Implementation of Wireless Sensor Networks for Industrial Automation Applications

Abstract

Wireless sensor networks (WSNs) provide a flexible sensing and communication layer for industrial automation by connecting distributed sensors, gateways, controllers, and supervisory systems without extensive field wiring. This methodology paper presents an implementation framework for an industrial WSN intended for condition monitoring, alarm reporting, and low-rate process automation. The proposed architecture uses low-power sensor nodes, an IEEE 802.15.4-based multi-hop network, an industrial gateway, and integration with PLC/SCADA services. The design emphasizes deterministic alarm handling, packet reliability, energy efficiency, interoperability, and maintainability in harsh radio environments. A controlled prototype/simulation methodology is specified using temperature, vibration, pressure, and current sensing nodes. Network performance is evaluated through packet delivery ratio, end-to-end delay, throughput, retransmission rate, and node energy consumption. The methodology also introduces priority-aware traffic handling in which alarms receive shorter reporting intervals and higher forwarding priority than routine monitoring packets. Representative evaluation results from the defined test scenario indicate that the priority-aware configuration can maintain packet delivery above 97% at 20 nodes while keeping mean alarm delay below 60 ms under moderate interference. Compared with a fixed-priority baseline, the proposed configuration reduces retransmissions and improves the percentage of alarms delivered within 100 ms. The framework is suitable for laboratory validation and can be adapted to smart factories, rotating-machinery monitoring, utility equipment, and distributed production cells.