiver able to reach all o of the devices. Any ZigBee device can be tasked wit th running the network. ZigBee is targeted at app plications that require a low data rate, long battery li ife, and secure networking.

Fig.5. ZigBee

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Fig.6. Receiver side

III. EXPERIMENT METHODOLOGY Workbench for System Analysis

IV. SIMULATION RESULTS Plot for speed, torque, output voltage and output current can be obtained. Two cases are considered here. Applying a load of 10 kg and applying a load of 40 kg. As the load increases, the speed reduces. It is shown in the first plot. But as the load increases the torque also increases. It is shown in the second plot. The output voltage and output current for a load of 10 kg is shown in the third plot. Plot for output voltage and output current for a load of 40 kg is shown in the fourth plot. In the fifth plot speed, torque and current values are shown for 10 kg load. Plot for speed, torque and current for 40kg load is shown in the sixth plot.

Fig.7. Experimental setup for the speed and torque analysis.

The workbench was designed to obtain the speed and torque on the motor shaft. Fig. 7 shows its sketch, which consists of a 110-W induction motor with nominal rotation speed of 1500 RPM. A metallic disc was fitted on the output shaft. 2 IR Sensors are used here. The disc on the shaft rotates in between the two IR sensors. Then the signals from the IR sensor are transferred to the embedded unit. The embedded unit processes the signals locally and the speed and torque values are obtained. The obtained values are transmitted to the monitoring unit using ZigBee. A pair of ZigBee module can act as transmitter and receiver.

Fig.8. Plot for Speed

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Fig.9. Plot for torque

Fig.12. Plot for speed, torque and current for 10kg load

Fig.10. Plot for output voltage and output current for 10 kg load

Fig.13. Plot for speed, torque and current for 40kg load

V. CONCLUSION This paper presented an embedded system integrated into a ZigBee based wireless sensor network (WSN) for online speed and dynamic torque monitoring in induction motors. Electrical signals from the motors were taken in noninvasive manner and given to the embedded system. The calculations for estimating the targeted values are done locally and then transmitted to a monitoring base unit using ZigBee based wireless sensor network. Speed of deployment, maintenance, low cost, security, reliability and throughput were the main advantages of using ZigBee. Even with the difficulties in data transmission using the WSN in some scenarios, the system was able to provide useful monitoring information. Plot for speed, torque, output voltage and output current are obtained from the simulation for different load values.

Fig.11. Plot for output voltage and output current for 40 kg load

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