The Industrial Internet of Things (IIoT) is one of todays hottest topics within the automation and manufacturing industries. Individuals and organizations that uses variable frequency drives have high expectations that the IIoT ecosystem will deliver on its promises of added value through increased productivity, predictive maintenance, and reduced asset downtime. The idea is to come up with a prototype of a remote monitoring system for VLT FC-302 Danfoss drives. A portal that interfaces with the cloud server and displays the current state of all connected drives.

1. 5/1/2018 VIT University
Muthamizh A (17MPE0001)
Mohammed Sajid (17MPE0027)
VIT University, Vellore.
Guided by
Dr. Umashankar S
IIOT in Variable Speed Drives

2. Objective
Our objective of the project is to come up with a prototype of a remote monitoring system for VLT FC-302 Danfoss
drives. Main objectives that are expected out of this project are:
1. The idea is to come up with a remote monitoring system for VLT FC-302 Danfoss drives. A portal that interfaces
with the cloud server and displays the current state of all connected drives.
2. Access control is to be implemented, where we can login and monitor the health of the drives that are installed
at local site.
3. Identifying a suitable remote terminal unit that will be installed at the client site and that can communicate to the
drive over Modbus as well as send the data to a Danfoss server through a GPRS connection.
4. Creating a portal that interfaces with the cloud server As a next step, customer based access control can be
implemented where in case of any abnormal behaviors observed in the drive, there should be a capability, by
which, the system can send a notification message to a preconfigured number so that an operator can be alerted.
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3. Introduction
The Global water Crisis
 Global water shortages, growth in urban population,
environmental regulations, and process inefficiencies
are all contributing to a crisis in the Water &
Wastewater industry.
 It is estimated that the amount of energy wasted as
a result of traditional methods of water processing
and delivery can be cut by up to 25%.
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4. Driving factor for the pump industry
1.Energy efficiency
2.System efficiency
3.Pump efficiency
4.Traceability
Challenges
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15.8%
6.7%
24.8%
13.7%
15.8%
6.7%
12.2%
22.5%
4.3%
Fans
Refrigeration
Material Processing
Pumps
Compressed Air
Material Handling
Other
Industrial motor energy use
 Electricity costs account for 40% of the total cost of
ownership (TCO) of a pump.
 By following energy management best practices, a
manufacturer can decrease the electrical
consumption of its pumping system by at least 30%,
yielding a 20% reduction in TCO and a return on
investment within 24 months for the pump operators.
Sources : internet
Energy Efficiency

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A smart pumping system along with IIoT enables an efficient system by:
 Establishing preventive maintenance plans for systematic inspection to detect potential
failures
 Enabling condition-based maintenance by monitoring pumping system data for an
accurate status and risk assessment
 Deploying corrective maintenance measures as needed in response to an
unanticipated problem or emergency
By monitoring operational parameters, an operator can ensure smooth operations
and adjust maintenance schedules as needed.
Solutions
System efficiency

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Energy efficiency
A smart pumping system along with IIoT enables energy efficient systems
through:
 Monitoring of pumps, which helps operators to detect higher energy usage
 Libraries and algorithms to ensure that pumps are running in energy efficient
manner
 Pumps driven by variable speed drives which can save up to 30% energy
compared to fixed speed pumps
Solutions

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Pump efficiency
A smart pumping system along with IIoT enables pump efficiency by:
 Monitoring operating curves in real time
 Ensuring, with intelligent algorithms, that pumps operate at their most optimized
point – which is defined as Q(bep) by EuroPumps
 Enabling pump system manufacturers and operators to ensure that the pumps
used are the appropriate size
Solutions

9. Object model Increases system efficiency
Internet
Gateway
Danfoss Server (IOT
Server such as
thingSpeak)
Monitoring Drive
Data
Suitable analytics
Alert message for
particular no. in
case of emergency
Raspberry Pi
VFD
MOTOR
PUMP
LEVEL
FLOW
PRESSURE
To water tank
I/ORemote Monitoring Unit
Power Supply
Ethernet connection
Cloud connection
Sensor data
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MCT 10 Software
Web-based database
management tool
Accessing
Data base
Hostinger web-
hosting
Remote monitoring using MCT 10 software

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 phpLiteAdmin is a web-based SQLite database admin tool written in PHP with support for
SQLite3 and SQLite2.
 Following in the spirit of the flat-file system used by SQLite, phpLiteAdmin consists of a
single source file, phpliteadmin.php, that is dropped into a directory on a server and then
visited in a browser.
 There is no installation required. The available operations, feature set, interface, and user
experience is comparable to that of phpMyAdmin.
Web-based database management tool for SQLite

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Hostinger web-hosting
SPEEDINRPM
TIME IN SECONDS

