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MAKER
I N N O VAT I O N S
SERIES
Sensors
and Protocols
for Industry 4.0
Industrial Applications of Maker Tech
—
G.R. Kanagachidambaresan
Bharathi N.
Maker Innovations Series
Jump start your path to discovery with the Apress Maker Innovations
series! From the basics of electricity and components through to the most
advanced options in robotics and Machine Learning, you’ll forge a path to
building ingenious hardware and controlling it with cutting-edge software.
All while gaining new skills and experience with common toolsets you can
take to new projects or even into a whole new career.
The Apress Maker Innovations series offers projects-based learning,
while keeping theory and best processes front and center. So you get
hands-on experience while also learning the terms of the trade and how
entrepreneurs, inventors, and engineers think through creating and
executing hardware projects. You can learn to design circuits, program AI,
create IoT systems for your home or even city, and so much more!
Whether you’re a beginning hobbyist or a seasoned entrepreneur
working out of your basement or garage, you’ll scale up your skillset to
become a hardware design and engineering pro. And often using low-
cost and open-source software such as the Raspberry Pi, Arduino, PIC
microcontroller, and Robot Operating System (ROS). Programmers and
software engineers have great opportunities to learn, too, as many projects
and control environments are based in popular languages and operating
systems, such as Python and Linux.
If you want to build a robot, set up a smart home, tackle assembling a
weather-ready meteorology system, or create a brand-new circuit using
breadboards and circuit design software, this series has all that and more!
Written by creative and seasoned Makers, every book in the series tackles
both tested and leading-edge approaches and technologies for bringing
your visions and projects to life.
G.R. Kanagachidambaresan
Bharathi N.
Sensors and Protocols for Industry 4.0: Industrial Applications of
Maker Tech
Acknowledgments�����������������������������������������������������������������������������xix
Preface����������������������������������������������������������������������������������������������xxi
vii
Table of Contents
viii
Table of Contents
ix
Table of Contents
Infrared Sensors�������������������������������������������������������������������������������������������������47
Infrared Obstacle Avoidance Sensor��������������������������������������������������������������47
ISB-TS45D Infrared Thermopile Sensor���������������������������������������������������������48
TCRT5000: Reflective Infrared Optical Sensor�����������������������������������������������49
HC-SR505 Mini Infrared PIR Motion Sensor Infrared Detector Module���������50
Raspberry PI Infrared IR Night Vision Surveillance Camera Module��������������51
Infrared Sensor Specifications����������������������������������������������������������������������52
Applications���������������������������������������������������������������������������������������������������52
Pressure Sensors������������������������������������������������������������������������������������������������53
BMP180 Digital Pressure Sensor�������������������������������������������������������������������53
Pressure Transmitter Sensor�������������������������������������������������������������������������54
Honeywell HSCSAAN010ND2A3 Pressure Sensor�����������������������������������������55
Air Pressure Sensor MPS20N0040D 40KPa (Differential Pressure)���������������56
Stainless Steel Pressure Transducer Sensor�������������������������������������������������57
Pressure Sensor Specifications���������������������������������������������������������������������57
Applications���������������������������������������������������������������������������������������������������58
Gas Sensors��������������������������������������������������������������������������������������������������������58
MQ135: Air Quality Gas Sensor����������������������������������������������������������������������59
AO-03 Gas Sensor�����������������������������������������������������������������������������������������59
TGS2610: Liquefied Petroleum Gas Sensor���������������������������������������������������60
Toluene Electrochemical Gas Detection Module: ME3-C7H8 gas sensor������61
MQ-5B: 24V LPG Propane Methane Combustible Flammable
Liquefied Gas Sensor�������������������������������������������������������������������������������������62
Specifications of Gas Sensors�����������������������������������������������������������������������62
Applications���������������������������������������������������������������������������������������������������63
Accelerometers���������������������������������������������������������������������������������������������������63
MPU6050: Triple Axis Gyro Accelerometer�����������������������������������������������������64
LIS2DHTR Accelerometer�������������������������������������������������������������������������������65
TE Connectivity 805-0500 Accelerometer�����������������������������������������������������65
x
Table of Contents
ADXL335 Accelerometer��������������������������������������������������������������������������������66
BMA400: Three-Axis Digital Accelerometer���������������������������������������������������67
Accelerometer Specifications������������������������������������������������������������������������68
Applications���������������������������������������������������������������������������������������������������69
Level Sensors������������������������������������������������������������������������������������������������������69
Water-Level Depth Detection Sensor�������������������������������������������������������������69
XKC-Y25 NPN Intelligent Noncontact Liquid Water-Level Sensor������������������70
Anti-Corrosion Water-Level Sensor with Ball Float Switch����������������������������71
Level Sensor Specifications��������������������������������������������������������������������������71
Applications���������������������������������������������������������������������������������������������������72
Summary������������������������������������������������������������������������������������������������������������72
xi
Table of Contents
RS 485���������������������������������������������������������������������������������������������������������������105
RS485 Master����������������������������������������������������������������������������������������������107
RS485 Slave������������������������������������������������������������������������������������������������110
Summary����������������������������������������������������������������������������������������������������������112
xiii
Table of Contents
Index�������������������������������������������������������������������������������������������������255
xiv
About the Authors
G.R. KANAGACHIDAMBARESAN completed
his PhD in information and communication
engineering at Anna University, Chennai, in
2017. He received his ME degree in pervasive
computing technologies from Anna University
in 2012 and his BE degree in electrical and
electronics engineering from Anna University
in 2010.
