Biju Patnaik University of Technology Rourkela

BIJU PATNAIK UNIVERSITY OF
TECHNOLOGY ROURKELA, ODISHA
A Major Project Report On
DESIGN, ANALYSIS AND

DEVLOPMENT OF REAL-TIME
INDUSTRIAL SAFETY SYSTEM
USING NODEMCU
Submitted By
2121294100 Aditya Chandra Biswal
2121294099 Abinash Dhal
2121294098 Abhishek Tripathy
2121294105 Anil Kumar Tripathy
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Raajdhani Engineering College
Bhubaneswar, Odisha-751017
Session-2024-25
BIJU PATNAIK UNIVERSITY OF
TECHNOLOGY ROURKELA, ODISHA
DESIGN, ANALYSIS AND DEVLOPMENT OF REAL-TIME

INDUSTRIAL SAFETY SYSTEM USING NODEMCU
A Major Project submitted in partial fulfillment of the requirements for the
Degree of
Bachelor of Technology in Electrical Engineering

by
Under the guidance of
Prof. Durga Prasanna Mohanty
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Raajdhani Engineering College
Bhubaneswar, Odisha-751017
Session-2024-25
BIJU PATNAIK UNIVERSITY OF TECHNOLOGY, ODISHA
Raajdhani Engineering College,
Bhubaneswar, Odisha
CANDIDATE’S DECLARATION
We hereby certify that the work which is being presented in the Project entitled
“DESIGN, ANALYSIS AND DEVLOPMENT OF REAL TIME INDUSTRIAL
SAFETY SYSTEM USING NODEMCU” in partial fulfillment of the requirements for
the award of the Degree of Bachelor in Technology and submitted to the Department of
Electrical & Electronics Engineering, Raajdhani Engineering College, Bhubaneswar,
Odisha is an authentic record of our own work carried out during the Academic Session
2024-25 under the supervision of Prof. Durga Prasanna Mohanty, Asst.Prof, REC,
Bhubaneswar, Odisha.
The matter presented in this Project has not been submitted by us for the award of any
other degree of this or any other Institute/University.
This is to certify that the above statement made by the candidate is correct to the best of
my knowledge.
Signature of Guide Signature of HOD

Prof. Durga Prasanna Mohanty Prof. Durga Prasanna Mohanty
Dept. Of Electrical & Electronics Engineering Dept. Of Electrical & Electronics Engineering
Raajdhani Engineering College, Bhubaneswar Raajdhani Engineering College, Bhubaneswar
Signature of External Examiner

BIJU PATNAIK UNIVERSITY OF TECHNOLOGY
ROURKELA, ODISHA
RAAJDHANI ENGINEERING COLLEGE

BHUBANESWAR-751017
ODISHA.
Bonafide Certificate
This is to certify that the project report entitled “DESIGN, ANALYSIS AND
DEVLOPMENT OF REAL TIME INSYSTRIAL SAFETY SYSTEM USING
NODEMCU” submitted by Aditya Chandra Biswal, Anil Kumar Tripathy, Abhinas
Dhal, Abhisek Tripathy to Biju Patnaik University of Technology, Rourkela, Odisha
towards partial fulfillment for the award of the Degree of Bachelor of Technology in
ELECTRICAL & ELECTRONICS ENGINEERING with this is a Bonafede record of
the work done under my supervision and guidance.
This project report has not been submitted to any other University or institute for the
award of any degree.
Signature of HOD Signature of Guide

Prof. Durga Prasanna Mohanty Prof. Durga Prasanna Mohanty
Dept. Of Electrical & Electronics Engineering Dept. Of Electrical & Electronics Engineering
Raajdhani Engineering College, Bhubaneswar Raajdhani Engineering College, Bhubaneswar
Signature of External Examiner

AKNOWLEDGEMENTS
We are grateful to The Dept. of Electrical Engineering for giving us the
opportunity to execute this project, which is an integral part of the curriculum in
B. Tech programming at the Raajdhani Engineering College, Bhubaneswar.
We will greatly be thankful to our respected and beloved Principal Prof. (Dr.)
Alok Kumar Mohapatra and our HOD Prof. Durga Prasanna Mohanty
who are the backbone for the success of our project. We would like to thank
Prof. Durga Prasanna Mohanty, HOD of Electrical Engineering Department
for his guidance, support and direction without which project would not have
taken shape. We would also like to take his opportunity to express heartily
gratitude for our project guide Prof. Pradyumna Mallick. Who provided us
with valuable inputs at the critical stage of the project execution.
It's our sincere thanks to all the Faculty Members of our department for their
immense support during the research work, & also thank the Non-Teaching
Staff Members of our department for their kind support and help in carrying out
the research work. And last but not the least we also thank my Parents &
Friends for their co-operations and encouragement in successfully completing
the project work.
Signature Regd. No.

ADITYA CHANDRA BISWAL 2121294100
ABHISHEK TRIPTHY 2121294098
ABINASH DHAL 2121294099
ANIL KUMAR TRIPATHY 2121294105
Date:
Place:Bhubaneswar
1. ABSTRACT:
This project aims to design a real-time industrial automation system with an
integrated safety control mechanism. The primary objective is to automate
industrial processes while ensuring the safety of both the machinery and the
personnel involved.
The system leverages advanced technologies such as IoT, AI, and Machine
Learning to monitor and control various industrial operations in real-time. It
includes sensors for data collection, actuators for process control, and a
central processing unit for decision-making.
The safety control system is designed to detect potential hazards and respond
promptly to prevent accidents. It uses predictive algorithms to anticipate
failures and trigger preventive measures. The system also includes
emergency stop functions and safety interlocks to ensure safe operation.
The project demonstrates the potential of integrating automation and safety
control in industrial settings. It highlights the importance of safety in
automation and provides a blueprint for future industrial automation projects.
The system’s real-time capabilities enhance efficiency, productivity, and
safety in industrial operations.
This project serves as a significant contribution to the field of industrial
automation, paving the way for safer and more efficient manufacturing
processes. It underscores the critical role of safety control systems in real-
time industrial automation.
TABLE OF CONTENTS
Abstract V
Table of Contents VI
CHAPTER-1 INTRODUCTION 1-5
1.1 Overview 01
1.2 Literature review 04
1.3 Objective 04
1.4 Motivation
CHAPTER-2 INDUSTRIAL AUTOMATION USING LOCAL ID 10-20
3.1 SYSTEM DESIGN 10
3.2 AUTOMATION SYSTEM DESIGN CYCLE 11
3.2.1 CHARACTERSTICS OF AUTOMATION SYSTEM 12
3.2.2 APPLICATIONS 13
3.2.3 CLASSIFICATIONS 14
3.2.4 HARD REAL TIME SYSTEM 16
3.3 PROJECT BLOCK DAIGRAM 17
20
CHAPTER-4 HARDWARE REQUIREMENTS 21-29
4.1 TRANSFORMER 21
4.2 VOLTAGE REGULATOR 7805 22
4.3 RECTIFIRE 25
4.4 FILTER 26
4.5 NODEMCU 26
4.6 PUSH BUTTON 26
4.7 RELAY 27
4.8 LED 28
4.9 IN4007 28
5 PN JUNCTION OPERATION 29
5.1 RESISTORS
5.2 CAPACITORS
5.3 RELAY DRIVER
5.4 BUZZER DRIVER
5.5 INDICATOR FOR PLC
CHAPTER-7 CONCLUSION AND SCOPE FOR FUTURE WORK 66-67
7.1 Conclusions 66
7.2 Scope For Future Work 67
REFERENCES 68
Chapter 1
Introduction
Background:
The advent of Industry 4.0 has revolutionized the way industrial processes
are carried out. Automation, coupled with real-time monitoring and control,
has become a cornerstone of modern industrial operations. This project
focuses on the design and implementation of a real-time industrial
automation system with an integrated safety control mechanism.
The system is designed to automate various industrial processes, including
but not limited to manufacturing, assembly, and quality control. It leverages
advanced technologies such as Internet of Things (IoT), Artificial
Intelligence (AI), and Machine Learning (ML) to monitor and control these
processes in real-time. The system can collect data from various sensors,
processing this data to make informed decisions, and controlling actuators to
carry out these decisions.
The safety control mechanism is an integral part of the system. It is designed
to ensure the safety of both the machinery and the personnel involved in the
industrial processes. The safety control mechanism includes features such as
hazard detection, emergency stop functions, and safety interlocks. It uses
predictive algorithms to anticipate potential failures and trigger preventive
measures.
In addition to these, the system is designed to be flexible and scalable,
allowing it to adapt to different industrial environments and processes. It is
also designed to be user-friendly, with a simple and intuitive interface that
allows operators to easily monitor and control the system. Furthermore, the
system is designed to be robust and reliable, with built-in redundancy and
fault-tolerance mechanisms to ensure uninterrupted operation.
The system also incorporates advanced data analytics capabilities, allowing
it to analyse the collected data and generate valuable insights. These insights
can be used to optimize the industrial
processes, improve product quality, and
reduce operational costs. The system also
includes a comprehensive reporting feature,
which allows operators and managers to
track the performance of the industrial
processes and make informed decisions.
Overall, this project represents a significant
advancement in the field of industrial automation. It not only automates the
industrial processes but also ensures their safe operation, thereby
contributing to the overall efficiency and productivity of the industrial
operations. It is a testament to the potential of technology to transform the
industrial sector and pave the way for a safer and more efficient future.
Overview:
The project at hand is a comprehensive endeavour to revolutionize industrial
automation by integrating a safety control system that operates in real-time.
This system is not merely an upgrade to existing protocols; it is a
transformative approach to how industrial operations are conducted,
monitored, and maintained. The overarching goal is to create a seamless
blend of efficiency, precision, and safety that propels industrial capabilities
into a new era of technological excellence.
At the core of this project lies the development of an intelligent automation
system that can self-regulate, adapt, and execute complex industrial tasks
with minimal human intervention. This system will be equipped with a
multitude of sensors that gather data across various parameters, ensuring that
every aspect of the industrial process is under constant surveillance for
optimal performance and safety.
The integration of a safety control mechanism is a pivotal aspect of this
project. It is not an afterthought but a foundational component that is woven
into the fabric of the automation system. This mechanism will utilize cutting-
edge predictive analytics to foresee potential hazards and implement
corrective measures proactively, thereby safeguarding both human operators
and machinery.
Moreover, the project aims to harness the power of IoT to create a network
of interconnected devices that communicate and collaborate to enhance
operational efficiency. AI and ML algorithms will analyse the data collected
to optimize workflows, predict maintenance schedules, and reduce
downtime, all while ensuring that safety remains uncompromised.
The user interface of the system will be a model of ergonomic design,
providing intuitive controls and clear visual feedback. This will empower
operators to manage the automation system with confidence and ease,
regardless of their technical background.
Scalability is a key objective, as the system is designed to grow and evolve
with the industrial enterprise it serves. Whether it is expanding to new
production lines or integrating with emerging technologies, the system’s
architecture will support a trajectory of growth and innovation.
Environmental sustainability is also a priority, with the system aiming to
minimize the carbon footprint of industrial operations. By optimizing energy
usage and reducing waste, the project contributes to a greener industrial
landscape.
Predictive maintenance is another cornerstone of the project, aiming to shift
the paradigm from reactive to proactive maintenance. This not only enhances
the longevity of equipment but also ensures that production is not halted
unexpectedly, thus maintaining a steady flow of operations.
Compliance with international standards is not just a requirement but a
commitment. The system will adhere to the strictest safety and quality
guidelines, reflecting a dedication to excellence and reliability.
Finally, the project provides robust training and support for all users.
Comprehensive documentation, interactive training modules, and responsive
customer service will ensure that the transition to this new system is smooth
and successful.
In summary, this project is a bold step forward in industrial automation,
promising a future where safety and efficiency are in perfect harmony. It is
an ambitious blueprint for a safer, smarter, and more sustainable industrial
environment.
Litterateur Review:
Cordeiro, Armando, (2018) had represented This study presents an
educational project for the interactive learning of Industrial Automation. The
objective of this project is to allow bachelor’s and master’s students of
Electrical Engineering of the Instituto Superior de Engen aria de Lisboa
(ISEL-IPL) to learn theoretical and practical fundamentals of Industrial
Automation through local and remote laboratory experiments.
Neumann, Peter. 4 (2004) had presented the fieldbus systems have been
successfully introduced in the industrial automation. Nowadays, a large
community is inventing the usage of Ethernet-based local communication
systems in this domain ensuring the real-time, safe, and secure behavior of
these systems. Future scenarios of geographically distributed production
plants or services require the use of heterogeneous networks consisting of
local and wide area and wired and wireless communication systems operated
by different authorities.
Thomsen, J-P. (2005) had presented Fieldbus technology in industrial

