Efficient Integrated Industrial Automation Using FPGA

Group Members
Kingsuk Bag IEC2018001
Shakti Majhwar IEC2018006
Shivam Vaishampayan IEC2018015

Indian Institute of Information Technology, Allahabad

Mentor:
Dr. Kavindra Kandpal
Assistant Professor
Department of Electronics & Communication
Indian Institute of Information Technology, Allahabad
Uttar Pradesh 211102, India
Email: kavindra@iiita.ac.in
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INTRODUCTION
 Each industry aims to improve efficiency and decrease production costs.
 Small manufacturers struggle to survive and prosper in India due to the
competition faced from large MNC’s.
 The main reason behind this is the Lack of Automation and the high cost
of modern technologies.
 We aim to design and implement an integrated and automated
prototype for the FMCG industry.
 Our prototype will monitor the manufacturing process in great detail.
 It will result in low operational costs, manual mistakes, and product
damage.
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Literature Review
 The recent years have witnessed a huge boom of Internet of things (IOT),
making it a part and parcel of our daily lives.
 It has achieved a great deal in making the things around us smart. From smart
homes to smart street lights , it is omnipresent.
 We aim to take IOT to the next level by implementing it in the industrial scenario
of our country and thus giving rise to Integrated Industrial Internet of
Things(IIIOT) (idea from paper 1).
 In this project we will strive to design a FPGA based hardware and software
driven intelligent system(idea from paper 3)
 This methodology will make the FPGA the central controller of the system and it
will be connected to sensor nodes via sensor gateways.
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Literature Review
 The use of FPGA provides us with flexibility and re-usability in our system. It
also contributes towards cost reduction and making the system more efficient .
(idea from paper 5)
 Moreover future applications could include the implementation of ML algorithms
which are easier to be applied in our system due to the reconfigurable nature of
FPGA.
 We are taking a bottom up approach towards the construction of the prototype.
First we begin at the individual nodes and work our way up to integrating them
by using the FPGA as the brain of the system. (idea from paper 6)
 We sincerely hope that this project can have an impact on the small scale
FMCG industries in our country.
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A Timeline Of The Implementation of IOT

AWS Emergence of
Internet Smartphones
Launched
World Wide Web Rise of Cloud
was invented at Computing Devices started
CERN in 1989 getting cheaper
and connected

1989 1992 2002 2006 2008 2011

Secure Launch of
TCP/IP
Transmission IPV6
TCP/IP allows OPC Unified Give rise to 340
PLCs to have Architecture (UA) undecillion unique IP
connectivity enables secure addresses
communications
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Resources To Be Used
1] FPGA - Artix-7, General Purpose

2] Sensor Gateway - Node MCU (ESP 8266)

3] Sensor Nodes - Node MCU (ESP 8266)

4] Sensors - DHT-11, IR,Ultrasonic sensor, Depth sensor, Gas sensor, RFID sensor, Motor
Controller,Servo Motors,Relay.

5] Softwares – Xilinx Vivado, Circuito.io

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Block Diagrams

Flow chart of the working prototype

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Basic Architecture of Project

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Description Of Control Module

Fluid Control Node Cold Storage Node

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Product Quality Control Node Mixer Tank Control Node

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Cold Storage Node

This is the node which controls and monitors the parameters which are related to the maintenance of
the cold storage where the finished products are stored . We measure the temperature and humidity of
the surroundings and send it to the mobile app. An alert is sent to the controller when the parameters
go below a certain threshold.
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Fluid Tank Level Monitor Node

This node helps in monitoring of the fluid levels of the various tanks which are involved in the
manufacturing of the product. In our example, we take the tanks as a Milk tank, a water tank and a
tank full of Liquid chocolate.
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Mixer Tank Control Node

This node control the volume of the incoming fluids into the mixer tank so that the right proportion
is met for the final mixture. We also monitor the level of the mixer tank to prevent any overflow of
the fluid from the tank.
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Product Quality Control Node

The product control node checks whether the product is present in the package before the product is
finally packaged. It accounts for all the ill manufactured products and a plastic slab attached with the
servo motor swats away the bad products to another side and allows the rest to pass.
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Description Of Safety Module

Fire Safety Node Safety From Gas Leakage

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Fire Safety Node

This node is responsible for protecting the factory and its workers from any possible fires. This keeps a
check on any possible situations of fire and automatically activates the array of water sprinklers which
are associated with it.
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Safety From Gas Leakage

This node is responsible for protecting the factory and its workers from any possible gas leakages. It
monitors he various levels of harmful and combustible gases present in the air. If the level of a gas is
beyond permissible limits, it sends a warning to the controller and cordons off that area .
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Description Of Operations Module

