IoT Based Industrial Grade Efficient Energy Monitoring System
Monitoring of electrical parameters is a key element in any Energy Efficiency approach. Implementation of monitoring equipment is the first step of this kind of approach, as it makes an assessment of the actual situation possible, before determination of the most relevant solutions. Then, it
2025-06-28 16:33:35 - Adil Khan
IoT Based Industrial Grade Efficient Energy Monitoring System
Project Area of Specialization Internet of ThingsProject SummaryMonitoring of electrical parameters is a key element in any Energy Efficiency approach. Implementation of monitoring equipment is the first step of this kind of approach, as it makes an assessment of the actual situation possible, before determination of the most relevant solutions.
Then, it is possible thanks to monitoring to permanently observe the operation of the installation. And finally, it is possible to quantify the Energy Efficiency improvement actions.
Now a days anything in industry is going to be up to date but since we are using some typical methods to do our task. Monitoring system in any industry is the value of the backbone for an industry. We made a system that’s monitors all energy parameters for an industry of different sources i.e. main power supply from power distribution companies and other sources like power generators, solar panel system or any other.
In previously we monitor all the parameter from different sources manually it’s not quite efficient. With the help of this project we have the access of all source parameter on single screen. Every individual source has different page or menu on screen from where we can monitor all our desire parameter. In future we can convert this project in an RTU (remote terminal unit) from which we can access all the system across all over the country or all over the world via internet.
As far as Energy Efficiency is concerned, measurement of electrical energy is of course number one. Active energy (in Kwh or Mwh) is generally the main component of the electricity bill. For an accurate assessment, measurement of active energy is recommended at different places in the installation, preferably at every workshop level. The measurement period should be limited, one week being a reasonable compromise in order to compare periods with similar activity levels.
Project ObjectivesThe main objective of this project is to convert the manual monitoring system into a smart monitoring system that’s help us to change the typical monitoring system that have not so much feature. This is project is for to make an easier way of monitoring of all parameter through MODBUS communication.
The main features of this monitoring system are:
Communication between acquisition and display devices, monitoring capability at the appliance and switchboard circuit’s level, every instant energy use information displays on Human Machine Interface(HMI) Communication between devices ensures greater flexibility and system’s ease of use. The system’s ability to monitor all sources parameters and informs the consumer about the balance of each sources load. The knowledge of average hourly energy use and electricity cost provides important information that motivates changes to consumer’s behavior. A computer connection is available to record measured data and to use it in many computer applications, such as, daily charting energy use data. An Electrical Energy parameters systems is required which can analyze multiple sources in a household/industry getting readings such as voltage, current, active power, apparent power, reactive power, power factor and frequency. With the help of a wired / wireless connection, the device can connect through MODBUS communication. The data can then be displayed on the platform’s graphical human machine interface. The platform allows users to access the data to the concern. Furthermore, it is required that the current information regarding the appliances can also be viewed on a local display with a menu interface.
Project Implementation MethodThe project will be implemented in modular form. First of all, the load will be decided to be two induction motors which are driven by variable frequency drives and that are considered to be supplied by two power sources let’s say Grid and Power Generator. The parameters of these electric supply sources will be monitored by Energy analyzers through the voltage and current values which are taken by means of current transformers. The Energy analyzers will be configured in such a way that they can be communicated through a MODBUS protocol. We will setup a Human Machine interface to display the parameters of both Electrical Sources and also an Ethernet interface to show these values on the internet as well thus making it an IoT node.
Following devices will be used:
- Induction Motors
- LS Variable Frequency Drives
- Energy Analyzers
- HMI Screen
- Ethernet Interface Module
IoT Server
Benefits of the Project- Accurate and fast energy monitoring.
- Reduction in operating costs as compare to manual process.
- Increasing production.
- Fully automatic load management system can be integrated.
- Efficiency & Maintenance easy.
Same system used for different purpose
Technical Details of Final Deliverable- Smart Monitoring System all data in one touch- You can just reach the data easily more than one source
- Proper Menu for all sources- proper menu for every sources from which you can extract all parameter
- Graphical Representation- Also have graphical representation of every source
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 80000 | |||
| VFD | Equipment | 1 | 10000 | 10000 |
| Motors | Equipment | 2 | 6000 | 12000 |
| Energy Analyzer | Equipment | 2 | 21000 | 42000 |
| Ethernet Interface Module | Equipment | 1 | 4000 | 4000 |
| Current Transformer | Equipment | 4 | 400 | 1600 |
| Power Supply | Equipment | 1 | 400 | 400 |
| Poster Printing, Report Binding etc | Miscellaneous | 1 | 10000 | 10000 |