Real-Time-Monitoring-Transformers

✅ Step 1: Define the System Components and Architecture

1.1 System Overview:

A Real-Time Transformer Monitoring System (RT-TMS) will consist of the following key modules:

  • Sensors: For measuring parameters such as temperature, current, voltage, oil level, and vibrations.

  • Microcontroller/Processor: To collect data from sensors and transmit it to a central server.

  • Communication Module: For data transmission (e.g., GSM, LoRa, Wi-Fi).

  • Data Processing Unit: Cloud-based server or local server for data processing and analysis.

  • Monitoring Dashboard: User interface for real-time data visualization.

  • Power Supply Unit: To power the entire system, possibly with solar backup.

  • Data Storage: Local storage (SD card) and remote storage (cloud).

✅ Step 2: Detailed Circuit Diagram and Schematic Design

We will need the following circuits:

2.1 Sensor Module Circuit:

  • Sensors to Include:

    • Temperature Sensor (e.g., PT100, LM35, DS18B20)

    • Current Transformer (CT) for current measurement

    • Voltage Divider Network for voltage measurement

    • Oil Level Sensor (ultrasonic or capacitive)

    • Vibration Sensor (accelerometer, e.g., ADXL335)

  • Microcontroller:

    • ESP32 or Arduino Mega (ESP32 is preferable for Wi-Fi and Bluetooth capability)

  • Circuit Design:

    • Multiplexers for handling multiple sensor inputs.

    • Signal conditioning circuits (e.g., amplifiers, filters).

    • Analog-to-Digital Converter (ADC) for sensors providing analog output.

2.2 Data Acquisition and Communication Module:

  • Microcontroller:

    • ESP32 for integrated Wi-Fi and Bluetooth.

    • GSM Module (e.g., SIM800L) for remote areas without Wi-Fi.

  • Communication Protocols:

    • SPI/I2C for sensor data transmission to the microcontroller.

    • MQTT or HTTP for data transmission to the server.

2.3 Power Supply Unit:

  • Power Source:

    • 5V/3.3V DC power supply (with voltage regulators)

    • Solar Panel + Battery Backup (for off-grid locations)

  • Power Circuit:

    • Step-down converter (e.g., LM2596) for 12V to 5V conversion.

    • Battery Management System (BMS) for solar power regulation.

✅ Step 3: Schematics and Circuit Diagrams

  1. Sensor Module Schematic: Showing temperature, current, voltage, oil level, and vibration sensors connected to the microcontroller.

  2. Power Supply Circuit: Solar panel, battery management, and power regulation.

  3. Data Transmission Circuit: ESP32/GSM module connections.

  4. Central Monitoring Unit (CMU): Data acquisition and transmission to cloud/local server.

✅ Plan of Action:

  1. Generate All Necessary Diagrams First:

    • Sensor Module Schematic

    • Power Supply Circuit

    • Data Transmission Circuit (ESP32/GSM/LoRa)

    • Central Monitoring Unit (CMU) Schematic

    • Complete System Block Diagram (integrating all modules)

  2. Detailed Step-by-Step Implementation and Simulation Guide:

    • Software Selection: KiCad, Fritzing, LTspice, or EasyEDA — all suitable for Arch Linux.

    • Installation Instructions: Detailed setup for each recommended tool.

    • Simulation Steps: Testing sensor circuits, data communication, and power regulation.

    • Data Visualization and Monitoring Setup: Real-time monitoring using MQTT Dash, Node-RED, or a custom dashboard.

    • Testing and Debugging: Fault injection and response analysis.

✅ Proceeding with Diagrams Generation:

I will now proceed with generating the first diagram:

  1. Sensor Module Schematic.

After that, I will proceed sequentially with the other diagrams. Once all diagrams are ready, I will provide a comprehensive step-by-step implementation and simulation guide.

Starting with the Sensor Module Schematic now. 👍👍 ![[Pasted image 20250509004747.png]]

Proceeding with the next diagram: Power Supply Circuit. Generating it now. 👍👍😊

![[Pasted image 20250509004809.png]]

Proceeding with the next diagram: Data Transmission Circuit (ESP32/GSM/LoRa). Generating it now. 👍👍😊

![[Pasted image 20250509004825.png]]

Proceeding with the next diagram: Central Monitoring Unit (CMU) Schematic. Generating it now. 👍👍😊

![[Pasted image 20250509004848.png]]

Complete System Block Diagram (integrating all modules) ![[Pasted image 20250509004912.png]]

✅ Step-by-Step Implementation and Simulation Guide

1. Required Software and Tools Setup (on Arch Linux):

  1. KiCad:

    • Install: sudo pacman -S kicad

    • Use for PCB design, circuit schematics, and simulation.

