An Industrial IoT system for wireless instrumentation: Development, Prototyping and Testing

The next generation machinery viz. turbines, aircraft and boilers will rely heavily on smart data acquisition and monitoring to meet their performance and reliability requirements. These systems require the accurate acquisition of various parameters like pressure, temperature and heat flux in real time for structural health monitoring, automation and intelligent control. This calls for the use of sophisticated instrumentation to measure these parameters and transmit them in real time. In the present work, a wireless sensor network (WSN) based on a novel high-temperature thermocouple cum heat flux sensor has been proposed. The architecture of this WSN has been evolved keeping in mind its robustness, safety and affordability. WiFi communication protocol based on IEEE 802.11 b/g/n specification has been utilized to create a secure and low power WSN. The thermocouple cum heat flux sensor and instrumentation enclosure have been designed using rigorous finite element modelling. The sensor and wireless transmission unit have been housed in an enclosure capable of withstanding temperature and pressure in the range of 100 bars and 2500K respectively. The sensor signal is conditioned before being passed to the wireless ESP8266 based ESP12E transmitter, which transmits data to a web server. This system uploads the data to a cloud database in real time. Thus, providing seamless data availability to decision maker sitting across the globe without any time lag and with ultra-low power consumption. The real-time data is envisaged to be used for structural health monitoring of hot structures by identifying patterns of temperature rise which have historically resulted in damage using Machine learning (ML). Such type of ML application can save millions of dollars wasted in the replacement and maintenance of industrial equipment by alerting the engineers in real time.


Outline/Structure of the Talk

1. Introduction: Importance and use case of wireless IoT based instrumentation systems

2.Systems engineering perspective: A modular design

2.1 Electronics enclosure design and Mechanical design

2.2 Selection of electronics and insulation material

3. The architecture of wireless sensor network

3.1 Protocols used in Industrial Wireless Networks

3.2 Architecture of wireless sensor network for high-temperature sensing

4. Wireless sensor system configuration

4.1 thermocouple, signal conditioner, transmitter and cloud database

4.2 WiFi communication protocol

5. Cost feasibility and Competitor benchmarking: Cost comparison of proposed IoT based thermocouple system with commercial systems

6. Development of software for real-time data acquisition and forecasting

7. Real-time demonstration of the system and concluding remarks

8. DIY tips for IoT based prototyping and deployment

Learning Outcome

  1. The audience will learn about a systems-level perspective on the design of complex IoT based wireless solution
  2. Practical understanding of mechanical and electrical design with a real-life example
  3. Understanding of basics of various WiFi based communication protocols and architecture design of wireless sensor network
  4. Understanding of industrial instrumentation and selection of electronic components for real-life application
  5. Practical lessons on the development of software for real-time data acquisition and forecasting using Python
  6. A DIY tutorial on how to design, prototype and test an industrial IoT system in a cost-effective yet efficient way

Target Audience

IoT developers, data scientists, electrical engineers, academic researchers, plant managers.

Prerequisites for Attendees

General awareness of sensor systems, interest in IoT, ML and data science are sufficient. The 45 mins talk will elaborate on each aspect of developing an IoT based system and its integration with Machine learning based fault detection for both industrial developers and Do-it-Yourself (DIY) enthusiasts.


schedule Submitted 3 years ago

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