Published April 24, 2017 © GPL3+

Industrial Energy Consumption Console

This is an industrial class console constructed to help in the data collection of industrial process.

BeginnerFull instructions provided4 hours1,501

Things used in this project

Hardware components

Siemens SIMATIC IOT2020

arduino proto shield

Omron G2R-1-S(S) SPDT Relay

4n35 optocoupler

LED (generic)

Resistor 10k ohm

Resistor 1k ohm

Jumper wires (generic)

Solderless Breadboard Half Size

Raspberry Pi WiFi adapter

Software apps and online services

Arduino IDE

Ubidots

Story

Project Idea

This idea is to use a Simatic IOT2020 as a console that allows us to collect the status of the operation of a gravel silos for a period of one year, this system has a dust collection system. The objective is to obtain the state (on/off) in which its components work, to characterize the behavior of the system and to review potential energy saving opportunities.

System Description

This system consists of three pairs of hoppers which are fed by means of a vibrating screen. The discharge to truck is through loading spouts when the discharge valves of the hoppers are operated, to avoid contamination by dust of the operational area. There is a dust collection system; this system performs the suction of dust on the points of capture: loading spouts, vibrating screen and the top of the silos, this suction must be made every time you work on filling some truck with gravel or when the silos are filled.

The original system was designed considering that it would be a single main line from the vibrating screen to the dust collector, and all other components would join this main line. This design requires a fan size 071 which will have a fan shaft power of 16.79 KW and an efficiency of 83.3%.

Operation

This mode of operation implies that the system will always work to the maximum capacity, regardless of whether the suction is being carried out from a single point of capture, or from all the capture points at the same time. This is because the same transport speed must always be maintained in the suction lines to prevent settling.

Solution

The solution to this dilemma is to connect each capture point with separate lines to the dust collector, this would allow us to vary the flow of the system according to the operating requirements, isolating the rest of the lines without having to worry about low transport speeds.

Options

The following figure shows the fan options we require for each mode of operation.

The simplest option is to leave a fan model 040 and a fan model 056 connected in parallel, we can work with model 040 for cases 2, 3, 4 and 5, we can work with model 056 for cases 6 and 7 and for Cases 1, 8 and 9 will operate both fans at the same time. To achieve this it is necessary to consider Vfds for both fans

The following figure shows the power consumption of both fans for the modes 1, 8 y 9.

Energy Savings

As we can see there are opportunities for energy savings in the modes of operation 2,3,4,5,6 and 7 the convenience of the investment depends on the cost of the modifications and the material required: two fans with Vfds, the instrumentation and valves with their actuators. Another important consideration in energy saving projects is the return of investment (ROI), the cost of electric energy, the electric demand, and the annual electric consumption. To obtain the annual electrical consumption we require the annual operating time of each operation mode, this is where our industrial console of electric consumption comes into play.

An extra advantage of using the Siemens IoT2020 platform is that in case the project has an economical feasibility, then the same IoT 2020 platform can be used for the control of fans and line isolation (and regulation) valves. With this in mind the cost of the investment could be reduced since we saved the cost of an industrial PLC.

The use of this information does not stop, only in this study of energy saving. This data can also be used in the maintenance of the equipment, in the sales area to establish market strategies, etc.

Cover proposal

Here a design for a cover, the center of this design is a small pcb with a pcb screw terminal block, this pcb also includes a 4 pin female header so you can get the security of a bolted connector for your input signals and the facility to connect this with the iot2020 board with standard male jumpers.
Now we know that siemens has released an IO Shield for the IOT2000 (article number 6ES7647-0KA01-0AA2), with this you can put aside the cover and the rest of the components mounted on the breadboard.

Schematics

Signals

The input signals to our console will come from the current electrical system, in the case of the loading spouts the signal of 24v will be taken from the solenoid switch PB2 of the discharge valve of the silo, in the case of the vibrating screen, the signal of 24v will come from the motor contactor switch.
With all the above we will have 3 input signals (output of a OR gate made by relays) from retractile sleeves and an input signal from the vibrating screen, this gives us 4 signals: I1 I2, I3 and I4

Code

Industrian Energy Consumption Console Code V1.0

Industrian Energy Consumption Console Code V1.0

Arduino

This code allows us to send the status (on / off) of the input signals via mqtt using the pubsubclient library, The way to collect the data from ubidots is through a .csv file, to facilitate the interpretation of the data collected, i ve chosen to create a variable for each possible combination of operating states of the system, this gives us a total of 14 variables, i also design this code so that only sends data to ubidots when any value is in the ON state, the time between data sending in on state is 1 min which gives us the resolution enough for our application, when a value returns to OFF state the code connects again to ubidots and changes the state of the variables to zero, although there are many variables the advantage of doing it this way is that we do not need to read all the columns of the inputs in the csv file at the same time to find the mode of operation as would be the case if we only had one variable for each input; To count the total time that a mode of operation has been ON we only need to make the sum of each column separately and dividing by 100 we will have the amount in minutes.
The structure of the code is as follows:
1. Connect AP.
2. Read board inputs
3. Compare inputs and write variables
4. IF any data is different from zero:
      A) assembling the data group
      B) make connection mqtt
      C) send data group
      D) disconnect mqtt
      C) wait a minute
      D) put variable sw = 1
    ELSE
         IF sw = 1
              A) assembling data group with variables = 0
              B) make connection mqtt
              C) send data group
              D) disconnect mqtt
              E) put variable sw = 0

