Use of ESP32 in Industrial Automation

Industrial Automation is adopting low-cost microcontroller in emerging field of Industrial IoT Solution, Use of ESP32 in Industrial Automation that saves time as well as reduces the human intervention so it clearly a green signal for the cost saving, reduces human error and also less human intervention in operation means safer environment. now a days every small to big industries adopting the automation in there operation so here to tackle out the need of automation they must go for the reliable and cheaper controller with best specification which will works great under the industrial condition. That’s the reason they are now a days boosting there use of esp32 in the industrial automation.

ESP32 is becoming very popular in industrial automation now a days because of its versatility and a vast use case in the industries various automation system it might be used for alerting or controlling non critical automation, This article explains the use of ESP32 in industrial automation, its applications, advantages, limitations, and real-world use cases.

Key feature of ESP32

• Is have Dual Core Processor
• Built-in WIFI and Bluetooth
• GPIO,PWM,ADC,DAC Pins
• Low Power consuption

Why ESP32 is Popular in Industrial Automation

Use of ESP32 in industrial automation now a days is very popular because of its robustness cost effective versatile mode of communication, wider application range from controlling a plc to live monitoring of critical equipment, in our modern industrial automation need the use case of such low cost low power consuming microcontroller are very necessary too, so due to its multi-use case application and wider compatibility low cost made ESP32 a popular in industrial automation.

Why Use ESP32 in Industrial Automation?

• Low cost compared to PLC – Now every small to big size machine need automation so if the need is not as much then why use PLC so, there they use ESP32 in Industrial Automation which is game changer doing all thing in cost effective manner
• Wireless Monitoring – As it has built-in WIFI Bluetooth is easier to have online monitoring on the go.
• Easy Cloud Integration – With ESP32 by using certain Library it very easy to integrate it via cloud for monitoring or controlling.
• It is also suitable for the Industrial 4.0 goal in the emerging field of IoT solutions.

Applications of ESP32 in Industrial Automation

In todays industry ESP32 mainly used for the Monitoring, used to interface with multiple IoT solution, controlling and various Industrial Automation and Digitalization need.

ESP32 for Machine Monitoring

There are many critical machine they need real-time monitoring for they vitals parameter here ESP32 is a Game Changer as it have the capability to integrate the data to cloud directely it give versatility to not only view the data locally but also the monitoring can be done via Cloud, Easy compatibility with the IoT is also very good factor for ESP32 to use it in the Machine Monitoring

For Example – In cement plant we have Slipring Motors where it is very necessary to monitors its vitals and its difficult to always open the lid and take temp so here you may use IoT temp Detector with ESP32 which can store the data in cloud and you can get live monitoring, it is very easily achievable as ESP32 have built-it WIFI and Bluetooth.

ESP32 for Motor Control and Protection

In Industrial Automation the motor control and protection plays a very crucial role, with the use of ESP32 in Industrial Automation for protection of motor is quiet simple as it have that potential to easily interfaced with Current sensing module, Voltage Sensing Module and can give output as a potential free contact will be used to turn on off or trip in abnormal condition as compare to the high costing PLC to do the same ESP32 can be used there.

For Example = In motor control logic mainly we use overcurrent protection so by interfacing a current sensing module and in programming we can set the nominal current of the motor with the help of our load calculator and then the ESP32 will compare the value with the running value and give tripping command to the circuit in overload condition arises. Also by using IoT temp. detection overtemperature protection can also be deployed.

ESP32 reliability in industrial Environment

A big question for ESP32 being a Low Cost Microcontroller Use of ESP32 in Industrial Automation is practically reliable or not, if we discuss the built quality and the logic in it for continuous operation this all made it a robust and reliable microcontroller for industrial environment as it don’t need ant major maintenance and also it can be operable in custom environment condition and it works well under such condition too, to be frank it have that capabilities to go to sleep mode use less power during idle condition makes it good in terms of reliability and also use case in practical industrial use.

So if we talk about the limitation of Use of ESP32 in Industrial Automation is no so much but for small project it is not recommend better go for the other replica cheap ones like – ESP8266 and many more.

Real World Use of ESP32 in Industrial Automation

In our day to day life now people are changing there lifestyles and moving to a digital way to live. here the automation is very necessary and the Use of ESP32 is also plays a very vital role in Automating the daily needs.

• Machine motioning for the crucial operative motor by equipping vibration sensor and temperature detection sensor and interfacing them with ESP32 and integrating the whole system to the cloud will be a very good for monitoring the machine live from anywhere or from any loaction.
• In real application in Sub Station where we need to maintain certain temperature there we can use temperature sensor and latch them with the ESP32 and by intergarting it to cloud we can monitor the live room temperature status via dashboard. also able to control the degree of cooling.
• Automatic on off timer for lighting in the plant premises can be achieved by Use of ESP32 in Industrial Automation.

ESP32 with LoRa for Remote Switching and Feedback

A practical Use of ESP32 in Industrial Automation example is the use of two ESP32 boards with LoRa modules to create a long-range remote switching and monitoring system.

System Description:

• One ESP32 is installed at the control center
• Another ESP32 is installed at the remote field location
• Communication is done using LoRa wireless technology
• The system supports ON/OFF switching with live status confirmation

Working Principle:

1. The control station sends a switching command (ON/OFF) using ESP32 + LoRa
2. The remote ESP32 receives the command and operates a relay or contactor
3. A feedback signal (aux contact / sensor) confirms the actual status
4. The remote ESP32 sends acknowledgment back to the control station

This creates a closed-loop control system, ensuring safe and reliable industrial operation.

Real World Use of ESP32 in Home Automation

• ESP32 can be used in Home Automation by intergarting it with Google Nest Mini to use the voice command to turn on or off light fan or other electrical appliances here ESP32 is used to make automated home can be use as safety device for your home by using the cloud connectivity.
• We can use it to make automatic water overflow alarming and pump switching system. by using water level sensor and relay module it will be very easy to adapt this microcontroller and save electricity and water too. because SAVE WATER TO WIN THE LIFE.
• Esp32 can be also used in automatic water dispenser and auto temp controller can also be made for the winter by turning off and on the heater by taking temperature sensor in loop with the sytem.

Disadvantages of ESP32

• Overkill of Small Project – As it comes with dual core processor some times it is very overkilling for the small projects
• Restricted GPIO pins – Some esp modules have very less number of GPIOs pins which effect to drive lots of IoT to be restricted.
• ADC Limitation – Use of ESP32 in Industrial Automation some times required precise Analog Io for which the ESP32 interference is higher in terms of reading and writing the Analog signal.
• Voltage Limitation – Sometimes when you need to power up a IoT with 5v then this microcontroller fails to drive there you need to use external source for interfacing that module.
• High Power Consumption – As it has the both protocol of WIFI and Bluetooth the rate of consumption of power will bit more when using this Built-in communication protocol making it less friendly for on battery operation.