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VLT EtherNet/IP MCA 121
The EtherNet/IP interface is designed to communicate with any system complying with the CIP EtherNet/IP
standard. EtherNet/IP provides users with the network tools to deploy standard Ethernet technology for
manufacturing applications while enabling Internet and enterprise connectivity.
 EtherNet/IP is an application layer protocol that is transferred inside a TCP/IP Packet. That means
that EtherNet/IP is simply the way data is organized in a TCP or UDP packet.
 All devices on an EtherNet/IP network present their data to the network as a series of data values
called attributes grouped with other similar data values into sets of attributes called Objects.
 There are EtherNet/IP Required Objects – Identity, TCP, Router that every device must have. The
EtherNet/IP Specification defines those objects.
 There are EtherNet/IP Application Objects that have the data for your specific device. For example, an
EtherNet/IP Drive device has a Motor Object. EtherNet/IP devices that support specific devices all
have the same set of EtherNet/IP application objects.

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 There are two kinds of messages that are transferred between an EtherNet/IP Scanner Device
(opens connections and initiates data transfers) and EtherNet/IP Adapter devices (provides
data to Scanners). These messages are Explicit Messages (asynchronous, as needed) and I/O
Messages (Data messages that are continuously transferred).
 EtherNet/IP is part of CIP, the Common Industrial Protocol. CIP defines the Object structure
and specifies the message transfer. CIP protocol over CAN is DeviceNet. CIP protocol over
Ethernet is EtherNet/IP.
 RTA is the leading supplier of EtherNet/IP technology. RTA can supply Royalty Free
EtherNet/IP Source Code Software stacks, EtherNet/IP PCBs, and Modules.

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Remote diagnostics and monitoring
Already a key service that many OEMs provide to customers, remote diagnostics gives the user the
ability to view and review machine and component data. This is an aspect which could be enhanced
further through the use of smart devices and data sharing.
What we learned:
As automation becomes more and more complex there is a growing need for experts. The issue is, there are
not enough engineers out there with the skills to identify and resolve problems as they come up. For
businesses to maximize profitability, it makes sense that they turn to OEMs for maintenance support. And for
the OEM there’s a huge opportunity to build long-term relationships.
At present the services offered by OEMs are typically reactive rather than proactive, and they are used to
help solve problems rather than prevent them. OEMs rarely use IIoT ready devices to perform continuous
monitoring. As globalization drives business growth, the need for remote monitoring becomes more
important. In particular, we see the use of bots and self- diagnosis from smart devices as the next step in
the technological evolution of autonomous machinery.
How to get ahead:
Remote diagnostics is a great way to begin conversations with customer around IIoT and how they can
reduce downtime. It will begin to open the doors to the next step: predictive maintenance.

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Predictive maintenance
Through the cloud we can log data, collecting performance information over time. This provides technical
experts with insights in order to resolve issues before they cause a breakdown. In addition many industries
service teams benefit from more accurate predictions to do with fault finding.
“Aggregate data would allow higher level analysis and a better understanding of
how to predict and prevent issues” -- OEM, AUSTRIA
What we learned:
In some applications, smart components such as drives provide enough information to identify failing
components. However, if organization makes bespoke or custom products then it may require a collaboration
with customer.
How to get ahead:
Considering while communicate the full value of predictive maintenance as a service. In our research, many
industries are saying that, their customers are sceptical about using cloud-based data management. Yet,
many of those same businesses use online CRM systems where all of their sensitive customer data is stored
in a cloud. Pulling together those comparisons may make a compelling argument.

17. Work Plan
Sl. no. WORK PERIOD
1 Literature survey and selection of topology 8th December 2017 – 1st January
2018
2 Study about IOT & application 1st January 2018 – 13th February
2018
3 Data retrieving and processing 13th February 2018 – 15th March
2018
4 Report Preparation 15th March 2018 – 20th March 2018

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References
[1]. W. Sung and Y. Hsu, “Designing an industrial real-time measurement and monitoring system
based on embedded system and ZigBee,” Expert Systems with Applications, Vol.38, No. 4,
pp. 4522-4529, 2011.
[2]. Mikho Mikhov, Nikolay Stoyanov, Georgi Stanchev, Zdravko Doichev” An Application of
Wireless Standards for Remote Monitoring of Electric Drive Systems ”www.ijerd.com Volume 2,
Issue 12 (August 2012), PP. 30-36.
[3]. Dr.R. Udayakumar ,Dr.V. Khanaa “Health monitoringsystem for induction motors”, www.ijecs.in
Volume 2 Issue 4 April, 2013 Page No. 1117-1122.
[4]. V. Jayalakshmi “Wireless Sensor Network for Performance Monitoring of Electrical Machine”,
Middle-East Journal of scientific Research 20 (8): 996-999, 2014.
[5]. M.A. Matin and M.M. Islam “Overview of Wireless Sensor Network”,
http://dx.doi.org/10.5772/49376

19. 5/1/2018 VIT University
Thank you