  2. Fritzing: (For simple breadboard schematics and prototyping) sudo pacman -S fritzing

  3. Arduino IDE: sudo pacman -S arduino

    • ESP32 board library installation:

      • Open Arduino IDE → Preferences → Additional Board Manager URLs: https://dl.espressif.com/dl/package_esp32_index.json

      • Go to Tools → Board → Board Manager → Install ESP32 library.

  4. PlatformIO:

    • Advanced alternative to Arduino IDE for debugging and version control. pip install platformio

  5. LTspice / Ngspice: (For analog and digital circuit simulations)

    • Install Ngspice: sudo pacman -S ngspice

  6. Mosquitto (MQTT Broker):

sudo pacman -S mosquitto 
sudo systemctl enable mosquitto 
sudo systemctl start mosquitto

  1. Node-RED:

    • Install Node.js and npm: sudo pacman -S nodejs npm

    • Install Node-RED: sudo npm install -g --unsafe-perm node-red

2. Hardware Component List and Specifications:

  1. ESP32 Development Board

    • 3.3V Logic, 12-bit ADC, Wi-Fi/Bluetooth connectivity.

  2. Sensors:

    • DHT22 - Temperature and Humidity Sensor.

    • ZMPT101B - Voltage Sensor.

    • ULN2003A - Oil Level Sensor (custom float switch or ultrasonic sensor).

    • Current Sensor (ACS712) - Current measurement.

  3. Communication Modules:

    • SIM800L GSM Module (for cellular communication).

    • LoRa Module (SX1278) (for long-range data transmission).

  4. Power Supply:

    • 12V Battery.

    • Buck Converter (12V to 3.3V/5V).

    • LM2596 Voltage Regulator.

  5. Central Monitoring Unit (CMU):

    • Another ESP32 or Raspberry Pi (for centralized processing and data storage).

  6. Data Storage and Display:

    • MicroSD Module.

    • LCD Display (I2C, 16x2).

  7. Connectors, PCB, Breadboard, Jumpers, etc.

3. Implementation Workflow:

3.1 Sensor Module:

  • Objective: Acquire data from sensors and transmit to ESP32 for processing.

  • Connections:

    • DHT22 → ESP32 GPIO 21 (Data)

    • ZMPT101B → ESP32 ADC Pin 36 (Analog Voltage Input)

    • ACS712 → ESP32 ADC Pin 39 (Analog Current Input)

    • Oil Level Sensor → GPIO 22 (Digital Input)

  • Code Implementation (ESP32):

#include <DHT.h> 
#include <Wire.h> 
#include <WiFi.h> 
#include <PubSubClient.h>  
#define DHTPIN 21 
#define DHTTYPE DHT22 
#define VOLTAGE_PIN 36 
#define CURRENT_PIN 39 
#define OIL_SENSOR_PIN 22  
DHT dht(DHTPIN, DHTTYPE);  
const char* ssid = "YOUR_SSID"; 
const char* password = "YOUR_PASSWORD"; 
const char* mqtt_server = "192.168.1.100";  
WiFiClient espClient; 
PubSubClient client(espClient);  

void setup(){   
	Serial.begin(115200);   
	dht.begin();   
	pinMode(OIL_SENSOR_PIN, INPUT);      
	WiFi.begin(ssid, password);   
	while (WiFi.status() != WL_CONNECTED){     
		delay(1000);     
		Serial.println("Connecting to WiFi...");   
	}    
	client.setServer(mqtt_server, 1883); 
}  

void loop(){   
	float temp = dht.readTemperature();   
	float humidity = dht.readHumidity();   
	int voltage = analogRead(VOLTAGE_PIN);   
	int current = analogRead(CURRENT_PIN);   
	bool oilStatus = digitalRead(OIL_SENSOR_PIN);    
	String data = String(temp) + "," + String(humidity) + "," + String(voltage) +       "," + String(current) + "," + String(oilStatus);
	client.publish("transformer/data", data.c_str());      
	delay(2000); 
}

  • Simulate in Fritzing:

    • Create a breadboard layout.

    • Include ESP32, sensors, and power supply.

    • Test sensor data transmission via the serial monitor.

3.2 Data Transmission Circuit:

  • Objective: Reliable communication via GSM and LoRa modules.

  • Connections:

    • SIM800L TX → ESP32 RX (3.3V Logic Level Shifter)

    • SIM800L RX → ESP32 TX

    • LoRa TX → ESP32 RX2

    • LoRa RX → ESP32 TX2

  • Code Implementation:

    • Add GSM and LoRa libraries.

