IoT in Manufacturing - S6 - Sensors, Participatory Sensing, Actuators
IoT in Manufacturing - S6 - Sensors, Participatory Sensing, Actuators
Session 6
Reference
R5 Internet of Things: Architecture and Design Principles Rajkamal. 1st
Edition, Mc Graw Hill
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Sensor Technology
Sensor senses a specific physical condition when that exhibits the
measurable change in a characteristic circuit parameter on the
change in specific physical condition or environment
Sensor Technology
A technology for designing the sensors and associated electronic
readers, circuits, and devices
Physical parameter Sensing
Senses a change in physical parameter
Temperature Acceleration
Pressure Orientation
Light intensity Location
Metal proximity to an object Vibrations
Smoke in proximity Smell, organic vapours or gases
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Sensor Technology
Transducer as Sensor
Converts physical energy like heat, sound, strain, pressure, vibrations and
motion into the electrical energy
Voice and changes in the sound, and is used to record voice or music
Electronic Circuit for Sensor
Connecting to the input at a sensor
Circuit input receives the output of a sensor/transducer
The circuit output variation is according to the variation in physical condition
Sensor Circuit
Receives the energy in form of variations in the currents, voltages, their phase-
angles or frequencies.
Sensor measures the variations in the parameters with respect to a reference or
normal condition and provides the value of sensed parameter after appropriate
calculations
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Sensor Technology
The term sensor should be distinguished from transducer. The latter
is a converter of one type of energy into another, whereas the former
converts any type of energy into electrical.
An example of a transducer is a loudspeaker which converts an
electrical signal into a variable magnetic field and, subsequently, into
acoustic waves.
This is nothing to do with perception or sensing.
Transducers may be used as actuators in various systems.
An actuator may be described as opposite to a sensor—it converts
electrical signal into generally nonelectrical energy.
For example, an electric motor is an actuator—it converts electric
energy into mechanical action.
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Sensor Technology
There are two types of sensors: direct and complex.
A direct sensor converts a stimulus into an electrical signal or
modifies an electrical signal by using an appropriate physical effect,
Whereas a complex sensor in addition needs one or more transducers
of energy before a direct sensor can be employed to generate an
electrical output.
A sensor may incorporate several transducers. e1, e2, and so on are various types
of energy. Note that the last part is a direct sensor.
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Need of Sensors
To monitor and learn the system
Needed not just for operating / controlling the system
Also for
Monitoring
Modelling - characterizing the system
Testing and qualification
Fault prediction, detection and diagnosis
Warning generation and surveillance
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Sensor Classification
All sensors may be of two kinds: passive and active.
A passive sensor does not need any additional energy source and
directly generates an electric signal in response to an external
stimulus; that is, the input stimulus energy is converted by the sensor
into the output signal.
The examples are a thermocouple, a photodiode, and a piezoelectric
sensor.
Most of passive sensors are direct sensors as we defined them
earlier.
The active sensors require external power for their operation, which
is called an excitation signal.
That signal is modified by the sensor to produce the output signal.
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Sensor Classification
The active sensors sometimes are called parametric because their own
properties change in response to an external effect and these properties can
be subsequently converted into electric signals.
It can be stated that a sensor’s parameter modulates the excitation signal
and that modulation carries information of the measured value.
For example, a thermistor is a temperature-sensitive resistor.
It does not generate any electric signal, but by passing an electric current
through it (excitation signal), its resistance can be measured by detecting
variations in current and/or voltage across the thermistor. These variations
(presented in ohms) directly relate to the temperature through a known
function.
Another example of an active sensor is a resistive strain gauge in which
electrical resistance relates to a strain. To measure the resistance of a
sensor, electric current must be applied to it from an external power
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Sensor Classification
Depending on the selected reference, sensors can be classified into
absolute and relative.
An absolute sensor detects a stimulus in reference to an absolute
physical scale that is independent on the measurement conditions,
Whereas a relative sensor produces a signal that relates to some
special case
An example of an absolute sensor is a thermistor: a temperature-
sensitive resistor.
Its electrical resistance directly relates to the absolute temperature
scale of Kelvin.
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Sensor Classification
Very popular temperature sensor—a thermocouple—is a relative
sensor. It produces an electric voltage that is function of a
temperature gradient across the thermocouple wires.
Thus, a thermocouple output signal cannot be related to any
particular temperature without referencing to a known baseline.
Another example of the absolute and relative sensors is a pressure
sensor.
