GUI Based Remote Control

of (Gas Reduction System)

using PIC Microcontroller

By

Essa Faiq Abdallh

Supervised by

Asst. Prof. Dr. Raghad Zuhair Yousif Professor Dr. Ayad Ghany Ismaeel

2013

Overview of Gas Reduction system

Represents a heart of the Erbil power station.

Responsible for regulating gas pressure and

temperature into desired values.

The power station uses the output of (GRS) as a fuel in

order to operate the station.

Overview of Gas Reduction system

Local Control Panel

Problems of GRS Manual Control

All operations of monitoring and controlling of GRS is handled by human.

The human driven control may include wrong decisions or late response.

The (gas reduction system) is far off from control room about (150)meter,so this distance cause a delay.

Aim of Thesis

1. Design an Automation system that Convert all the manually controlled operations of GRS machine in to computerized operations.

2. Monitoring and controlling of the GRS machine from remote location through GUI.

3. Limiting the probability of Faults and errors in the system due to human driven control.

4. Add automatic operation mode as a command Push button to the GRS machine in the GUI which allow automatic operations without human interaction.

5. Simulate the local manual control panel of GRS machine in to similar view but in software package form as a GUI for the system operator.

Continue (Aim of Thesis)

6. Prevent the human life from being in hazard in the industrial

environment.

7. Increase the accurate and quick in decision by converting

the manual operations by human into full computerize

activities.

Proposed System

Implementation Tools

Programming Language for the Embedded Software had

been written in (C Language) using MPLAB environment.

Visual Basic will be used for designing the final (GUI).

(PIC) Programmable Interface Controller to load the

final embedded software on it.

Microcontroller & Microprocessor

(PIC) Microcontroller

A (PIC) is A Programmable Interface Controller.

A (PIC) is a Production of Microchip Technology.

A (PIC) widely Used in our live aspect like mobiles,

plants, calculators and industrial robots.

Architecture of the PIC

Harvard VS Von-Neumann’s

PIC 3 Families

Internal PIC Memory Symbol

PIC 16 C XXX (Mean EPROM)

PIC 16 CR XXX (Mean ROM)

PIC 16 F XXX (Mean FLASH MEMORY)

Selected PIC16F877A

Features of PIC16F877A

It’s Content (40 pin) For I/P & O/P divide in to five PORTS (A, B, C, D, E) each port contain 8-Pins .

The type of Flash Memory Which Rewritable For many Times.

Can program by using C- Language.

Available in the local market .

Deals With Analog and digital inputs.

Proposed System Diagram

Communication between PIC

and PC is a serial port (RS232)

Data Exchange between PIC &

External word through RS232

Each signal has 8 data bits

Each signal has Start & Stop bit = 0

Loading the

Embedded S/W to

the PIC flash

memory through

USB cable

Connect the PIC

with GRS machine

through RS232

Functions of EasyPIC6 Board Kit

for PIC

System Design Specification

Collect all Design Related information

Design Proposal Hardware Components

Design Proposal Software Components

All H/W Components

considered (Review)

All S/W Components

considered (Review)

Integrate H/W & S/W Prototype

Implement the Final Integration System

N

N

Y

Y

Start

End

Flow chart of

generic S/W & H/W

Design

Mapping GRS (Input & Output)

signals to PIC Pins No.

#

(PIC)

Pins Label Indication Type Description

1 RA0 LED1 Fault Digital in CIRCULATION PUMP OVERLOAD

2 RA1 LED2 Run OK Digital in CIRCULATION PUMP IN OPERATION

3 RA2 LED4A Run Digital in IGNITION GAS

4 RA3 LED4B Fault Digital in LEAKAGE ALARM GAS VALVE

5 RA4 LED4 Fault Digital in BURNER MOTOR OVERLOAD

6 RA5 LED5 Run Digital in BURNER START

7 RB0 LED6 Fault Digital in BURNER DISTURB

8 RB1 LED7 Run Digital in BURNER IN OPERATION

9 RB2 LED15 Fault Digital in LSA- 00EKT21CL081

10 RB3 LED16 Fault Digital in PSA- 00EKT21CP083

11 RB4 LED17 Fault Digital in PSA+ 00EKT21CP082

12 RB5 LED18 Fault Digital in SAFETY CIRCUIT BURNER CONTROL

13 RB6 LED20 Fault Digital in LOW GAS PRESSURE

14 RB7 LED21 Fault Digital in TS+ 00EKT21CT081

15 RE0 LED22 Fault Digital in TA+ 00EKT21CT082

16 RC0 SWITCH3 SELECTOR Digital out SELECTOR SWITCH LOCAL/REMOTE

17 RC1

18 RC2 Buttom8 start Digital out BURNER START LOCAL

19 RC3 Buttom9 stop Digital out BURNER STOP LOCAL

20 RC4

RESET

Buttom10 RESET Digital out RESET BURNER CONTROL

21 RC5 SWITCH11 SELECTOR Digital out BURNER OPERATION LOCAL REMOTE

22 RC6

23 RC7 Buttom13 TEST Digital out TEST FLAME DETECTOR

24 RD0

SWITCH14 SELECTOR Digital out BURNER OPERATION MODE 25 RD1

26 RD2

27 RD3 Buttom19 RESET Digital out ALARM RECEIPT

28 RD4 Buttom23 TEST Digital out TEST TA+ 00EKT21CT082

29 RD5 Buttom25 TEST Digital out LAMP TEST

30 RD6 SWITCH26

EMERGENC

Y STOP Digital out EMERGENCY STOP

Dual Software levels

(Dual Programming Techniques)

First :- C- Language

using (MPLAB) for

programming (PIC) as

( Embedded S/W)

Second :- VISUAL

BASIC for designing

the final GUI as a

(PC Software)

Identifying ASCII Code Character

for each Input/output

Each input and output signal from the GRS machine

will named and identify as a special ASCII code character in order to recognize each signal alone.

