Pro Max 1

WOLAITA SODO UNIVERSITY
COLLEGE OF ENGINEERING
DEPARTMENT OF ELECTRICAL & COMPUTER
ENGINEERING (POWER STREAM)
SEMESTER PROJECT
TITLE: - GSM BASED SMART GENERATOR MONITORING
SYSTEM IN INDUSTRY
STUDENT NAME ID NO.

1. BOGALE WORKINEH ENG/R/613/10
2. EMEBET MOLLA ENG/R/374/10
3. GETACHEW ALMAW ENG/R/082/10
4. H/MARIAM TESHOME ENG/R/139/10
5. MISGIE MEKUANINT ENG/R/223/10
ADVISOR: MR. G/HIWOT G.
MARCH,2022
WOLAITA SODO, ETHIOPIA
Semester Project on GSM Based on Smart Generator Monitoring System in Industry 2022 GC
Declaration
We hereby declare that the project entitled Title of the Project is GSM Based Smart Generator
Monitoring System in Industry. submitted in partial fulfillment of the requirement for the award
of the degree in BSc Degree in Electrical and Computer Engineering (power Engineering),
Wolaita Sodo University, is a record of our own work carried out by us during the academic
year 2021/22 under the supervision and guidance of Advisor Mr. G/Hiwot , Department of
Electrical and Computer Engineering, College of Engineering. The extent and source of
information are derived from the existing literature and have been indicated through the project
at the appropriate places. The matter embodied in this work is original and has not been
submitted for the award of any other degree, either in this or any other University.
Student Name Signature

Bogale Workineh ______________
Emebet Molla ______________
Getachew Almaw ______________
H/Mariam Teshome ______________
Misgie Mekuanint ______________
This Project has been submitted for examination with my approval as a university
advisor.
Project Advisor Signature
Mr. G/Hiwot G. ________________
2022 GC i
WSU, Department of ECE (Electrical power stream)
Acknowledgement
First and for most, we are extremely grateful to the Department of Electrical and Computer
Engineering, for giving us the opportunity to carry out this project, which is an integral part of
the curriculum in Wolaita sodo university.
Secondly, we would like to express our earnest gratitude and regards to our project advisor Mr.
G/Hiwot in the Department of Electrical and Computer Engineering, for being the corner stone
of our project. It was his perpetual motivation and guidance during the period of doubts and
uncertainties that has helped us to carry on with this project.
Finally, we extend our gratefulness to one and all who are directly or indirectly involved in the
successful completion of this project work.
2022 GC ii
Table of Contents
Declaration ....................................................................................................................................... i
Acknowledgement ........................................................................................................................... ii
List of Figures .................................................................................................................................. v
Acronyms ........................................................................................................................................ vi
Abstract ..........................................................................................................................................vii
CHAPTER ONE.............................................................................................................................. 1
INTRODUCTION ........................................................................................................................... 1
1.1 Background of Study ............................................................................................................. 1
1.2 Statement of the Problem ...................................................................................................... 1
1.3 Literature Review .................................................................................................................. 2
1.4 Objectives of the project ........................................................................................................ 3
1.4.1 General Objective ........................................................................................................... 3
1.4.2 Specific Objectives .......................................................................................................... 3
1.5 Methodology........................................................................................................................... 3
1.6 Scope of the Project ............................................................................................................... 4
CHAPTER TWO ......................................................................................................................... 5
INTRODUCTION TO THE PROJECT ..................................................................................... 5
CHAPTER THREE......................................................................................................................... 6
SYSTEM COMPONENT DESCRIPTION AND CIRCUIT DESIGN .......................................... 6
3.1 Overall operation of the project ............................................................................................ 6
3.2 System description of the project .......................................................................................... 6
3.4 power supply circuit .............................................................................................................. 6
3.5 Temperature Sensor ............................................................................................................ 10
3.6 fuel level and oil level sensor................................................................................................ 12
3.7 12 V Dc fan motor .............................................................................................................. 13
3.8 GSM Modem ...................................................................................................................... 14
3.9 Serial Communication ......................................................................................................... 15
3.10 Engine Generator ............................................................................................................... 16
3.11 Main components of a generator ....................................................................................... 17
3.12 LCD (liquid crystal display) .............................................................................................. 18
3.12.1 LCD pin description for interfacing with Arduino .................................................... 19
3.13 Arduino kit ......................................................................................................................... 19
3.13.1 Power (USB) and pin configuration ............................................................................ 20
CHAPTER FOUR ......................................................................................................................... 22
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DISCUSSION AND RESULT ....................................................................................................... 22

