Scalable and Secure IoT-Driven Vibration Monitoring: Advancing Predictive Maintenance in Industrial Systems

The rapid evolution of Industry 4.0 has positioned Internet of Things (IoT) technologies as key enablers for smarter industrial operations, particularly in predictive maintenance and machine monitoring. This research proposes an innovative IoT-driven vibration monitoring system that addresses limitations in traditional approaches such as high costs, limited scalability, and insufficient real-time capabilities. Employing low-cost sensors, edge computing, and LoRaWAN-based communication, the framework enables efficient fault detection and operational analysis. Data from industrial machinery was collected over two months and analyzed using advanced signal processing and machine learning techniques to extract meaningful insights. The system demonstrated an accuracy rate of 92%, a detection latency of 150 milliseconds, and extended sensor life to 12 months, marking significant improvements over conventional methods. Furthermore, scalability tests showed stable performance across setups involving up to 500 sensors, even in challenging industrial conditions. This study also highlights cost reductions of 30% and a 25% decline in machine downtime, reinforcing its practical value for industrial applications. By delivering an adaptable, energy-efficient, and secure solution, this research advances the integration of IoT into industrial systems. It lays the groundwork for future enhancements, including real-world testing and multimodal data integration