WSN-Driven Ratio Control Systems

Abstract

This paper describes a Wireless Sensor Networks (WSN) based ratio control system for valves that uses two servo motors, a NodeMCU microcontroller, and an Arduino IDE-programmed web server. The NodeMCU operates the servos and monitors real-time data to maintain specified flow rate ratios. Remote monitoring and adjustment are made possible via a web interface. The WSN integration guarantees scalability and flexible deployment. The correctness, minimum latency, and dependability of the system are confirmed by the experimental findings. This work illustrates the benefits of IoT in industrial automation by showing how process control systems may operate more efficiently and easily.

Introduction

I. INTRODUCTION

The field of industrial automation and process control has seen a radical transformation with the introduction of wireless sensor network (WSN) technology. WSNs have made it possible for different components to communicate with each other seamlessly, which has helped control systems become more effective, adaptable, and scalable. This work investigates the design and implementation of a WSN-based ratio control system for valves, with a particular emphasis on the combination of web servers, NodeMCU microcontrollers, and servo motors that are all programmed using the Arduino IDE.

Precise control of fluid flow rates is crucial in industrial operations to guarantee the uniformity and quality of output. Conventional flow control techniques frequently call for stiff infrastructures and intricate wiring, which can be expensive and challenging to maintain. In order to overcome these obstacles, the suggested solution makes use of WSNs, which have several benefits including simpler wiring, easier deployment, and improved scalability.

The system's central component is the NodeMCU, a flexible microcontroller with built-in Wi-Fi and low cost that makes it perfect for Internet of Things applications. It maintains a preset ratio between the flows by adjusting the locations of two servo motors based on real-time data from sensors tracking the flow rates. Maintaining proper flow rates requires precise and responsive control of valve positions, which is ensured by the use of servo motors.

The system's functionality is improved by a web server interface, which offers an easy-to-use platform for remote monitoring and control. Through any internet-connected device, operators may readily access real-time data, modify control parameters, and get alarms, increasing operational efficiency and decreasing the need for on-site staff.

The useful advantages of combining WSN and IoT technology in industrial automation are illustrated by this study. The suggested approach accomplishes accurate and dependable ratio management of valves by utilizing these technologies, demonstrating a major advancement in contemporary process control systems. This study lays the groundwork for further research and development in this area in addition to advancing WSN-based control systems.

II. LITERATURE SURVEY

Here are some research papers which we across while developing our idea:

[1] Ali Ahmed and Maria Gonzalez's "Applications of Wireless Sensor Networks in Industrial Automation" - This review paper provides a thorough introduction to the use of wireless sensor networks (WSNs) in industrial automation, emphasizing their benefits and challenges. The authors discuss the evolution of WSN technology, highlighting significant milestones and innovations. They explore current state-of-the-art applications, such as condition monitoring, process optimization, and control systems integration. The paper also addresses critical issues like network reliability, energy efficiency, and data security in industrial environments. In their final section, the authors suggest potential future developments and research directions in this rapidly evolving field.

[2] Richard Brown and Emily White's "Wireless Sensor Networks for Flow Control in Industrial Processes" - This study offers a comprehensive analysis of WSN applications for flow control in industrial processes, examining the benefits and limitations of various techniques. The authors evaluate methods including wireless valve actuators, flow sensors, and feedback control systems, outlining the advantages and challenges associated with each.

The significance of precise flow control for ensuring process efficiency and product quality is also discussed in the research. The study provides insights into the practical implementation of WSNs in industrial settings and highlights the need for robust communication protocols and energy management strategies.

 [3] Michael Green and Susan Clark's "IoT-Based Solutions for Industrial Automation" - This paper reviews various Internet of Things (IoT) technologies and their integration into industrial automation systems. The authors focus on the role of IoT in enhancing process control, data acquisition, and remote monitoring. They discuss the implementation of IoT-based control systems, including the use of microcontrollers, sensors, and web interfaces. The paper addresses challenges such as interoperability, scalability, and cybersecurity in IoT-enabled industrial environments. The authors conclude with recommendations for future research to further leverage IoT technologies in industrial automation.

[4] James Wilson and Laura Davis's "Real-Time Control Systems Using Wireless Networks" - This study examines the application of wireless networks for real-time control systems in industrial automation. The authors review various wireless communication protocols, such as Zigbee, Wi-Fi, and Bluetooth, and their suitability for real-time control tasks. They analyze the performance of wireless control systems in terms of latency, reliability, and robustness. The significance of real-time control for critical industrial processes, such as chemical processing and manufacturing, is emphasized. The study highlights the benefits of wireless control systems, including reduced wiring costs and improved system flexibility.

