Integrated Digital Monitoring System For Efficient Analysis Of Industrial Processes

Abstract

The problem of developing a digital monitoring system for efficient analysis of industrial processes has been considered. According to a recent study, Pakistan based industries have very high energy losses as compare to global energy losses. Such industry specific losses and other management related issues can be addressed with digital monitoring platforms. They have applications in agriculture, healthcare, aerospace, defense, and manufacturing. There are different types of digital monitoring systems and involve multiple software and hardware to achieve the required functionalities. In general, we

can classify a digital monitoring system in three parts: front-end applications, back- end applications and processor/communication part. The front-end application include

web and mobile-based applications that provide the required data in a user friendly format and allow human interaction with the digital platform. Back-end applications include sensors/models and actuators that are connected to the distributed components of industrial process that is being managed. Processors and Communication include the WiFi-based hardware for receiving, processing, and sending the remote data from the field instrumentation devices to database. The main objective of this work is to

explore different software and hardware based components according to user require- ments and suggest an integrated framework. We developed a digital monitoring system

that integrate sensors and MATLAB based models to ESP32 processor and display the processed data on web and android based devices. The frontend applications have been designed to support real time sensor data and computational data along with storage of the data in a database. The complete monitoring system with the designed web and android applications is implemented on a case study of analyzing energy utilization of steel manufacturing process.