Inventory Management Node

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Inventory Management Node

This node takes care of the storage of the product in the form of crates. Each crate is associated with
a RFID tag for easy identification during dispatch. The ultrasonic sensors help in maintaining the
count of the total number of incoming and outgoing crates in the storage facility.
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State Diagram Of The Control Module

This FSM describes the working and transition of states that occur in the functioning of the
Control module. It works towards the proper functioning of the cold storage unit where the final
goods are stored. It is quintessential to maintain ideal conditions as any sudden change of
parameter in the cold storage unit can lead to catastrophic consequences. 
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State Diagram Of The Safety Module

This FSM describes the working and transition of states that occur in the functioning of the
safety module. The state diagram above has 5 states: Start, No_fire, Fire, No_leakage, Leakage.
The temperature and gas sensors collect the necessary data and send it to the FPGA through the
node MCU, which serves as both the sensor gateway and the A/D converter.
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Simulation Results Of The Safety Module

The FSM is initially in a start state. If the temperature remains below the acceptable ranges, the system
switches to the No_fire state, and the sprayers stay turned off. If the temperature rises above 50 degrees, the
device enters the Fire state and the water sprayers are enabled to extinguish the fires. Similarly, if the levels
of Gas remain below acceptable limits, it remains in the No_leakage state; however, if the levels surpass the
fixed values, the state changes to Leakage state, and the servo is prompted to switch ON to cordon off the
region where the gas leakage has occurred.
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Simulation Results Of The Control Module

The FSM is initially in the start state. After this, when FPGA receives temperature data, if the temperature is
less than 5 degrees, the temp_heat condition is activated, and the heater is enabled. As the temperature rises
above 50 degrees, the state temp_cool is activated, and the cooler is enabled.
If the humidity is less than 35%, the humidifier enters the humidifier_ON stage and turns on. Conversely, if
humidity is more than 70%, then the humidifier enters the humidifier_OFF stage, and the dehumidifier is
activated.
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RTL View Of Implemented Design

The RTL view of the implemented design has been shown here after performing the synthesis in the Vivado
tool. As can be observed the RTL representation of the module consists of 31 cells, 23 i/o ports in total and
these are connected via 70 interconnecting nets and together the implement the desired functionality.
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Synthesis Reports Of The Implemented Design

The synthesis report of the implemented design represents the detailed RTL component
statistics and the detailed RTL hierarchical component report. It also shows the peak memory
used and the part resources that have taken part in the implementation. 
The synthesis analysis report is also given below. It shows the utilization design
information which includes slice logic i.e. summary of registers by type, specific features,
primitives, blackboxes and instantiated netlists. 
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Power Analysis Of The Implemented Design

This above mentioned report represents the power analysis from the implemented netlists. It
displays the total on chip power, the power supplied to off chip devices and also gives a
description of the static and dynamic power consumed by the implemented design.
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Actual Implementation On FPGA

The above illustrated diagrams show the actual implementation of the design on the FPGA
board. It shows how the LUT, FlipFlops and MUX are connected, to actually carry out the
desired function.
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Screenshots Of The Android Application

This represents an Android application that will track various parameters such as the mixer tank
temperature, fluid tank levels, and cold storage parameters. It also displays the state of a gas
leak or a potential fire hazard.
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Screenshots Of The Inventory Management Website

This represents an inventory management website that can facilitate the packing, tracking, and
shipping of the various packages to consumers. It will maintain track of the products available,
the current location of shipments that are out for delivery, and the deliveries that are due.
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Conclusion & Summary

 Industrial automation has become a part and parcel of the recent manufacturing
industry and we strive to bring the various processes involved in automating a
industry in a single integrated efficient industrial automation system .

 In this project, we will try to integrate all of the above mentioned modules to automate
and draw meaningful conclusions.

 It will help factories to move up the ante so that they could survive and thrive in a
competitive market

 We believe that this project will have an impact on the small-scale FMCG industry.
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References
1. P. Charith et al., “A Survey on Internet of Things From Industrial Market Perspective”, IEEE Access, Vol.2,
pp.1660-1679, 2014.

2. C. Perera et al., “The Emerging Internet of Things Marketplace from an Industrial Perspective: A Survey,” IEEE
Transactions on Emerging Topics in Computing, Vol.3, No.4, pp.585-598, 2015

3. Chhatrawala et al., “FPGA Based Data Acquisition with Modbus Protocol,” Proceedings of 3rd IEEE International
Conference on Computer and Communications, pp.1251-1254, 2017.

4. T. Karuppiah, Dr. Periasamy, Dr. S. Muruganand,; “Embedded System Based Industrial Power Plant Boiler
Automation Using GSM Technology”, International Journal of Advanced Research in Computer and
Communication Engineering, Vol. 2, Issue 8, August 2013.

5. Bai et al., “Intelligent FPGA Data Acquisition Framework,” IEEE Transactions on Nuclear Science, Vol.64,
No.10, pp.2761-2764, 2017.
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