IoT Monitoring for Real-Time Control of Industrial Processes

Today’s industries require monitoring and control of all manufacturing processes. Computer integrated manufacturing (CIM) systems provide a framework for integrating production systems. In this regard, the Internet of things (IoT) has rapidly evolved to digitize and interconnect devices in industrial processes. However, to achieve the integration of a complete system implies high costs in software and hardware, which limits its penetration in medium and low size industries. For this reason, this project proposes the creation of a low-cost IoT platform whose objective is to monitor and analyze both physical and electrical parameters of an industrial process in real-time. To achieve this objective, the software and hardware specifications were defined and characterized, the conceptual design and detail of the prototype were made, and finally, the materialization was carried out. The platform was structured in two parts, a web video supervision module with a continuous monitoring camera ESP32-CAM and an interface that integrates the sensors that measure the physical and electrical variables of the environment. The experimental results show the effectiveness of the proposed system in a practical machining application on a CNC machine. With the data coming from the sensors, a database was generated to analyze and create temperature versus cutting speed control models to monitor the manufacturing process. Tests were performed on several materials, and the mathematical model of the system behavior was determined for each material in order to monitor and visualize the performance in the machining process. Finally, the cost of the project complies with the specifications proposed. © 2022, The Author(s), under exclusive license to Springer Nature Switzerland AG.