NAAN MUDHALVAN

EMBEDDED SYSTEM DESIGN FOR

INDUSTRIAL APPLICATION
UNIVERSITY COLLEGE OF ENGINEERING
PANRUTI
TITLE: IOT BASED MOTOR CONTROL

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

ENGINEERING

1. 422620105306 P.SRIPRASANNAA
2. 422620105301 V.JEEVA BETHAN
3. 422620105006 V.DEEPA
4. 422620105313 P.SELVAKUMAR

COURSE COURSE HEAD OF DEPARTMENT

INSTRUCTOR COORDINATOR
 TABLE OF CONTENT

CHAPTER NO. TITLE PAGE NO

LIST OF FIGURES

LIST OF TABLES

NOMENCLATURE

ABSTRACT 1

1 INTRODUCTION

1.1 Introduction 2

1.2 Existing system 3

1.3 Proposed system 4

2 LITERATURE REVIEW

2.1 Literature review 5

2.2 Objective of the thesis 7

2.3 Organization of the thesis 7

2.4 Summary 7

3 BLOCK DIAGRAM

3.1 Existing system 7

3.2 Proposed system 8

iv
 3.3 Components

3.3.1 Arduino UNO 9

3.3.2 GSM Module 10

3.3.3 Load cell 10

3.3.4 HX711 Module 11

3.3.5 NO NC Relay 11

3.4 Working principle 12

3.5 Flow chart 13

3.5.1 Flowchart explanation 14

4 HARDWARE DESCRIPTION

4.1 Connection and design

4.1.1 Schematic of the Arduino UNO 16

4.1.2 Schematic of the GSM Module 17

4.1.3 Schematic of the Load cell 18

4.1.4 Schematic of the HX711 Moule 19

4.1.5 Schematic of the NO NC Relay 20

V
 4.2 Hardware description

4.2.1 Design of the overall hardware system 21

5 CONCLUSION

5.1 Conclusion 22

6 REFERENCES

6.1 References 23

vi

LIST OF FIGURES
FIGURE. NO. TITLE PAGE. NO.

3.3.1 Arduino UNO 10

3.3.2 GSM module 11

3.3.3 Load cell 11

3.3.4 HX711 module 12

3.3.5 NC NO relay 12

3.4 GVM and GTM Standards 14

3.5 Flow chart 15

4.1.1 Schematic of the Arduino UNO 17

4.1.2 Schematic of the GSM module 18

4.1.3 Schematic of the load cell 19

4.1.4 Schematic of the HX711 module 20

4.1.5 Schematic of the NC NO relay 21

4.2 Hardware description 22

vii

LIST OF TABLES
TABLE TITLE PAGE NO

3.4 GVM and GTM standards 14

NOMENCLATURE

GSM Goble system for mobile

GVM Gross vehicle mass

GTM Gross tolerances mass

WIM Weigh – In – Motion

NO Normally open

NC Normally closed

viii
 ABSTRACT

The commonly used over load shutting down are wire fuse method which was
suggested by DEO for schooling Autos and Vans. Frequent replacement of fuse is needed
which will damage the system’s sensitivity that was the main drawback of the system.
We are going to evolve the system by using relay (which is normally closed and it opens
when it is trigged). And a GSM module used to interface with the microcontroller (such
that it will acts like a IOT based devices). The GSM module will send SMS to the DEO’s
system automatically whenever the vehicle reaches the semi-over load and overload
condition (vehicle’s system will be shutdown automatically).

1
 CHAPTER 1

1.1 INTRODUCTION

Now a days, many of the accidents of heavy vehicle happening due to over loading of vehicle
more than their limit. For an example, [1] recently in New Delhi 3 fatal accidents involving
heavy vehicles have been reported in the city, which have raised concerns over safety standards
possibly being overlooked by the owners and drivers of the vehicles. Till May 30 this year, 74
people were killed in 72 accidents involving trucks and heavy vehicles. While overloading the
vehicle, its losses their moment of inertia and Centre of gravity which leads to unsafe driving of
the vehicle by the drivers. Government was can’t able to control vehicle load tampering by the
drivers even though GVM Standards given by them.