Hardware Design Implementation

Input break down Circuit (24-5)VDC

(zener diode)

Output Switching Circuit (Relay)

Hardware & Embedded Software

Final Package

S/W and H/W Design

Remote access Via IP Network

& HTML page

The aim IP network

to enable GRS to be

remote controlling

& monitoring

HTML page

developed for

remote access

through Hyper links

Final System Design Algorithm

Initialize Initialize:

Selecting the Programmable Interface Controller = PIC16F877A

Define the Header file for the "PIC16F877A"

Set frequency of Crystal Clock oscillator = 8000000 Hz

Enable Interrupts ( )

Define the (PIC) used Pins:

Define Pins A0-A7

Define Pins B0-B7

Define Pins C0-C7

Define Pins D0-D7

Define Pins E0-E2

Input: A (A0-A5) Read the input signals from GRS to port A of PIC.

B (B0-B7) Read the input signals from GRS to Port B of PIC.

E (E0) Read the input signals from GRS to pin E0 of PIC.

Output: C (C0-C7) Activate Pins of PIC as output Instructions to GRS.

D (D0-D6) Activate Pins of PIC as output Instructions to GRS.

Continue Algorithm

Read Inputs Begin

Set up baud rate speed = 9600/bps for RS232 port

again While there is an input signals from GRS do

If input signal = logic 1

Then

identify the logic 1 signal in to ASCII code character

send the ASCII code Character via RS232 port and

display it on GUI

Read new input signal from GRS

Else

send the (ASCII+1)mode 26 via RS232 port and

display it on GUI

Read new input signal from GRS

Continue Algorithm

Send Outputs Commands

pushbuttons While there is an output signals command instruction from GUI do

If send output signal ASCII from GUI via RS232 port = logic1

Then

Comparing ASCII which send with previous identified ASCII

If both ASCII are matched

Then

Send Output PIC command through output pins and switch ON a specific relay

Else Send Output PIC command through output pins and switch OFF a specific relay

End while

Continue Algorithm

"Auto Operations Mode"

If "Auto Operations Mode" selected

Then

Read fault input signals

Reset all GRS fault by activate output relays

Start GRS system with automatic mode

End while

Return again

End

Previous GRS and Current

Status after Developing the GUI

Results

A real operation and testing results for proposed remote controller based on PIC microcontroller with graphical user interface.

The final proposal design (H/W and S/W) is connected with a real GRS machine at Erbil power station.

The GRS successfully responds to all alarm and signals through proposed design.

The ASCII code which assigns to the input or output signals given for each control has been tested by using (oscilloscope) waveform plotter.

Result of output commands &

Input Signals waveform

char. Signal ASCII Binary

a O/P 97 1100001

char. Signal ASCII Binary

z I/P 122 1111010

Result of Proving the computerize

and automatic operation of GRS

The proving stage is done by connecting the final proposal GUI Design with H/W and S/W components to the real GRS machine, the machine successfully started through the final GUI with high efficiency ,accurate and quick response time.

Result of Proving the GRS

Operation Performed Remotely

Two PCs are connected through bus LAN IP network one PC

at the GRS machine and the other in the remote location to allow access from remote location.

IP of remote PC

192.168.10.10

Result of operating of GRS

through GUI from remote location

In the final GUI there are two new push buttons added ,the first is

called (Auto operation system mode) which allows a full computerized automatic system mode selection and operation, a second new push button is called (general reset) which allows resetting

1. This thesis presents a dual software programming techniques

that are an embedded software which used for programming and

loading the C-language program to the PIC microcontroller ,while

the other software programming techniques is designing special

graphical user interface (GUI) by using Visual Basic as an

interfacing media between the human and the machine.

2. An embedded system is regarded as a product which contains a

microprocessor programmed to carry out some control functions

which works as a complete computer system.

3. The proposed system contain both of hardware and software

components were implemented and integrated as a complete

compatible system.

4. GUI using the Visual Basic program, performed excellently in

transmitting & receiving data to& from PIC through (RS232) port.

Conclusions

Continue Conclusions

5. The operation and monitoring of the GRS machine huddle and enhance by utilizing the features of (PIC16F877A) microcontroller, which create a better solution for the GRS problems.

6. The PIC microcontroller has been used in this thesis due to its low cost , availability in local market, low power consumption, and easy to program using C-Language .

7. A remote controlling machines via GUI is located on the devices which required a control and observation by the operator from time to time , also if the process control contains hazardous environment for doing some jobs like (power plants, chemical factories).

8. Today, most new technology products consist of a mixture of hardware and software components