A PROJECT REPORT ON

“IoT Based Factory Monitoring and Protection System”

             UNIVERSITY OF RAJSHAHI

A project paper submitted to the department of Electrical and Electronic Engineering, University of Rajshahi in partial fulfillment of the requirement for the B.Sc in EEE degree.

SUBMITTED BY

MD. Nafiul Haque

ID No: 1837822104 Registration No: 1837822104 Session: 2017-2018 Examination Year: 2021 Dept of Electrical and Electronic Engineering, University of Rajshahi

DECLARATION

DECLARATION I declare that the dissertation hereby submitted to the Department of Electrical and Electronic Engineering, University of Rajshahi, for degree of B.Sc. Engineering has not been submitted by me for a degree at this or any other University that it is my work in design and execution. This dissertation is a presentation of my project work. Wherever contributions of others are involved, every effort is made to indicate this clearly, with due reference to the literature, and acknowledgement of collaborative research and discussions.

Signature …..........................

Md. Nafiul Haque

ID No. 1837822104 Department of EEE University of Rajshahi.

Signature …………………….

Supervised by

Rakesh Swarup Mandal

Assistant professor & Head Dept. of EEE, TMSS Engineering College, Bogura.

Acknowledgements

First of all, I thank the almighty Allah who is most merciful, with His kindness & bless, I am completed my project. Now first I would like to express gratefulness & gratitude to my supervisor Rakesh Swarup Mandal, Assistant Professor and Chairman, Department of Electrical & Electronic Engineering of TMSS Engineering College (TEC) for his proper guidance, valuable advices, suggestion & inspiration to achieve my goal. He helps me inspecting by all means in every phase of the work and to critically review manuscript a concerned books and various published project reports. I would also express my gratitude to all other concerned respected teachers of EEE department who directly or indirectly encouraged and helped me to complete my project. I also give thank laboratory stuff & other of EEE department, for their help. I also grateful my loving parents and brother for their unconditional love and support. Finally, I a debt of gratitude and thanks to my friends for peaceful co-operation at critical moments of my project.

ABSTRACT

The proliferation of the Internet of Things (IoT) has revolutionized industries by enabling realtime monitoring, data analysis, and intelligent decision-making. In this context, the "IoT Based Factory Monitoring and Protection System" project presents an innovative solution to enhance factory safety, operational efficiency, and environmental awareness. Leveraging the capabilities of the ESP32-WROOM-32 module and an array of sensors including fire, ultrasonic, temperature, and humidity sensors, the system offers a comprehensive and dynamic approach to industrial monitoring. The project's core objective is to develop an integrated platform that collects, processes, and presents real-time data to factory personnel, empowering them with crucial insights into various operational parameters. The system employs advanced algorithms for detecting anomalies such as fires, abnormal temperature or humidity levels, and unauthorized access, triggering timely alerts and appropriate responses. The user interface, embodied in an OLED display, ensures intuitive and immediate access to critical information. Through a meticulous hardware implementation, the project establishes a solid foundation for data acquisition, while the software implementation adds intelligence and responsiveness to the system. The ESP32-WROOM-32 module orchestrates sensor data acquisition, MQTT communication, anomaly detection, and user interface management. A fire detection algorithm enhances safety by promptly identifying fire hazards and activating countermeasures. The project's significance lies in its potential to transform traditional factory environments into smart, connected spaces that prioritize safety and efficiency. It contributes to the broader discourse on Industry 4.0 by demonstrating how IoT technologies can revolutionize factory operations. By bridging the gap between physical processes and digital insights, the IoT Based Factory Monitoring and Protection System exemplifies the promise of IoT in reshaping industries for a safer, smarter, and more sustainable future.

Page No. DECLARATION i ACKNOWLEDGMENTS ii ABSTRACT iii CONTENTS iv Chapter 1: Introduction 1.1 Introduction 1 1.2 Background and Motivation 1 1.3 Problem Statement 1 1.4 Objectives 1 1.5 Scope and Limitations 2 Chapter 2: Project Details 2.1 Project Layout 3 2.2 Circuit Diagram of the Project 3 2.3 Components Required 4 Chapter 3: Components Description 3.1 ESP32-WROOM-32 development board 5 3.2 OLED Display 8 3.3 DHT-11 Temperature and Humidity Sensor 9 3.4 MQ-2 Gas Sensor Module 10 3.5 Relay module 3.6 Buzzer 3.7 LM35 Temperature sensor 3.8 Flame Sensor 3.9 Ultrasonic Sensor 3.10 Bulb holder 3.11 Electric led bulb Chapter 4: Hardware Implementation 4.1 Introduction 4.2 ESP32-WROOM-32 Module Integration 4.3 OLED Display Interface 4.4 Relay Control for Actuation 4.5 PCB Design and Implementation 4.6 Final Project and Connections v Chapter 5: Software Implementation 5.1 Introduction 5.2 Setting Up Arduino IDE 5.3 Blynk Account and Project Setup 5.4 Deploying Code 5.5 Monitoring and Interaction Chapter 6: Result and Discussion 6.1 Experimental Result 6.2 Advantages 6.3 Application Fields 6.4 Future Scope 6.5 Conclusion REFERENCE

CHAPTER 1

Introduction

1.1 Introduction:

In today's rapidly evolving industrial landscape, the integration of cutting-edge technologies has become essential for ensuring operational efficiency, productivity, and safety [1]. The advent of the Internet of Things (IoT) has brought forth a paradigm shift in how industries monitor and manage their processes, enabling real-time data acquisition, analysis, and decision-making. The focus of this project is to develop an IoT-based Factory Monitoring and Protection System that leverages the capabilities of the ESP32-WROOM-32 module along with various sensors to enhance factory safety and operational awareness.

