AI-Enhanced Embedded IoT System for Real-Time Industrial Sensor Calibration

This study presents the design and validation of an AI-enhanced embedded IoT system for real-time industrial sensor calibration. The proposed platform integrates a PT100 temperature sensor and a 4–20 mA pressure transmitter with an ESP32 microcontroller, enabling on-device data acquisition, processing, and wireless transmission. A lightweight multilayer perceptron (MLP) neural network, trained in Python with a hybrid dataset (synthetic and experimental) and deployed on the ESP32 via JSON weight files, performs local inference to estimate ideal sensor outputs and compute key performance metrics. Experimental tests under controlled laboratory conditions confirmed high accuracy, with efficiency above 98.6%, RMSE below 0.005 V, and absolute uncertainty margins of ±0.5 °C and ±0.07 bar. Additionally, 95% confidence intervals for RMSE and standard deviation demonstrated statistical reliability across all operating points. The prototype also addresses practical constraints, including ESP32 ADC nonlinearity, energy consumption, and multi-sensor scalability, while remaining portable and low-cost. The integration of edge AI capabilities demonstrates the feasibility of executing accurate neural network models directly on embedded microcontrollers, eliminating reliance on cloud-based processing. The proposed solution provides a robust proof-of-concept that is scalable, cost effective, and suitable for industrial IoT applications, predictive maintenance, and Industry 4.0 environments, with future work focusing on long-term drift evaluation and validation under real industrial conditions.