4.1 Flow chart of the project ..................................................................................................... 22
CHAPTER FIVE ........................................................................................................................... 25
CONCLUSION AND RECOMMENDATIONS........................................................................... 25
5.1 Conclusion ............................................................................................................................ 25
5.2 Recommendations ................................................................................................................ 25
References ...................................................................................................................................... 26
Appendix 1 ..................................................................................................................................... 27
Appendix 2 ..................................................................................................................................... 31
2022 GC iv
List of Figures
Figure 1.1 Methodology of the project .................................................................... 4
Figure 3.1 Block Diagram of the project ................................................................. 6
Figure 3.2 design of power supply circuit................................................................ 7
Figure 3.3 power supply simulation....................................................................... 10
Figure 3.4 LM35 temperature IC .......................................................................... 11
Figure 3.5 Temperature sensing circuit................................................................. 12
Figure 3.6 oil and fuel level sensing circuit............................................................ 13
Figure 3.7 12v Dc fan circuit .................................................................................. 14
Figure 3.8. GSM modem and pin configuration ................................................... 15
Figure 3.9 the configuration of virtual terminal ................................................... 16
Figure 3.10 diesel generator with its components ................................................. 17
Figure 3.11 LCD internal working principle......................................................... 18
Figure 3.12 LCD and pin configuration ................................................................ 19
Figure:3.13 Arduino-Uno and pin configurations................................................. 20
Figure 4.1 Flow chart of the system ....................................................................... 23
Figure 4.2 overall system simulation ..................................................................... 24
2022 GC v
Acronyms
AC Alternating current
C Capacitor
DC Direct current
EEPROM Erasable electrical programmable read only memo
F frequency
GND ground
GSM Global service for mobile
LCD Liquid crystal display
LED Light emitting diode
LM35 Temperature sensor
R Resistor
RL relay
RTD Resistance temperature detector
SMS Service for mobile system
VI Virtual terminal
2022 GC vi
Abstract
The electrical power systems are highly non-linear, extremely huge and complex networks. On
the other hand, all the developed and countries have not sufficient supply of power. This Project
focuses the detection of power failure and takes reflex action to solve the problem with help of
GSM communication. The power failure will be detected by relay, and it communicates to
Microcontroller to alerts the authorized person. In addition to that, parameters of Generator
like Fuel level, Oil level, Temperature, battery status, etc., are monitored and communicated to
authorized person. The acquired parameters are processed and recorded in the system memory.
If there is any abnormality in their process, according to some predefined instruction and
policies that are stored on the embedded system EEPROM then GSM alerts to concerned
person immediate
2022 GC vii
CHAPTER ONE
INTRODUCTION
1.1 Background of Study
The use of Generators has become a very common in almost every passive infrastructure
companies, Industries, hospitals, Townships etc. while using these Generators a number of
challenges are faced by the user such as maintaining the Quality of grid power, asset
protections, generator maintenance, capturing real time data, Remotely monitoring of the
generator, fuel theft monitoring, Data collection Analysis issues, Human dependency etc. The
Generator Monitoring System (GMS) is designed specifically for emergency power generators
to monitor engine operations and detect pre-alarms or failures. This insures us of increased
generator availability and a rapid response to service problems. The GMS monitors the power
generators placed at the remote areas and increases its Efficiency by monitoring the various
parameters of generator, Reporting critical Problems minimizes downtime and maximizes
availability by sending generator failure messages instantly to you for diagnosis and emergency
service dispatch if required. It works on GSM technology; GMS can monitor various
parameters such as external power supply, the battery voltage, fuel level, etc. This system
provides ideal solution to the problems caused in situations when a wired connection between
a remote appliance/device and the control unit might not be feasible. The project is aimed to
analyzing and testing the use of mobile phones to remotely monitor an appliance control system
through GSM based wireless communication.
1.2 Statement of the Problem
Power failure is a series problem in industry and to solve this backup generator should be
available. Therefore, the backup generator must continuously support electrical power and to
do this the generator parameters shall not exceed or lower the predetermined value. In fact, in
industry there is a mechanism to check different parameters of the generator but
there is no any method that informs the concerned body that any abnormality happens on it.
This implies that the technician or operator have to check each parameter by manual operation
and this is a time taken and moreover the generator may be damaged if no one check with the
fixed time. For example, the temperature may exceed the limit value and it will cause the
generator to be burnt not only this but also if the fuel level lowers beyond the normal level,
then the generator will not support any electric power.
2022 GC 1
1.3 Literature Review

1. Amitsachen et al have discussed the user can send commands in the form of SMS messages
to read the remote electrical parameters. This system also can automatically send the real time
electrical parameters periodically (based on time settings) in the form of SMS. This system can
be designed to send SMS alerts whenever the Circuit Breaker trips or whenever the Voltage or
Current exceeds the predefined limits. This project makes use of an onboard computer which
is commonly termed as microcontroller. [1]
2. KwangSeonAhn et al have discussed the Using remote management; you can check
operating hours, oil pressure, battery status, coolant temperatures, generated power output, fuel
level, GPS position and more. A notification also could be generated whenever a critical level
has been reached, such as when a generator has been running more than expected, or when the
running hours exceed the service interval.
3. HenrikArleving proposed system by using a cloud-based remote management solution with
a communication gateway can help reduce costs, avoid fuel theft and improve power generator
control. It can be difficult to focus on the right actions, simply because there isn’t enough
information on fuel levels, oil pressure or battery status for each generator. With a cloud-based
remote management solution, we can have immediate access to generator parameters via a
regular web browser being able to analyze each generator remotely enables you to better
understand their health and more efficiently schedule field service visits and Fuel theft can be
a significant problem.
4. ChetanPatil et al have discussed the design of BTS safety and fault management system the
measures are taken to rectify these problems. The method makes use of GSM modem which
gives the instant message about each activity happening in the site. The temperature sensors
will sense the temperature of the room and if it rises above the threshold value the GSM module
will send the message to the master mobile which is already set in the system.
5. Andriy Palamar et al proposed the system the Cellular phone containing SIM (Subscriber’s
Identifying Module) card has a specific number through which communication takes place.
The mode of communication is wireless and mechanism works on the GSM (Global System
for Mobile
communication) technology. Here, the communication is made bi- directional where the user
transmits and also receives instructions to and from the system in the form of SMS.
6. Vimalraj et al have described a distribution transformer have a long service life if they are
operated under good and rated conditions. However, their life is significantly reduced if they
2022 GC 2
are overloaded, resulting in unexpected failures and loss of supply to a large number of
customers thus effecting system reliability. This system provides flexible control of load
parameters accurately and also provides effective means for rectification of faults if any
abnormality occurs in power lines using SMS through GSM network.
7. A.P.Agalgaonkar et al have discussed the measurement and control of temperature, humidity
and the other parameters at different places. The Data Acquisition is defined as the process of
taking a real-world signal as input, such as a voltage or current any electrical input, into the
computer, for processing, analysis, storage or other data manipulation or conditioning.
1.4 Objectives of the project
1.4.1 General Objective
❖ The main objective of this project is to design and test smart generator
monitoring system using GSM technology and microcontroller.
1.4.2 Specific Objectives

