Design and Development of remote monitoring system for data flow and storage of spm using systems engineering approach

PC-based data monitoring uses a combination of modular hardware, application software, and a computer to take measurements. These systems share the common goal of data acquisition and processing of information. Data monitoring system or data acquisition system consists of a Main server PC for acquisition of number of channels. They acquire the data from sensor that are connected to different location and displayed in different units to display the information to operator and also to the main server.

This thesis is a development of Remote Data Monitoring System Engineering approach which is recommended to increase the effectiveness of plant operators so that the Machine data could be stored electronically. This system records process data of Special Purpose Machine wired to an electronic data collection system and to record the machine operation. Operators are able to manually collect the processed data and condition them to make the data available to users. System ensures the operator inspects the equipment at certain intervals and also checks the condition of machine. System also has the capability of automatic processing. This module is designed to be real time, low cost, light weight, portable and low power.

A hardware setup is developed and simulated using design software Proteus. Hence the control logic has been developed and implemented on two separate PIC microcontrollers, one for the remote operator panel of SPM‘s and the other for Master PC. A 4x4 matrix keypad is interfaced with the microcontroller on SPM unit which is used for sending the SPM data, by the machine operator. A 16x2 LCD is also interfaced to the controller in the SPM. The status of a key pressed is continuously displayed on to LCD. Microcontroller used at the Master PC, which always receives data from the SPM section, when any change occurs in its status. The front end panel for the master PC is designed using Lab VIEW. System continuously record the data in an excel sheet for 16 hours. From the study we conclude that the proposed system can totally eliminate the need for a human resource for monitoring data that would otherwise be required.