automation is not only relatively complex because of the number of solutions
possible, but also, and above all, because of the variety of applications.
Ironically, these in turn are responsible for the multitude of solutions
available. If the analysis of the basic needs is relatively standard, as they will
always involve connecting sensors, actuators, and field controllers with each
other, the options in architecture are numerous and can impose the need for
certain services. The required performances themselves and the QoS
expected fundamentally depend on the applications.
Schuster, Franka, and Andreas Paul. 2012. had presented Modern

automation is measured in terms of interoperability and easy administration.
Introducing technology focusing on these criteria, however, induce new
security risks to existing and future automation installations. Current security
approaches in automation do not keep pace with the rising security
challenges. Prevalent in automation is the use of access control to protect the
system from malicious activity, such as extern attacks.
Babayigit, Bilal, and Hamza Sattuf. 2019. had presented Nowadays, quick,
and uninterrupted access to information is crucial because of its influence on
our personal and professional lives. Even in industry, any factory manager is
keen to get real time information about the performance of the machines by
using various industrial monitoring tools
Pfrang, Steffen, and David Meier 2017. had presented Modern industrial
facilities consist of controllers, actuators and sensors that are connected via
traditional IT equipment. The ongoing integration of these systems into the
communication network yields to new threats and attack possibilities. In
industrial networks, often distinct communication protocols like ProfNet IO
(PNIO) are used. These protocols are often not supported by typical network
security tools. In this paper, we present two attack techniques that allow to
take over the control of a PNIO device, enabling an attacker to replay
formerly recorded traffic. We model attack detection rules and propose an
intrusion detection system (IDS) for industrial networks which can detect
those replay attacks by correlating alerts from traditional IT IDS with
specific PNIO alarms. Thereafter, we evaluate our IDS in a physical
demonstrator and compare it with another IDS dedicated to securing PNIO
networks.
Ferrer, Borja Ramis, and José Luis Martínez Lastra 2017. had presented
the connectivity of industrial automation domain systems has been enhanced
by the employment of information and communication technologies. This
permits the implementation of systems that are aligned with the vision of the
fourth industrial revolution, or Industry 4.0. In this scope, Cyber-Physical
Systems (CPS), i.e., integration of cyber and physical systems, enables the
control and monitoring of modern production lines.
McFarlane, Duncan, Sanjay Sarma, (2003) had presented Automated

identification systems which involve the automated retrieval of the identity
of objects are becoming a reality for monitoring items moving through the
manufacturing supply chain. Automated identification enables accurate,
timely information about a specific item to be stored, retrieved, and
communicated.
Kondratenko, Yuriy, Oleksiy Kozlov 2017. had presented This paper

presents the analysis of the Internet of Things (IoT) approach and its
application for the development of embedded monitoring and automatic
control systems (EMACS) for technological objects and processes that are
included in complex industrial systems. The functional structure and main
components of the generalized embedded monitoring and automatic control
system for complex technological objects and processes based on IoT
approach are given. The examples of IoT applications in design of
specialized EMACS for such complex technical objects as gas turbine
engines, floating docks, and specialized pyrolysis complexes (SPC) are
presented.
Hegazy, Tamir, and Mohamed Hafida (2014) had presented new cloud
services are being developed to support a wide variety of real-life
applications. In this paper, we introduce a new cloud service: industrial
automation, which includes different functionalities from feedback control
and telemetry to plant optimization and enterprise management. We focus
our study on the feedback control layer as the most time-critical and
demanding functionality. Today's large-scale industrial automation projects
are expensive and time-consuming. Hence, we propose a new cloud-based
automation architecture, and we analyze cost and time savings under the
proposed architecture.
Lesjak, Christian, Thomas Ruprecht, 2014. had presented Smart

maintenance constitutes an essential concept in Industry 4.0, where industrial
devices report their maintenance status to remote back-end systems and thus
predictive maintenance can be intelligently scheduled and carried out locally
at the affected device. This status data must be securely assignable to the
claimed device identities when transmitted remotely.
Lesi, Vuk, Zivania Jakovljevic (2021) had presented Internet of Things

(IoT) technologies enable development of reconfigurable manufacturing
systems—a new generation of modularized industrial equipment suitable for
highly customized manufacturing. Sequential control in these systems is
largely based on discrete events, whereas their formal execution semantics is
specified as control interpreted Petri nets (CIPN). Despite industry-wide use
of programming languages based on the CIPN formalism, formal verification
of such control applications in the presence of adversarial activity is not
supported.
Dey, Chanchal, and Sunit Kumar Sen 2020. had presented We present our
monitoring and decision framework for collaborative engineering for
globally distributed operation, support, maintenance, and services for
industrial automation. The framework provides relevant information to plant
operators, engineers, staff, and stakeholders to support the handling of
incidents, based on semantically appropriate factors such as personnel skills,
physical location of affected equipment and dependencies between plant
elements.
Darko, Lars, Henning Trek, 2012. had presented Nowadays the

deployment and commissioning of complex production processes or
Internet-enabled applications interacting with production systems requires a
time consuming and error-prone manual system configuration process. This
is due to the need to maintain a high level of determinism, safety, and
security of the production process itself and avoiding both safety-critical
failures and costly production interruptions.
Jain, Samyak, and K. Chandrasekaran2022. had presented There is a

growing trend in developing the wireless machine-to-machine (M2M)
communication for factory automation. Currently, most wireless protocols
for infrastructure less mobile ad-hoc networks focus on the mobility issue
and are mainly suitable for narrowband radio devices.
Rosa, Luis, Tiago Cruz, Miguel Borges de Freitas, Pedro Quitério, (2021)
The next generation of Industrial Automation and Control Systems (IACS)
and Supervisory Control and Data Acquisition (SCADA) systems pose
numerous challenges in terms of cybersecurity monitoring. We have been
witnessing the convergence of OT/IT networks, combined with massively
distributed metering and control scenarios such as smart grids. Larger and
geographically widespread attack surfaces, and inherently more data to
analyses, will become the norm.
Minchala, Luis I., Jonnathan Peralta (2020) had presented This paper
presents a performance evaluation of the development of the
instrumentation, communications, and control systems of a two-tank process
by using low-cost hardware and open-source software. The hardware used
for automating this process consists of embedded platforms (Arduino and
Raspberry Pi) integrated into programmable logic controllers (PLCs), which
are connected to a supervisory control and data acquisition (SCADA) system
implemented with an open-source Industrial Internet of Things (Iao)
platform.
Lanval, Tomas, Mikael Gidlund, 2017. had presented The Internet of
Things (IoT) is captivating the society because of its potential to rapidly
transform businesses and people's lives. It is widely believed that IoT will
also transform the industrial automation business in terms of improved
productivity, less cost, flexibility, and increased revenues. Hence, there are
some challenges that needs to be addressed when IoT is introduced to the
industrial automation domain.
Rentschler, Markus2014 had presented in the context of the 4 the industrial
revolution, the knowledge and management of the precise topological and
geographical location of industrial equipment is a growing necessity.
However, a holistic concept for topology and location management in
process- and factory automation networks down to the field level is yet
unknown. In this work, existing network and location management
mechanisms are surveyed for suitability in industrial automation networks.
Kumamoto, Halimon, Doston Khasanov (2021) had presented in recent

years, IoT systems based on various sensors have had a major impact on
people’s lifestyles and industries. Given the dynamics of the IoT-based
device manufacturing process, it is estimated that by the end of this year,
1,000,000,000 devices will be developed and used in industry worldwide.
However, the use of wireless networks to exchange data between such
devices is becoming a major problem. Therefore, the use of a 5G network is
currently considered as the optimal solution for IoT systems designed for
industrial automation.
Wu, Q. H., David P. Buse, J. Q. Feng (2004) had presented Due to the
complexity of modern industrial systems, a conventional automation system
is not capable of providing sufficient information management and high-
level intelligent approaches, as achieving these functionalities requires the
support of comprehensive data management and coordination between
system devices and heterogenous information.
McFarlane, Duncan (2002) had presented The Auto-ID Center has to date
focused on developing the essential infrastructure for dynamically
extracting, networking, and storing product data. These developments will
help to revolutionize the accuracy, quality and timeliness of data acquired by
Business Information Systems and should lead to major cost savings and
performance improvements as a result. This white paper introduces an
additional phase of Auto-ID research and development in which the nature
of operational and business decisions is reconsidered in the light of the
availability of ubiquitous, unique, item-level information. We refer to the
decision-making processes and the subsequent execution of these decisions
as control systems. The white paper will motivate the reasons for a control
systems research activity within the Auto-ID Project and will:
Abruzzian, Sikder M., Muhammad Naseeruddin, 2017. had presented

