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Corexel

Industrial Automation · 2024

Nexora Systems

Real-time industrial monitoring with ESP32 telemetry nodes

Delivered a unified monitoring dashboard, MQTT-backed telemetry network, and remote diagnostics across distributed plant assets.

  • ESP32 telemetry nodes
  • MQTT backbone
  • Remote diagnostics
Nexora Systems systems architecture

Context

Problem framing

Nexora Systems runs multi-line manufacturing plants where PLCs and legacy SCADA already own the critical path. Leadership needed live visibility into throughput, downtime, and edge device health without a rip-and-replace program or shift-disrupting cutovers. Corexel joined control-room operators, plant IT, and automation engineers in two discovery weeks to map signal sources, Wi‑Fi dead zones, and the minimum viable telemetry schema operators would actually trust on a night shift.

Challenge

Constraints

Shop-floor equipment spoke different protocols and sampling rates. Industrial Wi‑Fi introduced burst loss; any dashboard that lagged or dropped frames would be abandoned within days. Remote diagnostics had to work when VPN paths were congested, and firmware updates could not brick nodes mid-production. Security required device identity, topic isolation per line, and audit-friendly access for both Nexora staff and Corexel support.

Architecture

System design

ESP32 edge nodes normalize analog and digital inputs locally, apply back-pressure when brokers are unavailable, and publish versioned payloads over MQTT with per-line topic namespaces. A clustered broker tier handles fan-in; TimescaleDB stores time-series with retention policies aligned to operations review cycles. The React control surface prioritizes alert routing, line-level drill-down, and diagnostic playbooks—not vanity charts. FreeRTOS tasks separate acquisition, networking, and OTA with watchdog paths validated on the noisiest lines first.

Delivery

How we shipped

We piloted on two lines, hardened firmware against EMI and temperature swings, then expanded in waves with a remote diagnostics runbook Nexora operators own. Each wave included shadow comparison against SCADA totals, rollback scripts, and hypercare until p95 telemetry latency stayed under 200ms. Deliverables: real-time monitoring dashboard, ESP32 telemetry fleet, MQTT backbone, remote diagnostics, and edge firmware optimization—handed off with on-call pairing, not a slide deck.

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