1.2 Background and Motivation:

Factories and industrial environments are characterized by complex operations, critical machinery, and often hazardous conditions. Traditional methods of monitoring these environments often fall short in providing timely information and alerts to prevent potential mishaps or downtime. The rise of IoT technology offers a transformative solution by enabling the collection and analysis of real-time data from a myriad of sensors. This data-driven approach empowers factory operators and managers to make informed decisions, optimize processes, and ensure the safety of personnel and assets.

1.3 Problem Statement:

The existing methods of factory monitoring and protection often lack the ability to offer comprehensive and real-time insights into the various operational parameters. Manual monitoring can lead to delays in identifying anomalies, which may result in safety hazards, equipment damage, or production interruptions [2]. Thus, there is a need for an advanced system that seamlessly integrates sensors, data processing, and user-friendly interfaces to create a comprehensive Factory Monitoring and Protection System.

1.4 Objectives:

The primary objectives of this project are as follows:  Design and Integration: Develop a robust IoT-based system that integrates multiple sensors, including fire, ultrasonic, temperature, and humidity sensors, with the ESP32- WROOM-32 module [3].  Real-Time Monitoring: Enable real-time data acquisition from sensors placed strategically within the factory environment to monitor key parameters affecting safety and operations.  Anomaly Detection: Implement algorithms for detecting anomalies such as fires, abnormal temperature fluctuations, and unauthorized access, triggering immediate alerts and appropriate actions. 2  User Interface: Design an intuitive LCD display interface to present real-time sensor data and alerts, providing factory personnel with actionable insights.  Remote Accessibility: Explore the potential for remote monitoring and control via Wi- Fi connectivity, allowing authorized personnel to access the system's data and controls from remote locations.  Enhanced Safety: Improve factory safety by providing early warnings for potential fire hazards and adverse environmental conditions [4].  Efficient Resource Management: Facilitate efficient use of resources by providing insights into temperature and humidity conditions that may impact product quality or machinery performance [5].

1.5 Scope and Limitations:

While the IoT-based Factory Monitoring and Protection System offers substantial benefits, it's important to acknowledge its scope and limitations. The system's scope encompasses the integration of multiple sensors, data processing, and user interface design. However, the project does not address complex issues such as advanced predictive maintenance algorithms or integration with cloud platforms for extensive data analysis. As we delve into the subsequent sections of this report, we will detail the methodology employed to achieve the project objectives, the hardware and software components utilized, the implementation process, data collection, analysis, and interpretation of results, challenges encountered, future enhancements, and concluding reflections. Through this comprehensive exploration, we aim to showcase the potential of IoT technology in revolutionizing factory monitoring and protection, paving the way for safer, more efficient, and technologically advanced industrial operations.

CHAPTER 2

Project Details

2.1 Project Layout:

Figure 2.1 Block Diagram of the Project

The IoT Based Factory Monitoring and Protection System is structured around a dynamic and interconnected framework that encompasses both hardware and software elements. The layout is designed to seamlessly integrate various components, including the ESP32-WROOM-32 module, sensors (fire, ultrasonic, temperature, humidity), an OLED display, and many relay, to create a comprehensive solution for enhancing factory safety and operational awareness.

2.2 Circuit Diagram of the Project:

Figure 2.2 Circuit Diagram of the Project 4

2.3 Components Required:

Components Name Quantity

ESP-32 WROOM-32 development board 1pc
OLED Display 1pc
Buzzer 1pc
DHT-11 Temperature and Humidity Sensor 1pc
switch 1pc
Flame Sensor 1pc
MQ‐2 Gas Sensor Module 1pc
LM35 Temperature Sensor 1pc
Water Pump 1pc
Water Tank 1pc
PCB Board 1pc
Connecting Wires As required

CHAPTER 3

Component Description 3.1 ESP32-WROOM-32 development board: The ESP32-WROOM-32 is a versatile and widely used module developed by Espressif Systems. It combines Wi-Fi and Bluetooth connectivity with a powerful microcontroller, making it an excellent choice for a wide range of Internet of Things (IoT) applications. "ESP32-WROOM-32E" comes with a PCB antenna. [8] Pin Specification`:

EN - Enable Pin (Reset)
GND - Ground
VBAT - Battery Voltage Input (if using a battery)
3V3 - 3.3V Output
GND - Ground
EN - Enable Pin (Reset)
GND - Ground
GND - Ground
IO34 - General-purpose I/O Pin
IO35 - General-purpose I/O Pin
IO32 - General-purpose I/O Pin
IO33 - General-purpose I/O Pin
IO25 - General-purpose I/O Pin
IO26 - General-purpose I/O Pin
IO27 - General-purpose I/O Pin
IO14 - General-purpose I/O Pin
IO12 - General-purpose I/O Pin
IO13 - General-purpose I/O Pin
IO15 - General-purpose I/O Pin
GND - Ground
IO22 - General-purpose I/O Pin
IO23 - General-purpose I/O Pin
IO19 - General-purpose I/O Pin
IO21 - General-purpose I/O Pin
IO18 - General-purpose I/O Pin Figure 3.1 ESP32-WROOM-32 development board. Figure 3.2 Pin Specification of ESP32-WROOM-32 development board 6
IO5 - General-purpose I/O Pin
IO17 - General-purpose I/O Pin
IO16 - General-purpose I/O Pin
IO4 - General-purpose I/O Pin
IO0 - General-purpose I/O Pin
IO2 - General-purpose I/O Pin
IO15 - General-purpose I/O Pin
IO14 - General-purpose I/O Pin
IO12 - General-purpose I/O Pin
IO13 - General-purpose I/O Pin
IO16 - General-purpose I/O Pin
GND - Ground
IO39 - General-purpose I/O Pin Specification: Drive Type Dual high-power H-bridge Power Input(V) 4.5 to 9 Communication Interface Voltage(V) 3.3 Flash size (MB) 4 Operating Temperature (°C) -40 to 125 Transfer Rate (Kbps) 110 to 460800 AD0 1 channel ADC Length (mm) 49 Width (mm) 24.5 Height (mm) 13 Shipment Weight 0.06 kg Shipment Dimensions 6 × 4 × 2 cm 3.2 OLED Display: OLED displays are available in a range of sizes (such as 128×64, 128×32) and colors (such as white, blue, and dualcolor OLEDs). Some OLED displays have an I2C interface, while others have an SPI interface. One thing they all have in common, however, is that at their core is a powerful single-chip CMOS OLED driver controller – SSD1306, which handles all RAM buffering, requiring very little work from your Arduino. [9] . Figure 3.3 OLED Display 7 Features of the 128×64 OLED display: Display Technology OLED (Organic LED) MCU Interface I2C / SPI Screen Size 0.96 Inch Across Resolution 128×64 pixels Operating Voltage 3.3V – 5V Operating Current 20mA max Viewing Angle 160° Characters Per Row 21 Number of Character Rows 7 Pin Specification:  GND is the ground pin.  VCC is the power supply for the display, which we connect to the 5V pin on the Arduino.  D0 / CLK is the SPI Clock pin. It’s an input to the chip.  D1 / MOSI is the Serial Data In pin, for data sent from your microcontroller to the display.  RES (Reset) pin resets the internal buffer of the OLED driver.  DC (Data/Command) is used by the library to separate the commands (such as setting the cursor to a specific location, clearing the screen, etc.) from the data.  CS is the Chip Select pin. 3.3 DHT-11 Temperature and Humidity Sensor: The DHT11 is a commonly used Temperature and humidity sensor. The sensor comes with a dedicated NTC to measure temperature and an 8-bit microcontroller to output the values of temperature and humidity as serial data. The sensor is also factory calibrated and hence easy to interface with other microcontrollers. The sensor can measure temperature from 0°C to 50°C and humidity from 20% to 90% with an accuracy of ±1°C and ±1%. So if you are looking to measure in this range then this sensor might be the right choice for you. [10] Figure 3.4 DHT-11 Temperature and Humidity Sensor 8 DHT11 Specifications: Operating Voltage: 3.5V to 5.5V Operating current: 0.3mA (measuring) 60uA (standby) Output: Serial data Temperature Range: 0°C to 50°C Humidity Range: 20% to 90% Resolution: Temperature and Humidity both are 16-bit Accuracy: ±1°C and ±1% Pin Specification: 1 VCC Power supply 3.5V to 5.5V 2 Data Outputs both Temperature and Humidity through serial Data 3 Ground Connected to the ground of the circuit 3.4 MQ-2 Gas Sensor Module: The MQ2 gas sensor is simple to use and has two different outputs. It not only provides a binary indication of the presence of combustible gasses, but also an analog representation of their concentration in air. The sensor’s analog output voltage (at the A0 pin) varies in proportion to the concentration of smoke/gas. The higher the concentration, the higher the output voltage; the lower the concentration, the lower the output voltage. The animation below shows the relationship between gas concentration and output voltage. MQ-2 Specifications: Operating voltage 5V Load resistance 20 KΩ Heater resistance 33Ω ± 5% Heating consumption <800mw Sensing Resistance 10 KΩ – 60 KΩ Concentration Range 200 – 10000ppm Figure 3.5 MQ‐2 Gas Sensor Module 9 Pin Specification`:  VCC supplies power to the module. Connect it to the 5V output of your Arduino.  GND is the ground pin.  D0 indicates the presence of combustible gasses. D0 becomes LOW when the gas concentration exceeds the threshold value (as set by the potentiometer), and HIGH otherwise.  A0 produces an analog output voltage proportional to gas concentration, so a higher concentration results in a higher voltage and a lower concentration results in a lower voltage. 3.5 Relay module: A 5V relay module is a single or multi-channel relay module that works with a low-level trigger voltage of 5V DC. The input voltage can be from any microcontroller or logic chip that outputs a digital signal. Like most other relays, the 5V relay module is an electrically operated, electromagnetic switch that can be used to turn on or turn off a circuit. It consists of two parts: the relay itself and the control module. The relay contains the coil that creates the magnetic field, the armature that move to complete or disconnect a circuit, and contacts that open and close to operate the load switch. The relay control module is the interface or part of the relay module that the user interacts with. It contains the input terminals for connecting to the microcontroller, as well as the output terminals for connecting to the load. The control module also contains LED indicators for power and status and other devices such as protection diode, transistor, resistor, and other semiconductor devices necessary for its operation. Relay Module Pinout The 5V relay module pinout is composed of connections on the input side where it receives the trigger signal, and the output side where it controls the load. The input side, as shown in the above relay module circuit diagram, has 3 or 4 connections: These are listed and explained below. VCC – this is the power connection. It supplies 5V DC to the module and is normally connected to the positive terminal of the power supply. GND – this is the ground connection. It connects to the negative terminal of the power supply. Figure 3.6 Relay Module 10 IN1, IN2 – these are the inputs where the trigger signal is applied. IN1 is for a single-channel relay module, while IN2 is for a dual-channel relay module. The IN (Input) pin is connected to the output of the microcontroller, sensor, or logic device. The relay module output side has three connections:  NO (Normally Open) – this is the load connection when the relay is ON. When the relay is off, the NO maintains an open connection with the COM.  COM (Common) – The relay module connection labeled “COM” is the common connection for both the NO and NC (Normally Closed) pins.  