OPERATION AND MONITORING OF RECLAIMER USING

WIRELESS MESH NETWORK

By,

Kaviya.B(UR11EE114)

B.Tech-Final Year EEE

(2011 - 2015)

GUIDE(INTERNAL): GUIDE(EXTERNAL):

Mr.A.ShankarAssistant Professor, Karunya University.

Mr.M.RamachandranDy General Manager, Mine 1A, NLC.

OBJECTIVE:

• To operate and monitor the reclaimer lubrication system with a simple microcontroller unit of AT89S52 through zigbee wireless communication between the reclaimer unit and the control room.

• Automating the lubrication system of reclaimer parts like bucket wheel, under carriage, super structure which requires frequent lubrication to prevent bearing failures.

PERFORMANCE METRICES:

• Applying correct amount of lubricant at the right time and at the right place ensures increased productivity, reduced operating costs, more efficient lubrication.

NEED OF THE PROJECT:

• For mining machines like reclaimer, applying lubricant is often most effective.

• All critical components are lubricated, regardless of location or ease of access

• Proper lubrication of critical components ensures safe operation of the machinery.

• Less wear on the components means extended component life, fewer breakdowns, reduced downtime, reduced replacement costs and reduced maintenance costs.

• Measured lubrication amounts means no wasted lubricant

VB CONTROL PANEL BUCKET WHEEL VIEW:

OVERALL SNAPSHOT OF THE KIT:

DESCRIPTION:

We have designed the automation of lubrication system of reclaimer sections such as Bucket wheel and Under carriage using visual basic control panel. The parameters that will be considered in automating the lubrication system of stacker reclaimer will be ,

1) driving sequence 2) supply voltage 3) grease level in the grease tank (low and high) 4) motor ON\OFF 5) line1 Start\Stop 6) line2 Start\Stop 7) over pressure (greasing pipe) 8) over current relay.

• Whenever the reclaimer bearing requires lubrication, the motor turns on automatically and the grease starts to be pumped from the tank and when the greasing is completed, it turns off automatically.

DESIGN DETAILS OF THE COMPONENT MODULES:

1. Input Voltage to motor: 230V, 3PH, 50HZ

2. Power Supply – ADC: 5V– Simulator Circuit: 5V– Zigbee: 3.3V– Relay Module: 12V– Microcontroller: 5V

ANALOG INPUTS:3. Bearing temperature

4. Line Pressure

5. AC supply

DIGITAL INPUTS:6. Driving sequence

7. Supply voltage

8. Grease level

9. Line 1 limit switch

10. Line 2 limit switch

COMPONENTS INVOLVED:

1. Power supply 5V,12V,3.3V

2. AT89S52 microcontroller3. PCF8591 ADC4. 12V relays 5. RS232 6. Simulator circuit7. Zigbee transcieverSOFTWARE USED:8. Embedded C

programming9. Keil microvision software10. VB virtual control panel

POWER SUPPLY:•12 Diodes-IN4007•3 Diode-IN5822•3 Capacitos-1000uf/50v•3 capacitor-470uf/25v•3 capacitor-104pf•Regulator -LM2576-5V•LM2576-12V•LM2576-Adjustable•LM1117•Variable resistance of 10k

MICROCONTROLLER•4 diodes IN4007•8 resistors of 10K•10K potentiometer•Capacitors of 1000 micro farad, 104 pico farad, 470 microfarad of 25V, 10 microfarad of 63V, 33 pico farad•Voltage regulator 7805•AT89S52 microcontroller•PCF8591 ADC•Crystal 11.0592MHZ

RELAY:1. 10 Resistors 1 kilo

ohm2. 4 Transistors BC3373. 4 diodes IN40074. 4 12V relays5. Led6. 2 pin molex7. Berg strip

Contd….

CIRCUIT DIAGRAM:

Contd…

SWOT Update:

STRENGTH: Increased productivity Reduced operating costs More efficient

Lubrication

WEAKNESS: Signal failure between

two zigbee modules

OPPORTUNITY: Increased application in

major industries and plants that require frequent lubrication

THREATS: In case there is improper

functioning of sensors the lubricant will be wasted

CONCLUSION:• This project is to demonstrate that, the lubrication system parameters can be controlled using microcontroller where the input parameters like motor current, motor voltage, grease tank level which is driven by the motor, start and stop off greasing line to the rotating parts of reclaimer like bucket wheel, under carriage can be automated and monitored using microcontrollers.

• Thus in many ways the automatic control is much higher in performance than that of manual control and hence automation is feasible and attractive alternative to manual control.

• The overall budget of the project is Rs.12000

REFERENCE:

[1] A. Dhivya, J. Infanta and K. Chakrapani,“Automated Agricultural Process Using PLC and ZigBee” Journal of Artificial Intelligence, 2012.

[2] Liu Yang, Linying Jiang , Kun Yue ,Heming Pang, “ Design and Implementation of the Lab Remote Monitoring System Based on Embedded Web Technology”,2010.

[3] Khusvinder Gill, Shuang-Hua Yang, Fang Yao, and Xin Lu, “A ZigBee-Based Home Automation System”, MAY 2009.

[4] Izzatdin Abdul Aziz, Mohd Hilmi Hasan, Mohd Jimmy Ismail, Mazlina Mehat, Nazleeni Samiha Haron, “Remote Monitoring in Agricultural.