Industrial Temperature Monitoring & Control IoT Device

Designed and delivered a production-grade embedded IoT device for real-time boiler temperature monitoring and closed-loop control in an industrial environment.

Built around an ESP32-S3, the device continuously samples thermocouple/sensor data, applies configurable threshold logic, and drives control outputs to maintain safe boiler operating temperatures. A 4-inch industrial 4-digit 7-segment display provides clear floor-level visibility even in harsh, high-ambient-light conditions. Operators set temperature thresholds directly on the unit via a 4-button programmable interface — no external tools required.

The 4-layer industrial-grade PCB isolates high-voltage control traces from sensitive analog sensing circuits, with dedicated power and ground planes for noise suppression — critical in an EMI-heavy boiler environment. A USB-C interface enables direct ESP32 flashing without disassembly, simplifying firmware updates in the field. Robust C++ firmware handles sensor polling, debounced input handling, display refresh, and relay actuation within a deterministic control loop.

IoT connectivity via ESP32's built-in WiFi enables remote temperature logging and alert push — accessible from any browser or dashboard.