Wireless sensor network simulation for fault detection in industrial processes

Sensor data is extremely important to monitor machines at the shop-floor level and its environmental surrounding conditions for condition-based monitoring, machine diagnosis and process adaptation to new requirements. Based on the described scope, self-diagnostics and self-organizing capabilities are core functionalities of any Industrial Wireless Sensor Network (IWSN). In the present work, a simulated case study was developed with the main intent of validating techniques implemented for sensor data diagnosis of error detection and equipment failure. The scenarios explored try to mimic some common situations of a manufacturing environment when dealing with WSNs, where a piece of sensor equipment suddenly stops working or an unpredictable change in the environment leads to faulty data readings. This paper introduces Castalia and describes how it was used to simulate a direct application of an Optical Metrology System on an industrial Resistance Spot Welding process, which is composed of a camera and several luminosity sensors. More specifically, a sensor data validation module was proposed, implemented and used to extend Castalia functionalities.