Intelligent Symmetry-Based Vision System for Real-Time Industrial Process Supervision

Industrial environments still rely heavily on analog instruments for process supervision, as their robustness and low cost make them suitable for harsh conditions. However, these devices require manual readings, which limit automation and digital integration within Industry 4.0 frameworks. To address this gap, this study proposes an intelligent and cost-effective system for non-invasive acquisition of measurement data from analog industrial instruments, leveraging machine vision and Artificial Neural Networks (ANNs). The proposed framework exploits the geometric symmetry inherent in circular and linear scales to interpret pointer positions under varying lighting and perspective conditions. A dedicated image-processing pipeline is combined with lightweight ANN architectures optimized for embedded platforms, ensuring real-time inference without the need for high-end hardware. The processed data are wirelessly transmitted to a Human–Machine Interface (HMI) and web-based dashboard for real-time visualization. Experimental validation on pressure and flow instruments demonstrated an average Mean Absolute Error (MAE) of 0.589 PSI and 0.085 GPM, Root Mean Square Error (RMSE) values of 0.731 PSI and 0.097 GPM, and coefficients of determination (R2) of 0.985 and 0.978, respectively. The system achieved an average processing time of 3.74 ms per cycle on a Raspberry Pi 3 platform, outperforming Optical Character Recognition (OCR) and Convolutional Neural Network (CNN)-based methods in terms of computational efficiency and latency. The results confirm the feasibility of a symmetry-driven vision framework for real-time industrial supervision, providing a practical pathway to digitalize legacy analog instruments and promote low-cost, intelligent Industry 4.0 implementations.