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INDUSTRIAL CRANE CONTROLLED BY Wi-Fi
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1. INTRODUTION AND LITERATURE SURVEY:
1.1. INTRODUCTION
Human operators have difficulty driving cranes quickly, accurately and safely
because the heavy structure of the cranes responds slowly and its payload oscillates.
Manipulation difficulty is increased by non-intuitive control interfaces that require substantial
experience to master. This project presents a new type of interface that allows operators to
drive crane by simply moving human fingers with gloves on it. Basically in our project we are
going to control industrial crane using android application which is design by internet of things.
In andriod application, design wifi connection to connect wifi module. Basically, the
goal is that can control industrial crane using andriod application.
We will design andriod application in eclipse software. Once it is built and working, we will
control dc motor using Arduino and wifi module for crane.
FIG. 1.1.Crane
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FIG.1.2. ESP – 8266 Wi-Fi Module
Human gestures are undoubtedly natural. They may often prove more efficient and
powerful as compared to other modes of interaction. Gesture recognition has been proposed to
understand the action of a hand.
Humans and machines do not interface well. In an attempt to bridge the gap between
humans and the systems they interact with, a plethora of input methods have been devised:
keyboards, mice, joysticks, game controllers, and devised: keyboards, mice, joysticks, game
controllers, and of these devices remove the barrier between man and machine.
The objective of this project is to design a android application. Depending upon the
button of the application, the required object is moved. This method ensures effective
communication. The goal of the project is to design a useful and fully functional real world
system that efficiently translates android application logic into movement of objects. This
project is based on helping various mega-factories and industries to help them complete their
work easy and faster
The most common thing that people do when frustrated with devices is perform hand
gestures to try to show the device what they want it to do. Microcontroller gets the signal from
the wifi module and based on the signal controller control the dc motor. The device seems to do
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what the user wants, as though a direct line of communication exists between the user and the
hardware to be controlled
The old way of thinking: machines are there to do the sorts of work that users didn’t
want to do, like a dishwasher or a Roomba. The new way of thinking: machines are here to
help us do the things that we want to do, but are not able to, like a construction yard crane. If
users could reach a level of comfort with machines, as though using them was no more than
using an extension though using them was no more than using an extension of their own
bodies, perhaps they could get to a point where they thought of themselves as the ones.
1.2 LITERATURE SURVEY:
A crane is a type of machine, generally equipped with a hoist, wire ropes or chains, and
sheaves, that can be used both to lift and lower materials and to move them horizontally. It is
mainly used for lifting heavy things and transporting them to other places. It uses one or more
simple machines to create mechanical advantage and thus move loads beyond the normal
capability of a man. Cranes are commonly employed in the transport industry for the loading
and unloading of freight, in the construction industry for the movement of materials and in the
manufacturing industry for the assembling of heavy equipment.
The first construction cranes were invented by the Ancient Greeks and were powered by
men or beasts of burden, such as donkeys. These cranes were used for the construction of tall
buildings. Larger cranes were later developed, employing the use of human tread wheels,
permitting the lifting of heavier weights. In the High Middle Ages, harbor cranes were
introduced to load and unload ships and assist with their construction – some were built into
stone towers for extra strength and stability. The earliest cranes were constructed from wood,
but cast iron and steel took over with the coming of the Industrial Revolution.
Following is the diagram of the first simple crane constructed in the ancient time
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FIG. 1.3. Crane Model
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2. BLOKDIAGRAMS & COMPONENTS DETAILS:
2.1 BLOCK DIAGRAMS:
FIG 2.1 Block Diagram of the Project
DESCRIPTION:
Power supply:
The power supply section consist of step down transformers of 230V primary to 5Vsecondary
voltage for the +5V power supply .The circuit provides variable 12V to the motor drivers.
Microcontroller: ATMega 328
The ATMega 328P is a low-power CMOS 8-bit microcontroller based on the AVR enhanced
RISC architecture. By executing powerful instructions in a single clock cycle, the ATMega
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328P achieves throughputs approaching 1 MIPS per MHz allowing the system designed to
optimize power consumption versus processing speed.
ESP8266 – Wi-Fi:
ESP8266 is highly integrated circuit consists of a 32bit RISC processor. ESP8266 also includes
a built in 802.11 b/g/n WiFi circuit that is ready to be directly connected to an antenna. The
ESP8266 is currently available only in a 32pin QFN package, and there is just one IC in the
family.
The ESP01 module contains the ESP8266 MCU and a flash memory chip. There are two LED's:
a red one which indicates power is connected to the module, and a blue one which indicates data
flow, and can also be controlled by user programming. The WiFi antenna is the PCB trace that
covers the top of the module. It is called a Meandered Inverted-F Antenna (MIFA,) is
surprisingly efficient, and only mildly directional.
2.2 COMPONENT LIST

