INDUSTRIAL PROTECTION SYSTEM USING

ARDUINO AND BLUETOOTH MODULE

 CONTENTS

TOPICS PAGE NO.

CHAPTER - 1

1.1 ABSTRACT 1
1.2 INTRODUCTION TO EMBEDDED SYSTEMS 2
1.3 APPLICATION OF EMBEDDED SYSTEM IN
INDUSTRIAL PROTECTION 2-3

CHAPTER – 2

2.1 BLOCK DIAGRAM OF INDUSTRIAL

PROTECTION SYSTEM 4

2.2 HARDWARE REQUIREMENTS 5-17

CHAPTER – 3

3.1 CODING IN ARDUINO UNO 18-22

CHAPTER – 4

4.1 PHYSICAL MODEL 23

4.2 COMPONENTS USED 23

4.3 FUTURE SCOPE 24

4.4 CONCLUSION 25

4.5 REFERENCES 26
 LIST OF FIGURES AND TABLES

FIGURES PAGE NO.

CHAPTER – 2

2.1 BLOCK DIAGRAM OF INDUSTRIAL

PROTECTION SYSTEM 4

2.2 POWER SUPPLY CIRCUIT DIAGRAM 5

2.3 ARDUINO UNO BOARD 6

2.4 ATMEGA328 PIN MAPPING 6

2.5 LM35 SENSOR 7

2.6 LM35 CIRCUIT CONNECTION 8

2.7 IR FLAME SENSOR 8

2.8 FLAME SENSOR INTERFACING WITH

ARDUINO UNO 9

2.9 LIGHT DEPENDENT RESISTOR 9

2.10 MQ4 GAS SENSOR 10

2.11 MQ4 PIN DIAGRAM 10

2.12 MQ4 INTERFACING WITH ARDUINO UNO 10

2.13 HC05 BLUETOOTH MODULE 12

2.14 HC05 PIN DIAGRAM 12

2.15 BLUETOOTH MODULE COMMUNICATION 13

2.16 LCD 16×2 DISPLAY PIN DIAGRAM 14

2.17 LCD INTERFACING WITH ARDUINO UNO 15

2.18 3.5” × 3.5” 12V DC MOTOR 16

 2.19 9V BUZZER 16

2.20 9V LOW BATTERY VOLTAGE LED 17

INDICATOR CIRCUIT

CHAPTER – 4

4.1 PHYSICAL MODEL OF ARDUINO CONTROLLED

INDUSTRIAL PROTECTION SYSTEM 23

4.2 COMPONENTS USED FOR PHYSICAL MODEL

OF INDUSTRIAL PROTECTION SYSTEM 23

4.3 IOT BASED INDUSTRIAL PROTECTION SYSTEM 24

TABLES PAGE NO.

CHAPTER – 2

2.1 MQ4 GAS SENSOR SPECIFICATIONS 11

 CHAPTER-1
1.1 ABSTRACT

As the electronics systems has taken great strides of improvement their application to
embedded systems has provided us with various systems which are controlled by Arduino
UNO Board while it is triggered by input from sensors which then work logically according
to the code fed into the Arduino using an USB Cable. The various sensors which act as a
trigger for the system includes Temperature Sensor (LM35), IR Flame Sensor, Gas Sensor
(MQ4) and light sensor (LDR). Further, out of the many options for communication we used
the HC05 Bluetooth module and the monitoring of the system can be done by a mobile
application. A proper power supply is made as the driver circuit where the connection for V cc
at 5V is provided to the Arduino UNO.

In the future it will find its use through IoT where the communication module has to be
improvised upon and also the sensors updated. It would ultimately be the system which
would be smart enough to deal with most of the situations on its own and also remember the
past history of Industrial Accidents adding with it the current happenings.

Keywords: Arduino UNO, LM35, MQ4, HC05, LDR, IR Flame Sensor, IoT
1.2 INTRODUCTION TO EMBEDDED SYSTEMS

An embedded system combines mechanical, electrical and chemical components along with a
processor and computer to achieve a desired goal.

Comprehensively, it can be defined as a cyber-physical system, which monitors and controls

the physical processes, usually with feedback loops where physical processes affect
computations and vice versa.

There are three major parts of this process of Creating an Embedded System:

1) Modelling
• It is the process of gaining a deeper understanding of a system through imitation.
• It involves the problem formulation.
• It specifies “What” a system does.
2) Design
• It is the structured creation of artefacts.
• It specifies “How” a system does what it does.
3) Analysis
• It is the process of understanding the system through dissection.
• It specifies “Why” a system does what it does.

