Hybrid System Architecture for Cloud-Enabled Manufacturing Monitoring Using IoT Acoustic Emission Sensors

• Grant number: 25/02367-6
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: June 01, 2025
• End date: May 31, 2026
• Field of knowledge: Engineering - Electrical Engineering
• Principal Investigator: Fábio Romano Lofrano Dotto
• Grantee: Guilherme Augusto Fincatti da Silva
• Host Institution: Escola de Engenharia de São Carlos (EESC). Universidade de São Paulo (USP). São Carlos , SP, Brazil
• Associated research grant: 24/01374-6 - Development and Implementation of an Internet of Things-Based Acoustic Emission Sensor for Industrial Process Monitoring, AP.R

Abstract

This scientific initiation project, linked to the FAPESP regular research grant, aims to develop and validate a cloud-based solution for processing data acquiring from IoT acoustic emission sensors in machining operations. The project integrates local and remote servers using protocols such as MQTT and OPC-UA to ensure security, efficiency, and scalability within Industry 4.0 environments.The initial phase focuses on communication protocols, IoT, cloud computing, and industrial system integration to establish a strong basis for implementation. Following this phase, local and remote servers will be configured to enable data acquisition, storage, and processing. The study also explores algorithms for IoT frame compression, encoding, and decoding, along with techniques for classifying metal sheet thickness during the drilling process, both locally and in the cloud.Validation involves extensive testing with experimental and simulated data, allowing refinements to optimize performance, reliability, and scalability. The analysis includes evaluating server communication in terms of latency and data processing efficiency. The findings will be incorporated into the interim and final reports, contributing to at least one scientific article planned for publication.