Applications of safety-related control systems demand reliable and credible inputs from physical sensors, therefore there is a need to extend their capabilities to provide a validated input with high availability. Our main idea is to insert virtual sensors between physical sensors and the control system’s logic. The created solution can validate the values of real sensors and with the use of multiple virtual sensors we can achieve high availability in addition, therefore our solution is entitled as a virtual redundant sensor. It works by the digital twin’s concept and uses fusion function to calculate validated results. The fusion function is used to transform the measured values from the physical sensors according to designed numerical models. The selection of a numerical model with assigned fusion functions can be performed via the WEB-based graphical user interface. Proposal of the numerical model is created and validated on the experimental workplace with emulation of physical sensors and MQTT integration (smart IoT sensors). The results of testing have shown that our solution can be applied to validate the values of physical sensors. Proposed fusion functions calculated results according to the selected model in all cases, while non-standard cases were handled according to our definition. In addition, the high availability concept with a group of two virtual sensors has proven fast recovery and availability of results for safety-related applications as well.

With the development of MEMS sensors, the magnetometer has increasingly become a part of various wearable devices. The magnetometer measures the intensity of the magnetic field in all three axes, resulting in a 3D vector—direction and power. Calibration must be done before using a magnetometer, especially in wearable electronics, due to the low quality of the sensor and high proximity to other electromagnetic emission sources. Several magnetometer calibration algorithms exist in the literature, with most of them requiring multi-sided rotation. However, such calibration is highly impractical when the sensor is mounted on larger objects, e.g., vehicles, which cannot easily be rotated. Vehicles contain a large amount of ferromagnetic soft and hard material that affects the measured magnetic field. A magnetometer can be useful for an INS system in a car as long as it does not drift over time. This article describes how to calibrate a magnetometer using the GNSS motion vector. The calibration is performed using data from the initial section of the vehicle’s trajectory. The quality of the calibration is then validated using the remaining section of the trajectory, comparing the deviation between the azimuth obtained by GNSS and by the calibrated magnetometer. Based on the azimuth and speed of the vehicle, we predicted the position of the vehicle and plotted the prediction on the map. The experiment showed that such calibration is functional. The uncalibrated data were unusable due to the strong effect of ferromagnetic soft and hard materials in the vehicle.

Competitiveness in industry requires smooth, efficient, and high-quality operation. For some industrial applications or process control and monitoring applications, it is necessary to achieve high availability and reliability because, for example, the failure of availability in industrial production can have serious consequences for the operation and profitability of the company, as well as for the safety of employees and the surrounding environment. At present, many new technologies that use data obtained from various sensors for evaluation or decision-making require the minimization of data processing latency to meet the needs of real-time applications. Cloud/Fog and Edge computing technologies have been proposed to overcome latency issues and to increase computing power. However, industrial applications also require the high availability and reliability of devices and systems. The potential malfunction of Edge devices can cause a failure of applications, and the unavailability of Edge computing results can have a significant impact on manufacturing processes. Therefore, our article deals with the creation and validation of an enhanced Edge device model, which in contrast to the current solutions, is aimed not only at the integration of various sensors within manufacturing solutions, but also brings the required redundancy to enable the high availability of Edge devices. In the model, we use Edge computing, which performs the recording of sensed data from various types of sensors, synchronizes them, and makes them available for decision making by applications in the Cloud. We focus on creating a suitable Edge device model that works with the redundancy, by using either mirroring or duplexing via a secondary Edge device. This enables high Edge device availability and rapid system recovery in the event of a failure of the primary Edge device. The created model of high availability is based on the mirroring and duplexing of the Edge devices, which support two protocols: OPC UA and MQTT. The models were implemented in the Node-Red software, tested, and subsequently validated and compared to confirm the required recovery time and 100% redundancy of the Edge device. In the contrast to the currently available Edge solutions, our proposed extended model based on Edge mirroring is able to address most of the critical cases, where fast recovery is required, and no adjustments are needed for critical applications. The maturity level of Edge high availability can be further extended by applying Edge duplexing for process control.

The forest constitutes an essential and irreplaceable component of life for all organisms, with its primary significance lying in its role in creating a breathable atmosphere on Earth. Forests are vital for human health and well-being and hold significant ecological and economic value for humanity. This study aims to propose a method for identifying forest stands using artificial intelligence techniques. A custom dataset was developed, comprising high-quality satellite images that capture various structures such as forests, fields, roads, buildings, and lakes. This dataset was employed to train models from the category of convolutional neural networks that operate on the principle of instance segmentation. Several models, including YOLOv8, YOLOv5 and Mask R-CNN, were tested and compared. An optimal model was selected based on parameters such as detection accuracy, total training time, and the precision of labeling detected image elements. The selected model was then evaluated using images not included in the original training dataset to simulate real-world deployment scenarios. The final accuracy of best model achieved 91.67%. This model can detect the presence of forest stands in satellite images, as well as other features such as roads, buildings etc. The proposed method offers potential benefits for forest technicians, who can integrate it with other methods to monitor forest cover effectively.

In the paper, we share our research results and experiences with the industrial integration of IoT devices and OPC UA systems, assuming it is one of major enablers for Industry 4.0 use-cases. The main focus is paid on the numerical model of integration gateway, which could enable integration of various IoT devices, embedded and constrained systems, where implementation of full-scale OPC UA protocol is not possible. The goal is to create the appropriate model for OPC UA/IoT device integrations, verify and test it with implemented integration gateway. The gateway implementation scope and testing was concentrated on OPC DA and two major IoT protocols: MQTT and COAP.

Material tracking and localization are key applications of Industry 4.0 in manufacturing process control. Traditional approaches—such as barcode or QR code identification and RTLS-based localization using RF/UWB, 5G or GPS–require a large and complex infrastructure. As an alternative, this paper proposes an IoT-based solution that combines short-range Bluetooth Low Energy (BLE) communication with LPWAN LoRaWAN networks. Hybrid solutions using LoRaWAN and BLE technologies already exist, but pure localization based on BLE tags can lead to ambiguous asset identification in geometrically dense scenarios. Our paper aims to solve this problem with an alternative concept called Associated LoRaWAN Sensors (ALSs). An ALS enables logical grouping and integration of heterogeneous LoRaWAN sensors, providing their own data or directly scanning BLE tags. Sensor data can be combined and supplemented with new information, data, and events, supported by application logic (use case). Although ALS represents a general concept that could be applicable to various use cases (such as warehouse monitoring, object tracking), our paper will focus mainly on material tracking and validation in manufacturing. For this purpose, we designed a specific ALS model that integrates a classic LoRaWAN BLE sensor with an additional LoRaWAN magnetic contact sensor. The magnetic contact switch can provide validation of exact position, in addition to localization by BLE tag. Experimental validation using BLE tags (Trax 10229) and LoRaWAN sensors (IoTracker3, Milesight WS301) demonstrates the usability of the ALS model in typical industrial scenarios. We also measured RSSI and evaluated the accuracy of tag localization (3 × 25 = 75 tests) for the worst-case scenario: material validation on a machine with a BLE tag distance of ~0.5 m. While the traditional approach showed up to a 20% failure rate, our ALS model avoided the issue of incorrect accuracy. An additional magnetic switch in ALS confirmed that the correct carrier with the associated tag is attached to the machine and eliminated incorrect localization. The results confirm that a hybrid model based on BLE and LoRaWAN scanning can reliably support material localization and validation without the need for dense RTLS infrastructures.