The specific objectives of this project are: -
➢ To design temperature sensing circuit

➢ To design oil and fuel level sensing circuit
➢ To identify and prevent generator faults
➢ To interface GSM modern with the Arduino
➢ To develop the model using Arduino software
➢ To change the simulated electrical system and it into practical
1.5 Methodology
For successful completion of this project some steps will be followed to carry out different
tasks. Different literature will be revised relating to this project and data will be collected about
condition and control parameter of generator. Based on this parameter system model was
designed. Some software's were selected to develop the software programming. All the
required materials are not available Arduino software so some sensors like fuel level and oil
level sensors and conditional circuit were replaced by equivalent materials.
2022 GC 3
Literature review
Collection of data
Analyzing the selected

data
Simulate using Arduino

software
Figure 1.1 Methodology of the project

1.6 Scope of the Project
The scope of this project is to develop continuous real time condition monitoring and control
system for industry generator based on GSM. All the sensors were installed remotely to acquire
data from the Generator and transfer the data they acquire to Arduino mega microcontroller
board. A serial port communication is used between Arduino mega microcontroller based on
ATmega2560 and GSM modem.
Finally, the highest priority is given to the software design in order to develop a suitable
algorithm that will promptly interact with the Arduino and the GSM modem
2022 GC 4
CHAPTER TWO
INTRODUCTION TO THE PROJECT
The use of Generators has become a very common in almost every passive infrastructure
companies, Industries, hospitals, Townships etc. while using these Generators a number of
challenges are faced by the user such as maintaining the Quality of grid power, asset
protections, generator maintenance, capturing real time data, Remotely monitoring of the
generator, fuel theft monitoring, Data collection Analysis issues, Human dependency etc. The
Generator Monitoring Sy Power failure is a series problem in industry and to solve this backup
generator should be available. Therefore, the backup generator must continuously support
electrical power and to do this the generator parameters shall not exceed or lower the
predetermined value. In fact, in industry there is a mechanism to check different parameters of
the generator but
there is no any method that informs the concerned body that any abnormality happens on it.
This implies that the technician or operator have to check each parameter by manual
operation and this is a time taken and moreover the generator may be damaged if no one
check with the fixed time. For example, the temperature may exceed the limit value and it
will cause the generator to be burnt not only this but also if the fuel level lowers beyond the
normal level, then the generator will not support any electric power.
stem (GMS) is designed specifically for emergency power generators to monitor engine
operations and detect pre-alarms or failures. This insures us of increased generator availability
and a rapid response to service problems. The GMS monitors the power generators placed at
the remote areas and increases its Efficiency by monitoring the various parameters of generator,
reporting critical Problems minimizes downtime and maximizes availability by sending
generator failure messages instantly to you for diagnosis and emergency service dispatch if
required. It works on GSM technology; GMS can monitor various parameters such as external
power supply, the battery voltage, fuel level, etc. This system provides ideal solution to the
problems caused in situations when a wired connection
between a remote appliance/device and the control unit might not be feasible. The project is
aimed to analyzing and testing the use of mobile phones to remotely monitor an appliance
control system through GSM based wireless communication.
2022 GC 5
CHAPTER THREE
SYSTEM COMPONENT DESCRIPTION AND CIRCUIT
DESIGN
3.1 Overall operation of the project
The system has two parts, namely; hardware and software. The hardware architecture consists
of a stand-alone embedded system that is based on Microcontroller a GSM handset with GSM
Modem and a driver circuit. The GSM modem provides the communication by means of SMS
messages. The SMS message consists of commands to be executed. The SMS message is sent
to the GSM modem via the GSM public networks as a text message with a definite predefined
format. Once the GSM modem receives negative signal from the EB supply, it sends the SMS
to the user consisting of non-availability of power supply, fuel level, temperature of the coolant,
etc.
3.2 System description of the project

The project was be done with the help of the following block diagram.
Relay status Relay

deriver
Temperatu LCD
re sensor display
GSM
Fuel Arduin mode
Generator
level m
o
sensor
Oil level Mobile

sensor Power
supply
Figure 3.1 Block Diagram of the project
3.4 power supply circuit

The power supply circuit design is one of the important parts of this project, without a power
supply the electronic devices such as sensors, relay, fan, and LCD display will not function.
2022 GC 6
Similarly, a wrong power supply design will lead to the damaging of the electronic devices
used in this project.
The main power supplies needed for this project is 5VDC and +12 VDC in order to power on
the relay and other electronic devices. The design is done using a transformer, bridge rectifiers
and filter capacitor. Figure 3.1 shows the sequential process of designing a constant DC power
supply.
Figure 3.2 design of power supply circuit