1.3 APPLICATION OF EMBEDDED SYSTEM TO INDUSTRIAL

PROTECTION

1.3.1 MODELLING:
This involves the listing of parameters on which the protection system should operate
like:
• Accidental Fire
• Gas Leakage
• System to be online in time of power outage (LDR Sensor)
• Machines running at temperatures higher than specified (Temperature Sensor)

1.3.2 DESIGNING:
The solution of the above situations can be understood as follows:
• Accidental Fire detected by Sensor and then output is provided to Buzzer
which sets up the Fire Warning System.
• Gas leakage sensed by sensor which in turn runs the fan to ward off the gas.
• LDR Sensor specializes in operating as a switch based on the intensity of
light incident on it.
• Temperature Sensor sets off the alarm for stopping the machine from
overheating.
The idea of the solutions to the above listed parameters of the Modelling part would finally
lead us to the creation of a block Diagram of Components of the Industrial Protection system
which would comprise of several modules such as:

I) Microcontroller (ATMEGA328)
II) LED Display (16x2)
III) Fire sensor (IR Flame Sensor)

V) Temperature Sensor (LM35)

VI) Gas Sensor (MQ4)
VII) Bluetooth Module (HC05)
VIII) Smartphone Application for monitoring system

1.3.3 ANALYSIS:

This involves understanding each of the Previously mentioned blocks Under

the following points:
• Module Diagram
• Pin Mapping
• Interfacing with microcontroller
• Operating Voltage
• Basic Principle of Operation
 CHAPTER-2
2.1 BLOCK DIAGRAM OF INDUSTRIAL PROTECTION SYSTEM

Figure 2.1 - Block Diagram of Industrial Protection System

2.2 HARDWARE REQUIREMENTS

2.2.1 POWER SUPPLY:

Figure 2.2 - Power Supply Circuit Diagram

• This circuit consists of step-down transformer, full wave bridge converter, and 7805
voltage regulators.
o The step-down transformer decreases the 230V AC Supply to 10V AC Supply.
o This 10V AC supply is given to the full bridge converter it converts it to 10V
pulsating DC.
o This pulsating DC is provided to 7805 voltage regulator to give constant 5V DC
Voltage and cancel the pulsating component.
2.2.2 ARDUINO UNO:

Figure 2.3 - Arduino UNO Board

BLOCK: Microcontroller
TYPE: ATMEGA328
ANALOG/DIGITAL: digital
PINS FOR INTERFACE: 20 Pins

Figure 2.4 - ATMEGA328 Pin Mapping

 •
Arduino can be used can be used to develop interactive projects, taking input from a
variety of switches or sensors, and controlling a variety of lights, motors and other
[2]
physical outputs.
•
Arduino projects can be stand-alone, or they can communicate with various software
running on the computer. (e.g. Flash, Processing, MaxMSP)
•
The Arduino UNO is a microcontroller board based on the ATmega328.
•
It has 14 digital input/output pins (of which 6 can be used as PWM outputs), 6 analog
inputs, a 16 MHz ceramic resonator, a USB connection, a power jack, an ICSP header
and a reset button.
•
In our project A0, A1, A2, A3 serve as input for sensor connection.
•
D0 and D1 are connected to Bluetooth Module.
•
5V input is provided from power supply.

2.2.3 SENSORS

❖ TEMPERATURE SENSOR
BLOCK: Input

TYPE: LM35

ANALOG/DIGITAL- Analog

PINS FOR INTERFACE: 3

Figure 2.5 - LM35 Sensor

•
The LM35 is precision integrated-circuit temperature sensor, whose output voltage is
[3]
linearly proportional to the Celsius (Centigrade) temperature.
•
+5V power supply is provided by using 7805 regulator IC.
•
When IC senses the temperature, it gives linear voltage as +10.0mV/degree Celsius at
the Vout pin of IC which is connected to the +V(IN) of A/D Converter.
 +5V

Temperature sensor

1 3
Vcc GND

Vout
2

10K GND
To ADC
Resistor Capacitor
1µF

GND

Figure 2.6 - LM35 circuit connection

• LM35 produces 10mV for every degree of temperature change. It works in

accordance with Fan to control any sudden devastating change in temperature.

❖ FIRE SENSOR
BLOCK: Input

TYPE: IR Flame Sensor

ANALOG/DIGITAL: Analog

PINS FOR INTERFACE: 3

Figure 2.7- IR Flame Sensor

 Figure 2.8 - Flame Sensor interfacing with Arduino UNO

• A flame sensor is used to detect the presence of flames around its range.
• It consists of an IR Receiver, a comparator LM393, resistors, capacitor and a
potentiometer to adjust its sensitivity.
• The infrared waves from 760 nm to 1100 nm wavelength would be readily detected by
this sensor.
• The IR Receiver converts the wave intensity into corresponding current value.
• It can give analog as well as digital output.
• The sensor has a detection angle of 60 degrees in the forward direction.
• A Voltage of 3.3V to 5.2V can be used to power the sensor.