Microcontroller ATmega 328

Wifi Module – ESP8266

Power supply
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
Motor driver IC

DC gear motor
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2.2.1. MICROCONTROLLER ATMEGA 328

ARCHITECTURE OF ATMGA 328
The Atmega 328P is a low-power CMOS 8-bit microcontroller based on the AVR enhanced
RISC architecture. By executing powerful instructions in a single clock cycle, the ATmega
328P achieves throughputs approaching 1 MIPS per MHz allowing the system designed to
optimize power consumption versus processing speed.
Architecture is more code efficient while achieving throughputs up to ten times faster than
conventional CISC microcontrollers.
The ATMega328P provides the following features: 32K bytes of In-System Programmable
Flash with Read-While-Write capabilities,1K bytes EEPROM,2K bytes SRAM, 23 general
purpose I/O lines, 32 general purpose working registers, three flexible Timer/Counters with
compare modes, internal and external interrupts, a serial programmable USART, a byte-oriented
2-wire Serial Interface, an SPI serial port, a 6-channel 10-bit ADC (8 channels in TQFP and
QFN/MLF packages), a programmable Watchdog Timer with internal Oscillator, and five
software selectable power saving modes. The Idle mode stops the CPU while allowing the
SRAM, Timer/Counters, USART, 2-wire Serial Interface, SPI port, and interrupt system to
continue functioning. The Power-down mode saves the register contents but freezes the
Oscillator, disabling all other chip functions until the next interrupt or hardware reset. In Powersave mode, the asynchronous timer continues to run, allowing the user to maintain a timer base
while the rest of the device is sleeping. The ADC Noise Reduction mode stops the CPU and all
I/O modules except asynchronous timer and ADC, to minimize switching noise during ADC
conversions. In Standby mode, the crystal/resonator Oscillator is running while the rest of the
device is sleeping. This allows very fast start-up combined with low power consumption.
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Fig 2.2 Architecture of ATmega 328
The device is manufactured using Atmel’s high density non-volatile memory
technology. The On-chip ISP Flash allows the program memory to be reprogrammed In-System
through an SPI serial interface, by a conventional non-volatile memory programmer, or by an
On-chip Boot program running on the AVR core. The Boot program can use any interface to
download the application program in the Application Flash memory. Software in the Boot Flash
section will continue to run while the Application Flash section is updated, providing true ReadWhile-Write operation. By combining an 8-bit RISC CPU with In-System Self-Programmable
Flash on a monolithic chip, the Atmel ATmega48PA/88PA/168PA/328P is a powerful
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microcontroller that provides a highly flexible and cost effective solution to many embedded
control applications.
The ATmega 328P AVR is supported with a full suite of program and system development
tools including: C Compilers, Macro Assemblers, Program Debugger/Simulators, In-Circuit
Emulators, and Evaluation kits.
PIN DIAGRAM OF ATMEGA-328:
Fig 2.3 Pin Diagram

