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The Internet of Things (IoT) has become a fundamental element for digital transformation in industry, boosting efficiency, security, and innovation. This paper presents an IoT architecture designed for real-time monitoring and control of a virtual level station, addressing critical challenges in industrial automation. The level process is simulated using Factory IO and regulated by a control algorithm developed in TIA Portal V16, executed via PLC Sim Advanced. Data is acquired by Node-RED from the PLC and transmitted to an MQTT broker, while a dashboard hosted on Ubidots enables remote access. Historical data of key parameters is recorded to facilitate detailed analysis of process behavior. Its flexible design allows the simulated process to be easily replaced or expanded with additional sensors and parallel processes, providing significant scalability for future applications. Results show a 55ms response time, data transmission with less than 100ms latency (PLC to cloud), and system integrity during network failures. Based on the Industrial Internet Reference Architecture (IIRA), this system provides a replicable framework for Industry 4.0 implementations, particularly in: Digital twin development, safe operator training, and cost-effective modernization of existing systems.

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IoT Architecture Prototype for Real-Time Monitoring and Control in a Simulated Automation Environment

  • 会议论文

  • 发表日期：

    2026年

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  • Cristian P. Chuchico,
  • Clinton Semanate,
  • Fernando A. Chicaiza,
  • Marco Pilatásig

摘要

The Internet of Things (IoT) has become a fundamental element for digital transformation in industry, boosting efficiency, security, and innovation. This paper presents an IoT architecture designed for real-time monitoring and control of a virtual level station, addressing critical challenges in industrial automation. The level process is simulated using Factory IO and regulated by a control algorithm developed in TIA Portal V16, executed via PLC Sim Advanced. Data is acquired by Node-RED from the PLC and transmitted to an MQTT broker, while a dashboard hosted on Ubidots enables remote access. Historical data of key parameters is recorded to facilitate detailed analysis of process behavior. Its flexible design allows the simulated process to be easily replaced or expanded with additional sensors and parallel processes, providing significant scalability for future applications. Results show a 55ms response time, data transmission with less than 100ms latency (PLC to cloud), and system integrity during network failures. Based on the Industrial Internet Reference Architecture (IIRA), this system provides a replicable framework for Industry 4.0 implementations, particularly in: Digital twin development, safe operator training, and cost-effective modernization of existing systems.