Design of a Low‐Cost Efficient IoT Based SCADA System for Automating Different Textile Machines and Controllers for Central Monitoring

ABSTRACT Given the variety of equipment and controllers used in the textile industry, an efficient monitoring system is necessary. Current solutions are sometimes costly and rigid when merging different machine types and communication protocols. Our proposed supervisory control and data acquisition (SCADA) system, which is based on the internet of things (IoT), is affordable and efficient. It comprises a single master programmable logic controller (PLC) central processing unit (CPU) module that interfaces with several slave controllers via various communication protocols. Differentiable communication modules ensure efficient data aggregation and allow for protocol translation. Data is temporarily saved in database blocks by the master PLC and is shown in real‐time on the human machine interface (HMI) screen attached to it. An Arduino gateway connects the master PLC to a server for centralized data storage that may be accessed via a web application. Compared to earlier approaches, ours produced a 35% improvement in data aggregation efficiency and a 50% decrease in costs. This work presents an innovative step towards low‐cost, efficient central monitoring systems in the textile sector, with potential applicability in other industries requiring integrated machine and controller monitoring.