#include <WiFi.h>
#include <PubSubClient.h>

// These are the variables you will want to change based on your IOT data streaming account / provider
#define TOPIC "/v1.6/devices/YOURDEVICELABEL"
#define TOKEN "YOURUBIDOTSTOKEN"

char ssid[] = "YOURNETWORKSSID";
char pass[] = "YOURNETWORKPASSWORD";
int status = WL_IDLE_STATUS;
char payload[840];  // Reserve a char to store the Ubidots data. Account for 60 bytes per variable. 
char le[4];
char mqttBroker[] = "things.ubidots.com";
String response;
WiFiClient c;
PubSubClient client(c);

//DEFINING INPUT PINS
int PB1 = 2;
int PB2 = 4;
int PB3 = 7;
int PB4 = 8;

int A = 0;
int B = 0;
int C = 0;
int D = 0;
int E = 0;
int F = 0;
int G = 0;
int H = 0;
int I = 0;
int J = 0;
int K = 0;
int L = 0;
int M = 0;
int N = 0;
int sw = 0;

void setup()
{
  system("ifup wlan0");
  delay(1000);
  Serial.begin(9600);             

    
  while (status != WL_CONNECTED)
  {
    Serial.print("Attempting to connect to SSID: ");
    Serial.print(ssid);
    status = WiFi.begin(ssid, pass);
    delay(10000);
  }
  Serial.println("Wifi connected!");
  client.setServer(mqttBroker, 1883);

  
  pinMode(PB1, INPUT);
  pinMode(PB2, INPUT);
  pinMode(PB3, INPUT);
  pinMode(PB4, INPUT);

}


void loop()
{

  //READING INPUTS FROM ARDUINO BOARD
  int TO01 = digitalRead(PB1);
  int TO02 = digitalRead(PB2);
  int TO03 = digitalRead(PB3);
  int Llenado = digitalRead(PB4);
  
  // COMPARING INPUTS AND WRITING VARIABLES
  if (TO01 ==  1 && TO02 == 1 && TO03 == 1 && Llenado == 1)
    {
      A = 100;
    }
  else
    {
      A = 0;
    }
  
  if (TO01 == 1 && A == 0 && F == 0 && G == 0 && I == 0 && L == 0 && M == 0)
    {
      B = 100;
    }
  else
  {
      B = 0;
  }
  if (TO02 == 1 && A == 0 && F == 0 && H == 0 && J == 0 && L == 0 && N == 0)
    {
      C = 100;
    }
  else
  {
      C = 0;
  }
  if (TO03 == 1 && A == 0 && G == 0 && H == 0 && K == 0 && M == 0 && N == 0)
    {
      D = 100;
    }
  else
  {
      D = 0;
  }
  if (Llenado == 1 && A == 0 && I == 0 && J == 0 && K == 0 && L == 0 && M == 0 && N == 0)
    {
      E = 100;
    }
  else
   {
      E = 0;
   }
  if (TO01 == 1 && TO02 == 1 && A == 0 && L == 0)
    {
      F = 100;
    }
  else
  {
      F = 0;
  }
  if (TO01 == 1 && TO03 == 1 && A == 0 && M == 0)
    {
      G = 100;
    }
  else
  {
      G = 0;
  }
  if (TO02 == 1 && TO03 == 1 && A == 0 && N == 0)
    {
      H = 100;
    }
  else
  {
      H = 0;
  }
  if (TO01 == 1 && Llenado == 1 && A == 0 && L == 0 && M == 0)
    {
      I = 100;
    }
  else
  {
      I = 0;
  }
  if (TO02 == 1 && Llenado == 1 && A == 0 && L == 0 && N == 0)
    {
      J = 100;
    }
  else
  {
      J = 0;
  }
  if (TO03 == 1 && Llenado == 1 && A == 0 && M == 0 && N == 0)
    {
      K = 100;
    }
  else
  {
      K = 0;
  }
  if (TO01 == 1 && TO02 == 1 && Llenado == 1 && A == 0)
    {
      L = 100;
    }
  else
  {
      L = 0;
  }
  if (TO01 == 1 && TO03 == 1 && Llenado == 1 && A == 0)
    {
      M = 100;
    }
  else
  {
      M = 0;
  }
  if (TO02 == 1 && TO03 == 1 && Llenado == 1 && A == 0)
    {
      N = 100;
    }
  else
  {
      N = 0;
  }