    • Implement fallback communication logic — prioritize GSM over LoRa in case of LoRa transmission failure.

3.3 Power Supply Design:

  • Objective: Efficient power management and battery backup for field devices.

  • Circuit Design:

    • 12V Battery → LM2596 Buck Converter (5V)

    • 5V → ESP32 Vin, SIM800L Vcc, LoRa Vcc

    • Monitor battery voltage using a voltage divider circuit.

  • Simulation in LTspice/Ngspice:

    • Simulate power supply fluctuations.

    • Analyze current draw under different operating conditions (normal, transmission, low-power mode).

3.4 Central Monitoring Unit (CMU):

  • Objective: Collect, process, and display data from multiple transformers.

  • Modules:

    • ESP32, LCD Display, MicroSD Module, Wi-Fi module.

  • Data Processing Implementation:

import paho.mqtt.client as mqtt 

def on_message(client, userdata, message):     
	data = str(message.payload.decode("utf-8"))     
	print(f"Data Received: {data}")    
	with open("data_log.csv", "a") as file:         
		file.write(data + "\n")  
	client = mqtt.Client() 
	client.connect("192.168.1.100", 1883, 60) 
	client.subscribe("transformer/data") 
	client.on_message = on_message client.loop_forever()

4. Testing and Fault Injection:

  • Testing:

    • Simulate temperature spikes, overvoltage, and oil level drops.

    • Monitor response time and data accuracy in CMU.

    • Test transmission stability under poor signal conditions.

  • Fault Injection Plan:

    • Disconnect sensors one by one to observe CMU responses.

    • Introduce false data through UART to validate data integrity checks.

    • Simulate power interruptions to test power management.

5. Data Visualization and Dashboard Setup:

  • Node-RED Setup:

    • Configure MQTT nodes to receive data.

    • Display temperature, voltage, current, and oil level in real-time graphs.

  • Database and Analysis:

    • Store data in SQLite or InfluxDB for further analysis.

  • Dashboard Deployment:

    • Integrate Node-RED with Grafana for more advanced visualizations and alert configurations.

This setup plan is comprehensive. Would you like me to proceed with individual module testing procedures or provide the complete system integration and debugging plan? 👍👍🙂

Let’s proceed with a detailed Fritzing guide using the SparkFun ESP8266 Thing, as it’s a well-documented and widely used module.

✅ Step-by-Step Guide to Creating a Breadboard Schematic in Fritzing with SparkFun ESP8266 Thing

1. Setting Up Fritzing and Importing Parts:

  1. Open Fritzing:

    • Launch Fritzing from your applications menu or terminal using: fritzing

  2. Check Existing Parts Library:

    • Go to Parts Library (left sidebar).

    • Search for ESP8266.

    • If SparkFun ESP8266 Thing is not present, proceed to the next step.

  3. Import SparkFun ESP8266 Thing Part:

    • Download the Fritzing part from SparkFun’s official repository or a Fritzing parts site.

    • Go to File → Open and navigate to the downloaded .fzpz file.

    • The part will now appear in the My Parts bin.

2. Basic Breadboard Setup:

  1. New Project:

    • Go to File → New to create a new project.

  2. Add Breadboard:

    • In the Parts Library, search for Breadboard and drag it onto the workspace.

    • Resize and position it for clarity.

  3. Add the SparkFun ESP8266 Thing:

    • From My Parts, drag the SparkFun ESP8266 Thing onto the breadboard.

    • Align the pins with the breadboard rails for easy wiring.

3. Component Connections:

3.1 Power Supply:

  • Connect a 5V/3.3V power supply module to the power rails of the breadboard.

  • Wire the VCC pin of the ESP8266 Thing to the 3.3V rail.

  • Connect the GND pin to the ground rail.

3.2 DHT22 Temperature Sensor:

  • DHT22 Pins:

    • VCC → 3.3V rail

    • GND → Ground rail

    • Data → GPIO 4 (D2 pin on ESP8266)

    • 10kΩ pull-up resistor between VCC and Data pin.

3.3 Voltage Divider for Battery Monitoring:

  • Components: 10kΩ and 4.7kΩ resistors.

  • Voltage divider circuit:

    • VCC (Battery +) → 10kΩ Resistor → Analog Pin A0

    • A0 → 4.7kΩ Resistor → GND

3.4 Current Sensor (ACS712):

  • ACS712 Pins:

    • VCC → 3.3V rail

    • GND → Ground rail

    • OUT → Analog Pin A0

3.5 Oil Level Sensor:

  • Use a simple float switch or ultrasonic sensor.