Vehicles overloading can’t be controlled but the motion vehicles controlled. The motion control
can the vehicle are carried out by many methods. One of those method is wire fuse method. In
that method a wire is connected to suspension of the vehicle.

Whenever the vehicle is overloaded, the suspension of the vehicle is fully compressed, wire
Contact with the suspension which lied to breaking of circuit. This wire is replaced by series
Connected network. The network is consisting of GSM Module, Arduino UNO, Relay modules
and Load sensor. The GVM and GTM was adopted from the government guidelines.

2
1.2 EXISTING SYSTEM

All most all over the world load detection system is commonly used and for tracking purposes
additional device is used. Generally, the load detection system will be motoring the load carried
by the vehicle. Whenever the fixed level or critical level of loading is reached the system will
detect it automatically and the system will intimate the driver by an alarm or warning sound like
beep sound, extra. It is easily by passed by disconnecting the speaker or placing the device in a
sound resistance or sound proof area. When we coming to overload shutting down methodology
wire fuse method is used. Fuse wire or wire from fuse is connected to suspension system of the
vehicle. When the suspension of the vehicle is fully compressed (such that the vehicle is fully
loaded) fuse wire or fuse will break the circuit. This method is not commonly used, it is used in
the spring suspension vehicle only such that Autos, Tricycle, Minivan, etc. Even though it is
used in spring suspension vehicle, occurrences of error are cent percent and it will damage the
sensitive part of the vehicle system. When the process is accomplished, fuse should be replaced
to ignite the vehicle. It is a time taking process. Because of this, this method is not
recommended.

3
1.3 PROPOSED SYSTEM

To overcome this drawback of the existing system, the fuse wire or wire from fuse is replaced
by a sequence of components. The components are 1. Load detection sensor, 2. Microcontroller,
3. GSM system and 4.NC NO Relay. Depending upon the nature of load detection sensor, the
connecting is differed, for an example pressure type load sensor is used it can be connected in
two ways 1. Connected in between the axle bar and the base of the tipper of the vehicle. 2.
Connected in the spring end of the leaf suspension. In this prototype load cell type load
detection sensor is used. Microcontroller is powered by the vehicle battery supply and it is
controlling the entire unit. NC NO Relay is connected in between the fuse and the remaining
circuit of the vehicle at NC end of the relay. There by the drawbacks are overcoming, there no
fuse replaced is required and it came be easily ignite the vehicle by removing the excess load
and restarting the vehicle. The critical value is fixed as per the guideline of GVM of the
transport vehicles after revised safe axe load given by the government. The fixed GVM value is
chosen as the critical value to turn ON the system.

Government was permitted up to 5% tolerance during transport. This 5% tolerance limit

(GTM) is considered as the semi-over load condition. In this condition, the system will detect it
and it will send warning note to the reviser by the SMS through the GSM system. Beyond the
GTM limit, the system falls under over load condition. During this condition, the system will
send an alert note to reviser and the microcontroller will turn ON the relay and the circuit is
break by the relay. Even though, the system was restarted the vehicle can’t be ignited until the
load is removed. Since it is a prototype GSM limited is chosen as 1.5 kg and the GTM is chosen
as 1.75 kg.

