Hindawi

Journal of Sensors
Volume 2022, Article ID 8933442, 8 pages
https://doi.org/10.1155/2022/8933442

Research Article
Monitoring of Single-Phase Induction Motor through IoT Using
ESP32 Module

Abhinab Shukla ,1 S. P. Shukla ,2 S. T. Chacko ,3 Md. Khaja Mohiddin ,4

and Kinde Anlay Fante 5
1
Research Scholar, Department of Electrical Engineering, Bhilai Institute of Technology, Durg, Chhattisgarh, India
2
Faculty, Department of Electrical Engineering, Bhilai Institute of Technology, Durg, Chhattisgarh, India
3
Faculty, Department of Electrical Engineering, UPU Govt. Polytechnic, Durg, Chhattisgarh, India
4
Faculty, Department of Electronics & Telecommunication, Bhilai Institute of Technology, Raipur, Chhattisgarh, India
5
Faculty of Electrical and Computer Engineering, Jimma Institute of Technology, Jimma University, Jimma, Ethiopia

Correspondence should be addressed to Abhinab Shukla; [email protected]

and Kinde Anlay Fante; [email protected]

Received 1 September 2022; Accepted 5 October 2022; Published 9 November 2022

Academic Editor: Sweta Bhattacharya

Copyright © 2022 Abhinab Shukla et al. This is an open access article distributed under the Creative Commons Attribution
License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is
properly cited.

The condition monitoring of rotating machines for critical applications plays an important role in reducing downtime. With
Industry 4.0, the role of IoT in online condition monitoring of electrical machines has gained considerable significance. The
main aim of the paper is the use of IoT for online monitoring of motor parameters like current, temperature, vibration, and
humidity and observing its online trending using a web server. Data can be accessed in form of graphs and widgets by visiting
the web page. The advantage of this project is the real-time monitoring of the motor from any remote area and in case of any
abnormality operating personnel can take necessary steps for preventing complete breakdown. The proposed work can help
industry people in online monitoring of motors and in the future work can be extended for fault prediction and classification.

1. Introduction monitoring of motors and to generate regular notification

in case any parameter shoots up from its regular value [3, 4].
Condition monitoring of motors is very important, and a
maintenance schedule is always implemented for every elec- 2. Related Work
trical machine. In the proposed work with the use of IoT
technology motor parameters like temperature, current, In reference to various research papers, IoT technology is
voltage, and vibration can be accessed wirelessly. All these already being used for data collection and fault prediction
parameters can be analyzed by operator from anywhere of electrical motors. In this method, development boards like
and in case of any fault condition alert can be raised. IoT Arduino, Nodemcu, and Raspberry-pi are used as processor,
based condition monitoring when joined with machine and various sensors are interfaced with them for data collec-
learning can help in classification and prediction of faults. tion. With the use of Wi-Fi modules, all the parameters can
Electrical motors are work horse for any industry [1, 2]. be stored in cloud [1, 5–8]. In reference paper [4], Nodemcu
Electrical motors have to be maintained and monitored on has been used for acquiring motor parameters for traction
regular basis. Breakdown or faults in such rotating machines drive and upload it in cloud.
can hamper the industry in various ways. Proposed method Other work done in this field is condition monitor-
of monitoring motors can be used for real time parameter ing of motors using GSM modules and radio frequency
2 Journal of Sensors

Start

Connect to access point

Reconnect protocol

No Check for
successful
correction

Reading values from sensors

Upload data to web

server thingspeak

Display, vibration, current,

temperature, humidity

Figure 1: Flowchart showing entire process.

Micro USB 5v supply DC

Accelerometer

Current sensor ESP-32 board Voltage sensor

Temperature sensor

Wi-Fi router

Figure 2: Block diagram of hardware.

