Design and Implementation of Low-Cost Redundant Subsystems for PFAL Reliability

The increasing adoption of Plant Factories with Artificial Lighting (PFAL) has intensified the reliance on Internet of Things (IoT) technologies for real-time monitoring and control of environmental and operational variables. While IoT-based architectures enable precise resource management and productivity optimization, PFAL systems remain highly vulnerable to component failures, sensor malfunctions, communication faults, and energy disruptions, which may compromise crop integrity and system reliability. These risks are particularly critical in low-cost and small-scale PFAL implementations, where maintenance capacity and redundancy are often limited. Existing IoT-based PFAL monitoring systems typically address either hardware or software redundancy in isolation and rarely incorporate a dedicated maintenance-oriented fault detection layer validated under realistic multi-failure scenarios. This study addresses these challenges by proposing a low-cost redundant system architecture for PFAL applications that simultaneously integrates (1) hardware redundancy through multi-sensor configurations; (2) analytical redundancy based on residual generation and threshold-based fault isolation; and (3) a maintenance-oriented fault detection layer capable of identifying abnormal internal device conditions. Experimental validation was conducted using four hardware configurations—Arduino Nano with Ethernet, ESP32, STM32 with Wi-Fi, and STM32 with Ethernet—evaluated across five fault scenarios: dust accumulation, water exposure, high temperature, fire detection, and physical impact. The STM32 with Ethernet configuration consistently achieved the fastest fault detection response times across all tested scenarios. Future work will focus on the integration of machine learning-based predictive maintenance algorithms, multi-node PFAL network deployments, and long-term field validation.