NFN Switching Unit (SW)

End-to-End Industrial IoT Solution for Industrial Automation Hub / IoT Actuator

1. Project Overview

Client: Nexus Fish Network (NFN)

Device Type: Industrial Automation Hub / IoT Actuator

Role: Senior IoT Engineer (Firmware & Hardware Architect )

Core Tech: ESP32, 8-Channel Relay Logic, MQTT API

The NFN Switching Unit (SW) serves as the "Hands" of the Smart Aquaculture Ecosystem. While the Sensor Unit (SEN) gathers data, the SW Unit executes physical actions. It is an intelligent, cloud-connected actuator designed to automate high-load farm equipment such as Paddle Wheel Aerators, Air Pump & Diffuser Aerators, Automatic Feeders, and Water Management.

By replacing manual switchboards with this IoT-enabled solution, the system translates algorithmic decisions into physical reality, optimizing energy consumption and ensuring rapid response to critical water quality events.

2. Hardware Architecture

The device is engineered to handle the harsh electrical environment of agricultural sites while maintaining precise digital control.

Microcontroller: ESP32 (Dual-core) handling Wi-Fi/MQTT stacks and logic processing.
Actuation Interface: Equipped with an 8-Channel Relay Module capable of switching AC loads. This allows a single unit to manage multiple aerators and feeders simultaneously.
Power System: Powered by a stable 12V 2A DC Adapter, ensuring sufficient current for simultaneous relay coil activation without voltage sag.
Connectivity: Operates via a robust MQTT over Wi-Fi protocol, allowing for near-instantaneous (<200ms) triggering of devices from the cloud.

3. Operational Logic: AI-Driven Automation

Unlike traditional timers, the SW Unit operates on Dynamic Logic derived from the ecosystem's Sensor Nodes (SEN).

Scenario 1: Oxygen Automation (Energy Saving)
- Process: The SEN Unit detects Dissolved Oxygen (DO) dropping below a critical threshold (e.g., 4 mg/L).
- Cloud Logic: The server analyzes water dynamics and sends a command to the SW Unit.
- Action: The SW Unit triggers the Aerator relays immediately. Once DO levels normalize, the system turns them off, preventing energy wastage.
Scenario 2: Precision Feeding
- Process: The Cloud Schedule or AI Growth Model determines optimal feeding times.
- Action: The SW Unit activates the Feeder motors for precise durations, minimizing feed waste and water pollution.

Scenario 3: Smart Water Level Maintenance (Inlet Control)
- Trigger: The Ultrasonic Water Level sensor on the SEN Unit detects that the pond water level has dropped below the pre-set threshold (e.g., due to evaporation or seepage).
- Cloud Decision: The server verifies the reading and sends a "Refill" command via MQTT.
- SW Action: The unit triggers the relay for the Inlet Pump, filling the pond until the target level is reached, preventing water stress on the fish.
Scenario 4: Automated Quality Flush (Outlet & Inlet Sync)
- Trigger: The SEN Unit reports critical levels of toxic Ammonia (NH3) or high Turbidity that simple aeration cannot fix.
- Cloud Decision: The AI logic initiates a "Water Exchange Protocol."
- SW Action:
  1. Drain Phase: Activates the Outlet Pump to discharge the bottom layer of dirty water.
  2. Refill Phase: Once the water level drops to a safety limit, it automatically switches off the Outlet Pump and activates the Inlet Pump to introduce fresh water, restoring balance to the ecosystem.

"These logic cycles are fully configurable via the mobile app, allowing farmers to set specific thresholds for pump activation."

4. Reliability & Maintenance Features

To ensure industrial-grade reliability, the firmware includes several advanced maintenance features:

Internal Climate Monitoring (DHT22):
- Just like the SEN unit, the SW PCB includes an onboard DHT22 sensor. This continuously reports the internal temperature and humidity of the control box, allowing proactive maintenance if the enclosure overheats or seal integrity is compromised.
Unique Device Addressing:
- The firmware automatically generates a Unique ID based on the ESP32’s MAC Address. This allows the server to individually address and control hundreds of SW units across a large farm without IP conflicts.
Dynamic Configuration (OTA):
- The device supports Over-the-Air (OTA) updates and remote configuration. Can be reconfigured via the MQTT API without physical access to the device.

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NFN Switching Unit (SW)

End-to-End Industrial IoT Solution for Industrial Automation Hub / IoT Actuator

1. Project Overview

Get in touch at "ramim.cse.uctc@gmail.com"

https://www.facebook.com/IoTWithRamim/
linkedin.com/in/ramim256
+8801836655062

NFN Switching Unit (SW)

End-to-End Industrial IoT Solution for Industrial Automation Hub / IoT Actuator

1. Project Overview

Get in touch at "ramim.cse.uctc@gmail.com"

https://www.facebook.com/IoTWithRamim/linkedin.com/in/ramim256+8801836655062

https://www.facebook.com/IoTWithRamim/
linkedin.com/in/ramim256
+8801836655062