In modern industrial plants, real-time monitoring of utility systems like compressed air is essential for reliability, efficiency, and safety. In this project, we developed an Arduino-based remote monitoring system with a Visual Basic (VB) graphical user interface (GUI) to supervise an air compressor room from the control room.
This comprehensive guide explains the system architecture, hardware components, GUI design, communication method, working principle, advantages, and future scope of the project.
Project Overview
This project is designed to remotely monitor:
- Two Air Compressors
- Two Air Dryers
- Two Exhaust Blower Fans
- One Compressed Air Receiver Tank
- Real-time Air Pressure Value
The system enables a control room engineer to view equipment running status and tank pressure on a computer-based GUI developed using Visual Basic, while the field signals are acquired and transmitted by an Arduino microcontroller.
Objectives of the Project
- Monitor air compressor room equipment remotely
- Display real-time running status (RUN/STOP)
- Show compressed air tank pressure
- Improve operational reliability
- Reduce physical inspection requirements
- Provide centralized monitoring
System Architecture
The system consists of three main sections:
1️⃣ Field Level (Air Compressor Room)
- Two Air Compressors (Unit-A & Unit-B)
- Two Air Dryers (Unit-A & Unit-B)
- Two Exhaust Blower Fans
- Pressure Sensor installed in Air Receiver Tank
- Digital Status Feedback Signals (RUN/STOP)
2️⃣ Controller Level
- Arduino Board
- Digital Input Circuits
- Analog Input (Pressure Sensor)
- Serial Communication Interface (USB/RS232)
3️⃣ Control Room Level
- PC or Desktop Computer
- Visual Basic GUI Software
- Serial Communication Interface
Hardware Components Used
1. Arduino Microcontroller
The Arduino reads:
- Digital signals (Compressor Run feedback)
- Analog signal (Tank pressure sensor output)
It processes the signals and sends them to the PC via serial communication.
2. Pressure Sensor
- Installed on compressed air receiver tank
- Provides analog voltage proportional to pressure
- Arduino converts analog voltage into pressure value (Bar)
3. Air Compressors
Two compressors:
- Unit-A
- Unit-B
The system shows which unit is running and which is stopped.
4. Air Dryers
Two dryers:
- Unit-A
- Unit-B
Status displayed on GUI as:
- Running (Green)
- Stop (Red or Gray)
5. Exhaust Blower Fans
Used for room ventilation and temperature control.
 |
| Graphical User Interface |
The GUI is designed using Microsoft Visual Basic. It provides a graphical and user-friendly monitoring panel.
GUI Features
✔ Compressor Status Display
✔ Dryer Status Display
✔ Blower Fan Status Indicator
✔ Real-time Air Pressure Display
✔ Flow Direction Visualization
✔ Clean Industrial Layout
GUI Layout Explanation
🔵 Air Compressor Section
- Two compressor images
- Running unit highlighted
- Status text: “Unit-A Running” / “Unit-B Stop”
🟢 Blower Fan Section
- Circular animated indicators
- Rotational arrow for running condition
- Static icon for stopped condition
🟡 Air Dryer Section
- Two dryer units
- Running unit marked clearly
⚪ Compressed Air Receiver Tank
- Pressure display in Bar
- Real-time updated value
➡ Flow Direction
Arrows show:
Air Compressor → Receiver Tank → Air Dryer → Gas Turbine / GBC
Working Principle
Step 1: Data Acquisition
- Compressor Run feedback → Arduino Digital Input
- Dryer Run feedback → Arduino Digital Input
- Blower Fan status → Arduino Digital Input
- Pressure sensor → Arduino Analog Input
Step 2: Data Processing
- Arduino reads digital inputs (HIGH/LOW)
- Reads analog voltage (0–5V)
- Converts voltage to pressure value
Example:
Pressure (Bar) = (ADC Value / 1023) × Sensor Range
Step 3: Communication
- Arduino sends data via Serial Communication (USB/COM Port)
- Data format example:
C1=1,C2=0,D1=1,D2=0,P=7.5
Step 4: GUI Update
- VB software reads serial data
- Parses string data
- Updates GUI indicators
- Displays real-time pressure
Communication Method
- Serial Communication (USB/COM Port)
- Baud Rate: Typically 9600 or 115200
- Data format: Structured text string
Optional upgrades:
- RS485 for long distance
- Ethernet Shield
- Wi-Fi module (ESP8266/ESP32)
Why Arduino?
- Low-cost solution
- Easy programming
- Reliable for industrial monitoring
- Large community support
- Fast development
Advantages of This System
✅ Low Cost
✅ Easy Installation
✅ Real-time Monitoring
✅ Reduced Manpower
✅ Increased Safety
✅ Scalable System
✅ Simple Maintenance
Industrial Applications
This type of system can be used in:
- Power Plants
- Textile Mills
- Cement Factories
- Chemical Plants
- Food Processing Industries
- Oil & Gas Utility Systems
Future Improvements
To upgrade this Arduino-based monitoring system:
- Add Data Logging (CSV or Database)
- Add Alarm System
- Add SMS/Email Notification
- Integrate SCADA System
- Web-based Dashboard
- IoT Cloud Monitoring
- Automatic Load Sharing Logic
- Predictive Maintenance Feature
Comparison with SCADA System
| Feature | Arduino + VB GUI | Full SCADA |
|---|---|---|
| Cost | Low | High |
| Complexity | Simple | Complex |
| Maintenance | Easy | Requires Specialist |
| Scalability | Limited | High |
| Data Logging | Basic | Advanced |
This project works as a low-cost SCADA-like monitoring solution.
Safety Considerations
- Use opto-isolators for digital inputs
- Proper grounding
- Industrial-grade power supply
- Surge protection
- Shielded communication cable
Project Summary
This Arduino-based air compressor room remote monitoring system demonstrates how low-cost microcontrollers combined with Visual Basic GUI can create a powerful industrial monitoring platform.
It provides:
- Real-time equipment status
- Pressure monitoring
- Centralized supervision
- Improved operational efficiency
This project is ideal for engineers who want to develop a low-cost industrial monitoring system without investing in expensive SCADA infrastructure.
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