Lab Monitoring & Telemetry System
A centralized, multi-node telemetry and interlock system built for CarettaLab. It collects real-time status parameters, chiller diagnostics, and vacuum pressures across distributed instruments, delivering live metrics and instant alarm alerts to ensure 24/7 experimental safety.
System Architecture & Multi-Node Hardware Roles
The monitoring architecture relies on a lightweight, event-driven MQTT publish-subscribe backbone. Hardware roles are distributed across dedicated microcontrollers and single-board computers placed directly at instrument interfaces.
Raspberry Pi Central Server
Central Aggregator & Web Host
Acts as the primary hub hosting the FastAPI web server, WebSocket broadcast engine, and MQTT watchdog monitor. It aggregates telemetry from all distributed nodes and powers the live web UI at lab-monitor.geofratian.com.
Orange Pi Zero 3 Node
PLD 1 Instrument Interface
Dedicated Linux edge node connected via Ethernet to the Pulsed Laser Deposition (PLD 1) Productivity PLC. Runs a 24/7 background systemd service querying Modbus TCP tags and publishing JSON telemetry to the central broker.
ESP32 Microcontroller Node
Chiller Alarm Interlock
Low-power microcontroller interfaced with the SMC Sputter Chiller over RS-485 serial (Modbus RTU). Continuously evaluates alarm registers and heartbeat signals to issue instant notification triggers upon fault conditions.
Key System Capabilities
Continuous Vacuum & Process Monitoring
Reads chamber base pressure, process gas flow rates, target selection states, and laser pulse statistics across deposition systems to provide a complete real-time record of operational parameters.
Equipment Protection & Automated Alerts
Monitors cooling water loop temperatures, flow rates, and chiller fault codes to protect high-cost optics, turbo pumps, and target magnetrons from thermal or mechanical damage during overnight runs.
Real-Time WebSockets & Telemetry Stream
Streams live instrument updates directly to client web browsers over WebSockets, minimizing polling overhead and enabling sub-second response times on dashboard visualizations.
Fail-Safe Watchdogs & Resilient Services
Configured with systemd auto-restart policies, network auto-reconnect loops, and hardware watchdog timers to ensure uninterrupted operation even across university power blips or network resets.
Access the Live Dashboard
Monitor active vacuum states, chiller health, and deposition telemetry remotely via the live browser portal.
Go to lab-monitor.geofratian.com →