Smart 3 Phase Industrial Energy Monitoring

//Smart 3 Phase Industrial Energy Monitoring

Smart 3 Phase Industrial Energy Monitoring

About the Product

The SMART Three-Phase Industrial Energy Monitoring system is designed to enhance the efficiency and reliability of electrical systems in industrial settings. It provides comprehensive monitoring by measuring voltage, current, and power consumption across all three phases, offering valuable insights into load balance and helping to identify any imbalances that may affect system efficiency.

A key feature of the system is power factor measurement, which monitors the ratio of real power used to perform work to the apparent power supplied. This ratio is critical for assessing energy usage efficiency, with a power factor close to 1 indicating optimal energy use, while a lower power factor suggests inefficiencies.

Real-time data monitoring and logging are integral to the system, enabling immediate detection of anomalies or issues within the electrical system. In addition, the system stores historical data for trend analysis and performance evaluation, aiding in the identification of patterns and informed decision-making regarding energy management.

The system also includes an alert and notification feature, which sends warnings when abnormal conditions are detected, such as deviations in power factor or excessive energy consumption. This feature is crucial for allowing timely interventions to prevent potential issues.

Furthermore, the system can be integrated with other industrial systems, providing a comprehensive approach to monitoring and control. It offers detailed reports and analytics on energy usage and power factor, supporting continuous improvement in energy management. The user-friendly interface, often accessible via a web portal or mobile app, ensures easy access to data and system controls, making it convenient for users to manage and monitor the system effectively

Client

Singh and Sons Private Limited, Pune

Specification
  • Energy Meters:
  • Current Transformers (CTs):
  • Voltage Transformers (VTs):
  • Data Acquisition Modules:
  • Control and Processing Unit:
  • Microcontrollers/Processors:
  • Data Logger
  • Display and User Interface:
  • Communication Infrastructure:
  • Auxiliary Components:
Mobile Apps (Under Development)
  • Real-Time Monitoring:
  • Alerts and Notifications:
  • Historical Data Access:
  • Reports and Analytics:
  • System Control:
  • Dashboard Customization:
  • User Management:
  • Data Export:
  • Integration with Other Systems:
  • Integratewith other industrial systems or building management systems for a unified
  • Individual Machine efficiency and Predictive maintenance (Under Development)
Dashboard for Operator (Under Development)
  • Multi Machine management
  • Multi Location management
  • Real-Time Monitoring:
  • Historical Data Access:
  • Reports and Analytics:
  • System Control:
  • Dashboard Customization:
  • User Management:
  • Data Export:
  • Integration with Other Systems:
  • Integratewith other industrial systems or building management systems for a unified
  • Individual Machine efficiency and Predictive maintenance (Under Development)
Technology Used

Conceptual Design

  • CAD Software (CATIA): For designing the physical components, including the enclosures, PCB layout, and sensor placements.
  • System Modeling Software (MATLAB): For simulating the electrical system, including the 3-phase power measurement and power factor analysis.

Hardware Development

  • Microcontrollers/MCUs (TI MSP430): Serve as the central processing unit, handling data from sensors, performing calculations, and managing communication.
  • Current Transformers (CTs): For measuring the current in each phase. High-accuracy CTs are essential for reliable power and energy measurement.
  • Voltage Sensors (Potential Transformers): For measuring the voltage in each phase.
  • Power Factor Correction (PFC) ICs: To calculate the power factor and correct it if needed ( TI’s UCC28070).
  • Analog-to-Digital Converters (ADCs): For converting analog signals from CTs and voltage sensors to digital signals that can be processed by the MCU.
  • Signal Conditioning Circuits: Ensure that the signals from sensors are within the ADC’s input range and are free from noise.
  • Communication Modules (Wi-Fi, Ethernet, RS485, Modbus): For transmitting data to the cloud and allowing the device to communicate with mobile apps and dashboards.
  • Power Supply Modules (AC): To power the device.
  • Energy Meters (ICs like ADE7758): For precise measurement of active, reactive, and apparent power, as well as energy consumption over time.

Embedded Systems Development

  • Programming Languages (Python): For writing firmware that processes sensor data, calculates energy usage and power factor, and manages communication protocols.
  • Embedded Development Platforms (PlatformIO): For developing, testing, and deploying firmware on the microcontroller.
  • Real-Time Operating Systems (RTOS): For managing multiple tasks such as data acquisition, communication, and real-time processing.
  • DSP Algorithms: For accurate real-time calculation of power, energy, and power factor from raw sensor data.