The input source is 230v single phase with a frequency of 50Hz and this must be converted to
5v Dc and 12v Dc. The 5v in needed for the LCD and the 12v is for the relay coil and the fan.
After the bridge the 12 Dc is with a high ripple and is not smooth, and a shunt capacitor of
1000uF is a must to remove this ripple. The choice of the capacitor value needs to fulfil a
number of requirements. In the first case the value must be chosen so that its time constant is
very much longer than the time interval between the successive peaks of the rectified
waveform:
𝑅𝑙𝑜𝑎𝑑×C ≫ 1𝑓
Where:
𝑅𝑙𝑜𝑎𝑑= the overall resistance of the load for the supply
C= Value of capacitor in Farads
𝑓= the ripple frequency this will be twice the line frequency a full wave rectifier is used shown
below.
𝑓= 2× line frequency
𝑓= 2× 50=100Hz
2022 GC 7
C ≫ 1𝑓× 𝑅𝑙𝑜𝑎𝑑
C ≫ 1100𝐻𝑧×10K
C ≫ 1𝑢𝐹 and we have taken 1000uF
IC 7812 and 705 are voltage regulators which are used to produce a fixed voltage of 5V and
12V. The 1k and 2.2k ohm resistors are used for safety purpose. The above designed circuit is
simulated on Proteus software and the result is shown below.
The bridge rectifier converts ac voltage to dc voltage. The advantages of bridge rectifier are
❖ The center tap of the transformer secondary is eliminated.
❖ It provides output twice that of center taps circuits for the same secondary voltage.
❖ The peak inverse voltage is one half of the center tapped circuits.
Choosing diode
VREV (reverse voltage in diode) = VP – VF
VP= VO max + 2VF = 12.6 + 2 (0.7) = 14V
VREV = 14V – 0.7V = 13.3V
I (average forward current) =ILDC/2 = 35 mA
IFRM (forward repetitive current) = IL/t2 (t1+t2) = 500mA
Now from datasheet 1N4001 is chosen
For 1N4001 IF (surge) = 30A
So R surge = 𝑉𝑝𝐼𝑠𝑢𝑟𝑔𝑒 = 14𝑉30A = 0.5Ω
Choose standard 1 Ω
Designers recommend;
C2 = C3 = 0.1μF
For proper output of IC7805
Rectification circuit
Outputs 12VDC for 70mA load
Let’s allow 10 present ripple for the rectified output
Then: - R ripple = 0.1 * 12V
Vmax = 12V + 0.5 (1.2V) = 12.6V
Vmin = 12V – 0.5 (1.2V) = 11.4V
T = 150𝐻𝑧 = 20m Sec
Ө1 = sin-1(𝑉𝑚𝑖𝑛𝑉𝑚𝑎𝑥) = 65o
Ө2 = 90o – 65o = 25o
t2 = charging time = Ө2360∗𝑇 = 1.4m sec
2022 GC 8
t1 = discharging time = T2− 𝑡2 = 8.6m sec

Then C1= I𝑙𝑉𝑟 ∗ 𝑡1= 70m A ∗ 8.6m Sec1.2𝑉= 500μF
Use standard C1 = 470μF
Assume silicon diode
Vf = 0.7V, Vdc = 5v
Vprimary = 220v and
Vr = 10 percent of Vdc = 0.5v
So C1 = (IL*t1)/Vr
But IL= Vdc/RL = 5v/500 = 10mA and
Discharging time (t1) = 0.5T-t2
t2(charging time) = 1.17msec
T (period) = 1/50
So t1 = 15.5msec
C1 = (10mA*15.5msec)/0.5v = 310nF
Diode selection
Peak = Vmax + 2Vforward
= 5.25 + 2*0.7
= 6.65v
For a full wave rectifiers
V reverse = Vp = 6.65v
I forward(average) = IL/2 = 5mA
IFRM is repetitive surge current
IFRM = (T*IL/2)t2 = 10(15.5 + 1.17)/1.17
= 142.5 mA
From data sheet
IFSM = 10 A
So Rs = Vp/ IFSM = 6.65/10 = 0.667 Ώ = 1 Ώ
12 Volt DC Power Supply
V r = 0.1 * V dc
V max = 14.7 V
V min = 13.3 V
Let I𝑙 = 100m A
Ө1 = sin-1(𝑉𝑚𝑖𝑛𝑉𝑚𝑎𝑥) = 65o
2022 GC 9
Ө2 = 90o – 65o = 25o

t2 = charging time = Ө2360∗𝑇 = 1.4m sec
t1 = discharging time = T2− 𝑡2 = 8.6m sec
Then C1= I𝑙𝑉𝑟 ∗ 𝑡1= 100m A ∗ 8.6m Sec1.4𝑉= 615μF
Choose standard C1 = 1000μF
Choose C2 = 10μF
R s = 𝑉𝑝𝐼𝑠𝑢𝑟𝑔𝑒 = Vo max + 2Vf30A = 14.7+1.430=0.54 Ω
Choose standard R = 1.2 Ω.
Rectifier Ripple Bridge Voltage
Bridge Rectifier Ripple Voltage is calculated using equation 6 where, I is the DC load current
in amps, ƒ is the frequency of the ripple or twice the input frequency in Hertz, and C is the
capacitance in Farads.
𝑉𝑟𝑖𝑝𝑝𝑙𝑒= 𝐼𝑙𝑜𝑎𝑑𝑓×C. The fundamental frequency of the ripple voltage is twice that of the AC
supply frequency (100Hz) where for the half-wave rectifier it is exactly equal to the supply
frequency (50Hz).
Figure 3.3 power supply simulation
3.5 Temperature Sensor

The most common type of temperature sensors is; thermocouple, thermistor and Temperature
Detectors (RTDs). In this project a thermistor type LM35 temperature sensor is used due to the
following main advantage
❖ Lower cost
❖ Does not require any external calibration
❖ Linear output
❖ Precise and accurate output
2022 GC 10
LM35 is a basic temperature sensor that can be used for experimental purpose. It give the
readings in centigrade (degree Celsius) since its output voltage is linearly proportional to
temperature. It uses the fact that as temperature increases, the voltage across diode increases at
known rate (actually the drop across base-emitter junction of transistor). Its disadvantage is its
sluggish response.
LM35 has the following main features;
i. Calibrated directly in degree Celsius(centigrade)
ii. Linear +10.0 mV/ degree Celsius
iii. 0.5-degree Celsius accuracy guarantee able (at +25degree Celsius)
iv. Rated for full -55 to +150 degree Celsius range
v. Suitable for remote application
vi. Low cost due to wafer-level trimming
vii. Operates from 4 to 30 volts
viii. Less than 60 Micro ampere current drain
Figure 3.4 LM35 temperature IC