Automation of modern industrial plants require real-time tracking of object
locations and sensing of local and ambient parameters for variety of
applications such as counting and tracking of objects in assembly line,
detection, and positioning of failures of machines etc. Mostly, discrete Real
Time Location System (RTLS) performs object tracking in existing
industrial automation without its integration with the sensing and control
network, which constrains application's responsiveness. In this paper, we
propose an integrated solution of Wireless Positioning Sensor Network
(WPSN) that is designed for accuracy, reliability, scalability, and optimal
network operation. The proposed WPSN is applicable for harsh indoor
industrial environments for not only monitoring and control of plant
operations but also for identification, localization and tracking of assets and
inventory in industrial warehouses.
Koziolek, Heiko, Andreas Burger, 2020. had presented Software

development for industrial automation applications is a growing market with
high economic impact. Control engineers design and implement software for
such systems using standardized programming languages (IEC 61131-3) and
still require substantial manual work causing high engineering costs and
potential quality issues. Methods for automatically generating control logic
using knowledge extraction from formal requirements documents have been
developed, but so far only been demonstrated in simplified lab settings.
Moser, Michael, Michael Pfeiffer2014. Domain-specific modeling promises
to close the gap between an application domain and a solution domain. As
such it enables domain experts to directly model an application by means of
a domain-specific language and to fully generate a final software product
from the models. The advantages of domain-specific modeling have been
demonstrated from several industrial case studies in various domains.
However, domain-specific modeling is rarely applied in industrial
automation. We have designed and developed two DSM solutions in the
domains of injection molding machines and robot welding to enable domain
experts to directly program in both domains without detailed software
development expertise.
Villani, Valeria, Lorenzo Sabatini, Paulina Barańska, (2020) had

presented While modern production systems are becoming increasingly
technologically advanced, the presence of human operators remains
fundamental in industrial workplaces. To complement and enhance the
capabilities of human workers, approaches based on adaptive automation
have been introduced. They consist of adapting the behavior of the system
according to the user’s capabilities and effort. In this article, we present a
general holistic framework for adaptive automation, called INCLUSIVE,
that assists the operator during working tasks.
Nagorny, Kevin, Armando Walter Colombo (2012) had presented This

paper describes an approach for developing and implementing a service- and
multi-agent-oriented manufacturing automation architecture, being
particularly focused on functional features of the IEC 62264 L2 standard.
Sheu, Ruey-Kai, Yuan-Cheng Lin, (2020) had presented Sheet metal-based

manufacturing industries operate on several varieties of sheet metal parts.
Previously QR codes stickers were put on sheet metal parts for identification
by manual workers as per their respective shape and size features, thus
ensuring synchronized raw material flow for the manufacturing process.
However, identifying a particular type of sheet metal part based on its
different features is still a challenge for a trained manual operator.
Karunanidhi, Kalaivanan (2020) had presented Integrating Wireless

Sensor Networks (WSNs) and the Internet of Things (IoT) is to build a
heterogeneous device network for connecting, sharing and storing their
information in order to create the application environment as smart. It also
helps in industrial automation to predict and build a fault-tolerant
environment. The automation of industry can be made possible with the
emergence of new developments in sensor manufacturing and
communication.
Chen, Jiaming, Xinghua Cao (2010) had presented Wireless sensor and
actuator networks (WSANs) bring many benefits to industrial automation
systems. When a control system is integrated by a WSAN, and particularly if
the network scale is large, distributed communication and control methods
are quite necessary. However, unreliable wireless and multichip
communications among sensors and actuators cause challenges in designing
such systems.
Lokman, Tayeb Bin, Mohammad Touchily Islam 2020. had presented

Internet of things is the most updating technology in recent years. Now
anyone can easily monitor, measure, control, find updated information and
data like how much product produce in per hour, per day, per week of any
industry through IOT. And can observe continuous update of running
condition in sited anywhere. The paper proposes piece together with
monitoring, controlling, measuring, product counting and finding updated
information of any automatic industry using IoT.
Pfrang, Steffen 2018 had presented Modern industrial facilities consist of

controllers, actuators and sensors that are connected via traditional IT
equipment. The ongoing integration of these systems into the communication
network yields to new threats and attack possibilities. In industrial networks,
often distinct communication protocols like ProfNet IO (PNIO) are used.
These protocols are often not supported by typical network security tools. In
this work, we present two attack techniques that allow to take over the
control of a PNIO device, enabling an attacker to replay previously recorded
traffic.
Asensio, J., F. Ortuño (2013) had presented in this work, a complete
environment for the development of industrial automation programs based
on the IEC 61131‐3 standard and the Ploen TC6 scheme is presented. This
environment includes a specific editor for every programming language of
the standard, a set of translators for these languages and a compiler to
generate executable code. This paper describes the structure and features of
this application, as well as its advantages over other solutions. A new
method of translation into IL language is also suggested, which takes
advantage of the structured information provided by the TC6‐XML scheme
Bingeman, Thomas, Stamatis Karnowski’s, (2014) In the last decades,

industrial automation has become a driving force in all production systems.
Technologies and architectures have emerged alongside the growing
organizational structures of production plants. Every innovation had to start
from the latest state-of-the-art systems within the respective domain. While
investigating the introduction of service-oriented architectures to automation,
and even down to the shop floor, one must consider latest standards, proofed
technologies, industrial solutions, and latest research works in the
automation domain.
Adeosun, Ramoni, Gilberto 2020. had presented in this paper, we

investigate dynamic channel se- lection in short-range Wireless Isochronous
Real Time (WIRT) in-X subnetworks aimed at supporting fast closed-loop
control with super-short communication cycle (below 0.1 MS) and extreme
reliability (>99.999999%). We consider fully distributed approaches in
which each subnetwork selects a channel group for transmission to guarantee
the requirements based solely on its local sensing measurements without the
possibility for exchange of information between subnetworks.
Isana, Mauro, John Soldatos2017. had presented the advent of Industry 4.0
has given rise to the introduction of new industrial automation architectures
that emphasize the use of digital technologies. In this paper, we introduce a
novel reference architecture (RA) for industrial automation, which leverages
the benefits of edge computing, while using blockchain technologies for
flexible, scalable, and reliable configuration and orchestration of automation.
Objective:
Leverage the power of the Internet of Things (IoT) to revolutionize industrial
automation, maximizing efficiency, productivity, and safety.
Specific goals: Enhanced real-time monitoring: Integrate sensors and
connected devices throughout production lines to collect data on key
performance indicators (KPIs) such as temperature, pressure, and vibration.
This real-time data allows for immediate identification and resolution of
potential issues, minimizing downtime and ensuring smooth operation.
Predictive maintenance: Analyse sensor data using AI and machine learning
algorithms to predict equipment failures and proactively schedule
maintenance before critical breakdowns occurs. This preventative approach
minimizes costly downtime and extends the robot arm assembling products
in a factor Remote control and operation: Enable remote monitoring and
control of industrial facilities from anywhere in the world. This allows for
faster response times to emergencies and facilitates collaboration between
teams across diverse locations. Improved safety: Implement IoT-based safety
systems to identify and mitigate potential hazards in real-time. This can
include systems that detect gas leaks, smoke, and other dangerous
conditions, automatically triggering alarms and initiating safety protocols.
Increased data-driven decision making: Leverage the vast amount of data
generated by connected devices to gain insights into production processes
and make data-driven decisions. This data can be used to optimize resource
allocation, identify cost-saving opportunities, and develop new products and
services.
By achieving these objectives, the successful implementation of these
objectives will usher in a new era of industrial automation, characterized by
increased efficiency, productivity, safety, and profitability.
Motivation:
The motivation for this project is rooted in the pursuit of excellence in
industrial automation, ensuring that safety and efficiency are not mutually
exclusive but are complementary facets of modern industry. The drive to
innovate and push the boundaries of what is possible with current technology
is at the heart of this endeavour.
In an era where industrial operations are becoming increasingly complex, the
need for systems that can not only keep up with but also enhance these
processes is paramount. This project is motivated by the vision of a future
where machines and humans work in harmony, where the potential for
human error is minimized, and where the safety of every individual is
paramount.
The inspiration for this project also comes from a deep understanding of the
risks involved in industrial settings. Every year, countless accidents occur
due to lapses in safety measures or the failure of outdated systems. This
project aims to change that narrative by introducing a system that is designed
with the well-being of its operators as a core principle.
Furthermore, the motivation for this project is fuelled by the desire to
contribute to the sustainability of industrial practices. By optimizing
operations and reducing waste, we are not only improving efficiency but also
taking a step towards a more environmentally responsible industry.
The project is also driven by the challenge of integrating advanced
technologies such as IoT, AI, and ML into a cohesive system that enhances
real-time decision-making and process control. The potential to transform
data into actionable insights that can prevent accidents before they happen is
a powerful motivator.
Moreover, the project is propelled by the ambition to set new standards in
the industry. By aiming to exceed international safety and quality standards,
the project aspires to become a benchmark for future industrial automation
systems.
The motivation also stems from a commitment to the people who will
interact with the system. By providing a user-friendly interface and
comprehensive training, the project demonstrates a dedication to
empowering individuals to manage and control complex industrial processes
with confidence.
Additionally, the project is motivated by the potential for scalability and
flexibility. The ability to adapt and grow with the needs of the industry is a
testament to the forward-thinking approach that underpins this project.
The drive to provide a system that not only meets the current demands of the
industry but also anticipates future challenges is a key motivator. The project
is about looking ahead and ensuring that the system remains relevant and
effective in the years to come.
In conclusion, the motivation for this project is a blend of safety, efficiency,
sustainability, innovation, and empowerment. It is about creating a system
that not only meets the needs of today’s industry but also paves the way for a
safer, smarter, and more sustainable future. This project is not just about
automation; it is about elevating the entire industrial landscape to new
heights.
2. INTRODUCTION TO SAFETY IN INDUSTRIAL AUTOMATION:
Safety in Automation:
An Automation System is a combination of computer hardware and
software, and perhaps additional mechanical or other parts, designed to
perform a specific function. An Automation system is a microcontroller-
based, software driven, reliable, real-time control system, autonomous, or
human or network interactive, operating on diverse physical variables and in
diverse environments and sold into a competitive and cost-conscious market.
Safety in an industrial automation system is the harmonious integration of
various practices, technologies, and protocols aimed at minimizing the risk
of accidents and ensuring the well-being of personnel and the integrity of
machinery. It is a critical aspect that combines regulatory compliance, best
practices, and technological innovation to create a secure and efficient
production environment. Safety systems are designed to detect potential
hazards, enforce protective barriers, and initiate immediate corrective actions
if a risk is identified. This proactive approach to safety helps to minimize the
risk of injury and equipment damage, ensuring a secure and efficient
production environment. Safety in automation is a critical aspect that
combines regulatory compliance, best practices, and technological
innovation to create a harmonious and secure workplace. It is an ongoing
process that requires constant vigilance, adaptation, and improvement to
protect the most valuable assets in any industrial operation: human life and
health. Safety in automation involves the implementation of various
technologies and practices designed to prevent accidents and mitigate risks
associated with automated operations. It includes the use of sensors and
devices to detect unsafe conditions, emergency stop functions to halt
operations immediately in case of danger, safety interlocks to prevent
machinery operation when safety guards are open or unsafe conditions are
detected, and redundant systems to provide a backup in case of primary
system failure. Regular maintenance and inspections ensure all safety-related
components are functioning properly, and comprehensive training for
operators on the safe use of automation systems is provided. Safety in
automation is not just about preventing accidents; it is about creating a
system that is inherently safe by design. It requires a proactive approach
where safety considerations are integrated into every stage of the automation
system’s lifecycle, from design and implementation to operation and
maintenance. By prioritizing safety, organizations can protect their most
valuable assets—their people and their equipment—while ensuring the
smooth and efficient operation of their automated processes. Safety in
automation is a critical investment that pays dividends in the form of a
secure, productive, and sustainable industrial environment.
Characteristics of Safety in Automation System:
Safety in an industrial automation system is a multifaceted characteristic that
ensures the protection of human operators and the proper functioning of
machinery. It involves a proactive approach to risk management, where
safety considerations are integrated into every stage of the automation
system’s lifecycle. This includes the design, implementation, operation, and
maintenance phases. Safety in automation systems is characterized by the
use of advanced technologies such as sensors and emergency stop functions
that monitor and control the operation of automated equipment within safe
parameters. These systems are designed to detect potential hazards, enforce
protective barriers, and initiate immediate corrective actions if a risk is
identified. The goal is to minimize the risk of injury and equipment damage,
ensuring a secure and efficient production environment. Safety in automation
also encompasses adherence to international safety standards and
regulations, regular maintenance and inspections, comprehensive training for
operators, and the implementation of safety protocols and procedures. It
requires a commitment to continuous improvement through regular training,
technology upgrades, and process optimization. Safety in automation is not
just about preventing accidents; it’s about creating a system that is inherently
safe by design, requiring constant vigilance, adaptation, and improvement. It
is a critical investment that pays dividends in the form of a secure,
productive, and sustainable industrial environment, protecting the most
valuable assets in any industrial operation: human life and health.
APPLICATIONS:
Certainly! Here are ten applications of real-time industrial safety in
automation:
1. Automated Safety Inspections: Robots equipped with sensors
perform regular inspections of equipment and facilities to identify
potential safety hazards.
2. Predictive Maintenance: Machine learning algorithms analyse data
from machinery to predict failures before they occur, allowing for
timely maintenance and repairs.
3. Emergency Response Drones: Drones equipped with cameras and
sensors can quickly assess dangerous situations, providing real-time
information to first responders.
4. Worker Safety Gear: Smart safety gear such as helmets and vests
with embedded sensors can monitor a worker’s environment and vital
signs, alerting them to potential dangers.
5. Collision Avoidance Systems: Automated guided vehicles (AGVs)
use real-time sensors to detect obstacles and prevent collisions in
industrial settings.
6. Safety Protocol Enforcement: AI-powered systems ensure that
safety protocols are followed, such as verifying that workers are
wearing the correct protective equipment.
7. Fire Detection and Suppression: Advanced fire detection systems
use real-time monitoring to detect and suppress fires more effectively
than traditional methods.
8. Chemical Leak Detection: Sensors continuously monitor for
hazardous chemical leaks and automatically initiate containment
procedures if a leak is detected.
9. Machine Guarding: Automated systems monitor safety guards on
machinery to ensure they are in place and functioning properly,
preventing access to dangerous areas.
10.Safety Data Analysis: Big data analytics are used to analyse safety
incident reports and operational data to identify trends and improve
safety measures.
4. HARDWARE REQUIREMENTS:
HARDWARE COMPONENTS:
1. FLAME SENSOR
2. GAS SENSOR
3. RELAY DRIVER
4. NODE MCU
5. SMOKE SENSOR
6. DC WATER PUMP
7. BUZZER
8. RELAY
9. CPU FAN
10.3.7V BATTERY
11.CHARGING MODULE
12.SWITCH
13.USB CONNECTING CABLE
14.AC HOLDER FOR LOAD
15.LED BULB
SOFTWARE COMPONENT:
1. TELEGRAM API
2. TELEGRAM BOT
4.1 FLAME SENSOR:

