Introduction to Industrial IoT Gateway

In modern industrial environments, monitoring various parameters like temperature, pressure, humidity, and vibration is critical for operational efficiency and safety. This project demonstrates how to create an Industrial IoT (IIoT) gateway using the ESP32 microcontroller. The gateway will collect real-time data from industrial sensors, transmit it to the cloud, and enable remote monitoring and analysis for better decision-making and predictive maintenance.

Components Required

To build the ESP32-powered Industrial IoT gateway, you will need an ESP32 development board, sensors (temperature, humidity, pressure, vibration, etc.), a Wi-Fi or Ethernet connection for cloud communication, and a cloud service like ThingSpeak, AWS IoT, or an MQTT broker for data transmission.

• Set up the ESP32 development environment with the necessary libraries.
• Connect the industrial sensors (temperature, humidity, pressure, vibration) to the ESP32 board.
• Configure the cloud communication (Wi-Fi or Ethernet) for sending sensor data.
• Write code to collect sensor data and send it to the cloud platform using MQTT or HTTP.
• Visualize the collected data on a dashboard or mobile app for real-time monitoring.
• Test the system by simulating industrial conditions and observing the real-time data updates.

Formula: Industrial IoT System Efficiency = (Total Operational Data / Total Sensors) * 100

Components List

• 1 × ESP32 Development Board
• 1 × Temperature Sensor (e.g., DHT22, LM35)
• 1 × Humidity Sensor (e.g., DHT22)
• 1 × Pressure Sensor (e.g., BMP180)
• 1 × Vibration Sensor (e.g., SW-420)
• 1 × Wi-Fi or Ethernet Module (ESP32 has built-in Wi-Fi)
• 1 × Power Supply (e.g., 5V adapter or industrial-grade power supply)
• 1 × Cloud Service (e.g., ThingSpeak, AWS IoT, MQTT Broker)

Pin Configuration

• GPIO 34 (Temperature Sensor): Temperature sensor data pin connected to GPIO 34 of the ESP32.
• GPIO 35 (Humidity Sensor): Humidity sensor data pin connected to GPIO 35 of the ESP32.
• GPIO 32 (Pressure Sensor): Pressure sensor data pin connected to GPIO 32 of the ESP32.
• GPIO 33 (Vibration Sensor): Vibration sensor data pin connected to GPIO 33 of the ESP32.

For industrial applications, ensure the sensors are suitable for high-environmental conditions and accurate measurements.

Wiring and Connections

• -> GPIO 34 (Digital input)
• -> GPIO 35 (Digital input)
• -> GPIO 32 (I2C or Analog input)
• -> GPIO 33 (Digital input)

Code for ESP32-Powered Industrial IoT Gateway

1#include <WiFi.h>
2#include <PubSubClient.h>
3#include <DHT.h>
4#include <Wire.h>
5#include <Adafruit_Sensor.h>
6#include <Adafruit_BMP180_U.h>
7
8const char* ssid = "Your_SSID";
9const char* password = "Your_PASSWORD";
10const char* mqttServer = "mqtt_broker_address";
11const int mqttPort = 1883;
12const char* mqttUser = "username";
13const char* mqttPassword = "password";
14
15WiFiClient espClient;
16PubSubClient client(espClient);
17DHT dht(34, DHT22);
18Adafruit_BMP180_Unified pressureSensor;
19
20void setup() {
21  Serial.begin(115200);
22  WiFi.begin(ssid, password);
23  while (WiFi.status() != WL_CONNECTED) {
24    delay(1000);
25    Serial.println("Connecting to WiFi...");
26  }
27  Serial.println("Connected to WiFi");
28  client.setServer(mqttServer, mqttPort);
29  dht.begin();
30  pressureSensor.begin();
31}
32
33void loop() {
34  if (!client.connected()) {
35    reconnect();
36  }
37  client.loop();
38  float temperature = dht.readTemperature();
39  float humidity = dht.readHumidity();
40  float pressure = pressureSensor.readPressure();
41  float vibration = digitalRead(33);
42
43  String payload = "Temperature: " + String(temperature) + " Humidity: " + String(humidity) + " Pressure: " + String(pressure) + " Vibration: " + String(vibration);
44  client.publish("industrial_data/topic", payload.c_str());
45  delay(2000);
46}
47
48void reconnect() {
49  while (!client.connected()) {
50    if (client.connect("ESP32Client", mqttUser, mqttPassword)) {
51      client.subscribe("industrial_data/topic");
52    } else {
53      delay(5000);
54    }
55  }
56}

Code Explanation

• #include <WiFi.h>: This includes the Wi-Fi library to connect the ESP32 to a wireless network for cloud communication.
• PubSubClient client(espClient);: This line initializes the MQTT client to handle communication between the ESP32 and the MQTT broker.
• String payload = "Temperature: " + String(temperature) + " Humidity: " + String(humidity);: This constructs a string containing the sensor data (temperature, humidity, etc.) to send to the MQTT broker.
• client.publish("industrial_data/topic", payload.c_str());: This sends the sensor data (payload) to the MQTT broker on a specific topic for real-time monitoring.

Applications

• Remote monitoring of industrial environments (e.g., factories, power plants, oil rigs).
• Predictive maintenance based on real-time sensor data (e.g., vibration sensors for machinery health).
• Energy management by tracking temperature, humidity, and pressure in industrial systems.
• Improved safety by continuously monitoring environmental parameters such as temperature and pressure.

Conclusion

The ESP32-powered Industrial IoT gateway provides an affordable and scalable solution for real-time monitoring of industrial environments. By collecting and transmitting data from various sensors to the cloud, industries can benefit from better operational efficiency, predictive maintenance, and improved safety.