4
 CHAPTER 2
2.1 BASIC PRINCIPLE AND LITERATURE REVIEW
In the transport vehicles, load monitoring system is commonly used worldwide. In that system a
load monitoring sensor is placed in the vehicle, the sensor sends signals to the microcontroller
and that will process through it and fellows the company’s guidelines. Finally results in
producing a warning sound to the driver. For tracking of vehicle, a GSM system is incorporated
technological device is placed in the vehicle additionally. Many errors were happened to
irrelevant compression of the sensor in normal condition due damaged roads, ups and downs,
sudden breaking causing failure of it. Load monitoring is necessary to maintain the vehicles
durability, quality and capability of the vehicle. Every vehicle has their own standards like
tolerance level, speed capability etc. Governments are also set certain parameters GVM, GTM
etc., that should be followed by the transporting vehicles. Load monitoring system helps the
driver and owner to maintain to those limitation and parameter constantly.
1. Load detection system, in this a magnetoresistance distance sensor is placed in between the
body of the trailer and the axle line of the vehicle. This sensor maintains a constant distance
between the body and the axle line. Whenever the distance is reduced such that sensor
compressed the system will produces a warning sound [2].
2. Load tracking not only placed in vehicle; few systems are placed in the road by the
government for monitoring purposes. WIM (weigh – in – motion) and overload detection
system for Freight vehicles used in Indonesia [3-8].
3. This system was used to maintaining road pavement quality in several area in Indonesia is
essential since logistic distribution is mainly carried using land transportation.
4. Overloaded vehicle runs over the WIM, axle weight will be automatically recorded, and the
data is processed further to assess the compliance to maximum freight weight specified for that
vehicle by the government.
5. A vehicle overload detection system is proposed on geophone. Under normal circumstances,
when overload vehicles and ordinary vehicles pass through the road, the amplitude of the
ground vibration will be different, and the geophone sensor can detect tiny vibration of the
ground [9-14].
6. Based upon the vibration the system will classify the types of vehicles and loads in it. Based
on that result the system will note the data of the vehicle crossing it.
7. Load cell-based load monitoring system, in this system a pavement platform was made with
the load cell. Whenever the overloaded vehicle crossing over the platform, the system is
triggered by the Arduino, and the photo of the vehicle was captured by it [15].

5
2.2 OBJECTIVES OF THE THESIS
The main objective of the thesis is to design a protection system prototype using Arduino UNO
implementation and to prevent the mechanical over loading of the transporting vehicle which
will increase the life time of the vehicle and reduces the risk involved in the overloading vehicle
such as accidents extra.
2.3 ORGANISATION OF THE THESIS:
This thesis consists of six chapter.
Chapter 1 notifies a general introduction to motion control of the overloaded vehicle and
proposed methodology of the project.
Chapter 2 briefly explains the basic theory related to prototype and reviews some important
literatures and some previous related works.
Chapter 3 presents the design and specification of components that needed on constructing the
prototype and also explains how the block diagram and flow chart work along with the
schematic and the overall prototype.
Chapter 4 presents the schematic diagram representation of the components used in the
prototype.
Chapter 5 is for conclusions and future research recommendation

2.4 SUMMARY
In this chapter, the general introduction to design an over load shutting down system prototype
using Arduino UNO implementation. The review of objectives of this work along with the
thesis organization have also been briefed.

6
 CHAPTER 3
3. BLOCK DIAGRAM

3.1. EXISTING BLOCK DIAGRAM

Battery Fuse Key set panel Engine

Leaf suspension

Fig.3.1 EXISTING BLOCK DIAGRAM

These was the existing system’s block diagram. The general blocks in all vehicle are battery,
fuse, keyset wiring and fundamental wiring like head light wiring, indicator wiring, etc. An
additional wiring is added to fuse, as shown the block diagram. The other end of wire is
connected to spring suspension as shown. When the spring of the suspension is compressed
entirely due to heavy load, the wire is gotten short circuit this will lead to increasing in current
because of this, the fuse is getting break and the entire circuit is get open circuited, so the engine
can’t be ignited and finally the motion of vehicle is controlled. Though the system is so simple,
occurrences of error is high since the suspension of the vehicle will be fully compressed while
driving in bad road (ups and downs in the damaged road). Once this system is executed, they
can’t be restarted easily, until fuse is replaced by a new one, the vehicle can’t be ignited by the
driver. Because of this, the system is not widely used by the consumer.

7
3.2 PROPOSED BLOCK DIAGRAM

Battery Fuse Relay Engine Key set panel

HX711 Load
Arduino
Module Cell

GSM
Module

User
System

Fig. 3.2 PROPOSED SYSTEM’S BLOCK DIAGRAM

This is proposed system’s block diagram. The existing system is update by the series connected
embedded system components. The wire is replaced by load sensor, microcontroller and NC NO
relay module. The load sensors are mostly pressure transductor type since the parameter
considered is pressure applied by load. The relay is connected to the circuit at normally closed
side of it. The output from the sensor is processed by the microcontroller, when the output value
exceeds the GTM value, the microcontroller will turn ON the relay unit. Whenever the relay is
turned ON, the relay opens the circuit thereby the vehicles motion is controlled. Once the
system is executed the operation, the vehicle is restarted by pressing the restart switch of the
microcontroller.