As shown in the figure above the sensor has three terminals.
i. Input source; it ranges from 2.7V to 5V
ii. Ground
iii. Output; analogue voltage output ranges from 201mV to 20v
The code will be written in c code. Before we can get a Celsius reading of the temperature, the
analog output voltage must first be read. This will be the raw value divided by 1024 times 5000.
It is divided by 1024 because a span of 1024 occupies 5V. We get the ratio of the raw value to
the full span of 1024 and then multiply it by 5000 to get the millivolt value. Since the output
pin can give out a maximum of 5 volts (1024), 1024 represents the possible range it can give
out. The raw voltage over this 1024 (value) therefore represents the ratio of how much power
2022 GC 11
the output pin is outputting against this full range. Once we have this ratio.
Once this analog voltage in millivolts is calculated, we then can find the temperature in
Fahrenheit by the equation: ((Celsius * 9)/5 + 32).
Figure 3.5 Temperature sensing circuit
3.6 fuel level and oil level sensor

Level sensors detect the level of oil and fuel. This type of level sensor is float type angular
potentiometer. The sensor is immersed in oil, fuel and its mechanical output is given to angular
potentiometer. When there is any mechanical movement of float, there is voltage generation
corresponding to mechanical movement of float. That voltage is used for oil and fuel level
monitoring. The level measurement can be either continuous or point values. Point-level
sensors only indicate whether the substance is above or below the sensing point. Generally, the
latter detect levels that are excessively high or low. While we are design continuous level,
sensors measure level within a specified range and determine the exact amount of oil and fuel
in the generator oil and fuel tank.
Vout= Vin*𝑅2(𝑅2+𝑅1)
Vout max=Vin*𝑅2 𝑚𝑎𝑥(𝑅2 𝑚𝑎𝑥+𝑅1) = 5V*2.52.5+0.22 = 4.596V
Vout min=Vin*𝑅2 𝑚𝑖𝑛(𝑅2 𝑚𝑖𝑛+𝑅1) = 5V*00+0.22 = 0V
2022 GC 12
Figure 3.6 oil and fuel level sensing circuit
3.7 12 V Dc fan motor

When the temperature of the generator exceeds the maximum limit, a SMS text will be sent to
the authorized person to take action and based on the command sent from the authorized person
the generator will be forced to be switched off because the temperature is out of its normal
working range. This results in power failure for short period of time. Therefore, in addition to
informing the concerned body that the temperature is too high it is also possible to use dc fan
motor for cooling purpose. The fan will work only when the temperature exceeds the highest
limit and is off for temperatures below the maximum value. The fan motor coil gets its power
source from the Arduino output and the Arduino output connected to the fan contactor coil will
be high when the temperature
of the generator is too high.
2022 GC 13
Figure 3.7 12v Dc fan circuit

3.8 GSM Modem
A GSM modem is a specialized type of modem which accepts a SIM card, and operates over a
subscription to a mobile operator, just like a mobile phone. From the mobile operator
perspective, a GSM modem looks just like a mobile phone. When a GSM modem is connected
to a computer, this allows the computer to use the GSM modem to communicate over the
mobile network. While these GSM modems are most frequently used to provide mobile internet
connectivity, many of them can also be used for sending and receiving SMS and MMS
messages.
GSM modems can be a quick and efficient way to get started with SMS, because a special
subscription to an SMS service provider is not required. In most parts of the world, GSM
modems are a cost-effective solution for receiving SMS messages, because the sender is paying
for the message delivery. A GSM modem exposes an interface that allows applications such as
Now SMS to send and receive messages over the modem interface. The mobile operator
charges for this message sending and receiving as if it was performed directly on a mobile
phone. To
perform these tasks, a GSM modem must support an “extended AT command set” for
sending/receiving SMS messages.
2022 GC 14
Figure 3.8. GSM modem and pin configuration

GSM modules are manufactured by different companies. They all have different input power
supply specs. We need to double check our GSM modules power requirements. The GSM
module requires a 12 volts input, so we feed it using a 12V, 1A DC power supply. It can be
noticed that GSM modules which require 15 volts and some other which needs only 5 volts.
They differ with manufacturers. If we are having a 5V module, we can power it directly from
Arduino’s 5V out.
BOOTING UP THE GSM:
1. Insert the SIM card to module and lock it.
2. Connect the adapter to module and turn it ON!
3. Now wait for some time (say 1 minute) and see the blinking rate of ‘status LED’
(GSM module will take some time to establish connection with mobile network)
4. Once the connection is established successfully, the status LED will blink
continuously every 3 seconds.
3.9 Serial Communication

In this model serial communication from modem to microcontroller are done by connecting
Txd and Rxd pins to modem Rxd and Txd pin respectively. And the third pin of modem is
grounded. In our hardware architecture we have interface modem to microcontroller directly
without the use of Max232 or RS232 and having proper results with proper communication.
Max232 or RS232 both are used as logic converter. They both can work in CMOS logic level
or TTL logic level. If microcontroller works in TTL level and GSM Modem works in CMOS
level then logic converter like RS232 is interfaced to bring same logic level. But in our model
both Microcontroller and GSM Modem works in TTL logic level so here we have not used
Max232 0r RS232.Direct connections between modem and microcontroller is done.
2022 GC 15
Figure 3.9 the configuration of virtual terminal

