Controlling Three-Phase Induction Motor with an Internet of Things (IoT) Smart Industrial Panel

Abstract

With the transition from manual to auto systems, technology has been advancing globally. The smart control panel is the subject of this study. The electrical components of appliances can be inductive, resistive, or capacitive. The majority of inductive devices are motors. a three-stage There are many uses for induction motors in the global power system because of its many benefits, including low starting power, low maintenance cost, and widespread use. This paper discusses fault analysis in induction motors using MATLAB/SIMULINK, providing optimal protection combining traditional and IoT for both automatic and manual methods, and making it fully controllable according to the requirements of protection engineers for various loads. This is important for the economy and the motors\\\' longevity, as it ensures that they operate optimally with the best smart protection techniques. In this setup, the control elements include a molded-case circuit breaker for safety, a temperature and vibration sensor with an Internet of Things (IoT) based remote data collecting method for automatic protection, and a selector switch for human control and automatic operation.

Introduction

I. INTRODUCTION

 Inductive, capacitive, and resistive loads are all very common. In particular, inductive loads, which include AC and DC motors, see heavy use in a wide range of manufacturing processes. The desirable properties of induction machines—three-phase ims in industries and single-phase ims in homes including sturdy construction, cheap maintenance and operation cost, high starting torque, efficiency, and reliability make them the preferred choice for both types of machines [1-2-3]

More than that, there are a lot of problems that can happen to motors, such as problems with the stator, rotor, bearings, windings, lubrication, cooling, temperature rise, and vibrations [4-5]. In order to prevent any loss, condition monitoring is essential, as even a tiny malfunction might result in a significant motor failure and economic hardship for the industry [6].

There are a plethora of methods for controlling and monitoring motor operations. No matter the issue—operations, electrical, or mechanical—the Internet of Things (iot) has changed countless industries around the globe. The continual contact between machines ensures the crucial role of the internet of things.

As part of the M2M (Machine-to-Machine) communication requirements, machine-type concerns are currently being highlighted [4]. Connecting various pieces of hardware with an intelligence backbone to make operations smart and enable them to speak with one another without separate configuration is the essence of the Internet of Things (IoT).

The term "Internet of things" (IOT) describes a network that allows various devices to communicate with one another and receive intelligence, thereby turning them into smart objects. As a result, physical devices can exchange data with one another and set themselves up autonomously [8]. In 1999, Kevin Ashton coined the term "Internet of Things" (IOT) to describe a worldwide network [9]. We now routinely utilize the "IOT"- Internet of Things to sense, trace, address, and measure items through the Internet, or by radio frequency identification (RFID) [10], wireless networks [11], wide area networks (WAN) [12], etc. The items in question, which include not just consumables and building materials but also various electrical equipment [9, 13–16].

Using both manual and Internet of Things (IoT) methods to control loads is the focus of this article. We can utilize the automatic controlling system from anywhere over Wi-Fi, and it's really efficient and comfortable. There is no need for physical labor to operate the system, making its operation easy and rapid. If there is an issue with the automatic system, we may easily operate it manually. Additionally, we are concentrating on three-phase induction motor temperature and vibration abnormalities. Figure 1 is a flow diagram of the entire process.

In Section-II, the suggested sensors and hardware are detailed. In Section-III, the methodology for the entire system is detailed. In Section-IV, the results and Taking into account and assessing all of the facts and statistics in the study, the conclusion is given in Section-V.

II. EQUIPMENT AND SENSORS SUGGESTED

This study discusses the use of inductive loads, specifically a linear fluorescent lamp (LFL), both manually and through the internet of things (IoT). We have recently focused on inductive loads and how they function in both typical and non-standard environments. To run, control, and safeguard both motors, the following apparatus is employed.

1. MCCB (Molded case circuit Breaker)
2. Magnetic contactor
3. Selector Switch
4. Toggle switch
5. Pilot Devices
6. Current transformer (CT)
7. Single-Phase Transformer
8. Diode Bridge
9. VA Hz Meter
10. Node MCU
11. Relay Bunch
12. Temperature sensor
13. Vibration Sensor
14. AC motor (Three-phase Induction Motor)
15. DC motor
16. Linear Fluorescent Lamp (LFL)

The enlisted equipment is shown in Figure 2.

B. Hardware Part

The suggested equipment's interconnections are detailed in the methodology. In order to manually and remotely monitor and regulate the operation of three-phase induction motors and DC motors, there must be connections between various pieces of equipment. When it comes to loads like IMs, DC motors, and LFLs, there are two distinct kinds of wiring diagrams: one for power wiring and another for controlling them. To choose between manual and Internet of Things (IoT) operation of loads, a selection is provided. Using the Multisim software, we were able to create the circuit diagram in figure-04, which illustrates all of the loads and equipment clearly. A molded case circuit breaker (MCCB) serves as a safety mechanism in this control panel, activating in the event of a motor short circuit. Although there are numerous other circuit breakers in use, MCCBs are most often seen on the load side, which is also known as the secondary distribution. Three magnetic contactors are utilized in a parallel loop because of the important role they play in motor control and their incorporation into the control panel. Both approaches make use of magnetic contactors. We begin by controlling the contactors automatically using a NodeMCU, which communicates with one another and the outside world using Wi-Fi signals. In response to a command sent by the mobile app, the NodeMCU powers on the relay, which in turn activates the contactors. A three-phase power source is linked to the load via contactors. Because we have installed the contactors separately and can operate them individually through NodeMCU, we can individually connect the loads according to our requirements if we provide the command from our mobile device.

Next, we manually adjust the switches to operate the magnetic contactors and connect the load to the three-phase supply. As a backup, we also employ the manual switching technique. If our auto system fails to function because of a technical failure, we can simply link the load and supply by operating the contactor by hand.Although a dc supply is required for controlling the motor, we have been using it with a three-phase supply. By utilizing a rectifier in conjunction with a single-phase step-down transformer, we were able to convert the AC voltage to DC voltage, which the rectifier could then easily handle. Under normal and abnormal conditions, the pilot devices are operated using the three indicators: red, yellow, and blue. Because of their importance to motor operation, the meters measure voltage, current, and frequency.

Conclusion

The wide variety of uses for inductive loads has led to their widespread adoption in industrial settings. Building a smart system is crucial. With this setup, a smart panel is intended to control the loads by both manual and Internet of Things (IoT) means. Thanks to Wi-Fi, we can access the IoT control system from any location, making it both more efficient and more pleasant. Since no one needs to be physically present, it is a faster and easier operating system than a manual one. Not only will this make the system smarter, but it will also save labor costs. Nevertheless, the manual operating system is also utilized for backup assistance. It is easy to operate the system manually in the event that the automatic system fails to function owing to a technical issue. This smart panel is useful not only for these functions, but also for regulating and protection. If there is an issue with the electrical or mechanical side, we can remotely control it through the IoT. Additionally, MATLAB/SIMULINK takes into account electrical defects such as undervoltage and overloading in three-phase induction motors. When servicing or protecting the control panel, the molded-case circuit breaker is the tool of choice. Industries find this system useful for controlling purposes, and it has the potential to be expanded in the future to handle all kinds of motor defects and their forward and backward operations through the Internet of Things.

References

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Copyright

Copyright © 2024 Dr. A. Gowthaman, Dr. M. Mohammadha Hussaini, Dr. P. Govindasamy. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.