Supervisory Performance of Monitoring of Industrial Machines and Faults Monitoring Using IoT

Abstract

This paper presents the design and implementation of an IoT based supervisory system for real time monitoring and fault detection in three phase industrial machines. Using an Atmega328P microcontroller, current and voltage sensors, and temperature sensing, the system continuously tracks electrical parameters. On detecting anomalies—such as short circuits, overloads, voltage fluctuations, and overheating—it triggers alarms, isolates the faulty load via relays, sends SMS alerts via GSM, and logs data to the ThingSpeak cloud via Wi Fi. Laboratory testing under simulated fault conditions demonstrates high accuracy in detection, rapid notification, and reliable data logging, enabling predictive maintenance and enhanced safety in both industrial and domestic applications.

Introduction

Electrical faults in three-phase systems (e.g., short circuits, overloads, imbalances) pose serious risks. Traditional manual inspection is inefficient. This work presents a low-cost, IoT-enabled monitoring system using microcontrollers (Atmega328P and ESP8266) to enable real-time fault detection, alerts, and remote supervision—supporting Industry 4.0 goals.

Literature Review
Past solutions using Arduino/ESP8266 with GSM/Blynk/ThingSpeak offer basic monitoring but lack integrated load isolation and multi-parameter analysis. This system addresses those gaps.

Proposed System
A four-tier system includes:

1. Sensors (CT, PT, thermistor)

2. Controller (Atmega328P)

3. Actuators (relays, buzzer, LCD)

4. Communication (ESP8266 for cloud, SIM900 for SMS)

Sampling occurs every 500 ms with configurable thresholds.

Hardware Implementation
The system uses common components (Atmega328P, CT/PT modules, NTC thermistor, ESP8266, SIM900, relays, etc.) to monitor current, voltage, and temperature.

Working Principle

• Sensors feed analog signals to the microcontroller.

• The system triggers local alerts (LCD, buzzer, LED) and isolates faulty loads via relays.

• Remote alerts are sent via SMS and logged to ThingSpeak.

Results
All faults were detected and responded to in under 1 second, with reliable cloud and SMS alerts across 50+ tests.

Advantages

• Real-time multi-parameter monitoring

• Automatic fault isolation

• Remote alerts and data logging

Applications
Useful in industrial motor protection, smart homes, data centers, and renewable energy systems.

Conclusion

An IoT enabled supervisory system for three phase fault monitoring has been developed and validated. The integration of GSM SMS, cloud logging, and relay based isolation enhances safety and reduces downtime.

References

[1] S. Verma et al., “IOT Based Three Phase Transmission Line Fault Detection,” ICCCI 2022. [2] K. Nikam et al., “IoT Based Three Phase Transmission Line Fault Detection and Classification,” IRJET, vol. 09, no. 09, Sep. 2022. [3] P. Anaji et al., “Three Phase Fault Analysis and Detection in Transmission Line Based On IoT,” IJERT, vol. 10, no. 11, 2022. [4] S. Chopade et al., “Survey Paper On IoT Based Three Phase Fault Detection System With Web Dashboard,” IJARSCT, vol. 2, no. 1, Feb. 2022. [5] C.?S. Hiwarkar et al., “Fault Detection in Three Phase Transmission Line By Using IoT,” IJRAS Tech., 2022.

Copyright

Copyright © 2025 Harshvardhan T. Gaikwad, Nikhilkumar R. Kamble, Sushant P. Kamble, Pradnyavant S. Kamble, Sushant S. Jadhav, Sanyam V. Kothawale, K. A. Mhaskar. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.