An absolute-pressure sensor produces signal in reference to
vacuum—an absolute zero on a pressure scale.
A relative-pressure sensor produces signal with respect to a selected
baseline that is not zero pressure (e.g., to the atmospheric pressure).
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Sensor Classification
Classification based on the electrical domain of the output signal
Analogue / Analog Sensor
Digital Sensor
Quasi-Digital Sensor
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Sensor Classification
Analog Sensors
The output signal produced by the sensor is continuous and
proportional to the measurand.
Continuous in both magnitude and time
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Sensor Classification
Digital Sensors
Analog Sensors with digital Read out
Provide Digital (discrete output ) at discrete values of time.
Can be interfaced to the computational unit through serial interfaces
or parallel interfaces.
Eg: ADT7420- I2C temperature sensor
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Sensor Classification
Quasi-Digital Sensor
Sensors with frequency, period, duty-cycle, time interval, pulse
number or phase-shift output
Quasi-digital sensors utilize standardized digital signal voltage
levels with special modulation for representing output data.
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Sensor Classification
Quasi-digital- Frequency
SBE 3plus- Premium CTD Temperature Sensor
A CTD is an oceanography instrument used to measure the
conductivity, temperature, and pressure of seawater.
High accuracy industrial and environmental monitoring applications
Temperature in degree C is given by
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Sensor Classification
Analog / Digital / Quasi-digital :-
Analog sensors- provide measurements which are continuous in both
magnitude & time.
Analog sensor requires amplifier or filter in order to amplify or filter
the signal before making it useful to be measured.
Digital signals are more immune to noise.
Quasi-digital- Best of two worlds (analog & digital)- use digital
signal voltage levels with special modulation for representing output
data.
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Classification based on the measurand type
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Different Detectable Phenomenon
Stimulus Quantity
Wave (amplitude, phase, polarization),
Acoustic
Spectrum, Wave Velocity
Biological & Chemical Fluid Concentrations (Gas or Liquid)
Charge, Voltage, Current, Electric Field
Electric (amplitude, phase, polarization),Conductivity,
Permittivity
Magnetic Field (amplitude, phase, polarization),
Magnetic
Flux, Permeability
Optical Refractive Index, Reflectivity, Absorption
Temperature, Flux, Specific Heat, Thermal
Thermal
Conductivity
Position, Velocity, Acceleration, Force, Strain,
Mechanical
Stress, Pressure, Torque
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Sensor Characteristics
Transfer Function Dead Band
Span (Full-Scale Input) Resolution
Full-Scale Output Special Properties
Accuracy Output Impedance
Calibration Excitation
Calibration Error Dynamic Characteristics
Hysteresis Environmental Factors
Nonlinearity Reliability
Saturation Application Characteristics
Repeatability Uncertainty
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Sensor Selection
Purpose of the system
Specifications of the systems / Application technical / observable
and non-observable
Observable specifications include the information regarding
1.Inputs/ outputs-their type, range, format, tolerance, accuracy
etc.
2.Interface requirements esp. of importance in IoT
3.Environment of deployment
4.Form-factor, weight, etc.
Non-observable requirements include
1.Maintainability
2.Reliability
3.Portability
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Sensor Selection
1.Measurand of the sensor
what is the sensor expected to measure?
The primary or starting factor
2.Range-expected parameter ranges
3.Resolution-Granularity needed E.g. DS1620 0.5C resolution
4.Accuracy-different from resolution. Related to tolerance value
5.Environmental conditions-requires the grade of the sensor needed
6.Repeatability-How precise it is
7.Form factor-size of the sensor
E.g.: joint displacement sensors in robots
8.Cost-one of the most important consideration.
E.g.: GPS sensor on all WSN motes???
9.Weight
E.g. heavy sensor on robot’s arms
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Sensor Selection
10.Control interface needed - I2C, SPI, Serial
11.Output type – Analog / Digital / Quasi digital
Analog Sensors would require ADCs, additional h/w
12.Composition of the target - whether it is a metal or plastic or liquid
13.Sensitivity - how the o/p changes with i/p
Highly sensitive sensor-large fluctuations with small inputs sensitive
to noise also!
