Development of an IoT Platform for Condition Monitoring of Industrial Motors

The project's goal is to deploy and utilize IoT technologies to monitor and troubleshoot induction motors. To ascertain what precisely is prompting the induction motor to fail, the various parameters of the induction motor are investigated. Furthermore, several studies have discovered the relationsh

Project Title

Development of an IoT Platform for Condition Monitoring of Industrial Motors

Project Area of Specialization

Internet of Things

Project Summary

The project's goal is to deploy and utilize IoT technologies to monitor and troubleshoot induction motors. To ascertain what precisely is prompting the induction motor to fail, the various parameters of the induction motor are investigated. Furthermore, several studies have discovered the relationship between vibration, temperature, current, voltage, and bearing failures. Several approaches involve IoT-based instrumentation for collecting and processing the induction motor characteristics. IoT is a cloud platform, available on the web, contains the data that has been gathered. Timely alert notification is sent if any disfunction found in the parameters, which saves time and money by eliminating unnecessary downtime. This review examines the advantages of this approach also. Findings show how efforts were rooted and continuous monitored equipment was developed that have access to relevant data for predictive maintenance also.

Project Objectives

•We propose Low-Cost condition-based maintenance device for industrial motors to monitor and spot upcoming equipment failure so maintenance can be proactively scheduled when it is needed – and not before.

•The idea is that this real-time monitoring will give maintenance teams enough lead time before a failure occurs or performance drops below an optimal level.

•The idea behind less-costly device is to incubate this practice in small-scale local industries hence boosting up their productivity.

Project Implementation Method

Target

Monitor and diagnose the performance of a 3-phase induction motors and record critical parameters using an IoT platform.

Phase-1

Perform the whole diagnosis and monitor the process on a single Induction Motor.

Phase-2

Comparing the health monitoring of a faulty machinery with a healthy one and analyzing the results.

Phase-3

Development of an IoT platform to store the  data acquired from sensors and display it using a Cloud Platform.

Phase-4

Introducing multiple Actuating systems (motor/generators) and monitoring the behavior of them.

Phase-5

Concluding it by demonstrating the real time working of project.

Benefits of the Project

•Our product will help small scale local industries that can’t afford heavy investment to reduce their maintenance cost as well as motor stoppage time by installing a condition-based monitoring system for their Industrial Motors.

•Reduction or near elimination of unscheduled equipment downtime caused by equipment or system failure;

•Increased labor utilization;

•Increased production capacity;

•Reduced maintenance costs;

•Increased equipment lifespan.

Technical Details of Final Deliverable

The block diagram shows the entire picture of the work. The objective of condition monitoring of induction motor is achieved by continuously recording the considered parameters using various sensors. Accelerometer is used to record vibrations; LM 135 temperature sensors are used to record winding and bearing temperature, ACS712 current sensor for current, and a Voltage sensing circuit to measure voltage. All the sensors are connected to arduino microcontroller board which is to be installed at the motor site. The sensors will sense the parameters and are analyzed by the micro controller board to the instruction coded. The data sensed by different sensors can be seen on the serial monitor of Arduino IDE. The collected data can be stored on the IoT platform using Wi-FI module. Using serial communication between the micro controller and the ESP8266-01 board the data is initially transferred to ESP8266-01 board which can be seen on the serial monitor. Then using wi-fi functionally the data available at ESP8266-01 is uploaded to Thingspeak cloud platform. In order to upload the data to Thingspeak platform, an account is to be created and then a new channel is to be created, while creating a channel number of fields are to be selected depending on the number of parameters under monitoring. Each field is assigned with one parameter which is represented in graphical form. A web application is developed for continuous monitoring of parameters. Instant alert will be received on the web page for any abnormal operation of motor.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

IT

Other Industries

Others

Core Technology

Internet of Things (IoT)

Other Technologies

Augmented & Virtual Reality

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com