Why Microcontrollers Still Shine in an Industrial IoT World

Why Microcontrollers Still Shine in an Industrial IoT World

A Simple Microcontroller for Your Next IoT Project?

Should you use a powerful Raspberry Pi 5 or a simple microcontroller for your next IoT project? The answer might surprise you. When designing IoT applications, the first instinct might be to gravitate towards a powerhouse like the Raspberry Pi 5. After all, it runs a full version of Python, a complete operating system, and significant computing power. However, in real industrial settings, such as factory automation or remote environmental monitoring, the landscape is more nuanced. 

Temperature Monitor

For example, consider a manufacturing plant that needs to monitor the temperature of hundreds of machines. Using a simple microcontroller for each sensor is cost-effective and reliable, while a central Raspberry Pi 5 can gather data from all the sensors and perform complex analysis, optimizing the overall efficiency of the plant. The decision between a full-fledged device like the Pi 5 and a microcontroller often boils down to balancing power, reliability, and efficiency, depending on the role each device will play.

Power Consumption and Simplicity

Microcontrollers, like those based on the RP2040 chip or even a Pico running MicroPython, are incredibly energy efficient compared to a full Raspberry Pi. In industrial applications where hundreds of sensors are deployed, the cumulative power cost matters a lot. Microcontrollers can run for extended periods on battery power, often requiring only milliwatts of energy. In contrast, the Raspberry Pi 5 needs a stable power supply that may be too demanding for remote, battery-powered sensor applications. 

Additionally, microcontrollers are simpler by design—there's no operating system to maintain, no unnecessary processes running in the background, just straightforward execution of the task they’re assigned. This simplicity reduces both the likelihood of failures and the maintenance overhead, resulting in reduced downtime, fewer interventions, and lower failure rates. Moreover, microcontrollers like the Pico run significantly cooler than the Pi 5, which can be an important factor in environments where heat dissipation is a concern.

Reliability and Real-Time Performance

In industrial settings, reliability is crucial, and here is where microcontrollers have another significant advantage. Unlike a full Linux-based system that may occasionally freeze, require reboots, or need updates due to the complexity of running multiple processes, microcontrollers operate in a much more predictable way. They are designed to run the same code continuously with consistent timing. This makes microcontrollers ideal for applications that require real-time performance, such as monitoring critical temperatures in machinery or controlling actuators. 

Industrial Conveyor Belt System

For instance, in an industrial conveyor belt system, a microcontroller can instantly respond to sensor inputs to stop the belt if an object is detected out of place, ensuring safety and precision without any delay. Microcontrollers respond to inputs almost instantly because they aren’t competing with an operating system for processing time—something that even the powerful Pi 5 can't guarantee when dealing with a full Linux-based system.

Cost Efficiency and Scalability

Finally, the cost factor cannot be ignored. Industrial-scale IoT deployments are not about buying a single board but rather hundreds or even thousands of nodes. Microcontrollers are significantly cheaper, making them the logical choice when you need to keep costs in check. The Pi 5 is versatile and powerful, but with its higher price tag and more advanced capabilities, it's overkill for simple sensor tasks, such as monitoring temperature or detecting motion. The Raspberry Pi 5 8GB model costs around $80, while a Pico ranges from $3 to $7 depending on the version and whether it comes with headers. 

Microcontrollers provide a scalable solution, allowing you to deploy sensors throughout a factory or remote site at a much lower cost. Meanwhile, a Pi 5 can be used as a central hub, collecting data from multiple microcontrollers and performing tasks that are too complex for a microcontroller.

Conclusion

In summary, while the Raspberry Pi 5 is an impressive device, using it as a sensor node in an industrial IoT setup is like using a high-end tool for a task that a simpler solution could handle just as well. For example, deploying a Pi 5 for a basic temperature sensing task would be over-engineering, whereas using a microcontroller is more appropriate and efficient for such straightforward roles.

Efficient, Reliable, and Cost-Effective

Microcontrollers are designed to be efficient, reliable, and cost-effective for the simple yet essential roles they play. The Pi 5, on the other hand, shines when it's needed to orchestrate, compute, and provide the brains of the operation. The value of microcontrollers lies in their simplicity, allowing them to be the perfect partners in the broader IoT ecosystem. 

The Right Tool for the Job

Whether you are considering a small-scale project or a large industrial deployment, evaluating your specific needs will help you choose the right tool for the job. By combining the strengths of microcontrollers for simple, distributed tasks and the Raspberry Pi 5 for more complex processing, industries can create highly efficient and scalable IoT solutions.

Image:  Raspberry Pi