ESP32 in Industrial Automation Projects

Introduction

Industrial applications require reliable hardware that can withstand vibrations, heat, stress, and intensive use, with long-term availability of replacement parts. This ensures operational continuity without the need for reprogramming or new hardware, software, and firmware developments. For these reasons, custom-designed electronic boards are preferred over consumer solutions.

The Microcontroller (MCU)

The microcontroller (MCU) is the heart of boards for industrial automation. Historically, CJB has used processors from Intel, AMD, or ARM, as well as MCUs based on ARM architecture. However, due to high costs and limited availability of these components during peak market demand periods, CJB has sought alternative solutions to maintain competitive pricing and consistent supply, even during times of high demand.

A Solution from the Consumer World

Espressif has recently introduced high-performance MCUs for the consumer, semi-professional, and light-industrial markets. The ESP32, the most well-known processor, is widely used for its low cost and consistent availability, making it an ideal platform for the development of libraries, firmware, and hardware. The ESP32 natively supports USB, touch sensors, matrix displays, external memories, and various networking technologies (Bluetooth and Wi-Fi), making it suitable for integration into industrial boards.

Adapting the ESP32 for High-Reliability Industrial Use

Although the ESP32 is commonly used in consumer electronics, CJB has heavily invested in its architecture, progressively integrating it into high-reliability products. The ESP32 offers models that fully meet industrial requirements, including:

• Versions resistant to high temperatures and vibrations
• Integrated or expandable RAM and ROM
• Hardware watchdog and timers
• I/O protection from ESD and electromagnetic events
• Management of brownouts and voltage dips
• Protected procedures for firmware updates (DFU)
• Hardware reset, upgrade, or recovery
• Pre-certified versions for RF emissions
• Multiple internal ADC and DAC conversions
• Multiple PWM, PDM/Sigma-Delta controls
• Hardware programming via e-Fuses
• Integrated I2C, SPI, and multiple UART buses
• High availability and guaranteed supply for 8-10 years
• High retro-compatibility to facilitate firmware and library porting
• Support for Real-Time Operating Systems (RTOS)

CJB has developed proprietary drivers, libraries, and hardware/software integrations to make the ESP32 suitable even for the most delicate industrial environments.

Retrofitting Existing Electronics with ESP32

With experience in using the ESP32, CJB can quickly redesign "non-smart" electronics to meet modern wired and wireless connectivity needs. This upgrade modernizes the machinery fleet, making it interconnected and ready for connection to cloud or remote services.

If you need to develop or integrate industrial systems with the ESP32 MCU, please contact us for more information.