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August 22, 2026Scientific ReportsOpen Access

An intelligent internet of things-based artificial intelligence framework for adaptive mechanical process control and real-time performance optimization

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Authors

VSVijaya Bhaskar SaduGVGopala Rao L. V. V.GAGopala krishna A

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Overview

Experimental study demonstrates reduced error and energy consumption in industrial process control, indicating a viable model for smart manufacturing.

Key Points

  • Develop an Artificial Intelligence-Enabled Control System (AI-ECS) integrating IoT sensing and hybrid machine learning to optimize real-time control, energy efficiency, and predictive maintenance in dynamic industrial environments.
  • Integrated IoT sensor networks with hybrid Random Forest and Long Short-Term Memory algorithms alongside dynamically tuned PID and MPC controllers on an edge-computing platform.
  • Evaluated the framework on a continuous-flow industrial process testbed using multi-rate sensor sampling and MQTT communication over 24-hour and 30-day operational windows.
  • AI-ECS achieved a 73.3% relative reduction in Mean Absolute Percentage Error (MAPE) and decreased energy consumption by 9.1% compared to traditional PID, APC, and IoT-only setups.
  • Impending mechanical faults were detected up to 36 hours before failure across a 48-hour pre-failure monitoring window alongside faster disturbance rejection.

Cite This Study

Sadu et al. (2026) studied this question.

synapsesocial.com/papers/6a89600eca7ade938187f09ahttps://doi.org/10.1038/s41598-026-67298-z
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