3.10 Engine Generator
Generators are useful appliances that supply electrical power during a power outage and
prevent discontinuity of daily activities or disruption of business operations. Generators are
available in different electrical and physical configurations for use in different applications. In
the following sections, we will look at how a generator functions, the main components of a
generator, and how a generator operates as a secondary source of electrical power in residential
and industrial applications.
It is important to understand that a generator does not actually create electrical energy. Instead,
it uses the mechanical energy supplied to it to force the movement of electric charges present
in the wire of its windings through an external electric circuit. This flow of electric charges
constitutes the output electric current supplied by the generator. This mechanism can be
understood by
considering the generator to be analogous to a water pump, which causes the flow of water but
does not actually ‘create’ the water flowing through it. The modern-day generator works on
the principle of electromagnetic induction discovered by Michael Faraday in 1831-32. Faraday
discovered that the above flow of electric charges could be induced by moving an electrical
conductor, such as a wire that contains electric charges, in a magnetic field. This movement
creates a voltage difference between the two ends of the wire or electrical conductor, which in
turn causes the electric charges to flow, thus generating electric current.
2022 GC 16
Figure 3.10 diesel generator with its components
3.11 Main components of a generator

The main components of an electric generator can be broadly classified as follows;
(1) Engine
The engine is the source of the input mechanical energy to the generator. The size of the engine
is directly proportional to the maximum power output the generator can supply.
(2) Alternator
The alternator, also known as the ‘genhead’, is the part of the generator that produces the
electrical output from the mechanical input supplied by the engine. It contains an assembl of
stationary and moving parts encased in a housing. The components work together to cause
relative movement between the magnetic and electric fields, which in turn generates electricity.
(3) Fuel System
The fuel tank usually has sufficient capacity to keep the generator operational for 6 to 8 hours
on an average. In the case of small generator units, the fuel tank is a part of the generator’s skid
base or is mounted on top of the generator frame.
(4) Cooling Systems
Continuous usage of the generator causes its various components to get heated up. It is essential
to have a cooling and ventilation system to withdraw heat produced in the process.
(5) Lubricating System
Since the generator comprises moving parts in its engine, it requires lubrication to ensure
durability and smooth operations for a long period of time. The generator’s engine is lubricated
by oil stored in a pump. You should check the level of lubricating oil every 8 hours of generator
2022 GC 17
operation. You should also check for any leakages of lubricant and change the lubricating oil
every 500 hours of generator operation.
(6) Battery Charger
the start function of a generator is battery-operated. The battery charger keeps the generator
battery charged by supplying it with a precise float voltage. If the float voltage is very low, the
battery will remain undercharged. If the float voltage is very high, it will shorten the life of the
battery.
(7) Control Panel
This is the user interface of the generator and contains provisions for electrical outlets and
controls. The following article provides further details regarding the generator control panel.
Different manufacturers have varied features to offer in the control panels of their units. Some
of these are mentioned below.
3.12 LCD (liquid crystal display)

A liquid crystal display (LCD) is a thin, flat panel used for electronically displaying
information such as text, images and moving pictures. Its uses include monitor for computers,
televisions, instrument panels gamin device etc. using polarization of light to display objects.
A typical liquid crystal producing degree shift in the polarization of the light passing through
when there is no electric field present. When a voltage is applied, an electric field is produced
in the liquid, affecting the orientation of the molecules. This causes the polarization shift to be
reduced.
Figure 3.11 LCD internal working principle

Liquid crystal material emits no light of their own. For illumination of light-backlight and
reflective method used.
Reflective: it uses external light reflected by reflector behind the display. Example: watch,
calculator, this is achieved by combining a reflector with rear polarizer.
2022 GC 18
Backlight: light source is from a back light, and viewed from the front. Example: computer
display built in fluorescent tubes above, besides and sometimes behind the LCD.
3.12.1 LCD pin description for interfacing with Arduino

Pin 1 (VSS); is a ground pin and it is certainly needed that this pin should be grounded for
LCD to work properly.
VEE and VDD; are given +5 volts normally. However, VEE may have a potentiometer voltage
divider network to get the contrast adjusted. But VDD is always at +5V.
RS, R/W and E: These three pins are numbered 4, 5 and 6 as shown above. RS is used to make
the selection between data and command register. For RS=0, command register is selected and
for (a) Electric start and shut-down – Auto start control panels automatically start the generator
during a power outage, monitor the generator while in operation, and automatically shut down
the unit when no longer required.
(b) (d) Other controls – Phase selector switch, frequency switch, and engine control switch
(manual mode, auto mode) among others.
(8) Main Assembly / Frame
All generators, portable or stationary, have customized housings that provide a structural base
support. The frame also allows for the generated to be earthed for safety.
RS=1 data register is selected. R/W gives us the choice between writing and reading. If set
(R/W=1) reading is enabled. R/W=0 when writing.
D0-D7; The 8-bit data pins, D0-D7, are used to send information to the LCD or read the
contents of LCD's internal register.
Figure 3.12 LCD and pin configuration
3.13 Arduino kit

Arduino is an open-source platform used for building electronics projects. Arduino consists of
both a physical programmable circuit board (often referred to as a microcontroller) and a piece
2022 GC 19
of software, or IDE (Integrated Development Environment) that runs on your computer, used
to write and upload computer code to the physical board.
The Arduino platform has become quite popular with people just starting out with electronics,
with ATMEGA 328 data sheet based board. Unlike most previous programmable circuit
boards, the Arduino does not need a separate piece of hardware (called a programmer) in order
to load new code onto the board, It simply use a USB cable. Additionally, the Arduino IDE
uses a simplified version of C languages, making it easier to learn to program. Finally, Arduino
provides a standard form factor that breaks out the functions of the micro-controller into a more
accessible package.
Figure:3.13 Arduino-Uno and pin configurations
3.13.1 Power (USB) and pin configuration

