Real Time Production Monitoring Using Sensors

Abstract- The objective of the paper is production monitoring using sensors [HMDs], PLC and Client-Server programs. This has been practically implemented in the wire rod mill, Bhilai Steel Plant [SAIL]. Earlier the mill condition was only known to the persons on shop floor. The data from HMDs are processed and shown in mimics in real time so that any interested person can observe the real time rolling condition of the mill. The metal presence is each strand is sensed by a series of hot metal detectors [sensors], which are located at various points along the rolling line. Based on the metal presence, Digital Inputs of PLC have been taken. As the metal crosses these HMDs, DI of PLC becomes high and sets the PLC coil. The parameters value will be available in a PLC (programmable Logic Controller).An OPC server will communicate with the PLC to fetch the data and store with its database. The OPC server sends the data to OPC clients continuously whenever any PLC data changes. These data are processed and show in mimics in real time. The Mimic softwares (OPC clients) are written in Visual Basic. I