Industrial IoT Energy Monitoring Solution Using Microchip PIC, AVR, React Native, and WPF

Our client, a mid-sized manufacturing company, had many challenges with energy management and operational efficiency in all of their industrial plants. They needed a smart energy monitoring system that could perform real-time energy monitoring, predictive analytics, and seamless integration with their current industrial system.

They called us to create an integrated industrial solution for them that includes monitoring power consumption, tracking equipment efficiency, and providing actionable insights that will help them optimize energy efficiency and lower their operational costs.

To create an integrated industrial energy-monitoring solution that includes:

• Development of hardware based on Microchip's PIC and AVR microcontrollers
• Developing embedded software and firmware to gather real-time data
• Creating custom PCBs and constructing the industrial-grade housings
• Developing cloud-based and backend applications/infrastructure
• Developing REST APIs and SDKs for SCADA/ERP integration
• Manufacturing and implementing both QA processes and large quantities of products

Cross-platform software applications:

• Mobile App using React Native
• Desktop Application using WPF (.NET)
• Web-based dashboard

Our goal was to deliver a scalable, secure, and reliable solution to improve energy efficiency and reduce operational costs.

Device Summary

Category:

Intelligent Machinery Energy Consumption Measuring Device

Main Context:

Monitoring/Reporting of Machinery (Energy Usage) Consumption in Real Time

Highlights of Product Characteristics

• Ability to Monitor Energy (Voltage, Current, Power Factor and Usage) in Real Time
• Ability to Monitor Machinery on a Machine-to-Machine Basis
• Ability to Use Predictive Analytics to Detect Anomalies and Predict Maintenance Needs
• Software work on All Platforms (Web-based; Mobile App; Desktop)
• Integration with Cloud Systems and Ability to Review Historical Trends
• APIs and SDKs Available for SCADA, ERP, and IoT integration
• Over-The-Air Firmware Updates

Microprocessor Used

• PIC18F46K22 - This is used in a real-time monitoring for a power sensor and is also interfacing with other sensors.
• ATmega328P - This Microcontroller is used for additional processing power and communicating to the main processor.

Reasons Why Selected

• Low power required to continually monitor
• High-speed, accurate ADC's
• Very many peripherals (UART, SPI, I2C, PWM)
• Reliable for industrial use
• A well-established ecosystem that supports rapid product development

1. PCB & Hardware Design

• Multilayer PCB Design With Digital/Analog Isolation
• Sensors: CT, Voltage Divider, Temperature/Vibration Sensors
• Connectivity Options: RS485, Ethernet, WiFi
• Industrial Power Supply With Surge Protection
• Metal Enclosure (IP54/IP65)

2. Firmware & Embedded Development

• Real-time data acquisition and processing
• Sensor fusion algorithms for accuracy
• Protocols: Modbus TCP/RTU, MQTT (TLS), REST APIs
• Low-power operation modes
• OTA firmware update support

3. Industrial Design & Casing

• Heat-resistant metal enclosure
• Modular, easy-to-install design
• LED indicators for system status
• Compliance with industrial standards

4. Cloud Solution & Backend Architecture

• Azure IoT Hub/AWS IoT Core For Device Communication
• Time-Series Database/Relational Database
• Real-Time Analytics/Anomaly Detection
• Event-Driven Notifications Via Email/SMS/Push Notifications
• Scalable Microservices Architecture

5. Software Development

5.1 Mobile Application (React Native)

We created a mobile app using React Native allowing users to view and be alerted about their energy consumption from anywhere.

Main features include:

• Energy monitoring dashboard that is real-time
• Alerts for unusual energy use with push notifications
• Alerts for status of devices being monitored
• History data with visuals for monitoring energy consumption
• Ability to sync data while offline or in low connectivity situations
• Ability for secure login and role-based access to data

5.2 Desktop Application (WPF - .NET)

A powerful desktop application was built using WPF to provide advanced analytics and operational control for industrial users.

Key Features:

• Real-time multi-device monitoring dashboard
• Advanced analytics and trend visualization
• Report generation (Excel/PDF)
• Device configuration and firmware management
• Offline data logging and synchronization
• Integration with local industrial systems (SCADA-ready)

WPF enabled high-performance UI, rich data visualization, and seamless hardware interaction in industrial environments.

5.3 Web Dashboard

• Real-time monitoring and device management
• Energy consumption trends and reports
• Multi-user access and role-based dashboards

5.4 SDK & REST APIs

• Utilizing SCADA/ERP/3rd Party systems integration
• APIs designed for automation and analytics purposes
• Webhooks that trigger events based upon real-time activity

6. Manufacturing & Quality Assurance

• SMT and through-hole PCB assembly
• Functional testing of sensors and communication
• Environmental and vibration testing
• Automated firmware flashing and QA processes

• Launched in multiple industry plants
• 15-20% increase in energy efficiency
• Predictive analytics help minimize equipment downtime
• Mobile, desktop and web-based access allows for real-time monitoring
• Scalable backend with capacity to support hundreds of devices per plant
• Integrated with SCADA, ERP, and IoT systems seamlessly

A number of important aspects should be kept in mind when implementing an end-to-end IoT solution.

First, there is a need for integration across hardware, firmware, cloud, and software layers from beginning to end.

Second, PIC and AVR controllers should be used together to allow for efficient real-time processing. Third, the design must be industrial grade (for increased reliability).

Fourth, rapid mobile deployment across platforms occurred due to using React Native technology.

Fifth, WPF technology provided a strong solution for advanced analytics and control when deployed on desktop computers.

Sixth, leveraging cloud services and APIs enabled both scalability and a connection to other members of an IoT ecosystem. Finally, using over-the-air (OTA) updates provided long-term maintainability of all devices in an IoT field.

This project has demonstrated the additional benefits of utilizing an integrated understanding of embedded systems, cloud-based infrastructure, and cross-platform applications, to provide a comprehensive solution for energy management in industry.

We have delivered a scalable integrated energy management solution for the industries using the Microchip PIC and AVR controller hardware, with React Native mobile apps and WPF (Windows Presentation Foundation) desktop software that provides the ability to give real-time visibility and predictive analysis of the company's energy use and increase productivity by improving operational effectiveness of the organization.