PIN DESCRIPTION :
VCC - Digital Supply Voltage
GND – Ground
Port B (PB7:0) XTAL1/XTAL2/TOSC1/TOSC2
Port B is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit).
The Port B output buffers have symmetrical drive characteristics with both high sink and Source
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capability. As inputs, Port B pins that are externally pulled low will source current if the pull-up
resistors are activated. The Port B pins are tri-stated when a reset condition becomes active,
even if the clock is not running. Depending on the clock selection fuse settings, PB6 can be
used as input to the inverting Oscillator amplifier and input to the internal clock operating
circuit. Depending on the clock selection fuse settings, PB7 can be used as output from the
inverting Oscillator amplifier.
If the Internal Calibrated RC Oscillator is used as chip clock source, PB7..6 is used as
TOSC2..1 input for the Asynchronous Timer/Counter2 if the AS2 bit in ASSR is set.
Port C (PC5:0)
Port C is a 7-bit bi-directional I/O port with internal pull-up resistors (selected for each bit). The
PC5..0 output buffers have symmetrical drive characteristics with both high sink and source
capability. As inputs, Port C pins that are externally pulled low will source current if the pull-up
resistors are activated. The Port C pins are tri-stated when a reset condition becomes active,
even if the clock is not running.
PC6/RESET
If the RSTDISBL Fuse is programmed, PC6 is used as an I/O pin. Note that the electrical
characteristics of PC6 differ from those of the other pins of Port C.
If the RSTDISBL Fuse is unprogrammed, PC6 is used as a Reset input. A low level on this pin
for longer than the minimum pulse length will generate a Reset, even if the clock is not running.
Shorter pulses are not guaranteed to generate a Reset.
Port D (PD7:0)
Port D is an 8-bit bi-directional I/O port with internal pull-up resistors (selected for each bit).
The Port D output buffers have symmetrical drive characteristics with both high sink and source
capability. As inputs, Port D pins that are externally pulled low will source current if the pull-up
resistors are activated. The Port D pins are tri-stated when a reset condition becomes active,
even if the clock is not running.
AVCC
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AVCC is the supply voltage pin for the A/D Converter, PC3:0, and ADC7:6. It should be
externally connected to VCC, even if the ADC is not used. If the ADC is used, it should be
connected to VCC through a low-pass filter. Note that PC6..4 use digital supply voltage, VCC.
AREF
AREF is the analog reference pin for the A/D Converter.
ADC7:6 (TQFP and QFN/MLF Package Only)
In the TQFP and QFN/MLF package, ADC7:6 serve as analog inputs to the A/D converter.
These pins are powered from the analog supply and serve as 10-bit ADC channels.


FEATURES OF ATMEGA 328 :
High Performance, Low Power AVR® 8-Bit Microcontroller
1. Advanced RISC Architecture

131 Powerful Instructions – Most Single Clock Cycle Execution

32 x 8 General Purpose Working Registers

Fully Static Operation

Up to 20 MIPS Throughput at 20 MHz

On-chip 2-cycle Multiplier
2. High Endurance Non-volatile Memory Segments

4/8/16/32K Bytes of In-System Self-Programmable Flash program memory

(ATmega48PA/88PA/168PA/328P)

256/512/512/1K Bytes EEPROM (ATmega48PA/88PA/168PA/328P)

512/1K/1K/2K Bytes Internal SRAM (ATmega48PA/88PA/168PA/328P)

Write/Erase Cycles: 10,000 Flash/100,000 EEPROM

Data retention: 20 years at 85°C/100 years at 25°C

Optional Boot Code Section with Independent Lock Bits

In-System Programming by On-chip Boot Program

True Read-While-Write Operation

Programming Lock for Software Security
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3. Peripheral Features

Two 8-bit Timer/Counters with Separate Prescaler and Compare Mode

One 16-bit Timer/Counter with Separate Prescaler, Compare Mode, and Capture Mode

Real Time Counter with Separate Oscillator

Six PWM Channels

8-channel 10-bit ADC in TQFP and QFN/MLF package

Temperature Measurement

6-channel 10-bit ADC in PDIP Package

Temperature Measurement

Programmable Serial USART

Master/Slave SPI Serial Interface

Byte-oriented 2-wire Serial Interface (Philips I2C compatible)

