Industrial automation is quickly evolving, and today’s engineers and makers are pushing its boundaries using off-the-shelf hardware and open source tools. Hackster’s latest Impact Spotlights highlighted this transformation with three innovative projects that bring smart capabilities to existing equipment, enhance motor control, and simplify IoT deployments. From retrofitting legacy machines to real-time telemetry, these applications showcase just how accessible automation has become.
Retro-Logger
First guest speaker, Mukesh Sankhla, introduced his Retro-Logger – a device that’s designed to modernize legacy industrial equipment by logging data from older machinery. The unit acts as an IoT data logger and provides predictive maintenance and data analysis without the need for complete system overhauls.
Sankhla built his Retro-Logger around DFRobot’s FireBeetle ESP32-E microcontroller, an Arduino UNO, and a four-pin UART connector, which is standard on most legacy equipment. The logger garners operational data and sends it to cloud platforms like Google Firebase, which enables real-time monitoring and analytics without the need to replace existing equipment.
Retro-Logger supports a myriad of communication protocols, including RS-232, RS-485, Modbus, MQTT, and HTTP, making it compatible with a wide range of industrial equipment. It also incorporates security measures, including Secure Boot V2, which only executes authenticated firmware, protecting the system from potential security breaches.
DC Motor Position Control with Potentiometer and Arduino
Next guest speaker, Ivan Nestorovski, detailed his DC Motor Position Control platform that aims to deliver precision control of DC motors using readily available hardware. Nestorovski developed the controller around an Arduino UNO, which acts as the brain that processes inputs and controls outputs.
Nestorovski coupled the Arduino with an L293D motor driver shield that provides bidirectional control of an N20 geared DC motor, which handles current and voltage levels necessary to drive the platform. He also attached a B10K potentiometer that serves as a position feedback sensor by adjusting resistance based on its rotational position. All of the gears that connect a motor shaft to the potentiometer were 3D-printed.
The DC Motor Position Control platform functions by reading the analog voltage from the potentiometer, which reflects the current position of the motor shaft. The UNO calculates the difference (error) between the current and desired positions, while a proportional control algorithm adjusts the motor’s speed and direction. The L293D shield uses PWM signals from the Arduino to drive the motor. Real-time feedback, including current position, desired position, and error value, is displayed on the serial monitor, allowing users to adjust the system’s performance.
Remoto: IoT Plug-and-Play Firmware with MQTT
The final speaker, Alberto Perro, discussed Remoto – a plug-and-play firmware for the Arduino Opta with MQTT, web server control, and real-time telemetry. The device is equipped with custom firmware that supports Wi-Fi and RS-485 communication, making it a versatile platform for any number of projects.
Remoto takes advantage of the MQTT protocol to publish real-time input statuses and receive control commands, which integrates with a myriad of IoT ecosystems. The firmware provides an intuitive interface that lets users monitor input and output statuses, view MQTT connection details, and configure device settings, including name, IP address, MQTT broker credentials, and input modes (both analog and digital).
According to Perro, Remoto doesn’t require any programming knowledge as it uses a straightforward setup process that doesn’t require complex code or configurations. He’s also uploaded the source code on GitHub for those who would like to build their own.
Conclusion
Each of these projects proves that industrial automation doesn’t have to be expensive or even complex. Whether it’s breathing new life into old equipment, fine-tuning motor control, or streamlining IoT integration, these talented engineers are solving real-world problems with readily available components. Hackster’s Impact Spotlights showed just how far a little imagination and affordable, readily available hardware can go.