NC (Normally Closed) – this is the load connection. It connects to the COM terminal by default, or when the relay is OFF. Specifica􀆟on: No. of Channel 4 Trigger Voltage (VDC) 5 Trigger Current (mA) 20 Switching Voltage (VAC) 250@10A Switching Voltage (VDC) 30@10A Length (mm) 75 Width (mm) 55 Height (mm) 18 Weight (gm) 55 Shipment Weight 0.059 kg Shipment Dimensions 9 × 7 × 3 cm 3.6 Buzzer: This buzzer is an active buzzer, which basically means that it will buzz at a predefined frequency (2300 ±300 Hz) on its own even when you just apply steady DC power. If you are looking for a buzzer can produce varied tones from an oscillating input signal, then take a look at our buzzer. Some people prefer to get active buzzers since they can use them with steady DC power but also be able to produce some variety of tones by applying an oscillating signal. Some consider them to be more versatile than their cousin, the passive buzzer, which is the type that requires an oscillating signal to create any tone. It is possible, and often done, to still create different tones through an active buzzer when you apply an oscillating signal to the buzzer, but the spectrum of possible different tones is very limited and not as crisp or clean of Figure 3.7 Buzzer 11 sound as can be produced with a buzzer. One advantage to an active buzzer is that you can still produce a sound from the buzzer connected to a microcontroller, such as an Arduino, by just driving a standard high output on the connected pin. The benefits of this are that you don't need to use processing power, hardware timers, or additional code to produce sound. Specifications: Rated Voltage 5 V Operating Voltage 4~8 V Max Rated Current ≤32 mA Min. Sound Output at 10cm 85 dB Resonant Frequency 2300 ±300 Hz Operating Temperature -20°C to 45°C Dimensions (Excluding Pins) Height 9.16 mm (0.36") Diameter 11.78 mm (0.46") Weight 1.6 g (0.057 oz) 3.7 LM35 Temperature Sensor: LM35 is an integrated analog temperature sensor whose electrical output is proportional to Degree Centigrade. LM35 Sensor does not require any external calibration or trimming to provide typical accuracies. The LM35’s low output impedance, linear output, and precise inherent calibration make interfacing to readout or control circuitry especially easy. As such no extra components required to interface LM35 to ADC as the output of LM35 is linear with 10mv/degree scale. It can be directly interfaced to any 10- or 12-bit ADC. But if you are using an 8-bit ADC like ADC0808 or ADC0804 an amplifier section will be needed if you require to measure 1°C change. LM35 can also be directly connected to Arduino. The output of LM35 temperature can also be given to comparator circuit and can be used for over temperature indication or by using a simple relay can be used as a temperature controller. The LM35 device is rated to operate over a −55°C to 150°C temperature range, while the LM35C device is rated for a −40°C to 110°C range (−10° with improved accuracy). The LM35-series devices are available packaged in hermetic TO transistor packages, while the LM35C, LM35CA, and LM35D devices are available in the plastic TO-92 transistor package. The LM35D device is available in an 8-lead surface-mount small-outline package and a plastic TO- 220 package. Figure 3.8 LM35 Temperature Sensor 12 This sealed analog temperature probe lets you precisely measure temperatures in wet environments. The LM35 are precision integrated-circuit temperature sensors, with an output voltage linearly proportional to the Centigrade temperature. Features:
Temperature measuring range: 0...100°C
Operating Voltage: 4...30VDC
No. of Pins: 3
Case: TO92
Mounting: THT
Temperature measurement accuracy: 1% Specification: Package/Case TO-92-3 Mounting Type Through Hole Sensor Type Temperature Sensor Output Type Analog Voltage Maximum Supply Voltage (V) 30 Minimum Supply Voltage (V) 400.00% Operating Temperature Range (°C) -55 to 150 Shipment Weight 0.020 kg Shipment Dimensions 12 × 8 × 2.5 cm 3.8 Flame Sensor: A flame sensor is a device used to detect a fire. It is the most sensitive that can easily detect a fire and activate a fire alarm. The detection range of a flame sensor is the wavelength in 760 nm to 1100 nm range of light source. High temperatures can damage the sensor so we should place it at some distance. The detection distance is up to 100 cm. Its output is a digital or analog signal. It can be used as a flame alarm or in the firefighting robots. It works by detecting infrared radiation emitted from the fire. The detector detects this radiation and converts it into the analog and digital signals for the microcontroller to process. Features:  Indicator light: a green one for the switch, a red one for power.  Built in a potentiometer for sensitivity control.  Onboard signal output indication, output effective signal is high, at the same time the indicator lights up, the output signal can directly connect to microcontroller IO. Figure 3.9 Flame Sensor 13  Can detect fire or wavelength in 760 ~ 1100 nm nano within the scope of the light source.  Detection angle about 60 degrees, the flame spectrum especially sensitive.  The flame of the most sensitive sensors flames, the regular light is also a response, generally used for fire alarm purposes. Specification: Output Channel 1 Operating Voltage (VDC) 3.3 ~ 5 Mounting Hole(mm) 3 Length (mm) 32 Width (mm) 14 Weight (gm) 3 Shipment Weight 0.005 kg Shipment Dimensions 4 × 2.5 × 2 cm 3.9 Ultrasonic Sensor: Ultrasonic sensors are electronic devices that calculate the target’s distance by emission of ultrasonic sound waves and convert those waves into electrical signals. The speed of emitted ultrasonic waves traveling speed is faster than the audible sound. There are mainly two essential elements which are the transmitter and receiver. Using the piezoelectric crystals, the transmitter generates sound, and from there it travels to the target and gets back to the receiver component. To know the distance between the target and the sensor, the sensor calculates the amount of time required for sound emission to travel from transmitter to receiver. The calculation is done as follows: D = 1/2 T * C Where ‘T’ corresponds to time measured in seconds ‘C’ corresponds to sound speed = 343 measured in mts/sec Features:
Measures the distance within a wide range of 2cm to 400cm
Stable performance Figure 3.10 Ultrasonic Sensor 14
Accurate distance measurement
High-density
Small blind distance. Specification: Model HC-SR04 Operating Voltage (VDC) 5 Average Current Consumption (mA) 2 Frequency (Hz) 40000 Sensing Angle 15Â° Max. Sensing Distance (cm) 450 Weight (gm) 9 Sensor Cover Dia. (mm) 16 PCB Size (L x W) mm 45 x 20 Shipment Weight 0.014 kg Shipment Dimensions 5 × 4 × 3 cm 3.10 Bulb Holder: Bulb holders are mechanical devices that support lamps and connect them to electrical circuits. They hold light bulbs and make electrical contact to provide a bulb with power. bulb holders are used with most light sources for incandescent, fluorescent, and compact fluorescent lamps (CFL). Specification: Product Type Bulb Holder Voltage 250V. Current 5A. Frequency 50/60Hz Plugging 5000+ Figure 3.11 Bulb Holder 15 3.11 Led Bulb: The 18W LED light is a highly efficient and environmentally friendly lighting solution that offers both exceptional brightness and energy savings. With its compact design, it provides a powerful illumination suitable for various indoor and outdoor applications. The light emits a bright, crisp white light, ensuring excellent visibility and enhancing the overall ambiance of any space. Its low power consumption of significantly reduces electricity costs compared to traditional incandescent or fluorescent lights, making it an economical choice for long-term use. Additionally, the LED technology used in this light ensures a longer lifespan, saving both maintenance efforts and expenses. Specifica􀆟on: Wattage 0.5 W Lighting Color Red/Blue Base Type B22 Shape Round Type Aluminum LED Bulb Figure 3.12 LED Bulb