A flame sensor is a specialized detector designed to identify and respond to
the presence of fire or flames. These sensors play a crucial role in
maintaining safety in various environments, including factories, offices,
homes, and public spaces. Here is a detailed overview:
1. Types of Flame Sensors:
o Ultraviolet (UV) Flame Sensors: These sensors detect
ultraviolet radiation emitted by flames. Most fires produce UV
radiation, making these sensors highly sensitive. They are
effective for detecting hazards like halogen, metal fires, and
hydrocarbons.
o Infrared (IR) Flame Sensors: IR sensors operate by analysing
the IR spectral band for specific patterns emitted by hot gases.
However, they require a flickering flame movement for accurate
detection. Note that infrared radiation is also emitted by non-
flame sources like lamps and ovens.
o UV-IR Combined Sensors: These sensors combine both UV
and IR detection capabilities, providing better rejection of false
alarms. They offer a balanced approach by detecting both UV
and IR radiations.
2. Working Principle:
o UV Flame Sensor:
 Detects UV radiation at the ignition point of a fire.
 When a fire occurs, the sensor becomes alert and
generates a series of pulses.
 These pulses are processed by detector electronics,
triggering an alarm output.
 Commonly used to verify furnace operation and as part of
ignition systems.
o IR Flame Sensor:
 Monitors the IR spectral band for specific flame-related
patterns.
 Requires a flickering flame movement for accurate
detection.
 Can be prone to false alarms due to other sources of
infrared radiation.
o UV-IR Combined Sensor:
 Detects both UV and IR radiations.
 Offers improved rejection of false alarms compared to
separate UV/IR detectors.
3. Applications:
o Fire Control Systems: Flame sensors activate fire control
mechanisms, such as shutting off fuel lines or triggering fire
suppression systems.
o Industrial Furnaces: Used to ensure proper furnace operation
and prevent flameouts.
o Safety Alarms: Integrated into fire alarms and safety
equipment to provide early warning.
o Critical Environments: Deployed in places where fire hazards
pose significant risks.
4. Image of a Flame Sensor:
o Unfortunately, I cannot directly provide an image here, but you
can find visual representations of flame sensors online or in
technical documentation.
4.3 GAS SENSOR:
A gas sensor is a specialized device that detects the
presence or concentration of gases in the atmosphere. Its
primary function is to provide an early warning system for
potential gas leaks or hazardous conditions. Let us break
down its construction, types, and working principles:
1. Types of Gas Sensors:
o Metal Oxide-Based Gas Sensors (MQ Series):
 These sensors use metal oxide semiconductors (e.g., Tin
Dioxide - SnO2) as the sensing material.
 The sensing layer reacts with gases, causing changes in
electrical resistance.
 When exposed to a specific gas, the sensor’s resistance
varies, leading to a measurable output voltage.
 Commonly used for detecting combustible gases (e.g.,
methane, propane) and toxic gases (e.g., carbon monox-
ide).
o Optical Gas Sensors:
 These sensors rely on light absorption or emission prop-
erties of gases.
 They use optical techniques (e.g., infrared absorption) to
detect specific gas molecules.
 Suitable for applications where precise gas identification
is essential.
o Electrochemical Gas Sensors:
 Electrochemical reactions at the sensing electrode gener-
ate an electrical signal.
 Ideal for detecting toxic gases (e.g., hydrogen sulphide,
chlorine) and oxygen levels.
o Capacitance-Based Gas Sensors:
 Measure changes in capacitance due to gas adsorption on
the sensor surface.
 Used for detecting volatile organic compounds (VOCs)
and humidity levels.
o Calorimetric Gas Sensors:
 Detect gas-induced temperature changes.
 Useful for detecting flammable gases.
o Acoustic-Based Gas Sensors:
 Monitor sound waves generated by gas combustion.
 Primarily used for detecting gas leaks in pipelines.
2. Construction of a Metal Oxide Gas Sensor:
o Key Components:
 Gas Sensing Layer: The core element that interacts with
gases and exhibits varying electrical resistance.
 Heater Coil: Maintains the sensor at an elevated temper-
ature for optimal gas detection.
 Electrode Line: Connects the sensing layer to the ex-
ternal circuit.
 Tubular Ceramic: Provides structural support and insu-
lation.
 Electrode: Collects the electrical signal generated by the
sensing layer.
o The gas sensing layer’s resistance changes when exposed to
specific gases, leading to measurable electrical variations.
o The chemoreceptor (usually Tin Dioxide) conducts current
based on gas interactions.
o In the presence of oxygen, the sensor’s resistance decreases.
o When exposed to combustible gases, the resistance increases.
o The sensor’s output voltage reflects the gas concentration.
o Calibration ensures accurate readings for specific gases.
4. Applications:
o Gas Leak Detection: Used in industrial settings to identify
leaks (e.g., natural gas pipelines, chemical plants).
o Air Quality Monitoring: Deployed in offices, homes, and pub-
lic spaces to assess pollutant levels.
o Safety Alarms: Integrated into fire and gas detection systems.
o Environmental Monitoring: Detects harmful gases in the at-
mosphere.
4.4 RELAY DRIVER:

Certainly! Let us delve into the world of
relay drivers used in industrial safety
control systems. These components play a
critical role in ensuring reliable and safe
operation. Here is a detailed overview:
Relay Driver: Definition and Working
Principle
A relay driver is an essential device that interfaces between low-power
control circuits (such as microcontrollers or PLCs) and high-power loads
(such as motors, solenoids, or heaters). Its primary purpose is to amplify
and isolate the control signal, allowing safe and efficient switching of heavy
loads. Let us explore further:
1. Construction and Components:
o Optocouplers (opt isolators): These are commonly used in
relay drivers. An optocoupler consists of an LED (input side)
and a phototransistor (output side) within a single package.
o Transistors (Bipolar Junction Transistors - BJT or Field-
Effect Transistors - FET): Transistors amplify the control
signal and drive the relay coil.
o Diodes: Diodes protect the transistor from reverse voltage
spikes generated when the relay coil is de-energized.
o Base Resistor: Connected to the transistor’s base, it limits the
current flowing into the base.
o Flyback Diode (Freewheeling Diode): Placed across the relay
coil, it prevents voltage spikes during relay coil deactivation.
o When the low-power control circuit (e.g., microcontroller)
sends a signal (usually a logic level) to the relay driver input
(usually an optocoupler’s LED), the LED turns on.
o The phototransistor (output side of the optocoupler) conducts,
allowing current to flow through the transistor.
o The transistor amplifies this current and energizes the relay coil.
o The relay contacts close, connecting the high-power load (e.g.,
motor, heater) to the power supply.
o When the control signal is removed, the relay coil de-energizes,
and the contacts open, disconnecting the load.
3. Applications:
o Safety Control Systems: Relay drivers are crucial for safety
functions such as emergency stops, safety gates, and interlocks.
o Motor Control: Used to switch motor loads (e.g., conveyor
belts, pumps) in industrial machinery.
o Heating and Cooling Systems: Control heaters, fans, and
coolers.
o Lighting Control: Switch high-power lighting circuits.
o Process Automation: Interface with valves, actuators, and
solenoids.
4. Image of a Relay Driver:
can find visual representations of relay drivers online or in
technical documentation related to industrial control systems.
NODEMCU:
NODEMCU is a low-cost open
source IoT platform. It initially included firmware which
runs on the ESP8266 Wi-Fi SoC from Espressif Systems,
and hardware which was based on the ESP-12 module.
Later, support for the ESP32 32-bit MCU was added
NODEMCU is an open-source firmware for which open

source prototyping board designs are available. The name
"Nedelcu" combines "node" and "MCU" (micro-control-
ler unit). The term "Nedelcu" strictly speaking refers to
the firmware rather than the associated development kits.
Both the firmware and prototyping board designs are open source.
The firmware uses the Lua scripting language. The firmware is based on the
Elua project and built on the Espressif Non-OS SDK for ESP8266. It uses
many open source projects, such as Launceston[10] and SPIFFS.[11] Due to re-
source constraints, users need to select the modules relevant for their project
and build a firmware tailored to their needs. Support for the 32-
bit ESP32 has also been implemented.
The prototyping hardware typically used is a circuit board functioning as

a dual in-line package (DIP) which integrates a USB controller with a smal-
ler surface-mounted board containing the MCU and antenna. The choice of
the DIP format allows for easy prototyping on breadboards. The design was
initially was based on the ESP-12 module of the ESP8266, which is a Wi-Fi
SoC integrated with a Ten silica Extensa LX106 core, widely used in IoT ap-
plications (see related projects).
HISTORY:
Node MCU was created shortly after the ESP8266 came out. On
December 30, 2013, Espressif Systems[6] began production of the ESP8266.
[12]
Node MCU started on 13 Oct 2014, when Hong committed the first file of
Nedelcu-firmware to GitHub.[13] Two months later, the project expanded to
include an open-hardware platform when developer Huang R committed
the Gerber file of an ESP8266 board, named devkit v0.9.[14] Later that month,
Tuan PM ported MQTT client library from Contiki to the ESP8266 SoC
platform,[15] and committed to Nedelcu project, then Nedelcu was able to
support the MQTT IoT protocol, using Lua to access the MQTT broker. An-
other important update was made on 30 Jan 2015, when Thesaurus ported
the u8glib[16] to the Nedelcu project,[17] enabling Nedelcu to easily drive
LCD, Screen, OLED, even VGA displays.
In the summer of 2015, the original creators abandoned the firmware project,
and a group of independent contributors took over. By the summer of 2016,
the Nedelcu included more than 40 different modules.
ESP8266 Arduino Core:
As Arduino.cc began developing new MCU boards based on non-

