This project is an Embedded-based Industrial Automation & Control System that monitors and controls multiple machines using IoT (Industrial Dashboard). It includes real-time monitoring, production counting, fault detection, and alert system.
Industrial Automation Suite | DFOS + HMI + EMS Designed and developed an integrated Industrial Automation platform accessible through a single Web & Mobile dashboard for remote monitoring and control of manufacturing operations.
Key Modules:
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Real-time production monitoring for FMCG & manufacturing sectors
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Tracks total production, target achievement, and per-minute output
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Detects machine idle time, breakdown duration, and production loss periods
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Implements Start / Stop / Wait / Block logic for automated workflow control
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Displays live production analytics and graphs
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Helps reduce breakdown time and manpower dependency
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Real-time machine monitoring and remote control
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PWM-based machine speed control
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Displays live and historical machine performance data
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Tracks machine ON/OFF history and downtime reasons
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Improves operational efficiency with less manual intervention
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Monitors machine current, voltage, and power consumption live
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Sends maintenance alerts for abnormal power usage
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Automatically shuts down machines when power exceeds safety limits
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Live energy consumption dashboard with trend graphs
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Supports energy saving and preventive maintenance strategies
Technologies Used:
ESP8266 / IoT / Sensors / Embedded C++ / Web Dashboard / Firebase / Real-time Database / Automation Logic / Data Visualization
Impact:
Reduced manpower, minimized production loss, improved efficiency, and enabled smart factory remote operations.
- ESP8266 acts as the main controller
- IR Sensor detects production count
- Machines (M1–M4) are controlled via GPIO
- Industrial Dashboard provides remote monitoring and control
- Machines connected to D1, D2, D5, D6
- IR Sensor connected to D7
- Alarm (Buzzer/LED) connected to D0
- Power supply provided via 3.3V
- System initializes all pins and connects to WiFi
- Industrial Dashboard syncs machine states and speeds
- IR sensor detects object and updates production count
- Interlock logic ensures safe machine operation
- If any machine stops → alarm is triggered
- Data is stored in EEPROM for persistence
- Dashboard shows real-time production and machine status
- M1 → D1
- M2 → D2
- M3 → D5
- M4 → D6
- IR Sensor → D7
- Alarm → D0
Note
- Update WiFi credentials in
config.hbefore uploading code - Ensure all GPIO connections match the pin configuration section
- Dashboard and ESP8266 must be connected to the same network (or properly configured cloud)
- Calibrate IR sensor properly for accurate production counting
- EEPROM data may reset if flashing new firmware
Tip
- Use stable WiFi (2.4GHz) for ESP8266 to avoid disconnection issues
- Keep sensor wiring short and shielded to reduce noise
- Test each module (DFOS, HMI, EMS) individually before full integration
- Use proper power supply (3.3V regulated) for reliable performance
- Monitor dashboard logs to debug real-time issues quickly
Warning
- Do NOT connect ESP8266 directly to high voltage machines without proper isolation (use relays/opto-couplers)
- Incorrect wiring may damage ESP8266 or sensors permanently
- Ensure current and voltage limits are within safe range before enabling EMS auto-shutdown
- Avoid running system in unstable network conditions (may cause wrong automation triggers)
- This project is for educational/prototype use — industrial deployment requires safety certification
Important
- Ensure proper isolation (relay/opto-coupler) between ESP8266 and industrial machines
- Follow correct pin configuration before powering the system
- Verify automation logic (Start/Stop/Interlock) to avoid unexpected machine behavior
- Maintain stable cloud connectivity for accurate real-time monitoring
- Test system in simulation/prototype before real industrial deployment
Caution
- Avoid operating system with unstable WiFi network (may cause wrong triggers)
- Do not exceed sensor and module voltage/current limits
- Ensure proper grounding to prevent noise and false readings
- Sudden power loss may affect EEPROM data consistency
- Continuous operation without cooling may overheat components
✔ Real-time monitoring ✔ IoT control using Cloud ✔ Production counting ✔ Fault detection system ✔ EEPROM data storage ✔ Industrial interlock logic
- ESP8266
- Arduino IDE / VS Code
- Open Source Cloud (With Responsive Frontend, Backend & Database)
- Embedded C