❖ LIGHT SENSOR

Figure 2.9 - Light Dependant Resistor

•
A Light Dependent Resistor (LDR) or a photo resistor is a device whose resistivity is
[4]
a function of the incident electromagnetic radiation.
•
Normally, the resistance of a LDR is very high, sometimes as high as 1,000,000
ohms, but when they are illuminated by light, the resistance drops dramatically.
•
Basically, it acts as a switch in the circuit based on the only parameter e.g. the amount
of light incident on it.
•
It acts as a switch for the system to come online or become operational in times of
power outage or when the industry is not operational.
❖ GAS SENSORS

Figure 2.10 - MQ4 Gas Sensor Figure 2.11 - MQ4 pin diagram

Figure 2.12 - MQ4 interfacing with Arduino UNO

• The sensitive material of MQ-4 sensor is SnO2 , which has high sensitivity not only to
Methane (CH4) but also Propane (C3H8) and Butane(C4H10).
• The enveloped MQ-4 has in total 6 pins out of which 4 of them are used to fetch
signals and other 2 are used for providing heating current.
• It finds application in Domestic Gas Leakage detector, Industrial combustible Gas
detection System, Portable Gas Detector.
Table 2.1 - MQ4 Gas Sensor specifications
2.2.4 BLUETOOTH MODULE

Figure 2.13 - HC05 Bluetooth Module Figure 2.14 - HC05 Pin Diagram

Bluetooth serial modules allow all serial enabled devices to communicate with each other
using Bluetooth.

It has 6 pins as mentioned below:

1. Key/EN: It is used to bring Bluetooth module in AT commands mode. If Key/EN pin is set to
[6]
high, then this module will work in command mode. Otherwise by default it is in data mode.
The default baud rate of HC-05 in command mode is 38400bps and 9600 in data mode.
HC-05 module has two modes,

I. Data mode: Exchange of data between devices.

II. Command mode: It uses AT commands which are used to change setting of HC-
05. To send these commands to module serial (USART) port is used.

2. VCC: Connect 5 V or 3.3 V to this Pin.

3. GND: Ground Pin of module.

4. TXD: Transmit Serial data (wirelessly received data by Bluetooth module transmitted out
serially on TXD pin)

5. RXD: Receive data serially (received data will be transmitted wirelessly by Bluetooth
module).
6. State: It tells whether module is connected or not.
HC-05 Module Information

• HC-05 has red LED which indicates connection status, whether the Bluetooth is
connected or not.
• Before connecting to HC-05 module this red LED blinks continuously in a periodic
manner.
• When it gets connected to any other Bluetooth device, its blinking slows down to two
seconds.
• This module works on 3.3 V. We can connect 5V supply voltage as well since the
module has on board 5 to 3.3 V regulator.
• As HC-05 Bluetooth module has 3.3 V level for RX/TX and microcontroller can
detect 3.3 V level, so, no need to shift transmit level of HC-05 module.

Figure 2.15- Bluetooth Module Communication

2.2.5 LCD SCREEN

Figure 2.16 - LCD 16x2 Display Pin Diagram

• LCDs (Liquid Crystal Displays) are used in embedded system applications for
displaying various parameters and status of the system.

• LCD 16x2 is a 16-pin device that has 2 rows that can accommodate 16 characters each.

• LCD 16x2 can be used in 4-bit mode or 8-bit mode.

• It is also possible to create custom characters.
• It has 8 data lines and 3 control lines that can be used for control purposes.
• Current consumption is 1mA without backlight.
• Alphanumeric LCD display module, meaning can display alphabets and numbers.
• It can also display any custom generated characters.

• Available in green and blue backlight.

 Figure 2.17 - LCD Interfacing with Arduino UNO

• From the circuit diagram, we can observe that the RS pin of the LCD is connected to
the pin 12 of the Arduino.
• The R/W pin of LCD is connected to the ground.
• The pin 11 of the Arduino is connected to the enable signal pin of LCD module. The
LCD module & Arduino module are interfaced with the 4-bit mode in this project.
• Hence there are four input lines which are DB4 to DB7 of the LCD.
• The digital input lines (DB4-DB7) are interfaced with the Arduino pins from 5-2.
• To adjust the contrast of the display here we are using a 10K potentiometer.
• The current through the back LED light is from the 560-ohm resistor.
• The external power jack is provided by the board to the Arduino.
2.2.6 FAN

Figure 2.18 - 3.5” x 3.5” 12V DC Motor

• The 12V Fan is useful in accordance with the input from Gas and
Temperature Sensor.
• With the advent of higher efficient electronics system, the Fan is powered by
the small brushed DC Motor.
• When the protection system is online or operational then the Fan goes to 100% output
only once the temperature goes well beyond the prescribed minimum temperature set
previously.