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3.3 COMPONENTS

3.3.1 ARDUINO UNO

Fig 3.3.1 ARDUINO UNO

The Arduino UNO is an open – source microcontroller board based on the Microchip
ATmega328p microcontroller and developed by Arduino.cc. The board is equipped with sets of
digital and analog input/output(I/O) pins that may be interface to various expansion boards and
another circuit. The board has 14 digital(I/O) pin.

9
3.3.2 GSM MODULE

Fig 3.3.2 GSM MODULE 800

3.3.3 LOAD CELL

Fig 3.3.3 LOAD CELL

10
3.3.4 HX711 MODULE

Fig 3.3.5 NC NO 5V RELAY MODULE

Fig 3.3.5 NC NO 5V RELAY MODULE

11
WORKING PRINCIPLE
This prototype consists of two major consents: Semi-over load and Overload. The first
consent is Semi-over load condition. the government was permitted 5% tolerance with GVM of
the vehicle. That 5% tolerance is considered as GTM of the vehicle. The programing condition
of the microcontroller is simpler in this consent, the microcontroller will sense the GTM such
that semi-over load with the help of the load sensor and send warning message to predefined
number given by consumer with the help of the GSM module.
The second consent is the overload condition. when the output value exceeds the GTM value,
the system is automatically falls under this condition. In this condition, the microcontroller does
two operations simultaneously. One of the operations is turning ON the relay module, there by
the circuit is open circuited. And another one is sending alert message to the same predefined
number given by the consumer thought the GTM module.
The occurrences of error are rectified by taking of several output data from the load sensor for
a period of time again and again so the malfunction of the system is reduced. When the same
output value is detected by the microcontroller the process will be carried out by the
microcontroller, until the microcontroller will monitor the sequences continuously.
The GTM value of the vehicles are varies depending upon the nature of the vehicle. So that
same program can’t be used for all vehicle. Depending of the purpose the program is modified.
For an example 6 Tyree truck has GVM value 19,000 KGS and the GTM value 19,950 KGS.

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 Table 3.4 GVM and GTM standards

TYPES OF VEHICLES GVM(KGS) GTM(KGS)

6 Tyree Trucks 19900 19950
10 Tyree Trucks 28500 29925
14 Tyree Trucks 40000 42000
Vans 2000 2200
Mini Buses 3700 4030
Buses 6500 7150
Autos 500 550

Table 3.5 GVM and GTM values

13
 start

Port Initialization

Get a = Output value from the load sensor

Delay 10 sec Delay 10 sec

Get b = Output value from the load sensor

If
a=b

YES
NO YES
If b > GTM

GSM ON GSM ON

Send a warning SMS Send an alert SMS

Relay OFF Relay ON

stop

Fig 3.6 FLOW CHART

14
3.6.1 FLOW CHART EXPLANATION

Ports were initialized for the GSM module (TX, RX), Relay module (13), and Load cell
amplifier (3,4). The output value of the amplifier is initialized as a. Delay for 10 sec (this delay
process is done to reconfirm the output value). The present output value is initialized as b. Until
the a = b condition is satisfied, the above process is carried out again, and again. When the
condition is satisfied, it follows another condition a > GTM. If YES, the system carried out the
overload condition. If it is NO, the system falls on the semi-overload condition.
SEMI-OVERLOAD CONDITION, the GSM module is powered ON. The GSM module
receive signal from the Arduino, and send warning message such that “VEHICLE IS UNDER
TOLERANCE LIMIT”. The relay module is turned OFF.
OVERLOAD CONDITION, the GSM module is powered ON. The GSM module receive
signal from the Arduino, and send alert message such that “VEHICLE CAN’T BE RUNNED,
DUE TO OVERLOAD”. The relay module is turned ON and trips the circuit of the vehicle,
there by the motion of the vehicle can be controlled.

