Industry 4.0 Oriented Machine Health Monitoring Using PLC Logic Simulation
摘要
With the rise of Industry 4.0, the Internet of Things (IoT) has become a very important enabler for machine health monitoring and predictive maintenance. This paper presents MiLoC that means Microcontroller Based Logic Controller. This is a framework that is employing a microcontroller and replicating the scan cycle of a PLC on an ESP32 platform. The system simulates the scan cycle operation of a PLC by reading sensor data, sensor input, then execution logic and updating output. The system also incorporates FFT Fast Fourier Transform for signal processing and accurate measurement for vibration, current sensor along with TinyML. In this device we have done machine learning inference. The proposed system achieves 94.5% classification accuracy and average inference time of 48 ms. This maintains scan cycle jitter within plus or minus 2 ms. This approach enhances reliability, supports timely predictive maintenance and enables seamless integration with IoT platforms for remote diagnosis. The proposed system is very cost efficient, scalable and suitable for small industries, laboratories and educational environment in Industry 4.0.