Programmable Watchdog Timer with Separate On-chip Oscillator

On-chip Analog Comparator

Interrupt and Wake-up on Pin Change
4. Special Microcontroller Features

Power-on Reset and Programmable Brown-out Detection

Internal Calibrated Oscillator

External and Internal Interrupt Sources

Six Sleep Modes: Idle, ADC Noise Reduction, Power-save, Power-down, Standby,

and Extended Standby
5.
I/O and Packages

23 Programmable I/O Lines

28-pin PDIP, 32-lead TQFP, 28-pad QFN/MLF and 32-pad QFN/MLF
6.
Operating Voltage:

1.8 - 5.5V for ATmega 328P
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7.
Temperature Range:

-40°C to 85°C
8.
Speed Grade:

0 - 20 MHz @ 1.8 - 5.5V
9.
Low Power Consumption at 1 MHz, 1.8V, 25°C for ATmega 328P:

Active Mode: 0.2 mA

Power-down Mode: 0.1 μA
10.
Power-save Mode:

0.75 μA (Including 32 kHz RTC)
 CLASIFICATION OF AVR MICROCONTROLLERS :
1. ATmega48PA
2. ATmega88PA
3. ATmega168PA
4. ATmega328P
 COMPARISION OF AVR MICROCONTROLLER
The ATmega48PA, ATmega88PA, ATmega168PA and ATmega328P differ only in
memory sizes, boot loader support, and interrupt vector sizes.
TAB LE 2.1. Comparison of AVR microcontroller
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ATmega88PA, ATmega168PA and ATmega328P support a real Read-While-Write SelfProgramming mechanism. There is a separate Boot Loader Section, and the SPM instruction can
only execute from there. In ATmega48PA, there is no Read-While-Write support and no separate
2.2.5 ESP8266 Wi-Fi Module
ESP-12E WiFi module is developed by Ai-thinker Team. core processor ESP8266 in smaller
sizes of the module encapsulates Ten silica L106 integrates industry-leading ultra low power 32bit MCU micro, with the 16-bit short mode, Clock speed support 80 MHz, 160 MHz, supports
the RTOS, integrated Wi-Fi MAC/BB/RF/PA/LNA, on-board antenna.
Fig. ESP8266EX Block Diagram
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BASIC AT COMMAND OF ESP8266
Features:






