An Integrated IoT and Web-Based Framework for Energy and Machine Monitoring in SMEs

Abstract: This project is about creating a system that helps industries use energy wisely and keep their machines in shape. The system is called a Smart IoT-Based Energy and Machine Condition Monitoring System. It is meant to make industries use energy efficiently make sure machines are reliable and find problems in time. The system uses a computer called an ESP32 microcontroller to control everything. This computer is connected to sensors. There is a PZEM-004T energy sensor that checks how much voltage, current, power and energy are being used. There is also an SW-420 vibration sensor that checks if machines are vibrating much. There is a DHT11 temperature sensor that checks how hot or cold it is around the machines. The Smart IoT-Based Energy and Machine Condition Monitoring System is very useful, for industries. It helps them use energy wisely and keep their machines in shape. The Smart IoT-Based Energy and Machine Condition Monitoring System is a way to make industries run better. The sensor data that we collect is looked at carefully. We use a method to decide what is normal and what is not. This method is like a warning system that checks the data all the time to make sure it is within limits. If something is wrong like the energy consumption is too high or the machine is vibrating much or getting too hot the system sends us a message right away. It also sends the data to the internet through Wi-Fi so we can look at it later. We use websites like Firebase to look at the data, in real time keep a record of it and see what happened in the past. The system we are talking about is set up from the edge to the cloud. This means it can do things quickly and does not get too busy with a lot of data. It is also cheap to set up. When we tried it out the system was very good at monitoring energy it got it right 95% of the time. It was also very good at finding faults using vibrations it got it right 90% of the time. And it was very good at monitoring temperature it got it right 92% of the time. The system is a help because it can reduce the amount of energy that is wasted by about 20 to 25%. It can also help find faults which is about 30% better than old ways of monitoring. It can reduce the amount of time machines are broken and cannot be used by about 40%. This is a lot better than the ways of monitoring machines.

Keywords: Industrial IoT, Energy Monitoring, Machine Monitoring, Web applications, SME Industry, Fault Detection, Industrial Sensors.