Leveraging Arduino and Nordic Development Kits for Advanced Manufacturing Challenges
Using a Nordic or Arduino Development Kit for Smart Manufacturing
Smart manufacturing integrates IoT (Internet of Things) technologies to enhance production efficiency, quality control, and operational oversight. Here's how you can leverage a Nordic Semiconductor or Arduino development kit in this context:
Example: Real-Time Monitoring of Production Line Equipment with Arduino
Objective: To monitor the condition of critical machinery on a production line in real-time, alerting maintenance teams to potential issues before they lead to downtime.
Setup with Arduino:
Hardware Selection:
Arduino Board: Choose a robust Arduino board like the Arduino Mega or Arduino MKR series for multiple sensor connections.
Sensors:
Temperature Sensor: DS18B20 to monitor machine temperatures.
Vibration Sensor: ADXL345 for detecting anomalies in machine operation.
Current Sensor: ACS712 for monitoring energy consumption or detecting electrical issues.
Integration:
Connect the sensors to the Arduino board. For instance, temperature sensors can use the 1-Wire protocol, while vibration sensors might connect via I2C.
Software:
Write code to read sensor data:
This code snippet reads temperature and vibration data, which can be crucial for predictive maintenance.
Data Transmission:
Use an Arduino WiFi module or Ethernet shield to send data to a central server or cloud platform. Alternatively, for local networks, use serial communication to a local PC.
Alert System:
Implement logic within the Arduino code or on a connected server to analyze data and trigger alerts via text message, email, or even directly interfacing with factory systems for immediate action.
User Interface:
Develop a dashboard using platforms like Arduino Cloud, Node-RED, or custom web applications where real-time data can be visualized, and historical trends analyzed.
#include <OneWire.h>
#include <DallasTemperature.h>
#include <Wire.h>
#include <ADXL345.h>
// Initialize sensors
OneWire oneWire(2); // Pin for temperature sensor
DallasTemperature sensors(&oneWire);
ADXL345 adxl; // Acceleration sensor
void setup() {
Serial.begin(9600);
sensors.begin();
adxl.powerOn();
}
void loop() {
sensors.requestTemperatures();
float tempC = sensors.getTempCByIndex(0);
int x, y, z;
adxl.getAcceleration(&x, &y, &z);
Serial.print("Temperature: ");
Serial.print(tempC);
Serial.print("C, Vibration X: ");
Serial.print(x);
Serial.print(", Y: ");
Serial.print(y);
Serial.print(", Z: ");
Serial.println(z);
delay(1000); // Delay for stability
}
Benefits:
Predictive Maintenance: By continuously monitoring equipment conditions, you can predict when maintenance is needed, reducing unplanned downtime.
Efficiency: Real-time data can optimize machine operation or energy use.
Quality Control: Monitoring can help in maintaining consistent product quality by ensuring machines operate within optimal parameters.
Example: Using Nordic nRF52 for Wireless Sensor Network in Manufacturing
Objective: Implement a wireless sensor network to monitor multiple points across a large manufacturing floor without the need for extensive cabling.
Setup with Nordic nRF52:
Nordic nRF52840 DK: This kit supports Bluetooth Low Energy (BLE), which is ideal for low-power, low-cost sensor networks.
Sensors: Similar to Arduino, but with an emphasis on BLE-compatible sensors or modules that can interface with the nRF52.
Software:
Utilize the nRF5 SDK or the Arduino IDE with the Nordic nRF52 board support for programming.
Implement BLE mesh networking for a robust, wide-area sensor network:
This code snippet is meant to serve as an example of how to use Bluefruit with nRF SDK
Mesh Networking: Use BLE mesh to create a network where sensors communicate with each other, relaying information to a central gateway or directly to maintenance devices.
Data Collection and Analysis: Implement a BLE gateway or use existing smartphones/tablets for data collection, which can then be analyzed on cloud platforms for insights.
#include <bluefruit.h>
void setup() {
Bluefruit.begin();
Bluefruit.setTxPower(4); // Set max power for better range
Bluefruit.setName("Manufacturing-Sensor");
Bluefruit.Periph.setConnInterval(6, 12); // 7.5-15 ms
// Setup the Advertising Packet
Bluefruit.Advertising.addFlags(BLE_GAP_ADV_FLAGS_LE_ONLY_GENERAL_DISC_MODE);
Bluefruit.Advertising.addTxPower();
Bluefruit.Advertising.addName();
Bluefruit.Advertising.restartOnDisconnect(true);
Bluefruit.Advertising.setInterval(32, 244); // in unit of 0.625 ms
Bluefruit.Advertising.setFastTimeout(30); // number of seconds in fast mode
Bluefruit.Advertising.start(0); // 0 = Don't stop advertising after n seconds
}
void loop() {
// Your sensor reading and BLE transmission code here
}
Benefits of using Nordic in your build:
Scalability: Easily add or remove sensors without significant infrastructure changes.
Flexibility: Can cover large areas with less power consumption compared to traditional wireless solutions.
Cost-Effective: Reduces the need for extensive wiring, lowering installation costs.
Both examples illustrate how these development kits can be pivotal in modernizing manufacturing processes, offering real-time insights and enabling proactive maintenance strategies.
Once established on a development kit, consider creating custom PCBs depending on the scope of the project. For more information on transitioning from a development kit to a custom PCB, check out this article here.
Sources
https://rutronik-tec.com/single-board-arduino-uno-shield-compatible-dev-kit-from-nordic-semiconductor-supports-bluetooth-smart-ant-and-2-4ghz-designs/
https://www.arduino.cc/en/Guide/ArduinoPrimo/
https://www.digikey.com/en/product-highlight/n/nordic-semi/nrf52840-pdk-development-kit-for-nrf52840-soc
https://audioxpress.com/news/nordic-semiconductor-shows-development-kit-and-other-solutions-for-bluetooth-5-implementation