He is currently working as a Professor in
the Department of CSE at Vel Tech Rangarajan
Dr. Sagunthala R&D Institute of Science and Technology. He is also a
visiting professor at the University of Johannesburg. His main research
interests include the Internet of Things, body sensor networks, and fault-
tolerant wireless sensor networks.
He has published several reputed articles and undertaken several
consultancy activities for leading MNC companies. He has also guest
edited several special-issue books for Springer and has served as an
editorial review board member for peer-reviewed journals. He is currently
working on several government-sponsored research projects such as
ISRO, DBT, and DST, and he is a TEC committee member for DBT. In
addition, he is the editor-in-chief for the Next Generation Computer and
Communication Engineering series from Wiley. He is also the managing
director of Eazythings Technology Private Limited.
xv
About the Authors
xvi
About the Technical Reviewer
Massimo Nardone has more than 26 years
of experience in security, web/mobile
development, and cloud and IT architecture.
His true IT passions are security and Android.
He has been programming and teaching how
to program with Android, Perl, PHP, Java, VB,
Python, C/C++, and MySQL for more than
25 years. He has an MS degree in computing
science from the University of Salerno, Italy.
He has worked as a chief information security
officer (CISO), software engineer, chief security
architect, security executive, and OT/IoT/IIoT
security leader and architect.
xvii
Acknowledgments
Our heartfelt thanks to Apress, to Jessica Vakili, Aaron Black, James
Markham, and Sowmya Thodur for helping us throughout this project,
and to the executive editor, Susan McDermott. We sincerely thank the
Department of BioTechnology (DBT-India) for its funding (BT/PR38273/
AAQ/3/980/2020) on the smart aquaculture project.
xix
Preface
The fourth industrial revolution is accelerating across a wide range of
industries. Industry 4.0, as it’s come to be known, is characterized by
the integration of advanced technologies, such as the Internet of Things
(IoT), artificial intelligence (AI), and big data, to create intelligent and
interconnected systems that optimize industrial processes and improve
productivity. Sensors, in particular, are essential components of the IoT
and play a critical role in Industry 4.0 by capturing data about the physical
world, including temperature, humidity, pressure, motion, and other
parameters. This data is then transmitted to other devices and systems,
where it is analyzed to gain insights into the performance of machines and
processes. This, in turn, helps manufacturers make informed decisions
about how to allocate resources in the future.
The purpose of this book is to examine how sensors, and the IoT in
general, fuel Industry 4.0. This book is aimed at undergraduates as well as
researchers working to develop IoT solutions for the betterment of society
with the support of industry. We also delve into the ongoing transition
from Industry 3.0 to 4.0.
Source Code
All the source code used in this book can be downloaded from github.
com/apress/sensors-protocols-industry4.0.
Funding Information
Part of this book is supported by India’s Department of Biotechnology
(BT/PR38273/AAQ/3/980/2020).
xxi
CHAPTER 1
IIoT Supporting
Technologies:
Evolution, Concepts,
and Challenges
“Necessity is the mother of invention” is a saying that very much applies to
the evolution of technologies.
Existing technologies are constantly being improved, and new
technologies are being rapidly developed. The success of a technology
on the market relies on its reachability. A product needs to be accessible
to a wide variety of people in different geographical regions and age
groups. Users need to be exposed to the technology and then trained in
a user-friendly way and for a reasonable cost. Companies that can adopt
new technology quickly are the ones most likely to succeed in this ever-
changing world.
