Article citation information:
Haniszewski, T. Conception of the Arduino platform as a base for the
construction of distributed diagnostic systems. Scientific Journal of Silesian University of Technology. Series
Transport. 2016, 93, 31-40. ISSN: 0209-3324. DOI: https://doi.org/10.20858/sjsutst.2016.93.4.
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Tomasz HANISZEWSKI[1]
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CONCEPTION OF THE ARDUINO
PLATFORM AS A BASE FOR THE CONSTRUCTION OF DISTRIBUTED DIAGNOSTIC SYSTEMS
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Summary.
Systems for distributed parameter measurements are very expensive solutions;
however, they offer many possibilities in terms of real-time verification of
machine status. Of course, ready, complex and easy-to-use measuring systems can
be used, where the cost of such a solution may be prohibitive. In the case of
research carried out under the experimental sphere of an object, e.g., using a research
measurement system, it is possible to create a project for a system based
mainly on the Arduino platform. As an example, the concept of a distributed
measurement system will be presented, with the possibility for use on cranes
and conveyors, i.e., on the most common machines on industrial plants.
Keywords:
measurement, Arduino, diagnostics, distributed system, temperature,
acceleration, data transmission
1. INTRODUCTION
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In an era
of globalization and reduced human resources, as well as associated costs, it
is a necessity to eliminate every possible human part of the information
chain, which is also the weakest link. The system of distributed
measurement is based on a complex system of devices, not only measurement and
control equipment, but also data-processing systems and their localization both
inside and outside of the object or group of objects, e.g., industrial objects.
Depending on needs requirements, the necessary data for the machine and its
parameters need to be supplied continuously at a high or low frequency (for
coarse control). Depending on the amount of data, it is increasingly necessary
to fit the appropriate module with the transmission and processing of measured
data [1, 4, 5] and any data from the feedback loop of the diagnostic and
control system. They can be explosion-proof control systems on conveyor belts
transporting coal dust where, e.g., temperature sensors are often used at very
large distances and multiple measuring points are important. Other work systems
are proposed as an alternative to, e.g., fibre optic sensors used on conveyor
belts, to verify the temperature both in an environment of rollers and
sets of bearings at the gears (Fig. 1).
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(a)
(b)
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Fig. 1. Fibre optic temperature measurement (a)
at the gearbox bearing and
(b) along the conveyor [6]
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Systems
for distributed parameter measurements of objects are expensive solutions;
however, they offer many possibilities in terms of real-time verification of
operations on the object concerned. Of course, complex and easy-to-use
measuring systems can be used, but the cost may be prohibitive. In the case of
research involving scientific activities or within the sphere of
experiments on a real object, it can be tempting to design a bespoke system
based on the Arduino platform. As examples, the concept of a distributed
measurement system for use on an overhead crane (Fig. 2) and a system for use
on a conveyor belt will be proposed.
The first example will involve an
application for measuring the temperature and current, while the other example
will measure the acceleration and temperature, together with the verification
of skewing and approaches near the edge of the pathway, with the use of
ultrasound technology or laser beam scanning.
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Fig. 2. Overhead crane [3]
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2. SYSTEM CONCEPT
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The concept of a distributed
measurement system, as presented in Figure 3, is based, among other things, on
the Arduino platform and consists of a central diagnostic computer, which
supervises locally installed measurement modules, that is, the so-called nodes
(Fig. 4).
Fig. 3. Structure of distributed measurement
system (S.an = analogue signal and
S.di = digital signal)
Individual measurement modules are
equipped with sets of transducers for measuring currents, temperature and
vibrations of monitored elements, and a laser scanner, a distance sensor and
wireless systems designed to transmit data to a central diagnostic computer,
which supports a two-way data exchange between distributed measurement modules.
It uses both standard Wi-Fi and the GSM network, with limitations in terms of
both the range and the amount of transmitted data [2].
The bidirectional exchange of data
enables, among other things, connecting the right module to the corresponding
actuators of the machine (Fig. 3 and Fig. 4). The exchange of data within the
system does not necessarily have to take place only wirelessly; it can also
involve mixed systems using wired or standard protocols (i.e., RS 485 or RS
232), depending on the needs and resources for the construction of the system.
Fig. 4. Structure of nodes
conception
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Fig. 5. RockBLOCK Mk2 Iridium
SatComm Module [7]
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In the case of communication with
very distant measurement system nodes, a satellite connection using the Iridium
network can be used, where the basic cost of using that network is USD12 per
month, which locates it in the low-budget category system. An example of the use
of this technology is the simple-to-use Rock BLOCK Mk2 Iridium SatComm Module
(Fig. 5), which is capable of receiving and sending short messages from any
location on Earth. This module is based on the Iridium 9602 satellite modem.
The device operates with a voltage of 5 V and communicates via UART (RX,
TX). This allows for direct cooperation with the ATmega microcontrollers, which
are the basis for the Arduino platform, offering a satellite modem at a
low cost.
Due to the need for a constant
control system, which is under a continuous monitoring signal, the system can
be equipped with an operating system based on servomotors or cheaper
counterparts; for example, they can be servos to regulate the selected systems,
such as the control valves of hydraulic and pneumatic systems.
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Fig. 6. Example solution:
controlling node
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The exemplary solution of the
control node, as shown in Figure 6, could act as an indirect function between
the nodes and the diagnostic computer, which should be characterized by high
computing power; for this reason, it is recommended that a standard PC or a
compact microcomputer is used in this case, such as a Raspberry Pi. In the case
of the simplest solutions, a system control node, based on the Arduino
microcontroller YUN, has been proposed. Arduino YUN has integrated Wi-Fi
connectivity, which is compatible with the proposed measurement nodes to
be discussed later in this article, and uses a separate module for radio
transmission, which is responsible for transmitting and receiving only
measurement data. For example, the control node is equipped with an RTC and a
module for GSM communication, although, depending on the respective needs, any
module for communication over long distances will suffice, such as the
aforementioned satellite modem.
