IIoT-Enabled Real-Time Zinc Coating Weight Measurement System for Quality Control in Galvanized Wire Production

The galvanization process plays a crucial role in the protection of steel wire from corrosion by applying a uniform zinc coating. Achieving consistent coating weight is vital for product performance and durability. Traditional methods of coating weight measurement, often relying on periodic sampling and manual inspection, do not provide the necessary real-time feedback required for modern manufacturing environments. This paper presents an innovative Industrial Internet of Things (IIoT)-enabled zinc coating weight measurement system for galvanized wire production. The system integrates eddy current sensor, ESP32 IoT module, and ThingSpeak cloud analytics to provide real-time monitoring of coating thickness across both thick and thin coating lines. The study investigates the performance, efficiency, and reliability of this system in improving product quality, operational efficiency, and minimizing waste in the galvanization process. The integration of edge computing, cloud analytics, and advanced communication protocols offers significant contributions to the industry 4.0 paradigm, demonstrating the transformative potential of IIoT in smart manufacturing.