CHAPTER 4

Hardware Implementation 4.1 Introduction: The hardware implementation of the IoT Based Factory Monitoring and Protection System entails a meticulous selection of components, their strategic placement, interconnections, and considerations for power management and safety. [6] This section provides a comprehensive exploration of each hardware element's role, the circuitry involved, and the steps taken to establish a robust foundation for real-time data acquisition and analysis.[7] Figure 4.1 Testing phase of the project 4.2 ESP32-WROOM-32 Module Integration: The ESP32-WROOM-32 module serves as the central nervous system of the system, orchestrating data acquisition, processing, and communication. It is carefully integrated into the hardware setup, and its GPIO pins are allocated to interface with other components. Sensor Integration and Placement:  Fire Sensor: Positioned in areas prone to fire hazards, the fire sensor is connected to a digital input GPIO pin. Its placement is optimized for swift fire detection.  Ultrasonic Sensor: Placed to monitor distances, the ultrasonic sensor's connections to appropriate GPIO pins facilitate accurate distance measurements.  Temperature and Humidity Sensors: These sensors are situated strategically to capture environmental conditions. Their data connections to the ESP32's GPIO pins enable real-time temperature and humidity monitoring. 17  Gas Sensor: This sensor is used for sensing gas leakage. MQ-2 gas sensor has high sensitivity to LPG, Propane, and Hydrogen, also could be used for Methane and other combustible steam. 4.3 OLED Display Interface: The OLED display is seamlessly interfaced with the ESP32 module. Relevant GPIO pins are allocated for data and control signals. This display acts as the user interface, conveying real-time data and alerts to factory personnel. 4.4 Relay Control for Actuation: The relay is integrated to control external devices or trigger safety measures. Its connections to the ESP32's GPIO pins enable activation based on detected anomalies. 4.5 PCB design and implementation: PCB (Printed Circuit Board) design and implementation is a complex process that involves many steps and requires knowledge in various fields such as engineering, material science, chemistry, and more. The process usually starts with creating a schematic that shows how components are connected throughout the circuit board. This is followed by selecting the components, placing them on the PCB, routing signals and power planes. I am using easyEDA software to design my PCB.  PCB Layout Design: Use the schematic to create the physical layout of the PCB. Place components on the board while considering factors like signal integrity, power distribution, and thermal management. Route the traces to connect components, ensuring proper spacing and impedance control.  Design Rule Check (DRC): Run a DRC to catch potential errors in your design, such as incorrect trace widths, spacing violations, or other manufacturing issues.  Print and Etch the PCB: Once your design is ready, print it onto special PCB transfer paper using a laser printer. Transfer the toner from the paper onto a copper-clad board using heat .Etch the board using an appropriate etching solution to remove the excess copper and reveal the traces. Figure 4.2: 3-D view of the project Figure 4.2 Bottom layout of the project Figure 4.3 Top layout of the project 18  Drilling and Mounting Components: Drill holes for component leads and vias using a small drill press or a handheld drill with a suitable bit. Mount the components onto the board and solder them in place. Soldering requires skill and proper equipment, such as a soldering iron, solder wire, flux, and solder wick.  Testing: Before applying power, carefully inspect your solder joints and connections .Use a multimeter and continuity tester to check for shorts, opens, and correct connections .Apply power gradually and test the circuit's functionality. 4.6 Final Project and Connections: Detailed circuit diagrams visually represent the interconnections among components. These diagrams serve as blueprints to ensure accurate wiring and proper data flow. Wiring Management and Insulation: Effective cable management techniques are employed to organize and secure wiring, minimizing clutter and preventing interference. Insulation measures are implemented to safeguard against short circuits and potential hazards. Figure 4.4 Final Project-a Figure 4.5 Final Project-b