  • VCC → 3.3V

  • GND → Ground

  • Signal → GPIO 13 (D7 pin on ESP8266)

4. Fritzing Connections and Layout:

  1. Wire Connections:

    • Use colored wires to maintain clarity:

      • Red for VCC

      • Black for GND

      • Yellow for Data/Signal Lines

  2. Label Connections:

    • Right-click on each wire and select Label to clearly indicate sensor names and GPIO pins.

  3. Adjust Breadboard Layout:

    • Ensure that components are spaced logically to avoid wire clutter.

    • Organize power rails to clearly indicate 3.3V and GND.

5. Simulating and Debugging:

  • Fritzing itself does not support full electrical simulation but provides a clear visual layout.

  • For functional testing, proceed to Arduino IDE or PlatformIO with the actual hardware setup.

  • Verify power connections using a multimeter to prevent accidental shorts or over-voltage.

6. Exporting Schematic and PCB Layout:

  • Once the breadboard is complete, switch to the Schematic View and adjust connections as needed.

  • To export the schematic as a PNG or PDF, go to File → Export → As Image.

  • If proceeding to PCB design, switch to the PCB View, align components, and route connections.

Proceeding with the step-by-step Fritzing breadboard layout diagram for the setup.

✅ Step-by-Step Fritzing Breadboard Layout Diagram

Overview:

We are setting up a simple breadboard schematic that includes:

  1. SparkFun ESP8266 Thing

  2. DHT22 Temperature Sensor

  3. ACS712 Current Sensor

  4. Oil Level Sensor (using a float switch or ultrasonic sensor)

  5. Voltage Divider Circuit for Battery Monitoring

  6. Power Supply Rails (3.3V and GND)

Step 1: Preparing the Workspace

  1. Open Fritzing: fritzing

    • Go to File → New to start a new project.

  2. Set Grid and Layout:

    • Ensure the grid is enabled for precise component placement:

      • View → Set Grid Size → 0.1 inch.

Step 2: Adding Components

  1. Breadboard:

    • Go to the Core Parts Library.

    • Drag the Half-Size Breadboard onto the workspace.

  2. Power Supply Rails:

    • Connect the breadboard’s + rail to 3.3V and - rail to GND.

    • Use red wires for VCC and black for GND.

Step 3: Adding the SparkFun ESP8266 Thing

  1. Locate the Part:

    • If not present, import the part as a .fzpz file.

    • Drag the SparkFun ESP8266 Thing onto the breadboard.

    • Align it with a section of the breadboard to avoid excessive wire crossings.

  2. Power and GND Connections:

    • VCC → 3.3V rail

    • GND → GND rail

Step 4: DHT22 Temperature Sensor Wiring

  1. Place the DHT22 Sensor:

    • Place it to the right of the ESP8266 on the breadboard.

    • Pin Order (from left to right): VCC, Data, NC, GND

  2. Connections:

    • VCC → 3.3V rail (Red wire)

    • GND → GND rail (Black wire)

    • Data → GPIO 4 (D2 on SparkFun ESP8266) (Yellow wire)

    • Place a 10kΩ pull-up resistor between VCC and Data pin.

Step 5: ACS712 Current Sensor Wiring

  1. Place the ACS712:

    • Position it to the left of the ESP8266.

  2. Connections:

    • VCC → 3.3V rail

    • GND → GND rail

    • OUT → A0 pin (Blue wire)

Step 6: Oil Level Sensor Wiring

  1. Place the Oil Level Sensor:

    • Use a basic float switch or ultrasonic sensor.

    • Position it at the bottom left.

  2. Connections:

    • VCC → 3.3V rail

    • GND → GND rail

    • Signal → GPIO 13 (D7 pin on ESP8266)

Step 7: Voltage Divider Circuit for Battery Monitoring

  1. Components:

    • 10kΩ Resistor (R1)

    • 4.7kΩ Resistor (R2)

  2. Connections:

    • VCC (Battery +) → R1 → Analog Pin A0

    • A0 → R2 → GND

Step 8: Adjusting Layout for Clarity

  • Rearrange wires to maintain a clear path from components to the ESP8266.

  • Label each wire to indicate its function (VCC, GND, Data, Signal, etc.).

  • Adjust wire colors for consistency:

    • Red: VCC

    • Black: GND

    • Yellow: Data/Signal

    • Blue: Analog Signal

Step 9: Save and Export

  • Save the Project:

    • Go to File → Save As and name the project RT_Transformer_Monitoring.fzz.

  • Export the Diagram:

    • Go to File → Export → As Image (PNG).

    • Select Breadboard View to export the complete layout.