14.Response time - time required to observe a change corresponding to
a given input
15.Reliability - Measured in terms of probability of a failure
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Participatory Sensing (PS)
Sensing by the individuals and groups of people contributing
sensory information
PS, a process whereby individuals and communities use evermore-
capable mobile phones and cloud services
Collect and analyze systematic data
Use in discovery of new facts
The first PS projects appeared in the early 2000s and focused more
on city dweller campaigns to capture problematic situations (such as
road faults, air pollution, low-lit parts of the city), daily routines
(such as commuting by bike / car), personal individual health, or
even combinations thereof.
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Participatory Sensing (PS)
Roles, actors, engagement
There are several roles for the citizens or city authorities in a PS system.
An individual can potentially act as the Data Collector using her mobile
phone to collect sensor data. An individual or city authority can play the
role of the Collection System Operator who owns and operates the
collection system from multiple data collectors.
An Analysis Provider that processes, stores, and analyzes the collected
data can be assumed by any party (individuals, cities) that could also
prepare plans of, and execute actions based on, the conclusions of the
campaign (Action Responsible).
As a general observation, the city authorities typically assume the non-
data collector roles (Collection System Operator, the Analysis Provider,
and the Action Responsible) while the citizen’s major role is that of a
Data Collector, not excluding, however, any other combination of
assignments of roles to actors.
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Participatory Sensing (PS)
Depending on the degree of engagement of the different actors, there
are three main models of participation in a PS activity described
below:-
Collective design and investigation
In this model individual citizens design the sensing campaign,
participate in the data collection, and analyze and interpret the
collected data. Therefore, the citizens are fully empowered to
contribute to the change that they would like to see in their living
environment.
Public contribution
Individual citizens only take active participation in the data
collection phase organized by another individual or organization
(e.g. city authorities), but they don’t necessarily analyze or interpret
the results.
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Participatory Sensing (PS)
Personal use and reflection
Individual citizens monitor and record their daily lives for
themselves without any organized campaign.
A person may choose to refrain from sharing personal information
and details, or may choose to share certain specific information or
aggregation of collected information.
Therefore, the collected data are used mainly for personal reflection
or sharing and reflection within a very small and private group (e.g.
individual’s relatives).
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Participatory sensing process
During the Coordination phase the participants need to either
organize themselves, or be recruited by some other entity (e.g. city
authorities) within the context of a sensing campaign, and the
objective of the campaign needs to be communicated among all of
them.
Then the participants spend some predetermined amount of time to
capture (Capture phase) the desired sensing modalities using their
mobile phone applications or custom designed applications for the
sensing campaign.
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Participatory sensing process
The data entering a PS system does not need to originate only from the
data collectors. Several other publicly available sources, such as
weather, air quality, and traffic reports, could be used for drawing richer
conclusions.
The collected data are transferred (Transfer & Storage phase) to the data
collection system through the phone connectivity options and stored in
Internet servers (private or public). The data are then subject to pre-
processing (Process phase) so that the privacy of the data collectors is
preserved, and access control rules are added so that the data can be
accessed anytime by only authorized individuals or services.
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Participatory sensing process
The collected data are analyzed by relevant analysis tools, aggregated
(if possible), correlated with each other in order to detect patterns,
and in the end visualized for better understanding for the target group
of the campaign (Analysis and Visualization phase).
Last but not least, certain actions (Action phase) may be taken by
individuals or city authorities.
Feedback is present throughout the whole process and typically
assists the Capture phase of the processes.
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Participatory sensing process
If, for example, the captured data transfer and storage fails, then the
participant may be notified to re-transmit or re-capture the target
environment.
If Processing and Analysis and Visualization result in very little or
ambiguous information (e.g. when the processed picture has a bad
quality), or participants enter in an area of interest, then they may be
notified to (re)capture the situation if possible
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Participatory sensing Case study
In a modern developed city, people move from place to place in order
to commute to home, work, school, and extracurricular activities.
They walk, drive, or ride private or public means of transportation to
get from one point of the city to another, and their mobility is the
perfect solution that can ensure as close to complete sensing coverage
as possible.
Here bikers moving in the city (e.g. commuting between home and
work), carrying their mobile phones on themselves (Goldman 2009),
and possibly several other sensor devices on their bikes.
The bikers can have simple bikes with the only sensing device being
their mobile phone, or super-bikes equipped with sensors such as
microphones, magnetometers, GPS, CO2 meters, speedometers, etc.
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Participatory sensing Case study
The mobile phone plays the role of the sensor and the communication
device.
As bikers move in the city, all the data from the sensors are
transported to dedicated servers and stored and pre-processed.