Every Arduino board needs a way to be connected to a power source. The Arduino UNO can
be powered from a USB cable coming from your computer or a wall power supplies. It’s not
allowed to use a power supply greater than 20 Volts as you will overpower and thereby destroy
the Arduino. The recommended voltage for most Arduino models is between 6 and 12 Volts.
The pins on your Arduino are the places where it will connect wires to construct a circuit
probably in conjunction with a breadboard and some wire. They usually have black plastic
2022 GC 20
‘headers’ that allow you to just plug a wire right into the board. The Arduino has several
different kinds of pins, each of which is labeled on the board and used for different functions.
GND (3): Short for ‘Ground’. There are several GND pins on the Arduino, any of which can
be used to ground the circuit.
5V (4) & 3.3V (5): As we might guess, the 5V pin supplies 5 volts of power, and the 3.3V pin
supplies 3.3 volts of power. Most of the simple components used with the Arduino run happily
off of 5 or 3.3 volts.
Analog (6): The area of pins under the ‘Analog In’ label (A0 through A5 on the UNO) are
Analog In pins. These pins can read the signal from an analog sensor (like a temperature sensor)
and convert it into a digital value that we can read.
Digital (7): Across from the analog pins are the digital pins (0 through 13 on the UNO). These
pins can be used for both digital input (like telling if a button is pushed) and digital output (like
powering an LED).
PWM (8): the digital pins (3, 5, 6, 9, 10, and 11 on the UNO). These pins act as normal digital
pins, but it can also be used for something called Pulse-Width Modulation (PWM).
AREF (Stands for Analog Reference) (9): Most of the time you can leave this pin alone. It is
sometimes used to set an external reference voltage (between 0 and 5 Volts) as the upper limit
for the analog input pins.
2022 GC 21
CHAPTER FOUR
DISCUSSION AND RESULT
4.1 Flow chart of the project
The flowchart gives a diagram representation of the program algorithm. The system flowchart
is designed as shown below: first the program is initialized and power from the main supply
i.e. EEPCO is checked. If there is power absence from this supply, the generator is
automatically started and gives power so that there will be available power. Once it starts its
relay status must be checked continuously because when different fault happens like short
circuit, it trips and the generator output power does not reach at the consumer load. The relay
will trip only when short circuit happens or large current flows due to the fault and SMS text
will be sent to the authorized person’s mobile. When the generator works for a long period of
time, the temperature will be high and causes damage so there should be some mechanism to
cool. Two action must be done first SMS text is sent and 12V dc fan motor will be switched
ON. When the oil is used at time 500hr and the fuel level is below 220L SMS text will be sent.
2022 GC 22
A
Start
Initialize the system

