Algorithms for reliable data transmission for metal fill monitoring using Wireless Sensor Networks

Among the wide range of wireless sensor network applications, many require reliable data communications such that data packets can be delivered to the destination without loss. This thesis is focused on one such application, viz. metal-fill monitoring system for the lost foam casting process implemented using capacitive sensors and Wireless Sensor Networks. Experiments were carried out in the TTU foundry to measure Radio Signal Strength and Link Quality and characterize data packet losses. The problem of packet losses associated with wireless transmission of data using wireless sensor networks with emphasis on the foundry environment has been explored and two solutions were investigated. The first is based on Delayed Retransmission and is suitable for offline monitoring. The second is for online monitoring and is based on Erasure Coding using Cauchy Reed - Solomon codes. The two solutions have been tested and evaluated for the metal-fill monitoring application. The entire system from sensing to data transmission provides a flexible and cost effective method to monitor the metal fill process.