2.2.7 BUZZER

Figure 2.19 - 9 V Buzzer

• A buzzer is a small yet efficient component to add sound features to projects/system.
• It is a 2-pin structure hence can be used easily on bread board.
• This buzzer used here makes a continuous “Beep” sound when powered on.
• This buzzer generally works at 4-9 V but here +5 V DC Supply power the buzzer.
2.2.8 LED INDICATOR

Figure 2.20 - 9 V low battery voltage LED Indicator Circuit

• This is a very simple 9V Low Battery indicator Circuit which has two LEDs.

• It has 2 LEDs – Green and Red.

• Green LED light up when the battery Voltage is higher than 6.9 V
• Red LED lights up when the battery Voltage is below 6.9 V.
 CHAPTER-3

3.1 CODING IN ARDUINO UNO

3.1.1 CODE USED

#include<SoftwareSerial.h>

#include<LiquidCrystal>

LiquidCrystal lcd (12, 11, 10, 9, 8, 7); // (rs, en, d4, d5, d6, d7)
SoftwareSerial BT (2, 3); // RX, TX
int TempPin = 0; // analog A0
const int LDRPin =4; // Light Sensor
const int GasPin = 5; // GAS Sensor
const int LEDPin = 13; // Indicator
const int FLAMPin = 15; // Fire Sensor
const int FanPin = 17; //Fan
const int LightPin = 18; // Bulb
const int BuzzPin = 19; // Buzzer
int val, lit, gas, flm, temp, wirn, fan;
float mv;
float cele;
int settemp=50;
void setup () {
pinMode (LDRPin, INPUT);
pinMode (GasPin, INPUT);
pinMode (FLAMPin, INPUT);
pinMode (LightPin, OUTPUT);
pinMode (FanPin, OUTPUT);
pinMode (LEDPin, OUTPUT);
pinMode (BuzzPin, OUTPUT);
val=lit=gas=flm=mv=cele=wirn=0;

lcd. begin (20,4);

lcd. clear ();
 lcd. setCursor (0, 0);
lcd. Println (" WELCOME ");
lcd. setCursor (0, 1);
lcd.print ("Industrial Protection Sys");
lcd. scrollDisplayLeft ();
lcd. autoscroll ();
lcd. noAutoscroll ();

BT. begin (9600);

BT. Println ("Industrial Protection System");
delay (1500);
}

void loop () {
if (BT. Available ()) {
BTRData = (BT. Read ());
}

If (digitalRead (LDRPin)==HIGH)
{
digitalWrite (LightPin, HIGH);
lit=1;
}
else
{
digitalWrite (LightPin, LOW);
lit=0;
}

If (digitalRead (FLAMPin)==HIGH)
{
digitalWrite (FanPin, HIGH);
flm=1;
fan=1;
}
else
{
digitalWrite (FanPin, LOW);
flm=0;
fan=0;
}

If (digitalRead (GasPin)==HIGH)
{
gas=1;
}
else
{
gas=0;
}

gettemp ();
sendBT ();
display ();
delay (200);
}
void gettemp ()
{
val = analogRead (TempPin);
mv = (val/1024.0) *5000;
cele = mv/10;
if(cele>settemp||gas==1||flm==1)
{
wirn=1;
}
else
{
wirn=0;
}
}
void sendBT ()
{
BT. print("*T");
BT. print (String(cele));
BT. Print ("*");

BT. print ("*W");

if(wirn==0) {BT. print (String("R0G255B0"));} //green
if(wirn==1) {BT. Print (String("R255G0B0"));} //red
BT. Print ("*");

BT. print("*G");
if(gas==0) {BT. print (String("R0G255B0"));} //green
if(gas==1) {BT. Print (String("R255G0B0"));} //red
BT. Print ("*");

BT. print ("*F");

if(flm==0) {BT. print (String("R0G255B0"));}
//green if(flm==1) {BT. Print
(String("R255G0B0"));} //red BT. Print ("*");

BT. print ("*N");

if(fan==0) {BT. print (String("R0G255B0"));}
//green if(fan==1) {BT. Print
(String("R255G0B0"));} //red BT. Print ("*");

