A Secure Industrial Internet of Things (IIoT) Framework for Real-Time PI Control and Cloud-Integrated Industrial Monitoring

The explosion of Industry 4.0 has augmented the demand for secure, agile, and real-time industrial monitoring and control applications. In this paper, a secure Industrial Internet of Things (IIoT) system for real-time PI control and cloud-based industrial monitoring is proposed. The developed system combines Siemens S-300 PLC (programmable logic controller) and Node-RED platform that provides real-time data acquisition, display, and remote control for industrial parameters like Level/Water temperature. An integrated end-to-end data pipeline is implemented to allow transparent information exchange between the PLC, Node-RED dashboard, MQTT-based services, and cloud infrastructures, providing real-time data synchronization as well as remote access. The PI controller, whose parameters can be adjusted online using a website or mobile app, is implemented by our framework without loss of control loop stability. Safety is improved by authentic access and the regulation of the user’s rights in order to avoid undelegated system operation. The experimental validation in a real-world industrial automation lab reveals the robustness of the real-time monitoring, enabling concurrent visualization over multiple interfaces and satisfactory PI control performance. The results substantiate the efficiency, applicability, and reliability of the developed IIoT system for real-world industrial monitoring and control scenarios.