CHAPTER 5

Software Implementation 5.1 Software Implementation: The software implementation of the IoT Based Factory Monitoring and Protection System involves configuring the ESP32-WROOM-32 module to communicate with the Blynk IoT platform using the Arduino IDE software. This section provides a step-by-step guide to setting up the software components, integrating Blynk, and programming the ESP32 for effective data communication, analysis, and user interaction. 5.2 Setting Up Arduino IDE: Install the Arduino IDE software on my development computer. Configure the IDE for ESP32 development by adding the appropriate board manager URL and installing the ESP32 board package. Figure 5.1 Arduino installation 5.3 Blynk Account and Project Setup: Create an account on the Blynk platform (https://blynk.io/) if you don't have one. Create a new Blynk project and note down the Auth Token provided.  Blynk Library Installation: Within the Arduino IDE, navigate to "Sketch"

"Include Library" > "Manage Libraries." Search for "Blynk" and install the Blynk library.  Blynk Initialization: Include the Blynk library at the beginning of your code: #include <BlynkSimpleEsp32.h> Initialize Blynk with your Auth Token: char auth[] = "MY_AUTH_TOKEN";  Wi-Fi Connection: Connect the ESP32 to your Wi-Fi network by providing your network SSID and password: WiFi.begin("SSID", "PASSWORD"); Figure 5.2 Blynk library Installation 20  Sensor Data Acquisition: Use appropriate libraries to read data from sensors. For instance, read fire sensor data, ultrasonic distance, temperature, and humidity using GPIO pins or relevant communication protocols.  Blynk Widget Setup: In your Blynk project, add widgets (Virtual Pins) to correspond with each sensor and the LCD display. Configure the widgets' properties, such as their type (Gauge, Value Display, LED, etc.) and data display settings.  Blynk Connection and Data Transmission: Inside the void setup() function, initiate the Blynk connection: Blynk. begin(auth, "SSID", "PASSWORD");In the void loop() function, regularly call Blynk.run() to maintain the Blynk connection. Use Blynk's virtualWrite() function to send sensor data to the corresponding virtual pins on the Blynk app.  User Interface (Blynk App): Download the Blynk app from your preferred app store. Create a dashboard and add widgets that correspond to the virtual pins you used in your code. Configure widget properties to visualize and monitor sensor data, such as temperature, humidity, and distance. 5.4 Deploying Code: Compile my code in the Arduino IDE. Connect the ESP32 to my computer, select the correct board and port, and upload the code.

