PDF Machine Monitoring System Using Gsm Sms Technology

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MACHINE MONITORING SYSTEM USING GSM SMS TECHNOLOGY

By Hans Davin

A Bachelor’s Thesis

Submitted to the Faculty of Engineering

Department of MECHATRONICS

in partial fulfillment of the requirements for the Degree of

BACHELOR OF SCIENCES WITH A MAJOR IN MECHATRONICS

SWISS GERMAN UNIVERSITY EduTown BSD City

Tangerang – 15339 Island of Java, Indonesia

www.sgu.ac.id August 2010

Revision after the Thesis Defense on 9^th August 2010

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MACHINE MONITORING SYSTEM USING GSM SMS TECHNOLOGY Page 2 of 198

Hans Davin

STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, not material which to a substantial extent has been accepted for the award of may other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

_______________________________________ ________________

Hans Davin Date

Approved by:

________________________________________ __________________

Dr. Rusman Rusyadi M.Sc Date

________________________________________ __________________

Dipl.-Ing Maralo Sinaga Date

______________________________________ _________________

Chairman of the Examination Steering Committee Date

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Hans Davin

ABSTRACT

MACHINE MONITORING SYSTEM USING GSM SMS TECHNOLOGY By

Hans Davin

SWISS GERMAN UNIVERSITY Bumi Serpong Damai

Dr. Rusman Rusyadi M.Sc, Advisor Dipl.-Ing Maralo Sinaga, Co-Advisor

Machine monitoring is a very essential element on any process which involves machine. Most of the machine monitoring processes performed is not oriented in condition based monitoring. Condition based monitoring system is intended for condition based maintenance, which optimize the remaining life-time estimation. The condition based monitoring system can be improved even more by implementing GSM SMS technology into the system, which will provide mobility for the operator while keep being informed on the machine status. The most monitored elements on performing machine monitoring process are vibration, power, and temperature. In measuring vibration as the main element to determine the performance of a machine, Fast Fourier Transform algorithm is the best way to perform vibration monitoring.

Keywords: Global System Mobile (GSM), Short Message Service (SMS), Condition Based Monitoring (CBM), vibration, Fast Fourier Transform (FFT).

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Hans Davin

DEDICATION

I dedicate this thesis to God, my father Doddy Syianto, my mother Gouw Hok Lian, my sister Jessica Nathania, and my beloved one Vanesia Lauw.

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Hans Davin

ACKNOWLEDGMENTS

The author wishes to thank Dr. Rusman Rusyadi M.Sc as the advisor of the thesis and Dipl.- Ing Maralo Sinaga as the co-advisor for their support upon the thesis work. The author especially thanks Dr. Rusman Rusyadi M.Sc for his time and advice, which helped the author to solve the problem upon thesis work and also finish the thesis work.

The author also thanks all lecturers, who had helped the author by providing the author with the knowledge and allow the author to finish his thesis work.

The author would also show his gratitude to Vanesia Lauw, which had supported the author from the beginning of the thesis work. Gratitude is also given to my friends M. Louis Amalian and Rizky Novian, who also supported me on the thesis work.

The author shows his deepest gratitude to his parents for their support, which helped the author finish his thesis work.

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Hans Davin

TABLE OF CONTENTS

STATEMENT BY THE AUTHOR ... 2

ABSTRACT ... 3

DEDICATION ... 4

ACKNOWLEDGMENTS ... 5

CHAPTER 1 – INTRODUCTION ... 13

1.1 Background ... 13

1.2 Thesis Purpose... 14

1.3 Thesis Scope and Limitation ... 14

1.4 Problem Identification ... 15

1.5 Short Methodology ... 15

CHAPTER 2 – LITERATURE REVIEW ... 16

2.1 History of Machine Monitoring Bachelor’s Thesis at SGU ... 16

2.2 Condition Based Machine Monitoring ... 16

2.3 GSM (Global System for Mobile) Network ... 19

2.4 SMS (Short Message Service) Technology ... 21

2.5 Vibration Measurement ... 21

2.6 Temperature Measurement ... 23

2.7 Current Measurement ... 24

CHAPTER 3 – METHODOLOGY ... 25

3.1 Introduction ... 25

3.2 Mechanical Design ... 26

3.2.1 DC Motor ...26

3.2.2 Rubber Coupling ...27

3.2.3 Bearing and Shaft Holder...27

3.2.4 Drive Shaft ...28

3.2.5 Encoder ...28

3.2.6 Spring ...29

3.3 Electrical Design ... 29

3.3.1 Power supply ...29

3.3.2 MEMSIC 2125 Accelerometer ...31

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Hans Davin

3.3.3 LCD...32

3.3.4 LM35DZ Temperature Sensor ...34

3.3.5 ACS754LCB-050 Current Sensor...35

3.3.6 Wavecom Fastrack M1206B GSM Modem ...36

3.3.7 DT-AVR ATMega 128(L) CPU Module ...37

3.4 Algorithm Development ... 39

3.4.1 Reading Output of MEMSIC 2125 Accelerometer ...39

3.4.2 Reading Temperature and Current Sensor ...42

3.4.3 Sampling Time ...44

3.4.4 Digital Filtering ...45

3.4.5 Fast Fourier Transform (FFT) ...50

3.4.6 Over Vibration Detection Based on FFT ...52

3.4.7 Recording Normal FFT Pattern ...54

3.4.8 Plotting Into LCD ...55

3.4.9 Abnormality Detection ...58

3.4.10 SMS Alarm Sending ...69

3.4.11 Overall Program ...61

CHAPTER 4 – RESULT & DISCUSSION... 64

4.1 Introduction ... 64

4.2 Mechanical Results ... 64

4.3 Vibration Measurement Results ... 65

4.4 Temperature Measurement Results ... 85

4.5 Current Measurement Result ... 88

4.6 Plotting Using LCD ... 91

4.7 SMS Alert ... 93

CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 96

GLOSSARY ... 97

REFERENCES ... 98

APPENDIX A: Putchar Source Code ... 100

APPENDIX B: ADC Source Code ... 101

APPENDIX C: LCD Source Code ... 103

APPENDIX D: FFT Program Source Code ... 154

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Hans Davin

APPENDIX E: Main Program Source Code ... 156

APPENDIX F: LM35DZ Datasheet ... 168

APPENDIX G: ACS754xCB-050 Datasheet... 181

APPENDIX H: MEMSIC 2125 Datasheet ... 189

APPENDIX I: DT-Combo Basic Base Board Datasheet ... 191

APPENDIX J: DT-AVR ATMega 128 (L) CPU Module Datasheet ... 193

APPENDIX K: DT-IO Graphic LCD 12864 Blue STN White Backlight ver2.0 ... 195

APPENDIX L: Bill of Material ... 196

CURRICULUM VITAE ...197