Signal Processing and Data Analytics

  • Digital Signal Processing (DSP): For accurate measurement of electrical parameters such as voltage, current, frequency, and power factor. DSP algorithms are essential for filtering noise and improving measurement accuracy.
  • Power Quality Analysis: To detect and analyze power quality issues like harmonics, transients, and voltage sags or swells that can affect machine performance and efficiency.
  • Consumption Pattern Analysis: Using historical data to identify trends in energy usage, which can be used to optimize energy consumption and reduce costs.
  • Machine Efficiency Tracking: Analyzing energy input vs. mechanical output to assess machine efficiency over time, helping identify inefficiencies and maintenance needs.

Predictive Maintenance and Machine Learning (ML)

  • Predictive Maintenance Algorithms: Using ML models to predict when machines might fail or require maintenance based on historical data from sensors (e.g., vibration, temperature, energy consumption).
  • Anomaly Detection: Implementing ML models to detect deviations from normal operating patterns, which can indicate potential issues before they lead to downtime.
  • Energy Forecasting: Using historical data and ML to predict future energy consumption patterns, allowing for better energy management and planning.
  • Condition Monitoring: Continuous monitoring of machine parameters to assess health and performance, alerting operators to potential issues.

Mobile App Development (Underdevelopment)

  • Development Frameworks (React Native): For developing cross-platform or native mobile apps that allow users to monitor energy consumption, power factor, and receive alerts.
  • Backend Services Firebase): To manage user authentication, real-time data synchronization, and cloud storage.
  • Bluetooth/Wi-Fi SDKs: For integrating communication between the mobile app and the energy monitoring device.
  • UI/UX Design Tools (Figma): For creating an intuitive user interface for the app that displays real-time data and analytics.

Cloud Integration and Data Management

  • IoT Platforms (ThingsBoard): For managing device connectivity, data collection, processing, and storage.
  • MQTT/HTTP Protocols: For efficient and secure communication between the device and cloud services.
  • Real-Time Databases (Firebase Realtime Database): For storing time-series data, such as power usage logs, power factor trends, and historical data.
  • Data Analytics Tools (AWS QuickSight,): For analyzing data trends, generating reports, and visualizing energy consumption and power factor.

Dashboard Development (Underdevelopment)

  • Frontend Technologies (React.js, Angular): For developing a web-based dashboard that provides real-time monitoring and control over the energy monitoring system.
  • Backend Technologies (Node.js, Python with Flask/Django): For handling data processing, API integration, and user management.
  • Data Visualization Libraries (e.g., D3.js, Chart.js): To create interactive charts, graphs, and dashboards for visualizing energy data, power factor, and other metrics.
  • WebSocket/Real-time Communication: For live updates on the dashboard, ensuring that data displayed is current and accurate.

Testing and Quality Assurance

  • Simulation Tools (Proteus): For simulating circuit designs and verifying their functionality before hardware deployment.
  • Mobile App Testing Tools (Appium, TestFlight): For testing mobile apps across different platforms to ensure compatibility and performance.
  • Hardware-in-the-Loop (HIL) Testing: For testing the integration of the hardware and software in real-time conditions.
  • Field Testing: Deploying the prototype in an actual industrial environment to test accuracy, reliability, and robustness.

Manufacturing and Assembly

  • PCB Design Software (e.g., Altium Designer, Eagle): For designing the printed circuit boards that integrate all electronic components.
  • Surface Mount Technology (SMT): For assembling the PCBs with precision and efficiency, particularly important in industrial-grade devices.
  • 3D Printing: For producing the device casing, ensuring it is durable and suitable for industrial environments.
  • Compliance Testing: Ensuring the device meets industry standards for safety, electromagnetic compatibility (EMC), and energy efficiency (e.g., CE, UL certifications).
  • PCB Printing: Outsourced

Deployment and Maintenance

  • Over-the-Air (OTA) Updates: For remotely updating the firmware and software to add new features or fix issues.
  • User Documentation and Training: Providing detailed user manuals, installation guides, and training sessions to ensure proper usage and maintenance of the device.
  • Customer Support and Service: Offering technical support and maintenance services to address any issues and ensure long-term reliability.