Hardware
- STM32F4 industrial control hardware
- RS485 industrial communication interfaces
- LAN8742 Ethernet PHY
- Custom infrared temperature sensor
- Industrial process sensing systems
- RTU-to-TCP gateway devices
Industrial Automation
Industrial Drywall Process Monitoring and Telemetry System
Developed a distributed industrial process-monitoring system for drywall manufacturing using STM32 embedded hardware, Modbus RTU/TCP communication, custom infrared temperature sensing, and centralized Python-based monitoring software.
Summary
Engineering context
Developed a distributed industrial process-monitoring system for drywall manufacturing using STM32 embedded hardware, Modbus RTU/TCP communication, custom infrared temperature sensing, and centralized Python-based monitoring software.
- Category
- Industrial Automation
- Year
- Jul 2020 - Jun 2021
- Status
- Industrial Deployment
- Context
- Gostaresh Internet Ashya Parsian Co / IOTive (Jul 2020 - Jun 2021)
My Role
Embedded Systems and Industrial Automation Engineer
Technical Stack
System Architecture
- Distributed RS485 sensor network connected industrial monitoring nodes
- Sensors communicated over Modbus RTU across the factory floor
- STM32F4-based RTU-to-TCP gateways aggregated sensor data
- LAN8742 Ethernet PHY enabled industrial Ethernet communication
- Modbus TCP servers exposed process data to monitoring systems
- Python-based monitoring software visualized process telemetry
Engineering Challenges
- Designing reliable industrial RS485 communication across factory environments
- Developing stable RTU-to-TCP protocol gateway systems
- Building accurate industrial infrared temperature sensing hardware
- Integrating distributed industrial telemetry systems
- Maintaining reliable industrial Ethernet communication
Hardware / Firmware / Software
Firmware
- STM32F4 embedded firmware
- Modbus RTU communication stack
- Modbus TCP server implementation
- Industrial telemetry acquisition firmware
- Ethernet communication firmware
Software
- Python-based industrial monitoring software
- Process telemetry visualization
- Industrial monitoring dashboard
- Centralized process monitoring system
Sensors
- Infrared temperature sensing system
- Process monitoring sensors
- Dryer monitoring sensors
- Size monitoring systems
Protocols
- RS485
- Modbus RTU
- Modbus TCP
- Ethernet
- TCP/IP
Results / Outcomes
- Successfully deployed distributed industrial monitoring architecture
- Enabled real-time drywall process monitoring
- Monitored drywall mixture solidification process
- Implemented centralized industrial telemetry visualization
- Developed custom industrial RTU-to-TCP gateway hardware
- Integrated industrial sensing and process monitoring across factory operations
Gallery
Engineering Notes
Distributed Industrial Sensor Network
The lower-layer sensing architecture used:
- RS485 industrial networking
- Modbus RTU communication
- distributed industrial sensors
All sensors communicated through a shared industrial Modbus network distributed throughout the factory environment.
This architecture enabled scalable industrial process telemetry and centralized monitoring.
RTU-to-TCP Gateway Architecture
To integrate factory-floor telemetry into centralized monitoring software, I designed STM32F4-based RTU-to-TCP gateway devices.
These devices:
- collected Modbus RTU telemetry data
- interfaced with distributed industrial sensors
- exposed telemetry through Modbus TCP servers
- enabled centralized industrial monitoring over Ethernet networks
The gateway hardware used the LAN8742 Ethernet PHY for industrial Ethernet communication.
Custom Infrared Temperature Sensor
I also designed a custom passive infrared temperature sensing system used for monitoring drywall process temperatures.
The temperature-monitoring subsystem was critical for analyzing drywall mixture solidification behavior and dryer performance throughout production stages.
Monitoring Software
The centralized monitoring software was developed in Python.
The software:
- communicated with six distributed RTU-to-TCP gateways
- collected factory telemetry
- visualized process data
- monitored industrial process parameters
- provided centralized process visibility across the production environment
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