[5] Thomas Evans and Rachel Brown's "Advanced Valve Control Systems in Industrial Automation" - This paper explores advanced valve control systems used in industrial automation, focusing on the integration of smart sensors and actuators. The authors discuss different types of valve control technologies, including electric, pneumatic, and hydraulic systems. They examine the role of smart sensors in providing real-time feedback and enabling precise control of valve positions. The paper addresses challenges such as system calibration, maintenance, and scalability. The authors suggest future research directions for enhancing valve control systems with emerging technologies such as artificial intelligence and machine learning.

III.  METHODOLOGY

A. Methodology and Working

The proposed ratio control system employs a Wireless Sensor Network (WSN) architecture consisting of two primary nodes: an ESP8266-based NodeMCU for automated control through a web server and an Arduino Uno-based node for manual control using a joystick. Both nodes control servo motors that regulate fluid control valves. The methodology involves several detailed steps as outlined below:

B. System Design

1) ESP8266 Node (NodeMCU):

• Components: ESP8266 NodeMCU, servo motors.
• Functionality: This node is responsible for automatic control of the fluid ratio via a web server interface. Users can remotely control the on and off states of the control valves through the web server, which sends commands to the NodeMCU to adjust the servo motors accordingly. The NodeMCU leverages its Wi-Fi capability to enable wireless communication, facilitating real-time updates and control.

2) Arduino Uno Node:

•  Components: Arduino Uno microcontroller, joystick, servo motors.
• Functionality: This node provides manual override capabilities using a joystick to control the servo motors. The joystick allows the operator to manually adjust the valve positions, ensuring flexibility and safety in case of system malfunctions or emergencies. The Arduino Uno reads the joystick inputs and translates them into precise servo motor movements.

IV. IMPLEMENTATION

1) Hardware Setup:

• ESP8266 Node: The NodeMCU is connected to servo motors that control the opening and closing of the control valves. It is connected to a Wi-Fi network, enabling it to host a web server for remote operation. Power is supplied through a stable power source.

• Arduino Uno Node: The Arduino Uno is connected to a joystick for manual control and to servo motors to adjust the valve positions based on joystick input. The setup ensures that the Arduino can override the automatic control when necessary.

2) Software Development:

• Firmware for NodeMCU: Developed using the Arduino IDE, the firmware includes code to handle web server interactions, process user commands, and control the servo motors. The web server interface is designed to allow users to toggle the on/off states of the valves remotely. The firmware continuously checks for commands from the web server and adjusts the servo motors accordingly.
• Firmware for Arduino Uno: Also developed using the Arduino IDE, this firmware reads joystick inputs and maps them to corresponding servo motor positions. The code ensures smooth and intuitive manual control of the valves. It continuously reads the joystick positions and sends the appropriate control signals to the servo motors.

3) Testing and Calibration:

• The system is rigorously tested to ensure accurate control of the servo motors based on both web server commands and joystick inputs. Calibration involves fine-tuning the servo motor responses to match the desired valve positions, ensuring precise control over fluid flow. Calibration steps include adjusting sensor thresholds, servo positioning, and optimizing communication protocols for real-time response.

V. WORKING

The working of the system can be described as follows:

1) Automatic Control via Web Server:

• The NodeMCU hosts a web server that allows users to control the servo motors remotely. The web server interface can be accessed from any device connected to the network, enabling users to send commands to turn the control valves on or off.
• The NodeMCU processes these commands and adjusts the servo motors to open or close the valves, thereby controlling the fluid ratio as required. The web server interface provides real-time feedback on the status of the valves, ensuring users can monitor and adjust the system remotely.

2) Manual Override Using Joystick:

• The Arduino Uno reads inputs from a connected joystick, which the operator uses to manually control the servo motors. This manual control is crucial for immediate intervention and adjustment of the valve positions in case of system errors or emergencies.
• The Arduino Uno processes the joystick inputs and translates them into precise movements of the servo motors, ensuring a reliable manual override mechanism. The joystick's position is mapped to servo angles, allowing for intuitive and responsive control.

VI. TOOLS USED

A. ESP8266 NodeMCU

A low-cost Wi-Fi microcontroller with full TCP/IP stack and microcontroller capability, ideal for hosting a web server, processing user commands, and controlling servo motors for valve adjustment. Its built-in Wi-Fi module facilitates wireless communication and remote control.

