Exploring IIoT: Wireless Control Systems with ESP8266 as a Web-ServerController— Basic Experimentation

This research presents the design and implementation of a low-cost, modular Industrial Internet of Things training kit aimed at enhancing hands-on IIoT education in academic and experimental settings. The primary goal was to bridge the gap between theoretical learning and practical industrial automation through the development of a WiFi-enabled educational trainer based on the ESP8266 microcontroller. The system integrated DC and AC loads to simulate real-world electromechanical components commonly found in flexible manufacturing systems and computer integrated manufacturing. A web-based graphical user interface was developed using HTML, CSS and C++ within the Arduino IDE, facilitates wireless control. Seven different basic and fundamental experiments were conducted focusing on hardware architecture, device interfacing, wireless communication, and internet network connectivity. Results demonstrated effective control of resistor connected LED, DC, and three-phase AC loads, with a control response time of less than 250±2 ms and a wireless range up to approximately 30±2 meters. The novelty of this work lies in its accessible, scalable design tailored for IIoT literacy, especially in developing regions like Pakistan. While current limitations include basic analytics and lack of encryption, future enhancements are planned. The kit offers a practical foundation for IIoT skill development and supports smart manufacturing initiatives aligned with Industry 4.0.