IoT Enabled Real Time Load Height Monitoring and Control System Using PLC and HMI for Smart Industrial Solutions

Abstract

This paper presents a real-time IoT-enabled system for monitoring and controlling load height, integrating Programmable Logic Controllers with Human-Machine Interfaces, personal computers, and smartphones. Specifically designed for dynamic load height measurement, the system ensures precision and safety in industrial applications where accurate load control is critical. The research follows the System Development Life Cycle methodology for systematic design, implementation, and evaluation. The integration of IoT technology facilitates remote monitoring and control, offering users real-time data access through a cloud-based interface. The PLC processes sensor inputs to measure load height, and control signals are sent to adjust the system as necessary. The Haiwell C7S HMI provides a user-friendly interface for monitoring, controlling, and configuring parameters. Data is transmitted wirelessly to a central monitoring station, enabling remote supervision and decision-making. Key findings show that the system achieves a transmission delay of under 2 seconds, ensuring efficient real-time performance. Experimental results indicate the system provides accurate measurements and effective control actions.Additionally, the system is highly scalable, making it applicable across various industries such as warehousing, logistics, and manufacturing. This paper highlights the benefits of integrating PLC, IoT, and HMI technologies in creating a smart,automated load management system, contributing to improved productivity and operational oversight.