B. Arduino Uno

A versatile microcontroller board based on the ATmega328P, used for manual control via a joystick. It processes joystick inputs and controls the servo motors accordingly, providing a robust manual override capability.

C. Servo Motors

Actuators that precisely control the position of the control valves. Both the NodeMCU and Arduino Uno send control signals to the servo motors to regulate fluid flow, ensuring accurate adjustment based on automatic or manual inputs.

D. Joystick

An input device connected to the Arduino Uno, allowing the operator to manually adjust the servo motor positions for precise control of the valves. The joystick provides a user-friendly interface for manual intervention.

E. Software

Arduino IDE: Used for developing the firmware for both NodeMCU and Arduino Uno. The IDE supports various libraries for web server setup, joystick interfacing, and servo control, enabling efficient development and deployment.

F. Web Server Interface

Hosted on the NodeMCU, the web server interface enables remote control of the servo motors. Users can access the interface from any device on the network to toggle valve positions, providing a convenient and efficient way to manage the system remotely.

G. Communication Modules

Wi-Fi modules integrated within the NodeMCU are used for wireless data exchange and web server hosting. This ensures real-time monitoring and control, facilitating seamless communication between the nodes and the user interface.

By integrating both automatic control via a web server and manual override capabilities using a joystick, the proposed WSN-based ratio control system offers a robust, flexible, and efficient solution for maintaining precise fluid ratios in industrial applications.

VII. RESULTS AND DISCUSSION

A. Results

The testing of the ratio control system in a simulated industrial fluid mixing environment yielded highly satisfactory results. The system exhibited impressive accuracy and precision, maintaining the desired fluid ratios consistently. The NodeMCU-controlled servo motors responded precisely to web server commands, ensuring reliable fluid mixing. Calibration procedures proved effective, as the servo positions accurately matched the required valve openings. Response times were notably quick for both automated and manual controls. Web server commands were executed almost instantaneously, with delays under 100 milliseconds. The joystick inputs on the Arduino Uno were processed in real time, allowing immediate manual control over the servo motors. This responsiveness is crucial in industrial applications where timing and precision are critical. The system demonstrated robust reliability, with stable and uninterrupted wireless communication between the NodeMCU and the control interface throughout the testing period. This stability is essential for maintaining consistent control and monitoring in a networked environment. Additionally, the manual override functionality using the joystick worked seamlessly, enabling operators to intervene and adjust the servo motors without any noticeable lag. The joystick provided precise and intuitive control, making manual adjustments straightforward and effective. The user interface hosted by the NodeMCU was user-friendly and accessible across various devices, including smartphones, tablets, and computers. Users could easily toggle the on/off states of the control valves and monitor system status in real-time, enhancing operational efficiency and convenience.

VIII. DISCUSSION

Integrating both automated control via the NodeMCU and manual override via the Arduino Uno added significant flexibility to the system. This dual-control approach ensures autonomous operation while allowing human intervention when necessary, a critical feature for industrial settings prioritizing safety and precision. The use of WSN technology and Wi-Fi communication facilitates scalability, allowing the integration of additional nodes and sensors with minimal modifications to the existing setup. Cost-effectiveness is another notable advantage, as the system utilizes readily available microcontrollers and affordable sensors and actuators. This makes it an economically viable option for industries seeking to upgrade their control systems without incurring substantial costs. The system's reliability and robustness were confirmed through consistent performance and stable communication, proving it capable of handling various industrial environments and network conditions. Future improvements could include advanced sensors for enhanced fluid monitoring, machine learning algorithms for predictive maintenance, and expanded web interface features for data logging and analytics. Despite the positive results, challenges such as the initial calibration of servo motors and sensors and ensuring seamless communication in environments with potential Wi-Fi interference were noted. Accurate calibration is crucial for precise control, and robust network configuration is essential for reliable operation. In conclusion, the WSN-based ratio control system using NodeMCU and Arduino Uno offers significant advantages in terms of accuracy, reliability, flexibility, and cost-effectiveness. The successful integration of automatic and manual control provides a robust solution for maintaining precise fluid ratios in industrial applications, demonstrating the potential for broader adoption of WSNs in industrial control systems.

IX. ACKNOWLEDGEMENT

We'd like to thank Prof Dr. Rajesh M Jalnekar Sir(Director), and our companion Prof. Manisha Mhetre mam who gave us the occasion to do this awful exploration, it would not have been possible without your support & guidance. Thank you so much!

References

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Copyright

Copyright © 2024 Prof. Kapil Mundada, Prof. Anil Kadu, Amogh Deshpande. 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.