IoT-Based Industrial Machine Monitoring, Energy Analysis, and Safety Automation System

Abstract: The rapid growth of industrial automation and smart manufacturing has intensified the need for continuous, real-time monitoring of machine performance, energy consumption, and environmental safety parameters. Traditional industrial setups rely on manual inspection and SCADA-based systems that are reactive, labor-intensive, and incapable of providing instant automated responses. This paper presents an IoT-Based Industrial Machine Monitoring, Energy Analysis, and Safety Automation System aligned with Industry 4.0 concepts. The proposed system integrates a ZMPT004T voltage sensor, ACS712 current sensor, DHT11 temperature and humidity sensor, DS18B20 machine temperature sensor, and a flame detection sensor with an ESP32 microcontroller. Sensor data is continuously acquired, processed to compute voltage (V), current (A), power (W), and cumulative energy consumption (kWh), and displayed locally on a 20×4 I2C LCD. Simultaneously, all parameters are uploaded to the ThingSpeak cloud platform every 6 seconds for real-time graphical visualization and historical analysis. The Blynk mobile application provides a remote dashboard for machine monitoring and ON/OFF control via a relay module. Automatic safety mechanisms—triggered by over-temperature conditions (>40°C machine, >45°C industrial) or fire detection—immediately disconnect the machine and activate an audible buzzer alert. Experimental results confirm accurate multi-parameter sensing, reliable cloud transmission, effective LCD output in all operating modes including normal, fire alert, and temperature violation, and successful automated safety response. The system is cost-effective, easily deployable, and scalable for small, medium, and large industrial environments.

Keywords: IoT, Industry 4.0, Industrial Machine Monitoring, Energy Consumption Analysis, Safety Automation, ESP32, ThingSpeak, Blynk, DHT11, DS18B20, ACS712, ZMPT004T, Fire Detection, Predictive Maintenance, Smart Manufacturing.