IoT-based System for Real-Time Monitoring and Control of Pilot Plant: Performance Evaluation

In a time when industrial process monitoring and control are critically important, this paper introduces the development and assessment of an IoT system for real-time industrial process monitoring and control using a Firebase database for cloud data synchronization. This system combines multiple sensors, consisting of temperature, flow, and liquid level, along with actuators, overseen by an ESP8266 microcontroller. We analyzed key performance metrics, including sensor data accuracy, the time needed for command execution, and data transmission delays, under both regular and disrupted network conditions. The results show consistent performance, with little data packet loss, low execution latency for commands, and live updates to the Android application. Tests for scalability show that the system can manage up to 10 sensors and 5 actuators, with no decline in performance. An evaluation of the system's reliance on stable internet connectivity indicated that recovery times were fast after disruptions. Real-time data updates, command execution time, network latency, error rates, and scalability were illustrated in visual analysis of system behavior through graphs. This analysis confirms the potential of the system for industrial use cases that require consistent, real-time management and monitoring.