AVR processors like the ARM/SAM MCU and used in the Arduino Due,
they needed to modify the Arduino IDE so that it would be relatively easy to
change the IDE to support alternate toolchains to allow Arduino C/C++ to be
compiled for these new processors. They did this with the introduction of the
Board Manager and the SAM Core. A "core" is the collection of software
components required by the Board Manager and the Arduino IDE to compile
an Arduino C/C++ source file for the target MCU's machine language. Some
ESP8266 enthusiasts developed an Arduino core for the ESP8266 WIFI
SoC, popularly called the "ESP8266 Core for the Arduino IDE". [18] This has
become a leading software development platform for the various ESP8266-
based modules and development boards, including Nedelcu’s.
RST:
Reset input. A high on this pin for two machine cycles while the
oscillator is running resets the device. This pin drives high for 98 oscillator
periods after the Watchdog times out. The DISRTO bit in SFR AUXR
(address 8EH) can be used to disable this feature. In the default state of bit
DISRTO, the RESET HIGH out feature is enabled.
4.6 SMOKE SENSOR:

A smoke sensor is an electronic device designed to detect
the presence of smoke in the air. It serves as an essential
component in fire protection systems, providing early
warnings to building occupants and triggering appropriate
safety measures. Here’s how smoke sensors work:
1. Types of Smoke Sensors:
o Ionization Smoke Sensors:
 These sensors use a small amount of radioactive material
(usually americium-241) to ionize the air within a detec-
tion chamber.
 When smoke particles enter the chamber, they disrupt the
ionization process, causing a change in electrical con-
ductivity.
 The sensor detects this change and triggers an alarm.
 Ionization sensors are sensitive to fast-burning fires with
small smoke particles.
o Photoelectric (Optical) Smoke Sensors:
 Photoelectric sensors use a light source (usually an LED)
and a photodetector (usually a photodiode or phototran-
sistor).
 A light beam is directed across the detection chamber.
 When smoke enters the chamber, it scatters the light,
causing it to reach the photodetector.
 The sensor registers this scattered light and activates the
alarm.
 Photoelectric sensors are effective at detecting slow burn-
ing, smouldering fires.
o Combination (Dual-Sensor) Smoke Sensors:
 These sensors combine both ionization and photoelectric
technologies.
 They provide broader coverage and reduce false alarms
by considering different types of fires.
o Ionization Sensors:
 The ionization chamber contains a small radioactive
source that emits alpha particles.
 These particles ionize the air, creating a conductive path
between two electrodes.
 When smoke particles enter the chamber, they disrupt the
ionization process, reducing conductivity.
 The sensor detects this change and triggers the alarm.
o Photoelectric Sensors:
 The optical chamber contains a light source and a photo-
detector.
 In normal conditions, the light beam does not reach the
photodetector.
 When smoke enters the chamber, it scatters the light, al-
lowing it to reach the photodetector.
 The sensor interprets this change as smoke presence and
activates the alarm.
o Combination Sensors:
 These sensors use both ionization and photoelectric prin-
ciples for enhanced sensitivity.
 They analyse both particle density and light scattering to
determine the presence of smoke.
3. Applications:
o Residential and Commercial Buildings: Installed in homes, of-
fices, hotels, and public spaces.
o Industrial Facilities: Used in factories, warehouses, and manu-
facturing plants.
o Transportation: Integrated into aircraft, trains, and ships.
o Critical Infrastructure: Deployed in data centres, power plants,
and hospitals.
DC WATER PUMP:
A DC water pump is an electric pump designed to
operate on low voltage direct current (DC). Unlike their
AC counterparts, DC pumps offer advantages such as
quiet operation, energy efficiency, and suitability for off-
grid or solar-powered systems. Let us explore their
features, applications, and working principles:
1. Types of DC Water Pumps:
o DC Fountain Pumps: These compact pumps are ideal for solar
fountains, tabletop crafts, and decorative water features.
o DC Submersible Pumps: Used in aquariums, fish tanks, and
small water circulation systems.
o Solar-Powered DC Pumps: These pumps harness solar energy
through photovoltaic panels, making them suitable for remote
locations.
o When a DC water pump is activated, the following steps occur:
1. Power Supply: The pump receives low-voltage DC
power from a battery, solar panel, or other sources.
2. Motor Operation: The coil and commutator within the
motor rotate, while the magnetic steel and carbon brushes
remain stationary.
3. Direction Change: The commutator and brushes reverse
the current direction in the coil, ensuring continuous
rotation.
4. Impeller Action: The rotating impeller (usually inside a
housing) creates centrifugal force, pushing water
outward.
5. Water Flow: Water enters the pump through an inlet, and
the impeller propels it through the outlet.
6. Pressure and Circulation: The pump pressurizes and
circulates the liquid, serving various purposes.
3. Applications:
o Industrial Safety Control Systems: DC water pumps
contribute to fire suppression, cooling, and emergency water
supply.
o Automotive: Used in vehicle cooling systems and windshield
washer pumps.
o Household: For small-scale water circulation, garden irrigation,
and fountain displays.
o Water Wells: DC submersible pumps provide water in remote
areas.
o Off-Grid Systems: Solar-powered DC pumps ensure water
availability without grid electricity.
4. Image of a DC Water Pump:
can find visual representations of DC water pumps online or in
technical documentation related to industrial control systems.
BUZZER:
Buzzer: Definition and Working Principle
A buzzer is an audio signalling device that
converts electrical signals into sound. It is
commonly used in alarms, timers, printers,
computers, and other electronic products.
Buzzers can be categorized into different types
based on their technology and design. Let us
dive into the details:
1. Types of Buzzers:
o Piezoelectric Buzzers:
 Working Principle: Piezoelectric buzzers utilize the
piezoelectric effect in ceramic or crystal materials. When
an electric charge is applied, the material deforms,
generating a sound wave (buzzing noise).
 Tone Generation: By adjusting the input current, the
frequency of the sound can be altered, allowing for
various tones.
 Applications: Piezoelectric buzzers are commonly found
in electronic devices due to their compact size and
efficiency.
o Electromagnetic Buzzers:
 Working Principle: These buzzers rely on a coil of wire
and a flexible ferromagnetic disk. When a current flows
through the coil, a magnetic field is created, attracting the
disk, and producing sound.
 Tone Generation: The buzzing noise results from the
disk’s movement.
 Applications: Electromagnetic buzzers are used in
doorbells, alarms, and other applications where a louder
sound is required.
o Mechanical Buzzers:
 Working Principle: Mechanical buzzers use a
mechanical oscillator (such as a vibrating reed) to
produce sound.
 Tone Generation: The oscillator vibrates at a specific
frequency, creating audible vibrations.
 Applications: These buzzers were common in older
devices but have been largely replaced by more efficient
technologies.
2. Specifications:
o Colour: Typically, black.
o Frequency Range: Varies (e.g., 3,300 Hz for some buzzers).
o Operating Temperature: Ranges from -20°C to +60°C.
o Operating Voltage: Typically, 3V to 24V DC.
o Sound Pressure Level: Around 85 dBA at 10 cm.
o Supply Current: Usually below 15 mA.
o Piezoelectric Buzzers:
 Apply voltage to the piezoelectric ceramic material.
 The material deforms, creating a pressure difference.
 This deformation generates sound waves, resulting in the
buzzer’s characteristic buzzing noise.
o Electromagnetic Buzzers:
 Pass current through a coil of wire.
 The magnetic field attracts a flexible ferromagnetic disk.
 The disk vibrates, producing sound.
o Mechanical Buzzers:
 Mechanical oscillators (e.g., vibrating reeds) vibrate at a
specific frequency.
 These vibrations create audible sound waves.
4. Applications:
o Safety Control Systems: Buzzers alert users to emergency
situations, alarms, and warnings.
o Industrial Machinery: Used for process completion
notifications and fault indications.
o Consumer Electronics: Found in timers, appliances, and
electronic gadgets.
o Automotive: Used in car alarms and warning systems.
4.9 RELAY:
A relay is an electrically operated switch. Many relays use an
electromagnet to operate a switching mechanism mechanically, but other
operating principles are also used. Relays are used where it is necessary to
control a circuit by a low-power signal (with complete electrical isolation
between control and controlled circuits), or where several circuits must be
controlled by one signal.
A relay is an electrically operated switch. Current flowing through the