This chapter covers some successful emerging technologies such as
the Internet of Things (IoT), cyber physical systems, machine-to-machine
communication, edge and cloud computing, digital twins, AI and machine
learning, big data analytics, and the industrial Internet of Things (IIoT).
3. Orthoptera. Wings net-veined; fore wings narrow, hind wings folded (= our Orthoptera
after subtraction of Dermaptera).
4. Platyptera. Four net-veined wings; mouth parts adapted for biting (= Termitidae and
Mallophaga, parts of our Neuroptera).
8. Hemiptera. Mouth parts forming a beak for sucking. No palpi (= our Hemiptera).
The above eight Orders form the group Ametabola, while the following
eight constitute the Metabola:—
10. Mecaptera. Wings long and narrow (for a small part of our Neuroptera; the
Panorpatae of Brauer).
11. Trichoptera. Wings not net-veined (= our division of Neuroptera with the same name).
12. Coleoptera. Fore wings sheathing the hinder ones (= our Coleoptera).
14. Diptera. One pair of wings (= our Diptera after subtraction of Siphonaptera).
Although this system of the Orders of Insects has some valuable features
it is open to very serious objections, to which we can only briefly allude.
The Order Hemiptera with its extensive divisions, Heteroptera,
Homoptera, Coccidae, and Anoplura exhibiting great differences in
structure and considerable divergence in metamorphosis, is treated as
only equivalent to the little group Panorpatae (scorpion-flies); these latter
being considered a distinct order, although they are not very different in
structure or metamorphosis from the Orders he calls Neuroptera and
Trichoptera. The arrangement appears to be specially designed with the
view of making the Orders adopted in it fall into the two groups Ametabola
and Metabola. The propriety of such a course is more than doubtful since
very few of the Ametabola are really without metamorphosis, in the wide
sense of that term, while the Metabola include Insects with various kinds
of metamorphosis. Indeed if we substitute for the term Ametabola the
more correct expression, "Insects with little metamorphosis," and for
Metabola the definition, "Insects with more metamorphosis but of various
kinds," we then recognise that the arrangement is, like all others, a quite
artificial one, while it is of little value, owing to the development of so few
Insects being hitherto fully ascertained.
Brauer's Classification.
The chief characters on which Brauer bases his system are: (1) The
existence or absence of wings. (2) The condition of the mouth, and
whether it undergoes radical changes in the ontogeny, arriving thus at the
categories Menognatha, Metagnatha, and Menorhyncha, as we have
mentioned on p. 161. (3) The metamorphosis; the grouping adopted
being Ametabola, Hemimetabola, Metabola. (4) The number of the
Malpighian tubules; Oligonephria, Polynephria. (5) The nature of the
wings, the relative proportions of the thoracic segments, and some other
characters.
Thus it begins by a division of Insecta into winged and wingless; but the
winged division is made to comprehend an enormous number of wingless
Insects, whole subdivisions of Orders such as the Mallophaga being
placed in the winged series, although all are without wings. This first
division is indeed entirely theoretical; and if a classification on
generalisations were adopted, it would be more natural to begin with the
old division into Homomorpha and Heteromorpha, and treat the Order
Aptera as the first division of the Homomorpha, while the Heteromorpha
would commence with the Ephemeridae and Odonata, in which, though
the individual in the early part of the ontogeny is very different from the
perfect Insect, there is no marked division of the later larval and the pupal
stages. Brauer's system is also defective inasmuch as it takes no account
of the embryological or oogenetic processes, though these are of equal
importance with the later phases of the Ontogeny. Even as regards the
division into Orders, it is far from being free from reproach; for instance,
the separation of the Dermaptera from the Orthoptera, while Rhynchota
remains intact, although including a more extensive series of
heterogeneous forms; the division of the Neuroptera into widely
separated groups, each of which is treated as equivalent to the great
Orders, such as Coleoptera (in which Strepsiptera are included),
Hymenoptera, and Diptera, is not reasonable. The association of
Mallophaga and Termitidae, while Dermaptera are separated from
Orthoptera, is also undeniably arbitrary, and other similar disparities are to
be seen on scrutinising the details of the system.