802.11 b/g/n
Integrated low power 32-bit MCU
Integrated 10-bit ADC
Integrated TCP/IP protocol stack
Integrated TR switch, balun, LNA, power amplifier and matching network
Integrated PLL, regulators, and power management units
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Supports antenna diversity
Wi-Fi 2.4 GHz, support WPA/WPA2
Support STA/AP/STA+AP operation modes
Support Smart Link Function for both Android and iOS devices
Support Smart Link Function for both Android and iOS devices
SDIO 2.0, (H) SPI, UART, I2C, I2S, IRDA, PWM, GPIO
STBC, 1x1 MIMO, 2x1 MIMO
A-MPDU & A-MSDU aggregation and 0.4s guard interval
Deep sleep power <10uA, Power down leakage current < 5uA
Wake up and transmit packets in < 2ms
Standby power consumption of < 1.0mW (DTIM3)
+20dBm output power in 802.11b mode
Operating temperature range -40C ~ 125C
2.2.5 L293D:
FIG.2.12 L293D IC
Introduction:
The L293D motor driver is available for providing User with ease and user friendly
interfacing for embedded application. L293D motor driver is mounted on a good quality, single
sided non-PTH PCB. The pins of L293D motor driver IC are connected to connectors for easy
access to the driver IC’s pin functions. The L293D is a Dual Full Bridge driver that can drive up
to 1Amp per bridge with supply voltage up to 24V. It can drive two DC motors, relays,
solenoids, etc. The device is TTL compatible. Two H bridges of L293D can be connected in
parallel to increase its current capacity to 2 Amp.
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FIG.2.13 Pin Diagram
Features:
 Easily compatible with any of the system
 Easy interfacing through FRC (Flat Ribbon Cable)
 External Power supply pin for Motors supported
 Onboard PWM (Pulse Width Modulation) selection switch
 2pin Terminal Block (Phoenix Connectors) for easy Motors Connection
 Onboard H-Bridge base Motor Driver IC (L293D)
Technical Specification:
 Power Supply: Over FRC connector 5V DC
 . External Power 9V to 24V DC
 Dimensional Size: 44mm x 37mm x 14mm (l x b x h)
 Temperature Range: 0°C to +70 °C
2.2.6 DC GEAR MOTOR:
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FIG.2.14 DC MOTOR 10RPM
This DC motor with metal gear head is ideal for low RPM, High Torque application like
lifting an object through hook and also useful for various robotics applications. This motor has
following electrical and mechanical specification
SPECIFICATIONS:
 MOTOR TYPE: DC With gear box , Metal gear box
 BASE MOTOR: DC 3000 RPM
 SHAFT TYPE: CIRCULAR 6 mm Dia with Internal Hole for coupling, 23 mm shaft
Length
 MAXIMUM TORQUE: 6 KG-cm at 12 V
 RPM: 10 RPM AT 12 V
 WEIGHT: 150 Gms
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 MAX LOAD CURRENT: 450 mA at 12 V-10 RPM
FIG.2.15 CROSS SECTIONAL VIEW OF MOTOR
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3. CIRCUIT DIAGRAM
3.1 Circuit Diagram
FIG.3.1 Circuit diagram of Project
Description:
In this figure 3.1 circuit diagram of project explain here. In this, Arduino controller is
connected to ESP8266 Wi-Fi through serial communication pins i.e. RX and TX pin. Arduino
also connected with three different dc motors to perform operation. Using Andriod application
we can send data to Wi-Fi ESP8266 and ESP send the data to Arduino. Based on received data,
Arduino performs LEFT, RIGHT, FORWARD, REVERSE, UP and DOWN operation of Crane.
Here we are design Internet of thing – IOT based andriod application, in future we can also
control industrial crane remotely.
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4. SOFTWARE INFORMATION:
4.1 PROTEUS SOFTWARE:
What is proteus?
Basically PROTEUS is also simulating software but it helps you attach many
components with the 8051. Like resistors, capacitors, LEDs, LCDs, keypads, ICs etc. and these
are just few that I have named in general. It has a complete library and you will find everything
that you will ever need. You can design your complete circuit and then simulate it to view the
final output. This means that after perfecting your project on the programming side in KEIL,
you will need to simulate it on PROTEUS to determine the output of the hardware components.
The simulators I mentioned in my previous post were strictly for beginners. They just
show you the output of the microcontroller so you can learn how everything works. They will
accompany you as long as you are dealing with manipulating the data on the ports or registers.
Sooner or later, you will be going further and attaching external hardware to the 8051 but that's
exactly how we deal with it. So if you're talking about simulating a complete circuit then you
actually need PROTEUS for this.
FIG.4.1. PROTEUS SOFTWARE SCREEN
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Proteus Design:
PROTEUS is designed to be user-friendly and you will get the hold of it instantly.
There is no need to worry about some complex configuration / settings prior to simulation.
The basic steps

Place your components from the library

Connect them accordingly

Load HEX file (if 8051 is involved)

Simulate the circuit
Placing components:

Click the "Pick from library (P)" button as shown in the figure

Select any category

Select item from the list
FIG.4.2. COMPONENT SELECTION
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After selecting component, click anywhere in the design area to select it and then click
again to place it
FIG.4.3. COMPONENT PLACEMENT
Connecting Components:

Place all the required components

Connect the desired nodes by clicking at starting and ending points
FIG.4.4. CONNECTION OF TOOLS
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Load code:

