Mitigating Electromagnetic Noise When Using Low-Cost Devices in Industry 4.0

Transitioning toward Industry 4.0 requires major investment in devices and mechanisms enabling interconnectivity between people, machines, and processes. In this article, we present a low-cost system based on the Raspberry Pi platform to measure the overall equipment effectiveness (OEE) in real time, and we propose two filtering mechanisms for electromagnetic interferences (EMIs) to measure OEE accurately. The first EMI filtering mechanism is the database filter (DBF), which has been designed to record sealing signals accurately. The DBF works on the database by filtering erroneous signals that have been inserted in it. The second mechanism is the smart coded filter (SCF), which is used to filter erroneous signals associated with machine availability measurements. We have validated our proposal in several production lines in a food industry. The results show that our system works properly, and that it considerably reduces implementation costs compared with proprietary systems offering similar functions. After implementing the proposed system in actual industrial settings, the results show a mean error (ME) of −0.43% and a root mean square error (RMSE) of 4.85 in the sealing signals, and an error of 0% in the availability signal, thus enabling an accurate estimate of OEE.