coil of the relay creates a magnetic field which attracts a lever and changes
the switch contacts. The coil current can be on or off, so relays have two
switch positions and most have double throw (changeover) switch contacts
as shown in the diagram.
Relays allow one circuit to switch a second circuit which can be separ-
ate from the first. For example, a low voltage battery circuit can use a relay
to switch a 230V AC mains circuit. There is no electrical connection inside
the relay between the two circuits; the link is magnetic and mechanical.
The coil of a relay passes a relatively large current, typically 30mA for
a 12V relay, but it can be as much as 100mA for relays designed to operate
from lower voltages. Most ICs (chips) cannot provide this current, and a
transistor is usually used to amplify the small IC current to the larger value
required for the relay coil. The maximum output current for the popular 555
timer IC is 200mA so these devices can supply relay coils directly without
amplification.
Relays are usually SPDT or DPDT, but they can have many more sets
of switch contacts, for example relays with 4 sets of changeover contacts are
readily available. For further information about switch contacts and the
terms used to describe them please see the page on switches.
Most relays are designed for PCB mounting but you can solder wires
directly to the pins providing you take care to avoid melting the plastic case
of the relay.
The supplier's catalogue should show you the relay's connections. The
coil will be obvious, and it may be connected either way round. Relay coils
produce brief high voltage 'spikes' when they are switched off and this can
destroy transistors and ICs in the circuit. To prevent damage, you must con-
nect a Control diode across the relay coil.
The figure shows a relay with its coil and switch contacts. You can see
a lever on the left being attracted by magnetism when the coil is switched on.
This lever moves the switch contacts.
There is one set of contacts (SPDT) in the foreground and another be-
hind them, making the relay DPDT.
The relay's switch connections are usually labelled COM, NC, and NO:
 COM = Common, always connect to this; it is the moving part of the
switch.
 NC = Normally Closed, COM is connected to this when the relay coil
is off.
 NO = Normally Open, COM is connected to this when the relay coil is
on.
Applications of relays:
Relays are used to and for:
 Control a high-voltage circuit with a low-voltage signal, as in some
types of modems or audio amplifiers.
 Control a high-current circuit with a low-current signal, as in the starter
solenoid of an automobile.
 Detect and isolate faults on transmission and distribution lines by open-
ing and closing circuit breakers.
Time delay functions. Relays can be modified to delay opening or delay
closing a set of contacts. A very short (a fraction of a second) delay would
use a copper disk between the armature and moving blade assembly. Current
flowing in the disk maintains magnetic field for a short time, lengthening re-
lease time. For a slightly longer (up to a minute) delay, a dashpot is used. A
dashpot is a piston filled with fluid that is allowed to escape slowly. The
time can be varied by increasing or decreasing the flow rate. For longer time
periods, a mechanical clockwork timer is installed.
CPU FAN:
A CPU fan is a critical component in computer systems,
especially for central processing units (CPUs). Its
primary function is to cool down the CPU by dissipating
heat generated during operation. Here is a detailed over-
view:
1. Design and Types:

o Axial Fans: These fans have blades that rotate around an axis,
pushing air parallel to the fan’s axis. They are commonly used
in CPU coolers.
o Centrifugal Fans (Blower Fans): These fans direct air perpen-
dicular to the fan’s axis. They are efficient in compact spaces
and provide higher static pressure.
o Size and Connectors: CPU fans come in various sizes (e.g.,
80mm, 120mm) and connector variants (3-pin or 4-pin). The
connector type affects fan speed control.
o Thermodynamic Convection:
 A CPU fan follows the basic thermodynamic principle of
convection.
 When the CPU heats up during operation, it transfers heat
to the air molecules near its surface.
 The CPU fan blows air across the heat sink (attached to
the CPU) to cool it down.
 As the fan rotates, it displaces hot air and draws in cooler
air, aiding in heat dissipation.
o Heat Sink and Variable Speed Control:
 The heat sink, often made of metal with fins, absorbs heat
from the CPU.
 Modern CPU fans include heat pipes that connect to the
heat sink, enhancing efficiency.
 Sensors on the motherboard monitor CPU temperature.
 The fan adjusts its speed based on temperature: faster
when the CPU is hot, slower during idle or low-load peri-
ods.
 Variable speed control ensures efficient cooling without
excessive noise.
3. Importance in Industrial Safety Control Systems:
o Preventing Damage: By removing hot air, CPU fans prevent
damage to internal components due to overheating.
o Performance Optimization: Proper cooling ensures consistent
CPU performance.
o Avoiding System Crashes: Overheating can lead to system
crashes or hang-ups.
o Graphics Card Cooling: CPU fans indirectly cool down other
components like the graphics card.
4. Can a Computer Run Without a CPU Fan?
o Technically, a computer can run briefly without a CPU fan, but
it is not recommended.
o Prolonged operation without proper cooling risks CPU damage.
o Modern systems have built-in thermal protection mechanisms
that shut down the CPU if it gets too hot.
5. Where Does a CPU Fan Get Power From?
o CPU fans receive power from the motherboard via a 3-pin or 4-
pin connector.
o The motherboard controls fan speed based on temperature sig-
nals.
6. How Do You Know If Your CPU Fan Is Working?
o Listen for fan noise during start up.
o Monitor CPU temperature using software tools.
o Check BIOS settings for fan speed and temperature readings.
7. Does CPU Fan Affect Performance?
o Yes, efficient cooling positively impacts CPU performance.
o Overheating can lead to thermal throttling, reducing CPU speed.
8. Lifespan and Fan Speed:
o CPU fans can last several years.
o High fan speeds may reduce lifespan, but modern fans are de-
signed for durability.
3.7V BATTERY:
A 3.7V lithium-ion battery is a rechargeable energy storage
device with a nominal voltage of 3.7 volts per cell. These
batteries are widely used due to their high energy density, lightweight
design, and reliable performance. Let us delve into the details:
1. Chemistry and Components:
o Positive Electrode (Cathode):
 Typically made of lithium cobalt oxide (LiCoO2).
 During charging, lithium ions move from the cathode to
the anode, storing energy.
 The cathode significantly influences the battery’s voltage
and energy density.
o Negative Electrode (Anode):
 Usually constructed from graphite.
 Accepts lithium ions during charging and releases them
during discharging.
 The anode’s structure and material impact the battery’s
capacity and performance.
o Electrolyte:
 A liquid or gel-like substance containing lithium ions.
 Facilitates ion movement between the cathode and anode
during charging and discharging.
 The electrolyte’s composition and stability affect safety
and performance.
o Separator:
 A porous membrane that physically separates the cathode
and anode.
 Prevents direct contact between the electrodes to avoid
short circuits.
 Allows the passage of lithium ions while blocking elec-
tron flow.
o Electrochemical Reactions:
 During charging, lithium ions move from the cathode to
the anode through the electrolyte, storing energy.
 During discharging, the ions move back to the cathode,
releasing energy.
2. Voltage and Energy Density:
o The nominal voltage of a 3.7V lithium-ion battery represents
the average potential difference between the cathode and anode
during the discharge cycle.
o Variations exist based on cathode materials (e.g., lithium iron
phosphate or lithium manganese oxide), which may have
slightly different voltages.
o Lithium-ion batteries offer high energy density, making them
suitable for portable electronic devices.
3. Applications:
o Consumer Electronics:
 Power smartphones, laptops, tablets, and wearable
devices.
 Used in digital cameras, camcorders, and portable gaming
consoles.
o Industrial Applications:
 Backup power for emergency lighting systems.
 Powering IoT devices and sensors.
 Integration into safety control systems for alarms and
monitoring.
4. Safety Considerations:
o The 3.7V chemistry is preferred for consumer electronics due to
safety concerns associated with higher voltages.
o Other chemistries (e.g., lithium iron phosphate) may have
slightly different voltages but are less common in consumer
devices.
CHARGING MODULE:
A charging module is an electronic device de-
signed to regulate the charging process of bat-
teries. It ensures that batteries are charged
safely, efficiently, and according to their spe-
cific requirements. Let us delve into the details:
1. Components and Functions:
o Voltage Regulation: The charging
module regulates the charging
voltage to prevent overcharging,
which can damage the battery.
o Current Regulation: It controls the
charging current to prevent excessive flow, especially during
the initial charging phase.
o Protection Circuits: Charging modules may include protection
circuits to prevent overcharging, over-discharging, and over-
heating of the battery.
o Charge Detection: Some modules detect the battery’s state (e.g.,
fully charged, partially discharged) to adjust the charging pro-
cess accordingly.
o When connected to a power source (such as an AC adapter or
solar panel), the charging module:
 Converts AC power to DC power (if needed).
 Regulates the charging current and voltage based on the
battery type (e.g., lead-acid, lithium-ion).
 Monitors the battery’s voltage and adjusts the charging
process.
 Safely charges the battery until it reaches the desired state
(e.g., full charge).
3. Applications:
o Industrial Safety Control Systems:
 Charging modules ensure that backup batteries are always
ready for emergency use.
 They maintain battery health and prolong their lifespan.
 Used in mobile phones, laptops, power banks, and other
portable devices.
o Electric Vehicles (EVs):
 EV charging stations incorporate charging modules to re-
charge vehicle batteries.
o Proper charging prevents battery damage, reduces fire risks, and
ensures optimal performance.
o Overcharging or charging with incorrect parameters can lead to
battery failure.
SWITCH:
A switch is an electrical component that can make
or break an electrical circuit automatically or
manually. It allows the flow of electric current
when closed (ON) and interrupts the current flow
when open (OFF). Switches come in various types, each serving specific
purposes. Let us delve into the details:
1. Types of Switches:
o Single Pole Single Throw (SPST) Switch:
 A basic on/off switch that connects or breaks the connec-
tion between two terminals.
 When the switch is ON, the terminals are connected, al-
lowing current flow.
 When the switch is OFF, the terminals are not connected,
preventing current flow.
 Commonly used as toggle switches.
 ! SPST Switch
o Single Pole Double Throw (SPDT) Switch:
 Has three terminals: common (COM), normally open
(NO), and normally closed (NC).
 The COM terminal connects to either the NO or NC ter-
minal, depending on the switch position.
 Used for applications like three-way light switches.
 ! SPDT Switch
o Double Pole Single Throw (DPST) Switch:
 Controls two independent circuits.
 Has two sets of contacts that can be either open or closed
simultaneously.
 ! DPST Switch
o Double Pole Double Throw (DPDT) Switch:
 Has six terminals: two COM, two NO, and two NC.
 Can connect one COM terminal to either NO or NC ter-
minals.
 Used for reversing motor direction or other applications
requiring multiple switching options.
 ! DPDT Switch
o A switch operates by physically making or breaking an elec-
trical connection.
o When the switch is closed (ON), it completes the circuit, allow-
ing current flow.
o When the switch is open (OFF), it interrupts the circuit, pre-
venting current flow.
o Switches can be triggered mechanically (by physical move-
ment) or electronically (by sensors).
3. Applications:
o Safety Control Systems:
 Switches activate alarms, emergency stop buttons, or in-
terlocks.
 Used to ensure safe operation of machinery and equip-
ment.
 Light switches, power buttons, and toggle switches.
 Used in appliances, computers, and home automation
systems.
o Industrial Automation:
 Limit switches detect the presence or absence of objects
(e.g., doors, gates).
 Pressure switches monitor fluid pressure in hydraulic sys-
tems.
o Proper switch design and installation are critical for safety.
o Switches must withstand mechanical wear, temperature vari-
ations, and environmental conditions.
USB CONNECTING CABLE:

A USB (Universal Serial Bus) connecting cable
is a standardized cable used to establish commu-
nication and power supply between various
devices and a host controller (such as a computer
or smartphone). These cables play a crucial role
in connecting peripherals, transferring data, and
providing power. Here is a detailed overview:
1. Components of a USB Cable:
o USB Connectors:
 USB cables have two types of connectors: Type A and
Type B.
 Type A Connector: The rectangular connector typically
found on the computer side (host).
 Type B Connector: The square or trapezoidal connector
commonly used on peripheral devices (e.g., printers,
scanners).
 ! USB Connectors
o Wires Inside the Cable:
 USB cables typically have four wires:
 Red (Vaus): Carries +5V power supply.
 White (D-): Differential pair for data transfer (neg-
ative).
 Green (D+): Differential pair for data transfer
(positive).
 Black (GND): Ground wire.
o Twisted Pair Design:
 The D+ and D- wires are twisted together to reduce elec-
tromagnetic interference (EMI) and ensure reliable data
transmission.
o When you connect a USB device (e.g., keyboard, printer, flash
drive) to a computer using a USB cable:
 The host (computer) detects the device through the USB
port.
 The USB system software assigns an address to the
device.
 Data transfer occurs through the D+ and D- wires.
 The Vaus wire provides power to the device.
 The GND wire completes the circuit.
3. Importance in Industrial Safety Control Systems:
o USB cables connect safety devices (alarms, sensors) to control
systems.
o They facilitate data exchange and power supply for monitoring
and emergency response.
o Properly designed and shielded USB cables ensure reliable
communication.
4. USB Versions:
o USB 2.0: Maximum data rate of 480 Mbps.
o USB 3.0 (USB 3.1 Gen 1): Maximum data rate of 5 Gbps
(backward compatible with USB 2.0).
o USB 3.1 Gen 2: Maximum data rate of 10 Gbps.
AC HOLDER FOR BULB:

An AC holder for load (also known as a load con-
troller or load switch) is an electrical device used to
control the power supply to a load (such as motors,
heaters, or lighting) in an industrial setting. Its primary
purpose is to ensure safe and efficient operation while
minimizing risks. Let us delve into the details:
1. Components and Construction:
o Contractor: The core component of an AC holder is the con-
tactor. It consists of an electromagnetically operated switch with
contacts (usually made of copper or silver) that can handle high
currents.
o Coil: The contactor coil is energized by a control signal (usually
low voltage) to close or open the contacts.
o Contacts: The contacts are responsible for making or breaking
the electrical connection to the load.
o Enclosure: The entire assembly is enclosed in a protective
housing to prevent accidental contact and ensure safety.
o When the control signal (such as a switch or relay) activates the
contactor coil:
 The coil generates a magnetic field, pulling the contacts
together (closing the circuit) or releasing them (opening
the circuit).
 Closing the contacts allows current to flow from the
power supply to the load.
 Opening the contacts interrupts the current flow, discon-
necting the load from the power supply.
o The contactor ensures smooth and reliable switching of the
load, preventing voltage spikes and minimizing wear on the
switchgear.
3. Applications:
o Motor Control: AC holders are commonly used to start and
stop electric motors in industrial machinery.
o Heating Systems: They control heaters, boilers, and furnaces.
o Lighting Control: AC holders manage lighting circuits in
factories, warehouses, and outdoor areas.
o Safety Interlocks: Used in safety systems to disconnect power
during emergencies or abnormal conditions.
o AC holders must be properly rated for the load current and
voltage.
o They should have overload protection to prevent damage due to
excessive current.
o Enclosures must meet safety standards to prevent accidental
contact.
4.11 LED:
A light-emitting diode (LED) is a semiconductor light source. LEDs
are used as indicator lamps in many devices and are increasingly used for
lighting. When a light-emitting diode is forward biased (switched on),
electrons are able to recombine with holes within the device, releasing
energy in the form of photons.
This effect is called electroluminescence and the color of the light
(corresponding to the energy of the photon) is determined by the energy gap
of the semiconductor. An LED is often small in area (less than 1 mm2), and
integrated optical components may be used to shape its radiation pattern.
LEDs present many advantages over incandescent light sources including
lower energy consumption, longer lifetime, improved robustness, smaller
size, faster switching, and greater durability and reliability.
Types of LED’S:
Light-emitting diodes are used in applications as diverse as

replacements for aviation lighting, automotive lighting as well as in traffic
signals. The compact size, the possibility of narrow bandwidth, switching
speed, and extreme reliability of LEDs has allowed new text and video
displays and sensors to be developed, while their high switching rates are
also useful in advanced communications technology.
Electronic Symbol:
Fig 4.11(b): symbol of LED

4.13 RESISTORS:
A resistor is a two-terminal electronic component designed to
oppose an electric current by producing a voltage drop between its terminals
in proportion to the current, that is, in accordance with Ohm's law:
V = IR
Resistors are used as part of electrical networks and electronic
circuits. They are extremely commonplace in most electronic equipment.
Practical resistors can be made of various compounds and films, as well as
resistance wire (wire made of a high-resistivity alloy, such as
nickel/chrome).
The primary characteristics of resistors are their resistance and the power
they can dissipate. Other characteristics include temperature coefficient,
noise, and inductance. Less well-known is critical resistance, the value
below which power dissipation limits the maximum permitted current flow,
and above which the limit is applied voltage. Critical resistance depends
upon the materials constituting the resistor as well as its physical
dimensions; it is determined by design.
Resistors can be integrated into hybrid
and printed circuits, as well as
integrated circuits. Size, and position of
leads (or terminals) are relevant to
equipment designers; resistors must be
physically large enough not to overheat
when dissipating their power.
A resistor is a two-terminal passive electronic component which im-

plements electrical resistance as a circuit element. When a voltage V is ap-
plied across the terminals of a resistor, a current I will flow through the res-
istor in direct proportion to that voltage. The reciprocal of the constant of
proportionality is known as the resistance R, since, with a given voltage V, a
larger value of R further "resists" the flow of current I as given by Ohm's
law:
Resistors are common elements of electrical networks and electronic

circuits and are ubiquitous in most electronic equipment. Practical resistors
can be made of various compounds and films, as well as resistance wire
(wire made of a high-resistivity alloy, such as nickel-chrome). Resistors are
also implemented within integrated circuits, particularly analogy devices,
and can also be integrated into hybrid and printed circuits.
4.14 CAPACITORS:
A capacitor or condenser is a passive electronic component
consisting of a pair of conductors separated by a dielectric. When a voltage
potential difference exists between the conductors, an electric field is present
in the dielectric. This field stores energy and produces a mechanical force
between the plates. The effect is greatest between wide, flat, parallel,
narrowly separated conductors.
An ideal capacitor is characterized by a single constant value,
capacitance, which is measured in farads. This is the ratio of the electric
charge on each conductor to the potential difference between them. In
practice, the dielectric between the plates passes a small amount of leakage
current. The conductors and leads introduce an equivalent series resistance
and the dielectric have an electric field strength limit resulting in a
breakdown voltage.
The properties of capacitors in a circuit may determine the resonant
frequency and quality factor of a resonant circuit, power dissipation and
operating frequency in a digital logic circuit, energy capacity in a high-
power system, and many other important aspects.
A capacitor (formerly known as condenser) is a device for storing

electric charge. The forms of practical capacitors vary widely, but all contain
at least two conductors separated by a non-conductor. Capacitors used as
parts of electrical systems, for example, consist of metal foils separated by a
layer of insulating film.
A capacitor is a passive electronic component consisting of a pair of
conductors separated by a dielectric (insulator). When there is a potential dif-
ference (voltage) across the conductors, a static electric field develops in the
dielectric that stores energy and produces a mechanical force between the
conductors. An ideal capacitor is characterized by a single constant value,
capacitance, measured in farads. This is the ratio of the electric charge on
each conductor to the potential difference between them.
RECTIFIRE AND FILTER:
A rectifier is an electrical device
that converts alternating current (AC), which
periodically reverses direction, to direct current
(DC), current that flows in only one direction, a
process known as rectification. Rectifiers have
many uses including as components of power
supplies and as detectors of radio signals. Rectifiers may be made of solid-
state diodes, vacuum tube diodes, mercury arc valves, and other components.
The output from the transformer is fed to the rectifier. It converts A.C. into
pulsating D.C. The rectifier may be a half wave or a full wave rectifier. In
this project, a bridge rectifier is used because of its merits like good stability
and full wave rectification. In positive half cycle only two diodes (1 set of
parallel diodes) will conduct, in negative half cycle remaining two diodes
will conduct and they will conduct only in forward bias only.
Capacitive filter is used in this project. It removes the rip-
ples from the output of rectifier and smoothens the D.C. Output received
from this filter is constant until the mains voltage and load is maintained
constant. However, if either of the two is varied, D.C. voltage received at
this point changes. Therefore, a regulator is applied at the output stage. The
simple capacitor filter is the most basic type of power supply filter. The use
of this filter is very limited. It is sometimes used on extremely high-voltage,
low-current power supplies for cathode-ray and similar electron tubes that
require very little load current from the supply. This filter is also used in cir-
cuits where the power-supply ripple frequency is not critical and can be rela-
tively high. Below figure can show how the capacitor changes and dis-
charges.
In industrial and commercial applications push buttons can be linked
together by a mechanical linkage so that the act of pushing one button causes
the other button to be released. In this way, a stop button can "force" a start
button to be released. This method of linkage is used in simple manual
operations in which the machine or process have no electrical circuits for
control. Pushbuttons are often color-coded to associate them with their
function so that the operator will not push the wrong button in error.
Commonly used colors are red for stopping the machine or process and
green for starting the machine or process.
Red pushbuttons can also have large heads (mushroom shaped)

for easy operation and to facilitate the stopping of a machine. These
pushbuttons are called emergency stop buttons and are mandated by the
electrical code in many jurisdictions for increased safety. This large
mushroom shape can also be found in buttons for use with operators who
need to wear gloves for their work and could not actuate a regular flush-
mounted push button. As an aid for operators and users in industrial or
commercial applications, a pilot light is commonly added to draw the
attention of the user and to provide feedback if the button is pushed.
Typically, this light is included into the center of the pushbutton and a lens
replaces the pushbutton hard center disk.
(Push ON Button)
LDR:
A light dependent resisitor is a resisitor whose resistance

changes with the intensity of incident light. The working principle of light
dependent resistor is photoelectric effect. A light dependent resisitor is made
of a high resistance semiconductor. If the energy of the incident light is
greater than the band gap of the semiconductor, electron -hole pairs are
generated. The photogenerated electron-hole pair transits the device giving
rise to photoconductivity. The essential elements of a photoconductive cell
are the ceramic substrate, a layer of photoconductive material, metallic
electrodes to connect the device into a circuit and a moisture resistant
enclosed Light sensitive material is arranged in the form of a long strip,
zigzag across a disc shaped base with protective sides. For additional
protection, a glass or plastic cover may be included. The two ends of the
strip are brought out to connecting pins below the base as shown below.
The commercial photoconductive materials include cadmium

Sulfide (CdS), cadmium Selenide (CdSe), Lead Sulfide (PbS) and Indium
antimonide (InSb) etc., There is large change in the resistance of a cadmium
selenide cell with changes in ambient temperature, but the resistance of
cadmium sulfide remains relatively stable. Moreover, the spectral response
of a cadmium sulfide cell closely matches to that of a human eye. Hence,
LDR is used in applications where human vision is a factor such as street
light control or automatic iris control for cameras. The above-mentioned
features drive us to opt for CdS based LDR in our electronic circuit for
Automatic Street light controller.
VOLTAGE REGULATOR (7805 AND 7812):
The LM78XX/LM78XXA series of three-terminal positive

regulators are available in the TO-220/D-PAK package and with several
fixed output voltages, making them useful in a Wide range of applications.
Each type employs internal current limiting, thermal shutdown, and safe
operating area protection, making it essentially indestructible. If adequate
heat sinking is provided, they can deliver over 1A output Current. Although
designed primarily as fixed voltage regulators, these devices can be used
with external components to obtain adjustable voltages and currents.
FEATURES:
• Output Current up to 1A.

