Supervision Made Easier

COMPANY PROFILE:
KVS Technologies is a partnership company

promoted and managed by Kalpesh R. Vaghela and Shankar P. Sapavadiya. Main area of interest is with pharmaceutical industries. KVS Technologies Provides Validation, Services to the Pharmaceutical, Biotechnology and Medical Device Industries.

OUTLINE:
Introduction: What is Fault Diagnosis?

Importance: Requirement of fault diagnosis ?

Components: What is involved? Overview: How does the Hardware Work? Algorithm Details: How does it Work? Scope: Fault Diagnosis in Different Fields ?

What is Fault Diagnosis?

Fault: The partial or total failure of a device or

a system. Diagnosis: The ability to recognize where exactly has a failure taken place in the device or a system Detection: The ability to recognize that a fault has occurred in a device or a system.
Hence , Fault Diagnosis is nothing but the detection of any fault in a given device or system.

Need of fault diagnosis:

Pinpoints Problems.

Determines the Health of the System

Improves Operation Reliability. Reduces Operational Cost. Improves Maintenance.

Need of fault diagnosis: Cont..

If Faults are recognized

earlier they can be corrected and any damage to the system can be avoided. Accidents and Loss of Productive time can be avoided.

Need of fault diagnosis: Cont..

With a SMS system

attached to it the supervisor and the stations close by can be directly alerted without any wasting any time.

List of hardware used: Components

MICROCONTROLLER AT89S52

2X16 LCD
BUZZER MAX232 ADC0809 GSM MODULE

BLOCK DIAGRAM:
+ N1 N2
230 V

LM358
AC V AC A

2 16 LCD

CD 4093

ADC 0809

230 V

AUX POWER
5V 12 V

AT89S52

BUZZER
MAX 232

DR IVER

R ELAY

DR IVER
N2 N2

D2

GSM M O D EM

N1

N1

L M

L M

L M

N1

N2

PCB Layout:

Detail Circuit Diagram:

Block Diagram Description:

Voltage and Current are sensed by terminal PT and CT

respectively.
Detector circuit gives DC voltage proportion to the AC

parameters.
ADC measures this DC voltage and gives digital output. This digital output is measured by microcontroller and

measured values are displayed on LCD.

Block Diagram Description: Cont..

We can set voltage and current limit using

switch board.
If the voltage or current parameter measured

value exceeds the limit, alarm is created and

load is tripped and a SMS is send to other

station with the help of the GSM modem.

Block Diagram Description: Cont

In addition we are sensing the status of three fuses

through 3 points.
If fuse failure is there, the respective transistor conducts

and output becomes low.

This is sensed by the microcontroller and the status is

displayed on the LCD.

It also generates a local alarm and sends SMS to other

station through GSM modem.

Functions of the blocks used:

Microcontroller:
AT89S52 microcontroller is used here to which are attached an LCD, Buzzer and a relay. AT89S52 is a low power , highperformance CMOS 8bit

microcontroller with 8K bytes of insystem memory. programmable Flash

Functions of the blocks used:

LCD:
A 216 LCD is used for displaying the fuse, the voltage and current status.

Buzzer:
It sounds when the value of voltage or current increases beyond the pre-

defined value or when any of the fuse fails.

Relay:
This part is for the purpose of disconnecting the power supply when the balance reach zilch.

Functions of the blocks used: Cont

ADC0809:

CD4093 is a Schmitt gate and a 10k resistor with

1F capacitor gives 10 sec clock which is required

for ADC0809. ADC reads the DC voltage from the

voltage detector and current detector . It gives the

digital output which is read by the

microcontroller and displayed on LCD.

Functions of the blocks used: Cont

MAX 232:

Max 232 is required for interfacing the controller and GSM modem

GSM Modem:

It takes serial input from microcontroller and sends SMS to the

telephone number programmed. The GSM system is a frequency and time division system; each physical channel is characterized by a carrier

frequency and a time slot number. A GSM system frequency includes

two bands at 900 MHz and 1800MHz commonly referred as GSM-900 and DCS-1800.

Flow Chart:
Start

Configure LCD

Declaration of Variables

Initialization of Ports/Variables

LOOP

Delay 20 ms

Measure AC Voltage Measure AC Current

Read Status of Fuse 1

Read Status of Fuse 2 Read Status of Fuse 3

No

Is SW 1 pressed ?

Yes Send SMS

No

Is SW 4 pressed ?

Yes
Set Limits

No

Is AC V >OVLIMIT ?

Yes
Give OVALARM Send SMS

No

Is AC V <OVLIMIT ?

Yes Give OVALARM

Send SMS

4 No

Is AC A >OCLIMI T?

Yes Give OCALARM Send SMS

No

Is Fuse Failure ?

Yes Give Fuse Failure Alarm Send SMS

No

Is Parameter OK ?

Yes

Reset Alarm CLS Display Parameters on LCD

Scope:
Fault diagnosis is a complex interdisciplinary research field

that covers a wide and diverse range of engineering and science areas.
System modeling and identification, applied mathematics,

reliability and risk analysis, computing, communication,

control, signal processing, sensors and actuators as well as hardware and software implementation techniques all require fault diagnosis.

Scope Cont.. :
It also has a very wide application area

including many safety critical , life critical, and mission critical engineering systems in aerospace ,electrical, computer, and software engineering, mechanical and manufacturing , chemical and petrochemical, medical and biomedical engineering etc.

Scope Cont.. :
In the drive towards good manufacturing

practice and towards guaranteeing safe and efficient operation of end products under disturbed or fault conditions, support to and automation of fault analysis is essential.

Scope : Cont..
Occurrence of faults or equipment failure is a major cause

of suboptimal operation.
There is a growing realization that maintenance of the

equipment and the control loops in the face of such fault is the key to achieving long term economic success.
As a new emerging area in automatic control, fault

tolerant control has attracted more and more attention in recent years.