Temp > 100 Yes
Power
NO
failure
Oil used at Yes
t=500h
The generator Starts
no
Generator
relay status Fuel level
<220L yes
No
SMS text to
authorized person
Stop
A
Action will be taken
Figure 4.1 Flow chart of the system
The overall system contains the above listed sensors as input (temperature sensor, fuel and oil
level sensor and fault detector relay) and LCD, to display the parameters, GSM modem (virtual
terminal for simulation) and Fan as an output. The GSM modem is not available in the protues
software so an equivalent component is used to receive the transmitted information from the
Arduino i.e virtual terminal.
2022 GC 23
Figure 4.2 overall system simulation
2022 GC 24
CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion
The hunch delineated of this project is immense in the ever-changing technological world. It
allows a greater degree of freedom to an individual to sway via GSM. In particular the
suggested system will be a powerful, flexible and secure tool that will offer this service at any
time, and from anywhere with the constraints of the technologies being applied. The embedded
controllers are capable of sensing and controlling the various parameter of generator in normal
and abnormal condition. This proposed system provides the immediate solution for
catastrophic failure of generator using GSM communication. The embedded controller offers
a wide scope of application in the field of remote digital controllers in the diesel generator
industry.
5.2 Recommendations
Any work and investigation on Generator protection are very advantageous and challenging.
Based on the present time, it can be observed that the number of industries is increasing rapidly
which means the need of a backup generator is also increasing. Therefore, demands on
electricity will be high and these will lead to demands of highly sophisticated protection
devices, which will be incorporated in generator protection schemes.
Based on the work done in this project which protecting Generator using Arduino kit, some
improvements need to be made in the future work. It was noticed that use of oil and fuel may
not give exact value since the float may not turn the angular potentiometer at the required
position. Therefore, these sensors should be substituted by another smart sensors to gate
accurate reading of oil and fuel level of the generator like ultrasonic method of liquid
measurement.
In this project, the generator will be automatically turned OFF if its parameter i.e oil and fuel
level are out of the predefined limit so that the generator may not be exposed to any damage
but this causes power brake for a short period of time. Instead of doing this another mechanism
should be designed to fill oil and fuel whenever they are lower than the minimum limit.
2022 GC 25
References
[1] Amit, “Microcontroller Based Substation Monitoring and Control System with
GSM Modem” IOSR Journal of Electrical and Electronics Engineering, ISSN: 2278-
1676 Volume 1, Issue 6 (July-Aug. 2012).
[2] Mallikarjun Sarsamba “The Load Monitoring and Protection on Electricity Power
lines using GSM Network” International Journal of Advanced Research in Computer
Science and Software Engineering, Volume 3, Issue 9, September 2013 ISSN: 2277
128X.
[3] S.Vimalraj, R.B. Gausalya, “GSM Based Controlled Switching Circuit between
Supply Mains and Captive Power Plant”, International Journal of Computational
Engineering Research, vol, 03, no. 4, (2013).
[4] A. Palamar “Control System for a Diesel Generator and UPS Based Microgrid”,
Scientific Journal of Riga Technical University Power and Electrical Engineering, vol.
27, (2010).
[5] K. S. Ahn “Digital Controller of a Diesel Generator using an Embedded System”
International Journal of Information Processing Systems, vol.2, no. 3, (2006).
[6] H. Arleving, “Ways to cut power generator maintanence” the journal, (2013).
[7] C. Patil, C. Baligar, “Base Transceiver Station (BTS) Safety and Fault
Management”,International Journal of Innovative Technology and Exploring
Engineering, vol. 3, no. 7, (2013).
[8] Y. Jaganmohan Reddy, Y. V. Pavan Kumar, K. Padma Raju, A. Ramsesh, “PLC
Based Energy Management and Control Design for an Alternative Energy Power
System with Improved Power Quality”, International Journal of Engineering Research
and Applications, vol. 3, no. 3, (2013).
2022 GC 26
Appendix 1
#include <LiquidCrystal.h>
#include <SoftwareSerial.h>
SoftwareSerial SIM900(7, 8);
// initialize the library with the numbers of the interface pins
LiquidCrystal lcd(12,11,10,9,6,5);
//declare variables
float fuelOut;
float OL;
float fuel;
float oil;
float D;
int tempPin=A1;
int fan = 3; // the pin where fan is
int fuelPin=A2;
int oilPin=A4;
int overload=7;
int val=0;
float treshold=4.3;
String textForSMS;
char incoming_char=0;
int temp;
int tempMin = 100; // the temperature to start the fan
int tempMax = 70; // the maximum temperature when fan is at 100%
int fanSpeed
void setup(){
// set up the LCD's number of columns and rows:
lcd.begin(20, 4);
lcd.print("T=");
lcd.setCursor(0, 1);
lcd.print("F=");
2022 GC 27
lcd.print("O=");
Serial.begin(9600);
SIM900.begin(9600);
analogReference(DEFAULT);
pinMode(0,OUTPUT);
pinMode(2,OUTPUT);
pinMode(3,OUTPUT);
pinMode(4,OUTPUT);
pinMode(A1,INPUT);
pinMode(A4,INPUT);
pinMode(7,INPUT);
}
void loop()
{
val=digitalRead(overload);
2022 GC 28
floa avrtemp=0;
for (int i=0; i<= 4; i++)
{
mytemp [i]=analogRead(tempPin);
delay(10);
}
avrtemp=(mytemp [0]+mytemp [1]+mytemp [2]+mytemp [3]+mytemp [4])/5;
temp = (5*avrtemp*100)/1023;
if(temp < tempMin) { // if temp is lower than minimum temp
fanSpeed = 0; // fan is not spinning
digitalWrite(3, LOW);
}
if(temp >= tempMin) { // if temperature is higher than minimum temp
fanSpeed = map(temp, tempMin, tempMax, 32, 255); // the actual speed of fan
digitalWrite(3,HIGH);
analogWrite(fan, fanSpeed); // spin the fan at the fanSpeed speed
Serial.print(" , ");
delay(100);
Serial.println("Temperature is HIGH ");
delay(100);
}
int myfuel [5];
float avrfuel=0;
for (int i=0; i<= 4; i++)
{
myfuel [i]=analogRead(fuelPin);
delay(10);
}
avrfuel=(myfuel [0]+myfuel [1]+myfuel [2]+myfuel [3]+myfuel [4])/5;
OL = analogRead(oilPin);
fuelOut=(5*avrfuel*46)/1023;
oil=(5*OL*15)/1023;
D=(5*OL)/1023;
// print result to lcd display
2022 GC 29
lcd.print(temp,1);
lcd.print("C");
lcd.print(fuelOut,1);
lcd.print("cm");
lcd.print(oil,1);
lcd.print("cm");
// sleep...
delay(100);
SIM900.print("AT+CMGF=1\r");
delay(100);
SIM900.print("AT+CMGS=\"+251920941848\"\r");
delay(100);
if(fuelOut<220){
Serial.println("fuel is LOW ");
digitalWrite(2,HIGH);
delay(100);
}
else{
digitalWrite(2,LOW);
}
if(oil at t=500hr){
Serial.print(" , ");
delay(100);
Serial.println("Oil is LOW ");
delay(100);
}
if(val=HIGH){
Serial.println("fualt happen ");
}
}
2022 GC 30
Appendix 2
Table 1: Power supply circuit diagram root sheet
Table 2: 12 v dc fan circuit diagram root sheet
Table 3: Physical part list view
2022 GC 31

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WOLAITA SODO UNIVERSITY

STUDENT NAME ID NO.

ADVISOR: MR. G/HIWOT G.

Student Name Signature

Project Advisor Signature

Mr. G/Hiwot G. ________________

DISCUSSION AND RESULT ....................................................................................................... 22

1.3 Literature Review

1.4.2 Specific Objectives

➢ To design temperature sensing circuit

Analyzing the selected

Simulate using Arduino

Figure 1.1 Methodology of the project

3.2 System description of the project

Relay status Relay

Oil level Mobile

3.4 power supply circuit

Figure 3.2 design of power supply circuit

t1 = discharging time = T2− 𝑡2 = 8.6m sec

Ө2 = 90o – 65o = 25o

Figure 3.3 power supply simulation

3.5 Temperature Sensor

Figure 3.4 LM35 temperature IC

Figure 3.5 Temperature sensing circuit

3.6 fuel level and oil level sensor

Figure 3.6 oil and fuel level sensing circuit

3.7 12 V Dc fan motor

Figure 3.7 12v Dc fan circuit

Figure 3.8. GSM modem and pin configuration

3.9 Serial Communication

Figure 3.9 the configuration of virtual terminal

Figure 3.10 diesel generator with its components

3.11 Main components of a generator

3.12 LCD (liquid crystal display)

Figure 3.11 LCD internal working principle

3.12.1 LCD pin description for interfacing with Arduino

Figure 3.12 LCD and pin configuration

3.13 Arduino kit

Figure:3.13 Arduino-Uno and pin configurations

3.13.1 Power (USB) and pin configuration

Initialize the system

Figure 4.1 Flow chart of the system

Figure 4.2 overall system simulation

Table 2: 12 v dc fan circuit diagram root sheet

Table 3: Physical part list view

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