• Output Voltages of 5, 6, 8, 9, 10, 12, 15, 18, 24V.
• Thermal Overload Protection.
• Short Circuit Protection.
• Output Transistor Safe Operating Area Protection.
INTERNAL BLOCK DIAGRAM:

TRANSISTOR
BC547 (NPN) AND BC557 (PNP):
Transistors are three terminal active devices made from different

semiconductor materials that can act as either an insulator or a conductor by
the application of a small signal voltage. The transistor's ability to change
between these two states enables it to have two basic functions: switching or
amplification. Then bipolar transistors can operate within three different
regions:
 Active Region - the transistor operates as an amplifier and IC = β IB

 Saturation - the transistor is fully-ON operating as a switch and
IC = Isaturation
 Cut-off - the transistor is "fully-OFF" operating as a switch and
IC = 0
The word Transistor is an acronym and is a combination of the

words Transfer Varistor used to describe their mode of operation way back
in their early days of development. There are two basic types of bipolar
transistor construction, NPN and PNP, which basically describes the
physical arrangement of the P-type and N-type semiconductor materials
from which they are made. A transistor is made of a solid piece of
semiconductor material, with at least three terminals for connection to an
external circuit. The Bipolar Junction Transistor basic construction consists
of two PN-junctions producing three connecting terminals with each
terminal being given a name to identify it from the other two. These three
terminals are known and labeled as the Emitter (E), the Base (B) and the
Collector (C) respectively.
Bipolar Transistors are current regulating
devices that control the amount of current
flowing through them in proportion to the
amount of biasing voltage applied to their
base terminal acting like a current-controlled
switch. The principle of operation of the two transistor types NPN and PNP,
is the same the only difference being in their biasing and the polarity of the
power supply for each type.
SOFTWARE COMPONENT:
TELEGRAM BOT AND API:
Deep Dive into Telegram API and Bots for Your NodeMCU Project
The Telegram API and bots play a crucial role in enabling your NodeMCU
project to communicate with the Telegram messaging platform. Let us delve
deeper into these concepts and how they work together for your industrial
safety or automation application.
Telegram API: The Bridge Between Your NodeMCU and Telegram
Imagine the Telegram API as a specialized translator and facilitator. It
translates the instructions and data your NodeMCU wants to send (like
sensor readings) into a format that Telegram understands (JSON) and vice
versa. It also acts as the bridge, allowing your NodeMCU to make requests
to Telegram's servers and receive responses back. Here is a breakdown of
key API aspects:
 HTTP Requests and Responses: The API leverages the familiar HTTP
protocol, which your NodeMCU can handle using libraries like HTTP
Client. You will send HTTP requests containing specific commands
(methods) to designated URLs (endpoints) on Telegram's servers. The
API then responds with relevant data in JSON format.
 Methods and Endpoints: Think of methods as actions you want to
perform on Telegram. For example, the get Updates method retrieves
new messages sent to your bot, while send Message allows your bot to
send messages back to users. Each method has a unique endpoint
URL. You will construct HTTP requests specifying the desired
method and endpoint along with any necessary data.
 Authentication: Keeping Things Secure: Telegram uses an access
token system for authentication. You will create a bot using the Bot
Father account and obtain a unique token that identifies your bot. This
token needs to be included in your NodeMCU code's HTTP requests
for authorization.
Telegram Bot: Your Project's Representative in Telegram
A Telegram bot is a special type of Telegram account designed for
programmatic interaction. It does not require a phone number and acts as a
dedicated interface for your NodeMCU application within the Telegram
ecosystem. Here's how bots can be instrumental in your project:
 Customizable Functionality: Telegram bots are like blank canvases;
you program them to perform specific tasks. In your NodeMCU
project, your bot might:
o Receive Sensor Data: Your NodeMCU can send data collected
by its sensors (e.g., temperature, humidity) to the bot using the
Telegram API.
o Trigger Alerts: Based on sensor readings or external triggers,
the bot can notify users in designated Telegram chats or groups
about critical events or safety concerns. Imagine the bot sending
a message like: "WARNING! Temperature Exceeded Safe
Limit in Zone B!"
o Respond to Commands: Users can interact with your bot by
sending commands within Telegram chats. Your NodeMCU
code defines these commands and programs the bot's response.
For instance, a /get reading command might instruct the bot to
request the latest sensor data from the NodeMCU and display it
in the chat.
Connecting the Dots: Integrating Telegram API and Bot with NodeMCU
To create the magic of communication between your NodeMCU and
Telegram, follow these steps:
1. Create a Telegram Bot: Use Bot Father to create a bot and obtain its
access token. This token acts like a secret handshake, allowing your
NodeMCU to interact with Telegram.
2. Include an HTTP Library: Your NodeMCU code needs a library like
HTTP Client to make HTTP requests to the Telegram API.
3. Implement API Calls: Write code functions to interact with the API
using HTTP requests. These functions specify:
o The desired method (e.g., get Updates, send Message)
o The appropriate endpoint URL
o Any required data (e.g., sensor readings) formatted in JSON
4. Process Responses: Parse the JSON responses received from the API
to extract relevant information (e.g., new messages) and trigger
actions based on that data. For example, if the response indicates a
new message with a /get reading command, your code will initiate a
request to the NodeMCU for sensor data and then send it back to the
user via the bot.
Putting it All Together: A Powerful Combination
By effectively integrating the Telegram API and a bout with your NodeMCU
project, you unlock a whole new level of functionality:
 Remote Monitoring and Alerts: You can monitor sensor data from
anywhere in the world using Telegram. The bot can trigger alerts for
critical events, allowing for timely intervention.
 User Interaction: Users can interact with your project by sending
commands through Telegram, creating a user-friendly interface for
control and data retrieval.
 Flexibility and Scalability: The Telegram API offers a wide range of
methods, allowing you to customize your project's features. As your
project grows, you can easily scale the Telegram bot to handle more
users and interactions
SCOPE FOR THE FUTURE WORK:
The NodeMCU-based real-time safety system offers a solid groundwork, but its
potential extends far beyond its current capabilities. Future endeavours can see
the system incorporate a wider range of sensors, including those for machine
health, environmental monitoring, and even worker well-being. Machine
learning algorithms can be integrated to analyse sensor data for predictive
maintenance, risk assessment, and even trigger automated responses in critical
situations. Furthermore, improved communication and response protocols can
involve multi-factor authentication, integration with emergency response
systems, and development of user-friendly dashboards for real-time data
visualization. Advanced user interfaces can take the form of augmented reality
overlays, allowing workers to directly visualize safety hazards within their
environment. To ensure the system's robustness as it scales, future work should
focus on enhanced cybersecurity measures and cloud-based data storage and
management. By delving into these advancements, the NodeMCU-based system
can transform into a holistic solution, ushering in a new era of data-driven
industrial safety practices that prioritize worker well-being, operational
efficiency, and a proactive approach to risk mitigation.
CONCLUSION
In conclusion, real-time industrial safety systems built around the

NodeMCU offer a compelling solution for modern industrial environments.
The NodeMCU's low cost, ease of use, and Wi-Fi capabilities make it an
accessible platform for deploying a network of sensors that can monitor a
wide range of safety parameters. From temperature and gas detection to
unauthorized access and noise levels, these systems provide real-time data
that empowers personnel to identify and address potential hazards before
incidents occur.
Furthermore, the ability to transmit this data wirelessly allows for remote
monitoring and intervention. Alerts can be sent to designated personnel via
SMS, email, or an IoT dashboard, enabling a swift response to critical
situations. This not only safeguards live but also minimizes downtime and
potential equipment damage.
By implementing a NodeMCU-based real-time safety system, industries can
create a safer work environment for their employees, reduce the risk of
accidents and injuries, and promote a culture of proactive safety awareness.
As the technology continues to develop and integrate with additional
functionalities, these systems have the potential to revolutionize industrial
safety practices, making workplaces safer and smarter for everyone.
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BIJU PATNAIK UNIVERSITY OF

TECHNOLOGY ROURKELA, ODISHA

A Major Project Report On

DESIGN, ANALYSIS AND

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

DESIGN, ANALYSIS AND DEVLOPMENT OF REAL-TIME

Bachelor of Technology in Electrical Engineering

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

Signature of Guide Signature of HOD

Signature of External Examiner

RAAJDHANI ENGINEERING COLLEGE

Signature of HOD Signature of Guide

Signature of External Examiner

Signature Regd. No.

Thomsen, J-P. (2005) had presented Fieldbus technology in industrial

Schuster, Franka, and Andreas Paul. 2012. had presented Modern

McFarlane, Duncan, Sanjay Sarma, (2003) had presented Automated

Kondratenko, Yuriy, Oleksiy Kozlov 2017. had presented This paper

Lesjak, Christian, Thomas Ruprecht, 2014. had presented Smart

Lesi, Vuk, Zivania Jakovljevic (2021) had presented Internet of Things

Darko, Lars, Henning Trek, 2012. had presented Nowadays the

Jain, Samyak, and K. Chandrasekaran2022. had presented There is a

Kumamoto, Halimon, Doston Khasanov (2021) had presented in recent

Abruzzian, Sikder M., Muhammad Naseeruddin, 2017. had presented

Koziolek, Heiko, Andreas Burger, 2020. had presented Software

Villani, Valeria, Lorenzo Sabatini, Paulina Barańska, (2020) had

Nagorny, Kevin, Armando Walter Colombo (2012) had presented This

Sheu, Ruey-Kai, Yuan-Cheng Lin, (2020) had presented Sheet metal-based

Karunanidhi, Kalaivanan (2020) had presented Integrating Wireless

Lokman, Tayeb Bin, Mohammad Touchily Islam 2020. had presented

Pfrang, Steffen 2018 had presented Modern industrial facilities consist of

Bingeman, Thomas, Stamatis Karnowski’s, (2014) In the last decades,

Adeosun, Ramoni, Gilberto 2020. had presented in this paper, we

2. INTRODUCTION TO SAFETY IN INDUSTRIAL AUTOMATION:

4.1 FLAME SENSOR:

4.4 RELAY DRIVER:

NODEMCU is an open-source firmware for which open

The prototyping hardware typically used is a circuit board functioning as

ESP8266 Arduino Core:

As Arduino.cc began developing new MCU boards based on non-

4.6 SMOKE SENSOR:

A relay is an electrically operated switch. Current flowing through the

1. Design and Types:

USB CONNECTING CABLE:

AC HOLDER FOR BULB:

Light-emitting diodes are used in applications as diverse as

Fig 4.11(b): symbol of LED

A resistor is a two-terminal passive electronic component which im-

Resistors are common elements of electrical networks and electronic

A capacitor (formerly known as condenser) is a device for storing

Red pushbuttons can also have large heads (mushroom shaped)

A light dependent resisitor is a resisitor whose resistance

The commercial photoconductive materials include cadmium

The LM78XX/LM78XXA series of three-terminal positive

• Output Current up to 1A.

INTERNAL BLOCK DIAGRAM:

BC547 (NPN) AND BC557 (PNP):

Transistors are three terminal active devices made from different

 Active Region - the transistor operates as an amplifier and IC = β IB