The divisions of inferior value to the Order are, after repeated scrutiny by
many naturalists, becoming of a more satisfactory character, and
notwithstanding various anomalies, may be, many of them, considered
fairly natural.[111] Unfortunately entomologists have not been able to
agree on a system of terminology, so that for these subdivisions terms
such as sub-order, series, legion, section, tribe, etc., are used by different
authorities in ways so various as to cause much confusion. In the
following pages the terms sub-order and series will be used in a
somewhat vague manner, the term sub-order being preferred where the
group appears to be an important one and of a fairly natural character,
while the word series will be adopted when the groups are connected in a
conventional manner. The designation "family" will be used for groups of
subordinate importance; and as regards this term we may remark that
systematic entomologists are making genuine efforts to define the
"families" in an accurate and comprehensible manner. The endeavour to
make these systematic families dependent throughout the Class Insecta
on characters of similar morphological value has, however, scarcely been
entered on, and it is perhaps not desirable, seeing how very small a
portion of the Insects of the world have been critically examined, that
much effort should be yet expended on an attempt of the kind. It must be
admitted that the species of Insects should be obtained before they can
be satisfactorily classified, and it is estimated[112] that at least nine-tenths
of the Insects of the world are still unknown to entomologists.
Scudder has informed us[114] that not only were Insects abundant in the
Tertiaries, but that their remains indicate conditions of existence very
similar to what we find around us. "Certain peculiarities of secondary
sexual dimorphism accompanying special forms of communistic life, such
as the neuters and workers in Hymenoptera and the soldiers among the
Termitina, are also found, as would be expected, among the fossils, at
least through the whole series of the Tertiaries. The same may be said of
other sexual characteristics, such as the stridulating organs of the
Orthoptera, and of peculiarities of oviposition, as seen in the huge egg-
capsules of an extinct Sialid of the early Tertiaries. The viviparity of the
ancient Aphides is suggested, according to Buckton, by the appearance
of one of the specimens from the Oligocene of Florissant, while some of
the more extraordinary forms of parasitism are indicated at a time equally
remote by the occurrence in amber of the triungulin larva of Meloe,
already alluded to, and of a characteristic strepsipterous Insect; not only,
too, are the present tribes of gall-making Insects abundant in the
Tertiaries, but their galls as well have been found."
CHAPTER VII
Order I. Aptera.
Small Insects with weak outer skin, destitute throughout life of wings or their rudiments,
but with three pairs of legs; antennae large or moderate in size.
The above definition is the only one that can at present be framed to
apply to all the Insects included in our Aptera. Unfortunately it is far from
diagnostic, for it does not enable us to distinguish the Aptera from the
larvae or young individuals of many Insects of other Orders. There are,
however, certain characters existing in many species of Aptera that
enable their possessors to be recognised with ease, though, as they are
quite wanting in other members, they cannot correctly be included in a
definition applying to the whole of the Order.
We are thus brought in view of two of the most important generalisations
connected with the Aptera, viz. that these Insects in their external form
remain throughout their life in a condition resembling the larval state of
other Insects, and that they nevertheless exhibit extreme variety in
structural characters.
The Order includes two sub-orders, viz. (1) Thysanura, in which the hind
body (abdomen) is composed of ten segments, and there is no ventral
tube on its first segment; and (2) Collembola, in which the hind body
consists of not more than six segments, the first of which is furnished
beneath with a peculiar tube or papilla.
Thysanura.
This Insect (Campodea staphylinus) is, so far as external form goes, well
known, from its having been figured in many works on natural history on
account of its having been supposed to be the nearest living
representative of a primitive or ancestral Insect. The creature itself is but
little known even to entomologists, although it is one of the commonest of
Insects over a large part of Europe. It is numerous in the gardens and
fields about London and Cambridge, and abounds in damp decaying
wood in the New Forest; if there be only one species, it must possess an
extraordinary capacity for adapting itself to extremes of climate, as we
have found it at midsummer near the shores of the Mediterranean in
company with the subtropical white ants, and within a day or two of the
same time noticed it to be abundant on the actual summit of Mount
Canigou, one of the higher Pyrenees, where the conditions were almost
arctic, and it was nearly the only Insect to be found. The species is said to
exist also in North America and in East India. It is a fragile, soft Insect of
white colour, bending itself freely to either side like a Myriapod; the legs
are rather long, the antennae are long and delicate, and the two
processes, or cerci, at the other extremity of the body are remarkably
similar to antennae. It has no eyes and shuns the light, disappearing very
quickly in the earth after it has been exposed. If placed in a glass tube it
usually dies speedily, and is so extremely delicate that it is difficult to pick
it up even with a camel's hair brush without breaking it; so that we may
fear it to be almost hopeless to get enough specimens from different parts
of the world to learn what differences may exist amongst the individuals of
this so-called primitive Insect. Meinert, a very able entomologist,
considers that there is really more than one species of Campodea.
Fig. 91.—Campodea staphylinus. (After Lubbock, × 15.)