      
  //SENDING DATA (IF DATA != 0)
  if (A || B || C || D || E || F || G || H || I || J || K || L || M || N == 100) {
      
      sprintf(payload,"%s", "{\"A\":");
      sprintf(payload,"%s%d", payload, A);
      sprintf(payload,"%s%s", payload, ",\"B\":");
      sprintf(payload,"%s%d", payload, B);
      sprintf(payload,"%s%s", payload, ",\"C\":");
      sprintf(payload,"%s%d", payload, C);
      sprintf(payload,"%s%s", payload, ",\"D\":");
      sprintf(payload,"%s%d", payload, D);
      sprintf(payload,"%s%s", payload, ",\"E\":");
      sprintf(payload,"%s%d", payload, E);
      sprintf(payload,"%s%s", payload, ",\"F\":");
      sprintf(payload,"%s%d", payload, F);
      sprintf(payload,"%s%s", payload, ",\"G\":");
      sprintf(payload,"%s%d", payload, G);
      sprintf(payload,"%s%s", payload, ",\"H\":");
      sprintf(payload,"%s%d", payload, H);
      sprintf(payload,"%s%s", payload, ",\"I\":");
      sprintf(payload,"%s%d", payload, I);
      sprintf(payload,"%s%s", payload, ",\"J\":");
      sprintf(payload,"%s%d", payload, J);
      sprintf(payload,"%s%s", payload, ",\"K\":");
      sprintf(payload,"%s%d", payload, K);
      sprintf(payload,"%s%s", payload, ",\"L\":");
      sprintf(payload,"%s%d", payload, L);
      sprintf(payload,"%s%s", payload, ",\"M\":");
      sprintf(payload,"%s%d", payload, M);
      sprintf(payload,"%s%s", payload, ",\"N\":");
      sprintf(payload,"%s%d", payload, N);
      sprintf(payload,"%s%s", payload, "}");
      Serial.println(payload);
      
      
      while (!client.connected()) {
          Serial.print("Attempting MQTT connection...");
          // Attempt to connect
          if (client.connect("linkit-one",TOKEN,"")) {
              Serial.println("connected");
              } 
          else {
              Serial.print("failed, rc=");
              Serial.print(client.state());
              Serial.println(" try again in 5 seconds");
          // Wait 5 seconds before retrying
          delay(5000);
          }
      }
      client.publish(TOPIC, payload);
      client.disconnect();
           
      delay(60000);
      sw = 1;
      }    
            
      //SENDING DATA ZERO ONLY AFTER A CHANGE OF 100 TO 0 OF ANY VARIABLE      
       
  else{
  
      if (sw == 1){
      sprintf(payload,"%s", "{\"A\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"B\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"C\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"D\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"E\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"F\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"G\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"H\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"I\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"J\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"K\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"L\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"M\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, ",\"N\":");
      sprintf(payload,"%s%d", payload, 0);
      sprintf(payload,"%s%s", payload, "}");
      Serial.println(payload);

      while (!client.connected()) {
          Serial.print("Attempting MQTT connection...");
          // Attempt to connect
          if (client.connect("linkit-one",TOKEN,"")) {
              Serial.println("connected");
          } 
          else {
            Serial.print("failed, rc=");
            Serial.print(client.state());
            Serial.println(" try again in 5 seconds");
            // Wait 5 seconds before retrying
            delay(5000);
            }
          }
      client.publish(TOPIC, payload);
      client.disconnect();
      sw = 0;
      delay (1000);
      } 
  } 
}

Credits

Luis Alberto Salazar Salazar

2 projects • 5 followers

Mechanical Engineer Electronics hobbyst

Industrial Energy Consumption Console

Things used in this project

Hardware components

Software apps and online services

Story

Project Idea

System Description

Operation

Solution

Options

Energy Savings

Custom parts and enclosures

Cover proposal

Schematics

Signals

Relays

Protoboard

IOT2020 setup

Ubidots setup

Ubidots device panel

..

Ubidots results

Code

Industrian Energy Consumption Console Code V1.0

Credits

Luis Alberto Salazar Salazar

Comments

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Industrial Energy Consumption Console

Industrial Energy Consumption Console

Things used in this project

Hardware components

Software apps and online services

Story

Project Idea

System Description

Operation

Solution

Options

Energy Savings

Custom parts and enclosures

Cover proposal

Schematics

Signals

Relays

Protoboard

IOT2020 setup

Ubidots setup

Ubidots device panel

..

Ubidots results

Code

Industrian Energy Consumption Console Code V1.0

Credits

Luis Alberto Salazar Salazar

Comments

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