Individuals or city authorities retrieve anonymized raw data and
analyze them as well as let automatic analysis tools produce useful
statistics.
Raw data are transformed into statistics such as preferred bike routes,
traffic problems, road faults, air quality reports, ambient noise levels,
and evening light levels, and can be correlated with map and city
infrastructure information (e.g. road intersections).
Both types of data (raw and analyzed) can be presented to individuals
or action-responsible city authorities to remedy problems or
contribute to (re) planning of the city infrastructure.
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Participatory sensing Case study
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Participatory sensing Case study
Citizen journalism
Individuals monitor, record and report their findings though social
media (e.g. blogs, twitter feeds, social networking web sites), and
typically these reports are open to the public, unlike reports that
target personal use and reflection.
Citizen Journalism is an active sensing engagement, however, the
target audience for the sensing campaign is the journalist’s own
followers / readers / viewers.
The value of these citizen journalist reports is the freshness of the
reports because the individual witnesses are on scene before any city
authorities or news correspondents arrive.
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Participatory sensing Case study
Passive participation
The behavior of citizens is captured, stored, and analyzed, with actual
citizens often unaware of the fact that their behavior data could be
used for the public or the private sector.
In such cases, the data are (or should be) anonymized, and possibly
aggregated, in order to preserve the privacy of the citizens.
Examples include traffic cameras, or electricity metering of certain
neighborhoods, or credit card transactions.
Either city authorities or private companies collect data about
people’s behavior and use them for their own purposes, such as city
planning or targeted marketing.
Therefore, the target audience for the analyzed data is not necessarily
citizens or city authorities, but also private sector employees.
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Participatory sensing Case study
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Participatory Sensing (PS)
(a) Knowledge
Individuals Data discovery
Collectors: For example Phase 5: Analytics
communication fire data, and Data Phase 6
Phase 1: Visualization
waste collection need data Applications
coordination and Services
Group Data Collectors
Phase 4:
For example traffic lights
Data Processing
sending traffic density
Network
Identification of
and parking availability Sources
data, Automobiles Phase 3:Data
of participants
communicating traffic
of PS process
density at different Phase 2: Data
locations Capture
Data
Store
Social Sites Data;Twitter,
Facebook, LinkedIn, …
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Participatory Sensing (PS)
Six Phases PS Process
Phase 1 coordination, in which the participants of PS process
organize after identifying the sources
Phase 2 & 3 data capture, communication and storage on servers or
cloud
Phases 4 & 5—PS data processing and analytics, visualisation &
knowledge discovery
Phase 6 is for initiating appropriate actions
Applications of PS
Retrieving information individual and group of people
Weather, environment information, pollution
Information for waste management, road faults
Health, traffic congestion and urban mobility
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Industrial Internet of Things (IIoT)
Bicycle Manufacturing
Sensors at each manufacturing stage communicating the information
on completion of stage
IIoT application analyses that data on completion of each activity at
each stage
Data of breakdowns, work stoppages and failures at the stages.
Bicycle Manufacturing Company Steps
Synchronises various actions to remove the bottleneck
Due to the components supply
Manufacturing stage machinery failure
Human failures
Manufacturing Process Optimisation
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Industrial Internet of Things (IIoT)
Bicycle Manufacturing
Triangular Frame Brakes and seat posts Applications
Manufacturing Crank set and saddle
Manufacturing and Services:
Process Phase 1 manufacturing
Process Phase 6 Phase 12
Process Phase 7
Knowledge
discovery
Cold working and Gears Assembly, Phase 11:
Butting; Hollow Steel derailleurs handle Attachment of
Analytics and
Tubes bars and stems wheels, tyres and
Data
Manufacturing Manufacturing tubes
Visualization
Process Phase 2 Process Phase 5 Manufacturing
Process Phase 8
Phase 10:
Welding and Joining Aligning and Final Finish Data Processing
Tubes and frame Finishing Process Manufacturing
Manufacturing Process Phase 4 Process Phase 9
Phase 3 Sensors and
Processes Data
Communication
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Industrial Internet of Things (IIoT)
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Industrial Internet of Things (IIoT)
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Automotive IoT
Enables the connected cars
Vehicles-to-infrastructure technology
Predictive and preventive maintenances and autonomous cars
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Automotive IoT
Vehicle-to-Infrastructure Technology
Alerts and warnings for forward collision
Information of blind spots
Notification about a vacant parking space
Information of congested traffic on route to destination
Stream live music and listen to the latest news
Automotive IoT technology
Useful in predictive maintenance of an automobile by a service
centre application
The sense data communicates in real-time or stores and transmit
when the automobile reaches Wi-Fi node.
