Nowadays, the Industry 4.0 concept and the Industrial Internet of Things (IIoT) are considered essential for the implementation of automated manufacturing processes across various industrial settings. In this regard, wireless sensor networks (WSN) are crucial due to their inherent mobility, easy deployment and maintenance, scalability, and low power consumption, among other benefits. In this context, the presented paper proposes an optimized and low-cost WSN based on ZigBee communication technology for the monitoring of a real manufacturing facility. The company designs and manufactures solar protection curtains and aims to integrate the deployed WSN into the Enterprise Resource Planning (ERP) system in order to optimize their production processes and enhance production efficiency and cost estimation capabilities. To achieve this, radio propagation measurements and 3D ray launching simulations were conducted to characterize the wireless channel behavior and facilitate the development of an optimized WSN system that can operate in the complex industrial environment presented and validated through on-site wireless channel measurements, as well as interference analysis. Then, a low-cost WSN was implemented and deployed to acquire real-time data from different machinery and workstations, which will be integrated into the ERP system. Multiple data streams have been collected and processed from the shop floor of the factory by means of the prototype wireless nodes implemented. This integration will enable the company to optimize its production processes, fabricate products more efficiently, and enhance its cost estimation capabilities. Moreover, the proposed system provides a scalable platform, enabling the integration of new sensors as well as information processing capabilities.
Keywords: 3D ray launching; Industry 4.0; automation; industrial internet of things; manufacturing process; wireless channel; wireless sensor networks.