Integration of IoT, Automation, and Real-Time Analytics for Intelligent Pressure Control in Industry 5.0 Smart Manufacturing

The modern industrial revolution started when Industry 4.0 shifted to Industry 5.0 through the adoption of intelligent control strategies designed to promote sustainable operations with human-machine partnership. The research presents a noise-driven pressure control architecture based on fuzzy-PID c...

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Veröffentlicht in:IEEE transactions on consumer electronics Jg. 71; H. 3; S. 8653 - 8661
Hauptverfasser: Mohanty, Anita, Mohapatra, Ambarish G., Kumar Mohanty, Subrat, Alhayan, Fatimah, Alanazi, Rakan, Mujib Alshahrani, Mohammed, Burhanur Rehman, Mohammed, Gupta, Deepak
Format: Journal Article
Sprache:Englisch
Veröffentlicht: New York IEEE 01.08.2025
The Institute of Electrical and Electronics Engineers, Inc. (IEEE)
Schlagworte:
Adaptive control
Automation
Control systems
Controllers
Fifth Industrial Revolution
Fourth Industrial Revolution
Fuzzy control
Fuzzy logic
holographic interfaces
Industrial applications
Industry 4.0
Industry 5.0
IoT
Manufacturing
Predictive maintenance
Pressure control
Process control
Proportional integral derivative
Real time
real-time monitoring
Real-time systems
Smart manufacturing
Time response
Transmitters
Valves
ISSN:0098-3063, 1558-4127
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Zusammenfassung:The modern industrial revolution started when Industry 4.0 shifted to Industry 5.0 through the adoption of intelligent control strategies designed to promote sustainable operations with human-machine partnership. The research presents a noise-driven pressure control architecture based on fuzzy-PID controllers that combines IoT devices alongside real-time processing and an adjustable control mechanism for advanced manufacturing environments. The conventional use of PID controllers presents issues, as they encounter problems related to nonlinearities and slow dynamics, as well as manually set parameters, which lead to performance problems. Adaptive control actions resulting from fuzzy logic implementation enable the proposed system to respond better to process variations, thereby improving both efficiency and accuracy, together with response speed. The system structure includes predictive maintenance features alongside uninterrupted monitoring capabilities and cloud-based analytics that gain favourable results for reliability and scalability. Through its implementation, the system supports Industry 5.0 standards by offering holographic 3D visual interfaces and pressure system management through intuitive human control. The experimental setup containing dual pneumatic vessels proved that the proposed system outperforms typical PID controllers because it reaches higher accuracy at faster settling times with lower overshoot. The analysis addresses important problems, including data protection and system connection capabilities, as well as real-time response during industrial system changes in dynamic conditions. The combination of Industry 5.0 technologies with fuzzy control intelligence enables the proposed approach to optimize sustainability levels and reduce operational expenses, as well as increase process adaptability. The research delivers an advanced pressure control system based on human element integration, which meets the changing requirements of future industrial automation.
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ISSN:0098-3063
1558-4127
DOI:10.1109/TCE.2025.3580432