The service centre application schedules maintenance alerts and
predicts the failures and alerts for the actions
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Automotive IoT : IoT phases for phases for
predictive and preventive maintenances by Service Centre
Engine control Brakes system Wipers, Window Predictive
Sensors and sensors Screen Movements, preventive and
Actuators Scheduling
CAN Bus
maintenances
Applications
Axle Movement Shockers Air-conditioning and Services
Sensors Knowledge
discovery
Predictive
Gears Assembly and Driver Acceleration CAN Bus Analytics and
Steering Sensors Sensors
Data
Visualization
CAN Bus Cloud Server
Tyre conditions Coolant
Sensors temperature and Sensors and Processes
Oil Pressure Data Communication Internet
Sensors Gateway
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Automotive IoT
Autonomous Cars
Driverless cars (also known as autonomous cars or robotic cars)
Deploying LIDAR and laser 3D imaging technology
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Actuators – Introduction
Hardware devices that translate a controller command signal into a
change in a physical parameter
Actuator
Input: control signal Output: actuation
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Internet of Things actuator applications
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Actuators: Introduction
Usually the output of the actuator is mechanical (e.g., change of
position or velocity)
Since it converts one physical quantity into an alternative form, it is
also called as transducer.
Usually, a low-level command signal activates the transducer.
Therefore to drive the actuator, an amplifier is used to provide
sufficient power.
Mechanism
Logical
Signal Signal Final
Processing & Electric/ Hydraulic / Actuation
Amplification Pneumatic Element
Actuator
Sensor
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Classification: based on controlling phenomena
Actuators
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Electrical Actuators
Converts electrical energy into mechanical energy
DC motor
Solenoid
Relay
Buzzers
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Hydraulic Actuators
Hydraulic fluid amplifies the controller command signal
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Hydraulic Power Transmission
Liquid
container
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Hydraulic Actuators
Advantages:
Disadvantages:
High cost
May have leakage issues
Low resolution
Temperature effects performance
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Pneumatic actuators
Compressed air provides driving force
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Pneumatic actuators
Advantages:
Disadvantages:
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Classification: based on operation
Actuators
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Linear actuator
Linear actuators convert
energy into straight line
motions
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Rotary actuator
Rotary actuators convert energy to provide rotary motion
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Criteria for Choosing an Actuator
Stroke Length
Speed
Accuracy
Repeatability
Resolution
Peak Force/Torque
Mounting
Temperature Range
Frequency of Operation
Operating Environment
Maintenance
Safety
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Sensor Data Communication Protocols
Advantages of Bus for Inter-devices Communication
Simplifies number of interconnections compared to direct
connections between each of them
Provides a common way (protocol) of connecting different or same
type of I/O devices
Device interfaces communicate over same set of wires
Can add new device or system’s interface that is compatible with a
system’s I/O bus
Provides flexibility, allowing a system to support many different I/O
devices depending on the needs of its users and allowing users to
change the I/O devices that are attached to a system as their needs
change
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Sensor Data Communication Protocols
Serial Bus Interface
Uses a protocol for serial-communication
Microcontroller includes interfaces for serial-communication
UART, SPI, I2C and several other protocols enable the serial-
communication
Synchronous Serial-communication
Serial data using I2C or SPI interfaces in wired bus
communication
Automotive Sensors
Communicating serial data using LIN, CAN, MOST, IEEE 1394
serial protocols
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Sensor Data Communication Protocols
UART Serial Bus
Device sends 8-bit data at successive intervals, called baud
intervals
A start bit precedes the data (characters)
Then 8-bit data
Then a stop bit is 1 for a minimum interval equal to baud Interval
10 bauds per character
Each digit or command communicates 8-bits
Each character communicates 8-bit
Coded as per the ASCII (American Standard Code for
Information Interchange) code
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Sensor Data Communication Protocols
Software Serial Library
Integrated development environment (IDE) for a microcontroller
system provides a software serial-library
A library consists of number of programs.
Software serial-library has programs for number of protocols
Distinct programs for each serial interface protocol
Enables direct use of a protocol
For example, a library-program is used for reading an RFID tag
Another used for sending data to USB port
USB port is used for onward transmission to Internet
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Thank You…
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