Double click the 8051 component to open its properties

Browse for the HEX file as shown and select it
FIG.4.5. GENRATION OF HEX FILE
And don't worry, in PROTEUS, there is no need to provide the RESET circuit or crystal
oscillator to the microcontroller. It will work just fine even without it. The frequency can be
adjusted in the properties window as well.
The controls at the left-bottom corner will help you simulate the circuit in real time
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FIG.4.6. RUN CIRCUIT
The above picture is the complete circuitry for testing an LED on P2.0 like toggling
(ON / OFF) through programming but we will get to that part later on. At this point, you will
just see the LED glow if you have programmed it to be always ON. Again I am emphasizing
that there is no need for other connections to the microcontroller.
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4.2 ARDUINO SOFTWARE :
FIG.4.7. ARDUINO SOFTWARE SCREEN
Arduino is an open-source platform used for building electronics projects. Arduino
consists of both a physical programmable circuit board (often referred to as a microcontroller)
and a piece of software, or IDE (Integrated Development Environment) that runs on your
computer, used to write and upload computer code to the physical board.
The Arduino platform has become quite popular with people just starting out with
electronics, and for good reason. Unlike most previous programmable circuit boards, the
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Arduino does not need a separate piece of hardware (called a programmer) in order to load new
code onto the board – you can simply use a USB cable. Additionally, the Arduino IDE uses a
simplified version of C++, making it easier to learn to program. Finally, Arduino provides a
standard form factor that breaks out the functions of the micro-controller into a more accessible
package.
The Arduino software is where you will do most of your programming for the Arduino board.
The software is compatible with Windows, Mac OSX and Linux. The software is open-source,
and you can download the latest version from the Arduino Software page.
Programs for the Arduino are known as sketches. The image to the left shows an example of a
simple sketch that blinks an LED. It turns it on, waits a second, turns it off, waits a second and
loops until the Arduino is turned off. It really is that simple to get going.
The syntax, or the words and structure of the code, is similar to Java and C/C++. If you have
any experience in programming, you will find the Arduino very easy to use, and if you haven’t,
it is easy to pick up and there are a lot of tutorials and helpful people out there.
When the code is completed, you will want to upload it to the board. Before the code can be
uploaded, it needs to be compiled. Compiling basically takes your code, and converts it to code
that is readable by the Arduino.
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5. RESULT ANALYSIS
5.1 SOFTWARE WORK:
FIG.5.1 Interfacing of Arduino with motor in proteus
FIG.5.2Run Simulation
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6. ADVANTAGS & APPLICATIONS
6.1 Advantages
 Increase productivity
 Less physical effort
 Saving time
 Security enhancement
 No need to move up and down the truck bed or client to alivated and dangerous places
 Comfort
 Reducing injuries
 Improve working condition
6.2 Applications

In mega factories
FIG 6.1 Mega Factories
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Road construction
FIG 6.2 Road constructions
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Dockyard
FIG 6.3 Dockyards
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INDUSTRIAL CRANE CONTROLLED BY Wi-Fi
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Year: 2015-16
Building construction
FIG 6.4 Building Constructions
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INDUSTRIAL CRANE CONTROLLED BY Wi-Fi
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Year: 2015-16
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INDUSTRIAL CRANE CONTROLLED BY Wi-Fi
Year: 2015-16
CONCLUSION
"The Future of technology is computers and power electronics" The expected outcome would be
that the crane would be controlled by remotely using internet of things – IOT by Wi-Fi
application.
The crane will work according to andriod application signal like START, STOP, RIGHT,
LEFT, REVERSE AND FORWARD. The objective is to provide a smooth and stable and
safe motion, effective grasp and proportional motion tracking of the crane and fast tracking
response.
The industrial crane control by human hand was developed to demonstrate the possibility of
intuitive, simple, glove-based input general enough to be extended to other applications,
including hardware and software.
The crane control by Wi-Fi has the potential to start bridging the large gap between human ideas
and machine responses.
Internet of Things technology is gaining popularity in almost every area that utilizes smart
machines. In aircraft traffic controls, this technology can aid in detailing every part of location
information about the airplanes near to the airport.
In cranes, this can be used instead of remote so that easy picking and shedding of load can be
done at different locations. Smart Televisions are nowadays coming with this technology
making the user carefree about the remote and allowing him to use hands for changing the
channels or volume
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