Improve Your Skills with a "Free" Minized Dev Board Project Contest

Quite interesting kit it seems to me. I was away from this community & my e-stuff for a long time due to some issues. This is a good thing to catch up with my electronics stuff back. Well, I've been supervising my family business for a long time, there are many things we can do in that particular industry place. For example - when I first visited there I immediately told electrician to install ammeters on each motor for each phase to know real-time current consumption to avoid/warn any problems with motor winding. Also the big capacitors for PF correction. I have a concept in my mind for a long time why not make a system for that? as I wanted to know - daily updates on how long my main motor (125HP) has run to how much production per hour. Also how much electricity consumed per hour for that particular motor run. Moreover, Main Power line is near so I can use CT's and read current consumption via that system. I can hook up a few temperature & Vibration sensors on motor's of interest and know their real-time values. All these values gathered and processed might result in a system efficient to warn about any real-time problem might occur with motors.
To check whether everything is running fine we trust on ammeter for its reading, let me explain:
Current:-
This workplace has jerk load and current on 125HP motor usually changes every second based on the material load being fed. Usually, current reading jumps from 90A - 150A while running. sometimes on extreme load conditions, it touches 190A- 210A. We know if it stays in between 90A - 150A everything is fine, if it reaches 190A-210A for few seconds we need to take extreme care may be shut off the material being fed to the motor. If in any case motor keeps on running at peak temperatures greater then 200A motor winding will burn. Unfortunately, this has happened before.

Vibration:-
This part is interesting, The main motor runs a rotopactor machine. This machine has 8 Rulleys (each weighing about 38Kg) which are installed horizontally in between two Circular Rings (One is Hollow, made up of MS Iron combined weight 350 KG). This whole unit rotates on a shaft which is run by that motor. Now, care to be taken while installing those rulleys as these must be of the same weight (max weight difference can be 100Grams), two rulleys which has almost same weight are installed opposite to each other to maintain balanced rotation of the whole set. If care is not taken while installing these things this might get out balance and starts shaking. Vibrations can be felt as far as 100-150 meters that something is not right. This is how we know things need to be inspected. Also, these rulleys deteriorate constantly & need to be changed after running for a maximum a week.
The vibration sensor role is to detect the difference between normal vibrations to abrupt vibrations being made by machine. As, when rulleys are near its end they make ground more shaky. This is what needs to log i.e. day 1 vibration - Day 7 vibration. This log details will be fed to the system to make it capable of giving warnings.

Temperature:-
Both motor surface and rotopactor need to be hooked up with temperature sensors. I can't say about values on this one because I never got the opportunity to check its temperature other than my hand which does not have any TFT installed on it to tell temperature other than screaming it too hot shut it off. But after hooking up with sensors it will be logged on a daily basis. Algorithms for the system will be made accordingly after making logs.

All in all, system will log details for each sensor for normal run and abrupt change. Pre fed algorithm will be helpful in warning nearby Workers, Forman about the situation via Sound Alarms as well as Lights. Also, if everything works as I have thought, I will make all the system readings to be directed to me as well on phone/laptop via Wireless Wi-Fi network, IoT. Lights can also made to automatically turn on/off for evening/morning.

This kit or not I'll do it, I think time has come. Will update on the blog when I start this project, it will be fun.

Cheers !!

Quite interesting kit it seems to me. I was away from this community & my e-stuff for a long time due to some issues. This is a good thing to catch up with my electronics stuff back. Well, I've been supervising my family business for a long time, there are many things we can do in that particular industry place. For example - when I first visited there I immediately told electrician to install ammeters on each motor for each phase to know real-time current consumption to avoid/warn any problems with motor winding. Also the big capacitors for PF correction. I have a concept in my mind for a long time why not make a system for that? as I wanted to know - daily updates on how long my main motor (125HP) has run to how much production per hour. Also how much electricity consumed per hour for that particular motor run. Moreover, Main Power line is near so I can use CT's and read current consumption via that system. I can hook up a few temperature & Vibration sensors on motor's of interest and know their real-time values. All these values gathered and processed might result in a system efficient to warn about any real-time problem might occur with motors.
To check whether everything is running fine we trust on ammeter for its reading, let me explain:
Current:-
This workplace has jerk load and current on 125HP motor usually changes every second based on the material load being fed. Usually, current reading jumps from 90A - 150A while running. sometimes on extreme load conditions, it touches 190A- 210A. We know if it stays in between 90A - 150A everything is fine, if it reaches 190A-210A for few seconds we need to take extreme care may be shut off the material being fed to the motor. If in any case motor keeps on running at peak temperatures greater then 200A motor winding will burn. Unfortunately, this has happened before.

Vibration:-
This part is interesting, The main motor runs a rotopactor machine. This machine has 8 Rulleys (each weighing about 38Kg) which are installed horizontally in between two Circular Rings (One is Hollow, made up of MS Iron combined weight 350 KG). This whole unit rotates on a shaft which is run by that motor. Now, care to be taken while installing those rulleys as these must be of the same weight (max weight difference can be 100Grams), two rulleys which has almost same weight are installed opposite to each other to maintain balanced rotation of the whole set. If care is not taken while installing these things this might get out balance and starts shaking. Vibrations can be felt as far as 100-150 meters that something is not right. This is how we know things need to be inspected. Also, these rulleys deteriorate constantly & need to be changed after running for a maximum a week.
The vibration sensor role is to detect the difference between normal vibrations to abrupt vibrations being made by machine. As, when rulleys are near its end they make ground more shaky. This is what needs to log i.e. day 1 vibration - Day 7 vibration. This log details will be fed to the system to make it capable of giving warnings.

Temperature:-
Both motor surface and rotopactor need to be hooked up with temperature sensors. I can't say about values on this one because I never got the opportunity to check its temperature other than my hand which does not have any TFT installed on it to tell temperature other than screaming it too hot shut it off. But after hooking up with sensors it will be logged on a daily basis. Algorithms for the system will be made accordingly after making logs.

All in all, system will log details for each sensor for normal run and abrupt change. Pre fed algorithm will be helpful in warning nearby Workers, Forman about the situation via Sound Alarms as well as Lights. Also, if everything works as I have thought, I will make all the system readings to be directed to me as well on phone/laptop via Wireless Wi-Fi network, IoT. Lights can also made to automatically turn on/off for evening/morning.

This kit or not I'll do it, I think time has come. Will update on the blog when I start this project, it will be fun.

Cheers !!