What are embedded IoT systems and how do they work?

IoT embedded systems lie at the heart of the Industry 4.0 revolution. They are the backbone of smart factories, where data gathered from interconnected devices, machines, and systems allows manufacturers to optimise operational efficiency, streamline supply chains, ensure quality control and foster innovation.

In this article, we’ll explore what IoT embedded systems are, how they work, and how they can help you optimise the processes at your manufacturing company.  

Introduction to IoT and embedded systems

The Internet of Things (IoT) and embedded systems are two interconnected technologies that have revolutionised the way we live and work. IoT refers to a network of physical devices embedded with sensors, software, and connectivity, enabling them to collect and exchange data. Embedded systems, on the other hand, are specialised computer systems designed to perform dedicated functions within larger systems. Together, they form the backbone of modern smart technologies, driving innovation across various industries.

What is IoT?

IoT, or the Internet of Things, is a vast network of physical devices, vehicles, home appliances, and other items embedded with sensors, software, and connectivity. This network allows these devices to collect and exchange data with other devices and systems over the internet. IoT devices can range from simple sensors that monitor environmental conditions to complex systems that manage entire industrial processes. They are used in a wide array of industries, including healthcare, manufacturing, transportation, and smart homes, transforming how we interact with the world around us.

What is an embedded system?

An embedded system is a small computer system designed to perform a specific task or set of tasks. It typically consists of a combination of hardware and software components that work together to provide a particular function or service. Embedded systems are ubiquitous, found in consumer electronics like smartphones and smartwatches, industrial control systems, medical devices, and automotive systems. These systems are integral to the operation of many modern technologies, providing the necessary control and processing capabilities.

Characteristics of IoT embedded systems

Traditionally, embedded systems are a combination of hardware and software that perform a dedicated function and typically control the operations of a machine it’s embedded within. The hardware elements include microcontrollers or microprocessors, actuators and sensors. The software components include an operating system, device drivers, and application software.

The Internet revolutionised the way we interact with technology. Today, embedded systems also include communication models, like wi-fi, Bluetooth or cellular connectivity, which allow them to collect and exchange data over the Internet that can be used later for monitoring and various analyses. Embedded systems that are used in IoT devices are called IoT embedded systems.

IoT embedded systems possess several distinctive characteristics that set them apart from traditional embedded systems:

• Connectivity: IoT embedded systems are designed to connect to the internet or other networks, enabling communication with other devices and systems. This connectivity is crucial for data exchange and remote monitoring.
• Sensing and actuation: These systems often include sensors that detect changes in the physical environment and actuators that perform actions based on sensor data. This capability allows IoT devices to interact dynamically with their surroundings.
• Data processing: IoT embedded systems can process data in real-time, making decisions and taking actions based on the data they collect. This real-time processing is essential for applications that require immediate responses.
• Energy efficiency: Given that many IoT devices operate on batteries or other limited power sources, energy efficiency is a critical design consideration. IoT embedded systems are optimised to consume minimal power while maintaining functionality.

How do IoT embedded systems work?

IoT embedded systems enable devices to become part of the Internet-of-Things ecosystem. They are used widely in smart homes, healthcare, automotive and especially in the Industry 4.0 sector.

The sensors, which are part of the embedded system, gather information about physical surroundings, for example, temperature, vibrations or humidity. The collected data is then exchanged with other devices or systems over the Internet. The data can then be analysed and used to make more informed decisions, automate processes or provide real-time feedback on the state of a device.

IoT embedded systems bring many benefits to modern manufacturing. Let’s take a look at a couple of the most common applications.

Hardware and software for IoT embedded systems

IoT embedded systems are composed of both hardware and software components, each playing a vital role in their operation.

• Microcontrollers: These small computers are designed to perform specific tasks, often controlling sensors and actuators within the IoT embedded system.
• Sensors: Devices that detect changes in the physical world, such as temperature, humidity, or motion, providing the data needed for the system to function.
• Actuators: Devices that take action based on sensor data, such as turning on a light or activating a motor, enabling the system to interact with its environment.
• Communication modules: Components that allow IoT embedded systems to communicate with other devices and systems over the internet, facilitating data exchange and remote control.
• Power management: Systems that manage the power consumption of the IoT embedded system, ensuring efficient use of batteries or other power sources.

How are IoT embedded systems used in Industry 4.0?

Predictive maintenance

IoT embedded systems and embedded devices can be used to collect real-time data, such as temperature, pressure or vibration measurements, from machines at the manufacturing plant. Then, the data can be analysed using machine learning algorithms. The insights can help predict when maintenance is required, preventing unexpected downtime. It can also help minimise maintenance costs since the maintenance is done only when needed.

Quality control

IoT embedded systems, powered by embedded software, are often used to monitor the production line in real-time in order to detect potential defects in manufactured products. As a result, defects can be spotted quickly and corrected immediately, which means reduced waste and better product quality.

Smart logistics

Chain efficiency is a key factor for manufacturers. IoT systems can be used to track inventory levels and automate the ordering process. As a result, there’s a lower risk of stockouts or overstocking. What is more, IoT embedded systems can also be used to track the delivery of materials in a supply chain. Manufacturers can then track their inventory levels in real-time, improving supply chain efficiency and minimising delays.

Enabling remote monitoring and management

By gathering data from sensors, for example, thermostats, an IoT operating system in IoT embedded systems can monitor the performance and condition of machinery and equipment remotely. Real-time data can help identify potential problems and reduce the risk of failure by taking preventive actions on time. Also, the insights can help schedule maintenance activities based on the actual wear of the equipment, leading to increased device lifespan.

Production optimisation

Through collecting and analysing data from various points of the production process, such as machine parameters or worker input, IoT embedded systems, combined with innovative software development, can help identify possible bottlenecks or inefficiencies. Manufacturers can then make quick adjustments to optimise the production process.

Implement IoT embedded systems at your manufacturing company

IoT embedded systems, powered by specialised operating systems, are transforming the manufacturing industry by providing real-time data analytics, predictive maintenance, improved quality control, and more efficient supply chain management.

Implementing IoT embedded systems will allow you to achieve higher productivity and reduce costs. Visit our Industry 4.0 offering page to find out more about how we can help you, or contact us directly via the form below.