//display
#include <SPI.h>
#include <Wire.h>
#include <Adafruit_GFX.h>
#include <Adafruit_SSD1306.h>
#define SCREEN_WIDTH 128 // OLED display width, in pixels
#define SCREEN_HEIGHT 64 // OLED display height, in pixels
// Declaration for SSD1306 display connected using software
SPI (default case):
#define OLED_MOSI 19
#define OLED_CLK 18
#define OLED_DC 22
#define OLED_CS 23
#define OLED_RESET 21
Adafruit_SSD1306 display(SCREEN_WIDTH, SCREEN_HEIGHT,
OLED_MOSI, OLED_CLK, OLED_DC, OLED_RESET, OLED_CS);
/* Fill-in information from Blynk Device Info here */
#define BLYNK_TEMPLATE_ID "TMPL6UGGdT3NM"
#define BLYNK_TEMPLATE_NAME "IoT Based Factory Monitoring"
#define BLYNK_AUTH_TOKEN "DnGBnIVrz4KhEaoIQPmsKj0qp6U-Htb6"
/* Comment this out to disable prints and save space */
#define BLYNK_PRINT Serial
#include <WiFi.h>
21
#include <WiFiClient.h>
#include <BlynkSimpleEsp32.h>
// WiFi credentials.
char ssid[] = "Ranu Villa";
char pass[] = "12366111";
// DHT 11---------------------------------------------------
#include "DHT.h"
#define DHTPIN 13 // Digital pin connected to the DHT
sensor
// Uncomment whatever type you're using!
#define DHTTYPE DHT11
DHT dht(DHTPIN, DHTTYPE);
// DHT 11-------------x--------------x----------------------
//onewireTem------------------------------------------------
#include <OneWire.h>
#include <DallasTemperature.h>
#define ONE_WIRE_BUS 16
// Setup a oneWire instance to communicate with any OneWire
devices (not just Maxim/Dallas temperature ICs)
OneWire oneWire(ONE_WIRE_BUS);
// Pass our oneWire reference to Dallas Temperature.
DallasTemperature sensors(&oneWire);
//onewireTem----------x--------------x------------------------
//ultrasonic--------------------------------------
const int trigPin = 5;
const int echoPin = 17;
long duration;
int distance, distanceInch;
float oilLevel;
BLYNK_WRITE(V0){
if(param.asInt()==1){
digitalWrite(32,HIGH);
}else{
digitalWrite(32,LOW);
}
}
BLYNK_WRITE(V1){
if(param.asInt()==1){
digitalWrite(25,HIGH);
}else{
digitalWrite(25,LOW);
}
}
BLYNK_WRITE(V2){
if(param.asInt()==1){
22
digitalWrite(27,HIGH);
}else{
digitalWrite(27,LOW);
}
}
BLYNK_WRITE(V5){
if(param.asInt()==1){
digitalWrite(26,HIGH);
}else{
digitalWrite(26,LOW);
}
}
BlynkTimer timer;
float tempC=0;
int gas_value=0;
int flame_value=0;
double t=0;
double h=0;
const int buzzer=4;
void sendSensor(){
int value=analogRead(34);
gas_value = map(value, 0, 4096, 0, 100);
if (gas_value <= 55) {
digitalWrite(buzzer, LOW);
display.clearDisplay();
} else if (gas_value > 55) {
digitalWrite(buzzer, HIGH);
ledPrint("Gas Lekage!", gas_value);
}
Blynk.virtualWrite(V3,gas_value);
flame_value=digitalRead(14);
if(flame_value==0){
flame_value=1;
Buzzer();
ledPrint("Fire!",flame_value);
}else{
flame_value=0;
display.clearDisplay();
}
Blynk.virtualWrite(V4,flame_value);
h = dht.readHumidity();
23
// Read temperature as Celsius (the default)
t = dht.readTemperature();
Blynk.virtualWrite(V6,t);
Blynk.virtualWrite(V7,h);
//onewireTem
sensors.requestTemperatures(); // Send the command to get
temperatures
tempC = sensors.getTempCByIndex(0);
Blynk.virtualWrite(V8,tempC);
//onewireTem
//Ultrasonic
digitalWrite(trigPin, LOW);
delayMicroseconds(2);
digitalWrite(trigPin, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin, LOW);
duration = pulseIn(echoPin, HIGH);
// distanceCm= duration*0.034/2;
// distanceInch = duration*0.0133/2;
distance = (duration/2) / 29.1;
const int maxdis=14;
const int mindis=2;
oilLevel=((maxdis-distance)*100)/(maxdis-mindis);
// Serial.print(distanceCm);
Blynk.virtualWrite(V9,oilLevel);
if(oilLevel<=10){
digitalWrite(26,HIGH);
}else if(oilLevel>=90){
digitalWrite(26,LOW);
}
//Ultrasonic
}
void Buzzer(){
digitalWrite(buzzer,HIGH);
delay(500);
digitalWrite(buzzer,LOW);
}
void setup()
{
// Debug console
Serial.begin(115200);
//display........
// SSD1306_SWITCHCAPVCC = generate display voltage from
3.3V internally
if(!display.begin(SSD1306_SWITCHCAPVCC)) {
Serial.println(F("SSD1306 allocation failed"));
for(;;); // Don't proceed, loop forever
24
}
// Show initial display buffer contents on the screen --
// the library initializes this with an Adafruit splash
screen.
display.display();
// Clear the buffer
display.clearDisplay();
//display........
dht.begin();
//onewireTem
sensors.begin();
pinMode(32,OUTPUT);
pinMode(25,OUTPUT);
pinMode(27,OUTPUT);
pinMode(26,OUTPUT);
pinMode(14,INPUT);
pinMode(34,INPUT);
pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);
ledPrint("Connecting",0);
Buzzer();
pinMode(buzzer,OUTPUT);
Blynk.begin(BLYNK_AUTH_TOKEN, ssid, pass);
ledPrint("connected",1);
delay(2000);
timer.setInterval(500L, sendSensor);
}
void loop()
{
Blynk.run();
timer.run();
}
void ledPrint(char* text, int data) {
display.clearDisplay();
display.setTextSize(2); // Normal 1:1 pixel scale
display.setTextColor(SSD1306_WHITE); // Draw white text
display.setCursor(0,0); // Start at top-left corner
display.println(F(text));
display.setCursor(50,30);
display.setTextColor(SSD1306_BLACK, SSD1306_WHITE);
display.println(data);
display.display();
// delay(2000);
}

25 5.5 Monitoring and Interaction: Launch the Blynk app and log in with my Blynk account. Access the dashboard I created and observe real-time sensor data and alerts. Interact with widgets to visualize data and receive notifications. By integrating Blynk with the ESP32-WROOM-32 module using the Arduino IDE, the software implementation enables seamless data communication, user interaction, and visualization. The Blynk platform serves as the bridge between the hardware components and the user interface, allowing factory personnel to monitor critical parameters, receive alerts, and ensure a safe and efficient factory environment.

