Modelling of Advanced Sensor based Distributed Control System for Real- Time Prediction and Minimization of Power Loss in Industrial Automation Systems

This research study analyses the integration of a Distributed Control System (DCS) to optimise the efficiency and reliability of industrial automation, with a special emphasis on reducing power loss. Leveraging real-time sensor data and machine learning models, including Decision Trees, Artificial Neural Networks, and Random Forests, the research provides a proactive strategy to anticipating and avoiding anomalous current and voltage patterns. The DCS, armed with predictive maintenance procedures, emerges as a solid framework for reducing energy usage, assuring system stability, and limiting possible quality losses. Evaluation using performance ratings and confusion matrices reveals the efficiency of the proposed system in properly recognising and correcting deviations from normal operating circumstances. The results contribute not only to the progress of distributed control systems in industrial automation but also provide a realistic approach to real-time monitoring and predictive maintenance, supporting sustainability and operational excellence in manufacturing settings. This study sets a platform for future initiatives seeking to construct intelligent, adaptable systems for increased industrial automation performance.