Authors : Dr. Sayyad Naimuddin; Dipali Wankhade; Manasvi Parteki; Tanmay Mesharam; Vipin Suryavanshi; Simran Bhagat

Volume/Issue : Volume 10 - 2025, Issue 3 - March

Google Scholar : https://tinyurl.com/mucvfdxv

Scribd : https://tinyurl.com/ysvahw28

DOI : https://doi.org/10.38124/ijisrt/25mar1449

Google Scholar

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Note : Google Scholar may take 15 to 20 days to display the article.

Abstract : One of the primary challenges when integrating PLCs with IoT or remote monitoring systems is ensuring compatibility between the PLC’s I/O interfaces and the Wi-Fi module. This project presents a low-cost module utilizing the ESP8266 Wi-Fi module and ULN2003 driver to remotely control and monitor programmable logic controllers (PLCs) via Wi-Fi. The growing demand for affordable and efficient automation systems in industries, especially among small and medium-sized enterprises, has driven the need for wireless solutions. By integrating the ESP8266’s wireless communication capabilities and the ULN2003’s high-current load interfacing, the system provides a cost-effective alternative to traditional wired methods. This wireless module simplifies installation, reduces maintenance costs, and offers real-time control and monitoring via a user-friendly web interface accessible from any internet-enabled device. The proposed solution aligns with Industry 4.0 trends, enhancing operational efficiency and flexibility.

Keywords : PLC, ESP8266, Driver IC, Automation, WI-FI.

References :

1. J. Smith, et al., “Energy Efficiency and Wireless Capabilities of ESP8266,” Journal of IoT Applications, vol. 10, no. 2, pp. 45-52, 2018.
2. R. Johnson and T. Lee, “Wireless PLC Control and System Scalability,” Industrial Automation Review, vol. 7, no. 4, pp. 33-41, 2019.
3. H. Chen, et al., “Reliability of ULN2003 Driver in High-Current Applications,” Electronics and Control Systems, vol. 12, no. 3, pp. 22-29, 2020.
4. M. Ahmed and P. Kumar, “Real-Time Wireless PLC Monitoring Using ESP8266,” Automation Journal, vol. 9, no. 1, pp. 11-19, 2021.
5. L. Garcia, et al., “IoT Integration with PLCs: Scalability and Flexibility,” IoT Innovations, vol. 8, no. 5, pp. 50-58, 2020.
6. D. Brown, et al., “Security Challenges in Wireless Automation: WPA2 Encryption,” Industrial Cybersecurity Review, vol. 6, no. 2, pp. 18-26, 2017.
7. Y. Wang and Z. Li, “Cost Reduction Using ESP8266 in Automation Systems,” Smart Industry Journal, vol. 5, no. 3, pp. 30-37, 2018.
8. R. Patel, et al., “High-Voltage Control Using ULN2003 Driver,” Electronic Systems Journal, vol. 11, no. 4, pp. 25-32, 2019.
9. Fernandez and Q. Zhang, “Intuitive Web Interfaces for Real-Time Monitoring,” Automation and Control, vol. 14, no. 1, pp. 40-47, 2021.
10. T. Nguyen, et al., “Reducing Installation Costs with ESP8266-Based Systems,” IoT and Automation, vol. 7, no. 6, pp. 59-67, 2020.
11. K. Sharma and B. Gupta, “Cloud-Based Platforms for Remote Access: Kmesmart.com,” Smart Industry Innovations, vol. 10, no. 2, pp. 15-22, 2021.
12. G. Bedi, G. K. Venayagamoorthy, R. Singh, R. R. Brooks, and K.-C. Wang, “Review of Internet of Things (IoT) in Electric Power and Energy Systems,” IEEE Internet Things J., vol. 5, no. 2, pp. 847–870, 2018.
13. D. Minoli, K. Sohraby, and B. Occhiogrosso, “IoT Considerations, Requirements, and Architectures for Smart Buildings –Energy Optimization and Next Generation Building Management Systems,” IEEE Internet Things J., vol. 4, no. 1, pp. 269–283, 2017.
14. Qie. “A Comprehensive Review of Smart Energy Meters in Intelligent Energy Networks,” IEEE Internet Things J., vol. PP, no. 99, pp. 1–1, 2015.[
15. E. Spano, S. Di Pascoli, and G. Iannaccone, “Internet-of-things infrastructure as a platform for distributed measurement applications,” Conf. Rec. -IEEE Instrum. Meas. Technol. Conf., vol. 2015-July, pp. 1927–1932, 2015.
16. M. Rizzi, P. Ferrari, A. Flammini, and E. Sisinni, “Evaluation of the IoT LoRaWAN Solution for Distributed Measurement Applications,” IEEE Trans. Instrum. Meas., vol. 66, no. 12, pp. 3340–3349, 2017.
17. M. Oliveira Leme, F. Trojan, A. C. Francisco, and A. A. Paula Xavier, “Digital Energy Management for Houses and Small Industries Based on a Low-cost Hardware,” IEEE Lat. Am. Trans., vol. 14, no. 10, pp. 4275–4278, 2016
18. Zanella, N. Bui, A. Castellani, L. Vangelista and M. Zorzi, "Internet of Things for Smart Cities", IEEE Internet of Things Journal, vol. 1, no. 1, pp. 22-32, 2014.
19. Lee, L. Zappaterra, K. Choi and H. Choi, "Securing Smart Home: Technologies, Security Challenges, and Security Requirements", in Workshop on Security and Privacy in Machine-to-Machine Communications (M2MSec’14), 2014, pp. 67-72.
20. M. Andersson, Short-range Low Power Wireless Devices and Internet of Things (IoT), 1st ed. connectBlue, 2014, pp. 1-13.
21. Rahman, "Comparison of Internet of Things (IoT) Data Link Protocols", pp. 1-21, 2015.
22. F. Johari, "The security of communication protocols used for Internet of Things", Master of Science in Computer Science, Lund University, Sweden, 2015.
23. C. Gomez and J. Paradells, "Wireless home automation networks: A survey of architectures and technologies", IEEE Communications Magazine, vol. 48, no. 6, pp. 92-101, 2010.