CHAPTER 6

Result and Discussion 6.1 Experimental Result: My project has run successfully. It can read sensor data and show it to the Blynk app interface. It can also be successfully controlled by an on or off-switch. Necessary automation works finely and sends a notification when any kind of fault occurs. The interface of the Blynk app on laptop and Android is shown Below 6.2 Advantages:  Enhanced Safety: The system provides real-time monitoring of various parameters such as temperature, humidity, air quality, and other environmental factors that can impact worker safety. This information enables quick responses to prevent accidents and ensure worker safety.  Reduced Maintenance Costs: By monitoring critical aspects of the factory's operations, the system can identify potential issues before they become major problems, enabling quick and efficient responses. The system can use predictive maintenance algorithms to analyze data and detect patterns that indicate equipment failure.  Remote Monitoring and Control: The system provides a web-based interface that allows remote monitoring and control of the factory systems, enabling quick responses to issues from anywhere with an internet connection. Figure 6.1 Blynk App interface in Laptop Display Figure 6.2 Blynk App interface in Android 27  Energy Efficiency: The system can monitor energy consumption and identify areas where energy can be conserved, leading to reduced energy costs and a more sustainable operation. 6.3 Application Fields:  Manufacturing and Production Facilities: The system can be employed in manufacturing plants to monitor machinery health, detect anomalies, and ensure optimal operating conditions. Real-time data on temperature, humidity, and other parameters can help maintain consistent product quality.  Chemical and Petrochemical Industries: The system can provide early warning for hazardous conditions such as abnormal temperature increases or gas leaks, enhancing worker safety. Monitoring environmental factors ensures compliance with safety regulations.  Automotive Assembly Lines: Monitoring temperature and humidity levels can help prevent humidity-related defects in electronic components. Immediate fire detection can minimize risks in potentially flammable environments.  Food and Beverage Processing Plants: Accurate temperature and humidity monitoring ensures the preservation of perishable goods during production and storage. Fire detection can safeguard facilities where flammable materials are present.  Textile and Garment Industries: Monitoring humidity levels is crucial to prevent damage to raw materials and finished products. Fire detection provides an additional layer of safety in environments with combustible materials.  Pharmaceutical Manufacturing: The system aids in maintaining controlled environments required for drug production. Monitoring temperature and humidity ensures product integrity and regulatory compliance.  Energy Generation Facilities: The system can help monitor equipment health and temperature fluctuations in power generation facilities. Fire detection contributes to the safety of machinery and personnel.  Electronics Manufacturing: Monitoring temperature and humidity levels is essential to prevent electronic component damage. Fire detection helps safeguard sensitive manufacturing areas.  Heavy Machinery and Construction Sites: The system can monitor machinery conditions, including temperature, vibration, and potential hazards. Immediate fire detection can prevent equipment damage and downtime.  Agricultural and Greenhouse Operations: Monitoring environmental conditions such as temperature and humidity supports optimal plant growth. Fire detection can prevent potential crop damage in case of fire outbreaks. 28  Data Centers and Server Rooms: Monitoring temperature and humidity levels ensures optimal conditions for electronic equipment. Fire detection prevents potential hardware damage and data loss. 6.4 Future scope  Predictive Maintenance: The system can be further developed to include predictive maintenance features. This would involve analyzing historical data to predict when maintenance is required, preventing equipment failures and reducing downtime.  Integration with Other Systems: The system can be integrated with other industrial systems such as SCADA (Supervisory Control and Data Acquisition) systems, allowing for centralized monitoring and control of all industrial processes.  Real-time Monitoring of Production Lines: The system can be expanded to monitor the entire production line in real-time, enabling operators to detect and resolve issues quickly and efficiently.  Machine Learning and AI: The system can be enhanced using machine learning and AI algorithms to improve its performance and decision-making capabilities.  Autonomous Operation: The system can be developed to enable autonomous operation of industrial equipment, minimizing the need for human intervention and improving overall efficiency. 6.5 Conclusion: The IoT-based factory monitoring and protection system is a project designed to enhance the safety, security, and efficiency of manufacturing plants by incorporating various IoT technologies. The project involves the installation of sensors, and other monitoring devices throughout the factory to collect data on different parameters of the manufacturing process. The system's web-based interface enables factory personnel to monitor and control the manufacturing process and security system in real-time from any location with an internet connection. This remote monitoring and control can improve operational efficiency and reduce response time to any abnormalities or safety hazards. The total cost of this project is about 4200tk. 29 REFERENCES [1] Md. Ibne Joha & Md. Shafiul Islam (2021). "IoT-Based Smart Home Automation Using NodeMCU: A Smart Multi-Plug with Overload and Over Temperature Protection".2021 24th International Conference on Computer and Information Technology (ICCIT) [2] Alok Kumar Gupta & Rahul Johari (2019). "IOT based Electrical Device Surveillance and Control System".2019 4th International Conference on Internet of Things: Smart Innovation and Usages (IoT-SIU) [3] D. Vasicek, J. Jalowiczor, L. Sevcik and M. Voznak, "IoT Smart Home Concept", 2018 26th Telecommunications Forum (TELFOR), pp. 1-4, 2018. [4] T. D. Nguyen, V. K. Tran, T. D. Nguyen, N. T. Le and M. H. Le, "IoT-Based Smart Plug-In Device for Home Energy Management System", 2018 4th International Conference on Green Technology and Sustainable Development (GTSD), pp. 734- 738, 2018. [5] L. Coetzee and J. Eksteen, "The Internet of Things - promise for the future? An introduction", 2011 IST-Africa Conference Proceedings, pp. 1-9, 2011. [6] T. Chaurasia and P. K. Jain, "Enhanced Smart Home Automation System based on Internet of Things", 2019 Third International conference on I-SMAC (IoT in Social Mobile Analytics and Cloud) (I-SMAC), pp. 709-713, 2019. [7] T. Malche and P. Maheshwary, "Internet of Things (IoT) for building smart home system", 2017 International Conference on I-SMAC (IoT in Social Mobile Analytics and Cloud) (I-SMAC), pp. 65-70, 2017. [8] ESP32-DevKitC V4 (2022). "ESP32-DevKit". [Online]. Available: https://docs.espressif.com/projects/esp-idf/en/latest/esp32/hw-reference/esp32/getstarted- devkitc.html [9] SparkFun Electronics. (2021). "OLED Display 0.96" (Qwiic) ". [Online]. Available: https://learn.sparkfun.com/tutorials/qwiic-oled-display-hookup-guide [10] Adafruit Industries. (2021). "DHT11 Basic Temperature and Humidity Sensor". [Online]. Available: https://www.adafruit.com/product/386

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