2.1. Measuring node: temperature,
current
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The system implementing the current
measurement and the temperature surrounding the rollers is shown in block
diagram form (Fig. 7). This system is based on the ATmega328 microcontroller
placed on the board of an Arduino Pro Mini. For the measurement parameters of
the system, two sensors are used. The first one is a current sensor working on
the basis of the Hall effect, i.e., ACS709 ±75A (Fig. 8a), and the second one
is a digital temperature sensor, i.e., TMP102 (Fig. 8b). When measuring the
surface temperature of the component is required, a non-contact sensor can be
used, based on the infrared sensor TMP007.
Fig. 7. Measuring node: temperature,
current
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The power supply circuit is
implemented with the use of a lithium polymer battery as a source of
energy for step-up and step-down converters. It generates 3.3 and 5 V, for the respective
circuits, even when the voltage drops across the battery. The data collected
from the sensors are directly saved by the microcontroller to an SD card and
sent using the radio module nRF24L01+. In the case of the proposed solution,
data transmission was separate from the receipt and transmission of control
commands.
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Fig. 8. Sensors for a) current
ACS709 ±75A [8] and temperature TMP102 [9]
The nRF24L01+ board system is
responsible for data transmission, while the ESP8266 board system is
responsible for the transmission of commands to control the Wi-Fi, along with a
simple web server with a panel showing basic data about the working node.
Control expands the capabilities of the system and provides an opportunity for
a quick check of the selected nodes, without needing physical access to
the root node.
2.2. Measuring node: acceleration
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The system implementing the
acceleration measurement is shown in block diagram form (Fig. 9). This system
is based on an ATmega328 microcontroller placed on the board of an Arduino
Pro Mini. For the measurement of system parameters, an MMA8452Q sensor was
used, which is a three-axis accelerometer.
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Fig. 9. Measuring node: acceleration
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The power supply circuit is
implemented in the same way as for the node responsible for current and
temperature measurements, i.e., using a lithium polymer battery as a source of
energy for step-up and step-down converters, which generate 3.3 and 5 V,
respectively.
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Fig. 10. Prototype of the
measurement node responsible for the measurement of accelerations
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The nRF24L01+ board is responsible
for the data transmission system, while a Wi-Fi ESP8266 board is responsible
for the transmission of commands to control the system, as in the case of the
node responsible for the measurements of temperature and current. An exemplary
implementation of the circuit is shown in Figure 10.
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2.3. Measuring node: distance, obstacles
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The system implementing the distance
measurement and examination of the obstacles in the pathway is shown in block
diagram form (Fig. 11). This system is based on an ATmega328
microcontroller placed on the board of an Arduino Pro Mini. For the measurement
of parameters, a LIDAR-Lite precise laser distance sensor is used, operating in
a range of 0 to 40 m with an accuracy of 0.025 m, and a precise two-dimensional
laser scanner is used for detecting obstacles, operating in the area of 360°C
in a range of 6 m. The laser scanner is characterized by a refresh rate of
2,000 samples per second.
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Fig. 11. Measuring node: distance, obstacles
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The power supply circuit is
implemented in the same way as a node responsible for current and temperature
measurements, i.e., using a lithium polymer battery as a source of energy for
step-up and step-down converters, which generate 3.3 and 5 V, respectively.
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a) b)
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Fig. 12. a) Distance measurement:
LIDAR-Lite [10] and
b) environment scanner: RPLIDAR [11]#12#
The nRF24L01+ board is responsible
for the data transmission system, while the ESP8266 board system is responsible
for the transmission of commands to control the Wi-Fi, as in the case of
the node responsible for the measurements of temperature and current.
3. CONCLUSION
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The article presents the concept of a
distributed measurement system to be used on a selected research object,
with a specific focus on cranes and conveyors. The proposed system is based on the measurement nodes, characterized by
extremely low cost and sufficient accuracy for experimental systems and
objects. The author does not specify parameters and costs due to the
possibility of using various types of sensors and microcontrollers, which
directly impact on the cost, among other things. An example application of the
proposed system could be based on the continuous examination of machine status,
e.g., overhead cranes in their full-duty cycle.
The measurement system is applicable in terms of the verification of the
maximum acceleration values inside the girder in the process of lifting the
load, as well as the direct adjustment of the speed and the state of rope
tension. As a consequence, it is necessary to reduce the danger to people and
the structure dynamic surpluses, along with verifying the skewing process
for cranes with a large bridge span with the use of sensors based on laser
environment scanning.
References
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1.
Haniszewski
Tomasz, Damian Gąska. 2013. „Overhead travelling crane vibration research using
experimental wireless measuring system”. Transport Problems 8 (1):
57-66. ISSN 1896-0596.
2.
Maćkowski Michał. 2008. „Badania rozproszonych
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dissertation, Poznań: Politechnika Poznańska.
[In Polish: „The study of distributed measurement systems with data
transmission in GSM network”. PhD dissertation,
Poznan: Poznan University of Technology].
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http://www.seeedstudio.com/depot/RPLIDAR-360-degree-Laser-Scanner-Development-Kit-p-1823.html.
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Received
22.06.2016; accepted in revised form 15.09.2016
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Scientific Journal of Silesian University of
Technology. Series Transport is licensed under a Creative Commons Attribution
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