Development of wireless embedded automation system for batch process

Presently industrial automation is growing rapidly emphasizing on centralized monitoring and independent control of sub-systems. This increases the number of remote sub-systems, which need intermediate communication. Another challenges observed are the reduction of system size and the maintenance cost with flexibility in operation. Regulatory, repetitive sequential control and interlocking are the typical mandatory requirements for batch execution and safety. This paper presents development and analysis of prototype system for wireless controlling and monitoring of the batch process experimental set-up. It proposes the efficient utilization of ARM micro-controller for the real-time monitoring and control of temperature and level. A graphical user interface using Visual Studio.NET is developed to operate the plant remotely. This facilitates the user to control, supervision and data acquisition through wireless communication between laboratory set-up and user interface via ZigBee protocol. Sensitivity and linearity analysis of RTD output and ultrasonic level sensor output is carried out citing fair linearity of RTD and level sensors calibration. Additionally errors in calculated and observed output at ADC are also investigated. The normal operation and safety interlocks have been identified, executed & validated to mitigate the hazardous events in plant considering the possibility of failure of temperature and level sensors. The proposed system is developed successfully and works in defined manner with overall satisfactory performance.