Practical use cases and architectures
Complete solutions designed to connect the factory floor (OT) to corporate management and supervision systems (IT/SCADA/MES).
ESP32 Wi-Fi NAT repeater
An original project that turns the ESP32-S3 into an access point, Wi-Fi client and NAT gateway, with an embedded configuration portal and DNS propagation for clients.
Factory floors and technical offices can have Wi-Fi blind spots. Commercial routers are bulky and require dedicated power infrastructure.
ESP-IDF firmware with NAPT enabled in lwIP. The device connects to the main network through the Station interface, creates its own network through the Access Point interface and forwards traffic between both, propagating the router DNS through DHCP—the step often missing when a client connects but cannot browse. Arduino Core is not suitable here because its lwIP build does not include IP forwarding.
Complete industrial project catalog
ESP32 Wi-Fi NAT repeater
An original project that turns the ESP32-S3 into an access point, Wi-Fi client and NAT gateway, with an embedded configuration portal and DNS propagation for clients.
Factory floors and technical offices can have Wi-Fi blind spots. Commercial routers are bulky and require dedicated power infrastructure.
IIoT gateway for isolated machines
A gateway bridges equipment and systems that use different communication methods: it reads factory-floor data, organizes it and delivers it over local Ethernet to SCADA or MES platforms using OPC UA as the integration standard.
Many industrial gateways are expensive. For a machine with hundreds of real-time tags that investment may make sense, but for a water pump, motor, compressor or another isolated node the question is whether a gateway costing about BRL 5,000 is justified. This project will investigate that boundary.
Industrial ESP32 gateway: Modbus RTU to MQTT
RS-485 communication gateway for transparent conversion of Modbus RTU data into JSON-formatted MQTT topics for SCADA and MES.
Legacy power meters and variable-frequency drives in an electrical panel communicate only through Modbus RTU over RS-485, preventing direct visualization in web systems.
Embedded Wi-Fi configuration web portal
A web portal embedded in the firmware binary, opened by a technician's phone to configure Wi-Fi in the field, scan networks and store settings in NVS.
Maintenance technicians need to change the SSID, Wi-Fi password and MQTT broker IP without reprogramming the board through a USB cable.
Motor temperature and vibration monitoring
Predictive-maintenance sensor using a triaxial MPU6050 accelerometer and Type K thermocouple on large electric motors.
Unexpected bearing failures and overheating in electric motors cause unplanned downtime and operating losses.
ESP32 connected to a SCADA platform
Direct integration of ESP32 telemetry with an industrial SCADA environment through secure MQTT over TLS, heartbeat and alarm management.
Companies need to consolidate telemetry from multiple industrial sites in one cloud platform with SMS or email alerts.
Industrial production counter with ESP32
Real-time piece-counting system with an inductive optical sensor, hardware/software debounce and production-speed calculation.
Manufacturing lines without automation lose visibility into hourly production rates and depend on manual entries.