In this blog post, we will discuss some real-time project ideas for Industry 4.0. These projects are designed to help manufacturers make better decisions, optimize their operations, and improve their bottom line. We hope that these project ideas will inspire you to start your own Industry 4.0 project. With the right tools and technologies, you can make a real difference in the way your company operates.
What is Industry 4.0:
A simple Google search reveals that Industry 4.0 refers to the digital transformation of manufacturing and related industries using advanced technologies such as the Internet of Things (IoT), artificial intelligence (AI), big data, cloud computing, and robotics.
However, the real meaning of Industry 4.0 is simple: to increase productivity and reduce losses. This can be achieved by increasing manufacturing efficiency and productivity, reducing losses, efficiently managing power, and deploying early warning systems.
The advancement in sensors and the affordability of electronic chipsets has provided engineers with a great opportunity to come up with innovative monitoring and automation solutions. Additionally, the abundance of communication protocols has made it possible to connect these electronic devices to networks and make them available remotely. IoT plays a vital role in Industry 4.0, as most manufacturing plants want to monitor their production in real time as well as remotely monitor their manufacturing units
Keeping in view the requirements of Industry 4.0, here are a few projects that can be considered. In upcoming blogs, we will provide the procedure to develop each of these projects.
Note: The difficulty level of each project increases gradually. This means that the first project is the easiest one, and the last project will be the most difficult to implement. Readers are advised to follow each and every project to build proper knowledge.
Project 1 IoT based Temperature and Humidity Monitor:
Our first project is a simple one that monitors the temperature and humidity of a room and sends the data to a server. Users can then monitor this data from any remote location. At first glance, you might think this is an extremely easy project with limited or no use. However, these types of monitors are sold in the market for quite a high price. They are mainly used in hospitals (operating theaters), clean rooms (in pharmaceutical manufacturing plants), and NABL or certified labs (where equipment testing is performed).
For this project, you can use the following: 1. Microcontroller: Either ESP 8266, ESP32 or ATmega 328 with ethernet. 2. Firmware: Arduino IDE (for ease of usage) or anyother compatible IDE (eg. AVR Studio for ATmega 328) 3. Sensor: While many people use the DHT11 sensor, we do not recommend it unless you are a beginner. For industrial use, you need a good sensor that provides stable readings. Therefore, we will be using the AM2305 (which works well, provides stable readings, and uses the 1-wire protocol). 4. Server: You can use your laptop as a server or create a cloud-based server using services such as AWS or PythonAnywhere.com. We recommend using Python and Flask for backend development, as this will make the development process easier. 5. Communication: You may need to install MQTT for ease of communication. However, you can also use simple HTTP requests if you prefer.
Project 2 Smart IoT Based Power Monitor with Early Warning System:
The main goal of this project is to create an IoT-based monitoring system that can monitor the power consumption of a connected load and also provide early signs of malfunction in the appliance using a machine learning algorithm. In Industry 4.0, AI and ML play an extremely vital role in analyzing data and helping staff and higher-level management make informed decisions to increase productivity and efficiency.
For this project, you can use the following: 1.Microcontroller: You can use the same family of microcontrollers mentioned in project 1. The firmware development process will also be the same. 2.Sensor: For power consumption, you can use the CSE7759B IC manufactured by CHIPSEA. This IC will measure all three parameters: voltage, current, and power. 3.Server and communication: You can use the same server and communication protocols as in project 1. 4.Relay: To make things more interesting, you can use a relay that can be used to remotely turn ON and OFF the connected appliance.
Project 3 Smart IoT based 3 Phase Switch with Power Monitoring and early warning system (Advancement over Project 2)
Now, whatever we did in Project 2 was for general-purpose single-phase appliances and equipment. However, industrial equipment and machinery typically use three-phase 440V power with higher current and power ratings. To monitor the power of such machinery, you may need to upgrade your design and make it more robust to handle the industrial environment. Here are some hardware and software environments that we would suggest:
For this project, you can use the following: 1. For microcontrollers and firmware development we will keep on using what we used in project 1&2 2. Sensor : Here the sensor mentioned in project 2 is not usable as it only works in a single phase power supply. So for measuring power in a three phase unit, you have to measure the current and use the generalized formulas. Now for measuring the current you have to utilize a much more robust method such as a current transformer (aka CT). 3. Server and communication will remain the same 4. Now we cannot use normal relays in industrial 3 phase environment. So, we have to upgrade them and use something called as Contactors (which work on higher current)
Project 4 Autonomous Robot for Factory Logistics (Quite futuristic)
This project will involve you in solving a major problem related to factory logistics. As we are aware, big giants like Amazon and Flipkart face issues such as sorting, labeling, and so on, when it comes to goods.
Similarly, places such as seaports have the same issue, which involves a lot of manpower. Here, you can come up with and develop autonomous robots that will automatically sort logistics, label them, and place them in the correct locations. Now, for an individual, this can be quite difficult to make, but you can always make a prototype. And for designing and making the prototype, you can make a simple robot that can be connected to the internet and communicate with the server. This can be simply made by using a single-board computer (SBC) such as the BeagleBoard or Raspberry Pi. The server will take care of all the movements, and the robot will run all the actual movement algorithms.
Project 5 Hospital Automation System
This is the need of the hour. Hospitals desperately need some technological upgrades. My recent visit to a large government hospital in my vicinity has shown how much we are lacking. Even in 2023, the hospital was using a paper-based token and patient calling system. Patients have to wait in long queues for hours, wasting time. We can build a system where patients can register from an application from home and get an appointment. Hospitals also need good automation in operating theaters, such as measuring and reporting air quality, temperature, humidity, etc., by the engineering team. However, doctors need patient reports, X-rays, MRI scans, etc. You can create a system that meets the needs of both the engineering team and doctors by using touch-based solutions and integrating sensors.