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CHAPTER 4
HARDWARE DESCRIPTION

4.1 CONNECTION DESIGN

4.1.1 SCHEMATIC OF THE ARDUINO UNO

Fig 4.1.1 SCHEMATIC OF THE ARDUINO UNO

16
4.1.2 SCHEMATIC OF THE GSM MODULE

Fig 4.1.2 SCHEMATIC OF THE GSM MODULE

17
4.1.3 SCHEMATIC OF THE LOAD CELL
 Fig 4.1.3 SCHEMATIC OF THE LOAD CELL

18

4.1.4 SCHEMATIC OF THE HX711 MODULE

 Fig 4.1.4 SCHEMATIC OF THE HX711 MODULE

19

4.1.5 SCHEMATIC OF THE NO NC RELAY

 Fig 4.1.5 SCHEMATIC OF THE NO NC RELAY

20
4.2 HARDWARE DISCRIPTION
 Fig 4.2 HARDWARE DISCRIPTION

21
CHAPTER 5

5.1 CONCLUSION
 The prototype employed the implementation of Arduino UNO as the controller to control the
motion the over loaded vehicle, implementation of code to the Arduino UNO to show the
working of the system. This prototype has been successfully tested by users which controls the
motion of the vehicle.
There are several improvements that can be developed in the future (a) the source code can
be modified and can be used as Smart lock also. (b) The system can be evolved, by using an
android application like Where is My Train, by this we can detect the speed of the vehicle and
current location.

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CHAPTER 6

6.1 REFERENCES
[1] Pankhuri Yadav and Sakshi Chand, “How overloaded and heavy vehicles pose threat to
commuters in Delhi”, in THE TIMES OF INDIA, 2022.
[2] Xin-Xin Qiao, Yi-Ding Zhao, “Vehicle overload detection system based on
magnetoresistance sensor” 2018 International Conference on Electronics Technology
(ICET), 102-108, 2018.
[3] A H Masyhur, I P Nuprasetio, B A Budiman and T P B Utomo, Design and Prototyping of
Weigh- In – Motion and Overload detection system for Fright vehicle, ISAIME,2019.
[4] Public Works Office 2011 Minister of Public Works Regulation No. 19 Year 2011 on Road
Technical Requirements and Design Criteria (Jakarta – PUPR) – in Indonesian.
[5] Budget Review Center, Indonesian People’s Representative Council 2017 Road Preservation
Study 2015 and 2016 (Jakarta: DPR RI).
[6] Wang H, Zhao J and Wang Z “Impact of Overweight Traffic on Pavement Life Using weigh-
In-Motion Data and Mechanistic – Empirical Pavement Analysis” (Department of Civil and
Environmental Engineering, The State University of New Jersey), 2015.
[7] Jacob B and Beaumelle V, “Improving Truck Safety” in Potential of Weigh – in – Motion
Technology IATSS Research, 2010.
[8] Xiong L, Zhuo F, Liu X, Wang F and Chen Y, Optimal Design of Moving Average Filter an
Its Application in Distorted Grid Synchronization, 2015 IEEE Energy Convers.
[9] Siquan Hu, Min Kong and Chundong She, Design of vehicle Overload Detection System
based on geophone, ISAI,2017
[10] Huang P Y “Journal of Qiqihar University” in Natural Science Edition 2016.
[11] Luo F L, Yi B J and Luo L B Equipment for Geophysical Prospecting in 2005.
[12] Istiaq Jamil Siddique, Mohammad Ishak Khan, Muhammed Mahbuhur Razzaque,
“Development of Economical Overload Detection system for Maritime Vehicles in
Bangladesh, in Journal of Maritime Research 14 (3), 75 – 78, 2017.
[13] Libo Zhuo, Gang Wu, “An overload behavior detection system for engineering transport
vehicles based on deep leaning” in AIP Conference Proceedings 1955 (1), 040038, 2018.
23
[14] Arno de Coning, Alwyn J Hoffman, “Overload Control Centre bypass detection system”
in17th International IEEE Conference on Intelligent Transport Systems (ITSC), 1904 –
1905, 2014.
[15] Tiangong Hu, “A framework of truck overload intelligent monitoring system”, in 2011
Fourth International Symposium on Computational Intelligence and Design 2, 107 – 110,
2011.
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