Smart Fault-Tolerant Sensor Monitoring System

A Modbus RTU-based Industrial Automation Solution with Adaptive Polling & Encrypted IoT Integration for Industry 4.0.

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🚀 Overview
Industrial environments require reliable, real-time monitoring systems for hazard detection and predictive maintenance.
This project modernizes Modbus RTU (RS485) by integrating:

• Adaptive polling algorithm – prioritizes critical sensors (gas/flame).
• Fault detection system – real-time alerts and logging.
• AES-encrypted IoT bridge – secure cloud connectivity (MQTT/Blynk).
• Python Tkinter GUI – lightweight SCADA alternative.

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✨ Extended Description
This project upgrades legacy Modbus RTU networks to Industry 4.0 standards. It combines Arduino-based sensor nodes with a Python-based master that features intelligent polling and fault detection. Real-time data is securely transmitted to the cloud for remote monitoring, making it ideal for industrial automation, factory floors, and predictive maintenance.

Applications:

• Industrial hazard detection (gas/fire/temperature).
• Smart factories and Industry 4.0 automation.
• Remote monitoring of critical environments (oil & gas, chemical plants).

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🔧 Key Features

• 35% reduction in Modbus traffic with adaptive polling.
• Real-time fault detection in <3 seconds.
• Secure AES-encrypted data push to MQTT/Blynk dashboards.
• Modular architecture – easily extendable to other sensors.

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🖥 System Architecture

[ Sensors ] → [ Arduino (Slave) ] → [ RS485 Bus ] → [ Python Master ]
                     ↓                          ↓
             Fault Detection        Cloud Dashboard (MQTT/Blynk)
                     ↓                          ↓
                Tkinter GUI              Encrypted Data Logs

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📁 Repository Structure

arduino/
   smart_modbus_slave.ino
python_master/
   main.py
tests/
   test_sample.py
docs/
   image 1.png
config.example.yaml
requirements.txt
README.md
LICENSE

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📦 Quick Start
1. Clone Repo

git clone https://github.com/<your-username>/smart-modbus-rtu-iot-monitoring.git
cd smart-modbus-rtu-iot-monitoring

2. Install Dependencies

pip install -r requirements.txt

3. Run the Python Master

python python_master/main.py

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📷 Screenshots

(Upload images in docs/ and update the links below)

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🔮 Roadmap

• Modbus TCP/IP Support.
• AI-based anomaly detection.
• Mobile app dashboard integration.
• Wireless node support (LoRa/ESP32).

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📚 References

• Modbus Protocol Specifications
• PyModbus Documentation
• MQTT Protocol
• AES in Python

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👤 Author

Sakthivardhan Sankar
LinkedIn