In Machilidae the dorsal plates of the hind body are reflexed to the under
surface so as to form an imbrication covering the sides of the ventral
plates, and the eyes are largely developed; by which characters the
family is distinguished from the Lepismidae. The pair of large compound
eyes (Fig. 92, O) is a remarkable feature, being indeed unique in the
Aptera. The structures (o, o′) that Oudemans considers to be simple eyes
have, in external appearance, a resemblance to the fenestrae of the
Blattidae; Grassi states, however, that not only are they eyes, but that
they are of almost unique structure, being, in fact, intermediate between
simple and compound eyes.
All the Thysanura possess salivary glands. In Campodea there are about
sixteen extremely short Malpighian tubules, or perhaps glands
representing these organs; Japyx is destitute of these structures; Machilis
maritima has twenty elongate tubules; in Lepisma also they are long, and
apparently vary in number from four to eight in different species. The
proportions of the three divisions of the alimentary canal differ extremely;
there is a very large proventriculus in Lepisma, but not in the other
families; coecal diverticula are present on the anterior part of the true
stomach in Machilis and in Lepisma, but are wanting in Campodea and in
Japyx.
The dorsal vessel seems not to present any great differences in the sub-
order. Grassi says there are no alary muscles present, but Oudemans
describes them as existing in Machilis, but as being excessively delicate.
The male organs in Campodea are very similar in size and arrangement
to the ovaries, there being a single large tube or sac and a short vas
deferens on each side of the body. In Japyx there is a sac on each side,
but it is rendered double by a coecum at its base, and there are long and
tortuous vasa deferentia. In Lepisma there are three pairs of coeca on
each side, segmentally placed and opening into a common duct. In
Machilis there are three retort-shaped sacs on each side opening near
one another into a common duct, the vasa deferentia are elongate, and
are very curiously formed, being each double for a considerable length,
and the separated portions connected at intervals by five transverse
commissural ducts.
Still more remarkable and obscure in function are the vesicles found near
the appendages; we figure a pair after Oudemans, showing them in the
exserted state. In the retracted state the outer portion of the vesicles is
withdrawn into the basal part P (Fig. 95), so that the vesicles are then
only just visible, being concealed by the ventral plate. The abdominal
appendage is not retractile. In Machilis there are twenty-two of these
vesicles, arranged either two or four on one ventral plate of the hind body.
They are also present in Campodea, where there are six pairs. They are
usually said to be absent in Japyx and in Lepisma, but Haase shows[119]
that Japyx possess a pair placed behind the second ventral plate of the
abdomen. The vesicles appear to be exserted by the entrance of blood
into them, and to be retracted by muscular agency. Much difference of
opinion prevails as to their function; it appears probable that they may be
respiratory, as suggested by Oudemans.
Collembola.
The study of the Collembola is much less advanced than that of the
Thysanura, comparatively little having been added to our knowledge of
the group since Lubbock's monograph of the British forms was published
by the Ray Society in 1873. Why the Collembola should be neglected
when the Thysanura attract so much attention is as inexplicable as many
other fashions are.
The family Lipuridae consists of a few very small and obscure Insects of
soft consistence. They move slowly, and, owing to the absence of any
leaping power, attract attention less readily than the other Collembola do.
Two genera are generally recognised, and they should probably form
separate families; indeed, in Lubbock's arrangement they do so. In one of
the genera (Anoura) the mouth is very imperfect, no mandibles or
maxillae having been detected, while in the other genus (Lipura) these
organs exist.
The two most characteristic organs of the Collembola are the spring and
the ventral tube. The first of these is an elongate structure attached to the
underside of the abdomen near its extremity, either on the penultimate or
ante-penultimate segment. It consists of a basal part, and of two
appendages attached thereto. It is carried under the Insect bent forwards,
and is retained in this position by means of a catch which projects from
the under surface of the third segment of the body, descending between
the two branches of the spring, and passing under the extremity of its
basal segment. It is considered that the spring is elastic, is flexed under
the body by muscular action, and, being retained in this position of
restraint by the catch, when the latter is removed the spring extends by
reason of its elasticity, and the leap is thus executed. Whether this is
really the exact method of leaping is, however, doubtful, for Lubbock says
that the catch "only exists in certain genera"; while in its structure it does
not appear to be well calculated to retain in position an organ that by
virtue of its elasticity is constantly exerting a considerable force.
Fig. 99.—Smynthurus fuscus, with exsertile vesicle (a) protruded from
ventral tube; b, the spring extended.