IoT-Enabled Supervised Learning-Based Prediction Model for Smart Instrumentation Controllers in Signal Conditioning Systems

Abstract

This study proposes an intelligent Machine Learning (ML)-based smart controller for industrial flow process systems to enhance accuracy, adaptability, and robustness compared to conventional Proportional–Integral–Derivative (PID) controllers. The main idea is to replace reactive PID tuning with a proactive data-driven control strategy capable of predicting deviations and adjusting process parameters in real time. The objective is to develop and evaluate supervised learning models that can replicate and improve PID performance using real-time operational data collected from a flow process station. The proposed system integrates Internet of Things (IoT) sensors and edge computing to continuously acquire and process flow rate, pressure, and valve position data for model training and testing within the WEKA platform. Four classifiers—Linear Regression, Multilayer Perceptron (MLP), Sequential Minimal Optimization Regression (SMOreg), and M5P model tree—were compared using Mean Squared Error (MSE), Root Mean Squared Error (RMSE), Relative Absolute Error (RAE), and model-building time as key evaluation metrics. Experimental results demonstrated that the M5P pruned tree model achieved the best overall performance with an MSE of 0.0024, RMSE of 0.0577, and model-building time of only 0.03 seconds, outperforming Linear Regression (RMSE = 0.0028), MLP (RMSE = 0.026), and SMOreg (RMSE = 0.0279). The findings show that the M5P-based controller closely replicates PID behavior while offering superior predictive accuracy, faster computation, and self-adaptive learning capabilities. The novelty of this research lies in demonstrating that an IoT-enabled, data-driven smart controller can achieve real-time predictive control without requiring explicit mathematical models, thereby simplifying tuning complexities and paving the way for autonomous, scalable, and intelligent control systems in Industry 4.0 environments.