BT. print("*L");
if(lit==0) {BT. print (String("R0G255B0"));} //green
if(lit==1) {BT. Print (String("R255G0B0"));} //red
BT. Print ("*");

}
void display ()

{
lcd. clear ();
lcd. setCursor (0, 0);
lcd. println ("Gas Sensor:");
if(gas==1) {lcd. Println ("Alert");} //warning
if(gas==0) {lcd. Println ("Normal");} //normal
lcd. setCursor (0, 1);
lcd. println ("Room Light.:");
if(lit==1) {lcd. println("ON");} //warning
if(lit==0) {lcd. println("OFF");} //normal
lcd. setCursor (0, 2);
lcd. println ("Fir. :");
if(flm==1) {lcd. Println ("Alert");} //warning
if(flm==0) {lcd. println ("Normal");} //normal
lcd. setCursor (0, 3);
lcd. println ("Room Temp.:");
lcd.print(cele);
}
 CHAPTER-4

4.1 PHYSICAL MODEL

Figure 4.1 - Physical Model of Arduino Controlled Industrial Protection System

4.2 COMPONENTS USED

Figure 4.2 - Components used for Physical Model of Industrial Protection System
4.3 FUTURE SCOPE
Industrial protection system powered by the temperature sensor (LM35), IR Flame Sensor,
Gas Sensor (MQ4) and Light Sensor (LDR) would further develop into a smart system which
[7]
would keep updating itself from the everyday functioning of the Industry using IoT.
IoT would operate keeping in mind afresh on the old database of hazards in similar industries
and also the communication modules can be of various types with a great further scope of
development to not only provide free bandwidth for better communication between online
systems and the offline module but also help create self-sustainable automated smart
industrial protection system.

Figure 4.3 - IoT Based Industrial Protection System

4.4 CONCLUSION
In this project various sensors like temperature, gas, flame and also light to enable the
industry to deal with safety issues. The bluetooth module (HC05) is used as a communication
block in this project while the coding and controlling is taken care of by the Arduino UNO.
The systems can be monitored and controlled by a Mobile App. This system is quite efficient
in handling most of the hazards the Industry might face in its running lifetime.

This system can alert and also provides the immediate remedy for any abnormality detected
by the sensors. With further development of Big Data, Cloud Computing and IoT
Technologies, this system would be capable of taking smart decisions during times of
mayhem, but this would further call for a development in communication module as well as
sensors, buzzer, fan and Microcontroller.
4.5 REFERENCES

[1] S.Sai Mahesh, T. Sri Harsha, N Srujan, “Sensors Data Monitoring using IoT & Industrial
Protection System” IJSRD- International Journal for Scientific Research and Development,
Vol 6, Issue 02, 2018. ISSN (online) : 2321-0613.

[2] Reshma Shindhe, Ritika Pardeshi, Archana Vishwakarma, Nayan Barhate, “Need for
Wireless Fire Detection Systems using IoT” International Research Journal of Engineering
and Technology (IRJET), Volume 04, Issue- 01, Jan, 2017. e-ISSN: 2395-0056, p-ISSN:
2395-0072

[3] Abhishek Sharma, Sudha Pal, Vaishnav jain, “IoT Based Smart Security System for
Prevention of Industrial Hazards” International Research Journal of Engineering and
Technology (IRJET). Volume 05, Issue 03, March 2018. e-ISSN: 2395-0056, p-ISSN: 2395-
0072.

[4] Deepashri K M, Sachidanand P B, “Industrial Appliances Control using Android Mobile

& Bluetooth Technology” International Journal of Engineering and Manufacturing Science
Volume 08, Issue 01. Number 01 (2018), pp. 33-42.

[5] P.Surya Teja, V Murali Krishna, and Dr. Ch. Raju, “Industry Supervision System by using
Arduino & IoT” International Journal for Advanced Research in Electronics and Communication
Engineering (IJARECE), Volume 6, Issue 3, March, 2017. ISSN: 2278-909X.

[6] Bhavik Pandya, Mihir Mehta, Nilesh Jain, Sandhya Kadam, “Android Based Home
Automation System Using Bluetooth & Voice Command - Implementation” International
Research Journal of Engineering and Technology (IRJET), Volume 03, Issue 04, April 2016.
p-ISSN: 2395-0072, e-ISSN: 2395-0056.

[7] BhosaleKiran Uttam, Galande Abhijeet Baspusaheb, Jadhav Pappu Shivaji, Prof. Pisal R.S,
”Industrial Automation using IoT” International Research Journal of Engineering and
Technology (IRJET), Volume 04, Issue 06, June 2017. e-ISSN: 2395-0056, p-ISSN: 2395-
0072.