Monitoramento de Processos Industriais: Sistema Inteligente de Baixo Custo

Abstract

This Final Graduation Project presents the development and validation of a Low-Cost Intelligent System for Industrial Process Monitoring, applied to the simulation of a chemical mixer. The proposal arises from the need for real-time mo nitoring solutions aligned with Industry 4.0 principles and accessible to small and medium-sized enterprises. The main objective was to demonstrate that, through an optimized engineering design and the use of low-cost components, it is possible to build a reliable system for measuring and processing critical process variables level, temperature, and current. The methodology comprised three stages: design, im plementation, and experimental validation. The system was built using an Arduino Unomicrocontroller, an HC-SR04 ultrasonic sensor (level), a DS18B20 digital sensor (temperature), and a 4–20 mA signal conditioning circuit for current measurement. The prototype was assembled on a test bench simulating a mixing tank with a DC motor, whose voltage–current converter circuit allowed correlating motor current with process load. Control logic and real-time visualization were implemented using the Processing software. Experimental tests demonstrated that the system correctly responded to predefined limits: level above 15 cm, temperature below 15 °C or above 50 °C, and current exceeding 18 mA, triggering the corresponding alerts. Quanti tative analysis indicated a maximum relative error of 4.0% for the level sensor and 1.2% to 1.67% for the temperature and current sensors, confirming high precision and stability. In conclusion, the proposed system achieved its goal, providing accu rate and reliable monitoring at low cost. Future improvements include reducing level sensor instability under high agitation, integrating the system into cloud computing platforms, and implementing predictive maintenance algorithms, consolidating the prototype as a practical solution for Industry 4.0 applications.