IoT Based Motor Fault Detection System

Description

#IoTMotorMonitoring #ArduinoProjects #MotorFaultDetection #IoTDefence #ArduinoUNO #FinalYearProject #CapstoneProject #SmartIndustry #ThingSpeakIoT #IoTBasedMonitoring   #VibrationMonitoring #IndustrialAutomation #IoTSafety

📘 Introduction

Electric motors are the backbone of industries, households, defense systems, and smart automation, driving everything from heavy equipment to household appliances. But motor faults like overcurrent, overvoltage, overheating, insulation degradation, vibration, or mechanical imbalance can lead to severe damage, unplanned downtime, and safety risks. Traditional fault detection methods rely on manual checks or delayed response systems, which tend to miss making timely alerts.

This project demonstrates an IoT-Based Motor Fault Detection System with Arduino UNO, which uses several sensors like a current sensor, voltage sensor, DHT11 (humidity & temperature), accelerometer (for vibration monitoring), and relay to sense motor health in real time. Sensor data is shown locally on a 20×4 LCD Display and also uploaded to ThingSpeak IoT Cloud through the ESP8266 Wi-Fi module for remote monitoring. If there is abnormal motor behavior, the system creates a buzzer alarm and can drive the AC motor through relay switching to avoid catastrophic breakdowns. This preventive system facilitates industrial safety, predictive maintenance, and operation reliability.

🎯 Objectives

• To monitor motor current, voltage, vibration, and temperature-humidity in real time.
• To display sensor readings on a 20×4 LCD Display for on-site monitoring.
• To upload IoT data to ThingSpeak Cloud using ESP8266 Wi-Fi for remote monitoring.
• To provide alerts via buzzer during motor faults.
• To control motor operation with a relay during dangerous conditions.
• To improve safety, reduce downtime, and enable predictive maintenance.

📊 Block Diagram

                                                                            Block Diagram: IoT Based Motor Fault Detection System

🔁 System Overview

• Arduino UNO – Main microcontroller unit.
• Current Sensor – Monitors current drawn by motor.
• Voltage Sensor – Tracks supply voltage levels.
• DHT11 Sensor – Measures ambient temperature & humidity.
• Accelerometer – Detects vibrations or imbalance in motor operation.
• 20×4 LCD Display – Shows live readings of all parameters.
• ESP8266 Wi-Fi Module – Uploads sensor readings to ThingSpeak IoT cloud.
• Relay Module – Switches motor ON/OFF based on fault conditions.
• Buzzer – Provides audio alerts during abnormal conditions.
• AC Motor – Load under monitoring.
• ThingSpeak – Real-time visualization and data analytics of motor performance.
• Power Supply – Battery/DC adapter.

🛠️ Components Required

1. Arduino UNO
2. Current Sensor (ACS712 or similar)
3. Voltage Sensor
4. DHT11 Temperature & Humidity Sensor
5. Accelerometer Module (e.g., ADXL335/ADXL345)
6. Relay Module
7. Buzzer
8. 20×4 LCD Display
9. ESP8266 Wi-Fi Module
10. AC Motor (for testing)
11. Resistors & Voltage Divider Circuit (for ESP8266)
12. Power Supply (Battery/DC Adapter)
13. Jumper Wires & Connectors

⚙️ Methodology

The system constantly tracks motor parameters through sensors: current, voltage, ambient temperature, humidity, and vibration. The Arduino UNO reads sensor data, processes it, and checks it against preset safe limits. In the event of abnormal readings—like overcurrent, variation in voltage, overheating, or high vibration—the Arduino trips the buzzer for an alarm and can also switch off the AC motor through the relay module to avoid damage.In parallel, the readings from all sensors are also shown on a 20×4 LCD for immediate local observation. For remote access, the Arduino talks to the ESP8266 Wi-Fi module, which transfers the data to ThingSpeak Cloud. The ThingSpeak platform allows graphical representation and long-term data trends, assisting engineers in recognizing patterns and forecasting impending faults.This combined strategy of local monitoring + IoT cloud logging provides early detection, remote monitoring, and predictive maintenance, minimizing the likelihood of catastrophic failure and enhancing system reliability.
The system continuously monitors motor parameters with sensors: current, voltage, ambient temperature, humidity, and vibration. The Arduino UNO reads the sensor data, processes it, and compares it with previously set safe limits. If there are abnormal readings—like overcurrent, voltage fluctuation, overheating, or excessive vibration—the Arduino gives a warning through the buzzer and also can cut off the AC motor through the relay module to avoid damage.At the same time, all sensor values are displayed on a 20×4 LCD for real-time local observation. For remote access, the Arduino talks to the ESP8266 Wi-Fi module, which transfers the data to ThingSpeak Cloud. The ThingSpeak platform offers graphical representation and past data trends, enabling engineers to spot patterns and forecast future failures.

This combined strategy of local monitoring + cloud logging using IoT guarantees timely detection, remote monitoring, and predictive maintenance, minimizing the probability of large-scale failures and enhancing system reliability.

💡 Title Suggestions

• IoT Based Motor Fault Detection System using Arduino
• Smart AC Motor Health Monitoring with IoT & Arduino UNO
• Arduino-Based Real-Time Motor Fault Detection with ThingSpeak IoT Cloud
• IoT-Enabled Vibration, Temperature & Current Monitoring System for Motors
• Predictive Maintenance for AC Motors using IoT and ESP8266

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🔖 What’s Included in Your IoT Solar Monitoring Project Kit?

💯 Fully Working & Assembled
📘 Docs – Includes synopsis, PPT, report & diagrams
🔄 Circuit & Block Diagrams – Clear and labelled
💻 Arduino Code + Training – Upload & customize easily
⚙️ Working Principle Explained
📦 Component Specs + BOM
📑 Datasheets Provided – For sensors and modules
🔌 Complete Wiring Guide
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Contact us:
👨🏼‍🏭 Vipin Kumar Sharma
Ph.D., M.Tech, B.Tech in ECE
🎓 Lecturer 🚀 #Researcher #Robotics #IoT

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