✅ Detailed Step-by-Step Implementation in Fritzing

1. Launch Fritzing and Set Up the Workspace

  • Open Fritzing from your terminal or applications menu.

  • Start a New Project:

    • Go to File → New.

    • Save the project as RT_Transformer_Monitoring.fzz.

2. Add the Breadboard

  • In the Core Parts Library, locate the Half-Size Breadboard.

  • Drag and drop the breadboard onto the workspace.

  • Ensure the breadboard is horizontally aligned for clarity.

3. Add the SparkFun ESP8266 Thing

  1. Search for ESP8266 in My Parts or Core Parts:

    • If not found, download and import the .fzpz file for the SparkFun ESP8266 Thing.

    • Go to File → Open and navigate to the downloaded .fzpz file.

  2. Placement:

    • Position the ESP8266 module vertically, aligning the VCC and GND pins to the power rails.

    • Ensure there is enough space on the breadboard for other components.

4. Wiring the Power Rails

  • Power Connections:

    • Connect the + rail to 3.3V on the ESP8266 using a red wire.

    • Connect the - rail to GND on the ESP8266 using a black wire.

  • Additional GND Pins:

    • The ESP8266 Thing has multiple GND pins; connect one GND pin to the ground rail to provide a common ground.

5. Adding the DHT22 Temperature Sensor

  1. Search for DHT22 in the Parts Library:

    • If not available, import the .fzpz file for the DHT22 sensor.

  2. Place the DHT22 to the Right of the ESP8266:

    • Align it with the breadboard’s power rails.

  3. Wiring the DHT22:

    • VCC Pin: Connect to the 3.3V rail (red wire).

    • GND Pin: Connect to the GND rail (black wire).

    • DATA Pin: Connect to GPIO 4 (D2) on the ESP8266 (yellow wire).

    • 10kΩ Pull-Up Resistor:

      • Connect between VCC and DATA pin.

6. Adding the ACS712 Current Sensor

  1. Search for ACS712 in the Parts Library:

    • If not available, we can use a generic 3-pin sensor module and label it as ACS712.

  2. Place the ACS712 on the Breadboard:

    • Position it to the left of the ESP8266 for logical wiring.

  3. Wiring the ACS712:

    • VCC Pin: Connect to the 3.3V rail.

    • GND Pin: Connect to the GND rail.

    • OUT Pin: Connect to A0 (ADC Pin) on the ESP8266 (blue wire).

7. Adding the Oil Level Sensor

  1. Select a Generic Sensor Module:

    • If using a float switch, use a 2-pin sensor module.

    • If using an ultrasonic sensor, use a 4-pin sensor module.

  2. Place the Sensor Module on the Breadboard:

    • Position it at the bottom left.

  3. Wiring the Oil Level Sensor:

    • VCC Pin: Connect to the 3.3V rail.

    • GND Pin: Connect to the GND rail.

    • Signal Pin: Connect to GPIO 13 (D7) on the ESP8266 (green wire).

8. Adding the Voltage Divider for Battery Monitoring

  1. Add 10kΩ and 4.7kΩ Resistors:

    • Place them vertically on the breadboard.

  2. Wiring the Voltage Divider:

    • VCC (Battery +): Connect to one end of the 10kΩ resistor.

    • A0 Pin: Connect to the junction between the 10kΩ and 4.7kΩ resistors.

    • 4.7kΩ Resistor: Connect the other end to the GND rail.

9. Organizing the Layout and Labeling Connections

  • Wire Management:

    • Keep the wires as short as possible to maintain clarity.

    • Use distinct colors for each connection type:

      • Power (VCC): Red

      • GND: Black

      • Data/Signal: Yellow

      • Analog Signal: Blue

      • Control Pins: Green

  • Label Connections:

    • Right-click each wire and select Label to indicate its function, e.g., DHT22 DATA → GPIO 4 (D2).

10. Reviewing the Layout and Saving the Project

  • Double-Check Wiring:

    • Verify each connection against the step-by-step instructions to ensure accuracy.

  • Save the Project:

    • Go to File → Save.

    • Name the project RT_Transformer_Monitoring_Breadboard.fzz.

  • Export the Diagram as PNG:

    • Go to File → Export → As Image (PNG).

    • Choose Breadboard View to export the complete layout.

Implementation Checkpoints:

  • ✅ All sensors are connected and properly labeled.

  • ✅ Voltage divider circuit is correctly implemented.

  • ✅ Power and ground rails are consistently wired.

  • ✅ ESP8266 pin connections are accurate and clearly labeled.

Would you like to proceed with the next step, which involves testing and debugging the circuit in Fritzing and preparing for Arduino IDE coding? 👍🙂

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