Design and Implementation of a Smart Industrial Gateway for CNC Machines Using ESP32-WROOM-32
DOI:
https://doi.org/10.32628/IJSRSET251302Keywords:
Industry 4.0, Smart Industrial Gateway, ESP32-WROOM-32, CNC Machines, FreeRTOS, Modbus RTU, IoT, Real-Time Monitoring, Cloud Communication, Energy Consumption, Predictive Maintenance, HTTP Transmission, Embedded SystemsAbstract
The advancement of Industry 4.0 has revolutionized manufacturing systems by introducing intelligent, interconnected environments aimed at enhancing operational efficiency, minimizing downtime, and enabling data-driven decision-making. This paper presents the design and implementation of a Smart Industrial Gateway developed using the ESP32-WROOM-32 microcontroller. The system is designed to monitor and log key operational signals from CNC machines, specifically machine status, cycle status, alarm signals, and emergency triggers. Real-time signal acquisition is achieved through hardware interrupts, with concurrent processing managed by the FreeRTOS operating system. The collected data is stored locally in a binary format, with each entry timestamped using NTP synchronization. A multi-layered communication system ensures reliable internet connectivity, prioritizing GSM, Ethernet, and Wi-Fi, and enabling secure data transmission to a central cloud server using HTTP. The system also integrates Modbus RTU communication over RS485 for reading energy consumption data from industrial meters. Upon internet availability, the system automatically uploads the stored data and deletes it from the local memory, optimizing storage. The proposed solution enhances visibility into machine status and energy usage, facilitating timely diagnostics and supporting energy-efficient operations. This work lays the foundation for implementing predictive maintenance strategies and remote diagnostics in traditional manufacturing setups, contributing to the broader adoption of Industrial Internet of Things (IIoT) technologies.
📊 Article Downloads
References
H. Gehlot, M. Aatif, M. Sufyaan, and V. C. Parihar, "Integration of ESP32 with ENC28J60 Ethernet Module for Embedded Systems Networking," International Journal of Research Publication and Reviews, vol. 5, no. 12, pp. 2392-2398, Dec. 2024.
E. W. Pratama and A. Kiswantono, "Electrical Analysis Using ESP-32 Module in Real-Time," Journal of Electrical Engineering and Computer Sciences, vol. 7, no. 2, pp. 1273-1284, Dec. 2022. DOI: https://doi.org/10.54732/jeecs.v7i2.21
D. Hercog and T. Lerher, "Design and Implementation of ESP32-Based IoT Devices," Sensors, vol. 23, no. 16, pp. 6739-6749, 2023. DOI: https://doi.org/10.3390/s23156739
R. Ma, "Organic Light-Emitting Diodes (OLEDs)," Handbook of Visual Display Technology, pp. 1–22, 2016, doi: 10.1007/978-3-642-35947-7_79-2. DOI: https://doi.org/10.1007/978-3-642-35947-7_79-2
D. Patel, C. Maiti, and S. Muthuswamy, "Real-Time Performance Monitoring of a CNC Milling Machine using ROS 2 and AWS IoT Towards Industry 4.0," IEEE EUROCON 2023 - 20th International Conference on Smart Technologies, Torino, Italy, pp. 776-781, 2023. DOI: https://doi.org/10.1109/EUROCON56442.2023.10199020
H. El-Khozondar et al., "A Smart Energy Monitoring System using ESP32 Microcontroller," e-Prime - Advances in Electrical Engineering, Electronics and Energy, vol. 9, pp. 100666, 2024. DOI: https://doi.org/10.1016/j.prime.2024.100666
B. Siddhartha, A. P. Chavan, G. K. HD, and K. N. Subramanya, "IoT Enabled Real-Time Availability and Condition Monitoring of CNC Machines," 2020 IEEE International Conference on Internet of Things and Intelligence System (IoTaIS), Bali, Indonesia, pp. 78-84, 2021. DOI: https://doi.org/10.1109/IoTaIS50849.2021.9359698
M. Dafare, S. Waghmare, A. Bhoyar, A. S. Titarmare, and P. Chandankhede, "LoRa-Enabled Smart RS485 Data Logger and MQTT Gateway for Industrial IoT Applications Using ESP32," 2023 International Conference on Circuit Power and Computing Technologies (ICCPCT), Kollam, India, pp. 1297-1302, 2023. DOI: https://doi.org/10.1109/ICCPCT58313.2023.10245760
X. Zhang, X. Wei, and W. Li, "Internet of Things for Energy Efficiency: A Review," IEEE Access, vol. 7, pp. 34793-34807, 2019.
S. Z. B. Fathi, H. Mohammadi, and H. Shayeghi, "IoT and Industrial Automation for Manufacturing Systems: A Review," Journal of Industrial Information Integration, vol. 19, pp. 100132, 2020.
F. B. Bastani, M. K. Ho, and A. M. Khan, "Wireless Sensors and Actuators Network for Industrial IoT Applications," IEEE Transactions on Industrial Electronics, vol. 64, no. 6, pp. 4702-4711, Jun. 2017.
M. Taha, A. B. Mohamed, and S. Ahmed, "Integration of IoT for Smart Manufacturing: A Review," IEEE Access, vol. 9, pp. 27280-27298, 2021.
R. Pratama, D. Kurniawan, and M. Wahyudin, "Energy Management and Monitoring for IoT-Enabled Manufacturing Systems," IEEE Transactions on Industrial Informatics, vol. 16, no. 6, pp. 3708-3716, 2020. DOI: https://doi.org/10.1109/TII.2019.2941739
E. L. I. M. Anwar and M. N. S. H. F. A. Rahman, "Smart Manufacturing Using IoT and Machine Learning: A Review," Journal of Electrical Engineering and Technology, vol. 15, no. 2, pp. 1101-1112, 2021.
K. K. Chien, W. B. Lee, and H. S. Lee, "A System for Monitoring the Performance of CNC Machines Using IoT," Journal of Manufacturing Processes, vol. 38, pp. 482-489, 2019.
S. P. S. Harish and S. B. S. Ganesan, "IoT-Based Monitoring and Control of CNC Machine Parameters," International Journal of Advanced Research in Computer Science and Software Engineering, vol. 7, no. 8, pp. 25-30, 2017.
M. S. Hossain, P. B. K. Yadav, and M. M. Islam, "IoT-Driven Energy Management Systems: Challenges and Opportunities," IEEE Internet of Things Journal, vol. 8, no. 4, pp. 3082-3091, 2021.
A. Ghoreishi, R. S. H. Alavi, and B. S. G. Shabani, "An IoT-Based Smart Gateway for Machine Monitoring and Data Acquisition in Industrial Applications," IEEE Transactions on Industrial Electronics, vol. 68, no. 4, pp. 3398-3408, 2021.
L. W. K. Y. Kuan, "A Smart Gateway for IIoT-Based Manufacturing: A Case Study," Journal of Intelligent Manufacturing, vol. 30, pp. 3071-3082, 2019.
M. H. Lou, R. Kumar, and L. A. Ghorbani, "Cloud-Based IoT Systems for Smart Manufacturing: A Review," IEEE Cloud Computing, vol. 5, no. 2, pp. 78-90, 2018.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 International Journal of Scientific Research in Science, Engineering and Technology
This work is licensed under a Creative Commons Attribution 4.0 International License.