Table 1: Motor rating. In most of the previous work done, sensors that have
been used for parameter collection are ADXL 345, ACS
Name Power Speed Voltage Frequency
7212, and LM 35 as acceleration, current, and temperature
1PH induction motor 320 W 1350 RPM 220 V 50 Hz sensors, respectively [8, 11]. In contrast to it in reference
paper [9], piezoelectric transducer is used to collect vibra-
tion data for motors and storing it in cloud using
waves [9, 10]. Hardware module consists of printed cir- Nodemcu.
cuit board, and along with these, sensors, ICs, and pro- In reference paper [10], it can be analyzed that after data
cessors are mounted. Data collected is sent to control acquisition, various fault detection methods can be adopted,
and monitoring room. Hence, operator can go through and it has been concluded that MCSA method is best for
all the real time data and can take decisions as per fault detection in electrical motors [12, 13]. Motor current
requirement [2, 3]. signature analysis is a popular predictive maintenance tool
Journal of Sensors 3

Figure 3: Experimental setup.

complete breakdown. With things, speak cloud platform

limits can be set for each field [24]. If in any abnormal con-
R1
dition the parameter value of motor increases and breaches
10 kΩ the set limit then an alert or notification can be sent to oper-
Input from ator. Such protocol can play very important role for protec-
Current Sensor tion of motors [25, 26].
Output to Prediction of faults and its classification of indus-
R2
20 kΩ ESP-32 trial machines can also be possible. The real time data
from motors can be given to trained artificial neural
network, and the output of the ANN model will be
the prediction of fault and its type [27]. If the fault
is of incipient stage, machine can be scheduled for
Figure 4: Signal conditioning circuit for 5-volt reference to 3.3 volt. maintenance. In future, the proposed work can be
expanded for having fault prediction and its classifica-
tion for various motors.

for electrical motors, and it mainly uses current spectrum for

analysis [14, 15]. 4. Block Diagram of Hardware
Figure 2 shows the block diagram which explains the inter-
3. Proposed Work connections between the sensors and processor. Block dia-
gram also elaborates the type of sensor and data which has
In the proposed work, ESP32 board is used as processor.
to be collected from motor. The ESP32 module is powered
Sensors used for collecting parameters are DHT 11, ACS
with a 5 V 2A adapter.
712, and ADXL 345. Data collected from various sensors
are uploaded to cloud using THINGSPEAK platform. All
the live data of parameters can be seen using IoT platform 4.1. Development Boards and Sensors
inform of graphs and widgets [16, 17]. Assembled hardware
has been used with a single-phase induction motor, and 4.1.1. ESP32. ESP32 is a series of low-cost, low-power system
results were discussed for it. Figure 1 explains the flowchart on a chip microcontroller with integrated Wi-Fi and dual-
for entire process in the proposed work. When the supply is mode Bluetooth [28]. The ESP32 board has 15 ADC pins,
given to ESP32 board, it connects with the access point [18, and each pin has 12-bit resolution with range from 0 to
19]. The sensors connected to motors start delivering signals 4095.
to GPIO pins of ESP32 board. As real time data gets
uploaded to cloud operator in the field can monitor current, 4.1.2. Current Sensor. A hall effect current sensor called the
vibration, temperature, and humidity of motor from any ACS712 is used to measure current. It is both cost-effective
part of world with only requirement of internet in laptop and provides a precise solution for AC and DC current
or smart phone [20, 21]. detection. Its output sensitivity ranges from 66 to 185 mV/
Operating personnel working on the motor can monitor A. A hall effect current sensor called the ACS712 is used to
the data in real time. In case, any of the parameter magni- measure current [29]. It is both cost-effective and provides
tude crosses the limit [22, 23]. Operator can start the shut- a precise solution for AC and DC current detection. Its out-
down process which will prevent the machine from having put sensitivity ranges from 66 to 185 mV/A.
4 Journal of Sensors

Figure 5: Assembled circuit.

Figure 6: Vibration graph of motor.

4.1.3. Vibration Sensor. The vibration sensor or accelerome- capacitor [31]. The output remains high enough to be trans-
ter utilized is the ADXL 335, a tiny, thin, low-power, three- mitted to the microcontroller. As a result, a potential divider
axis accelerometer with signal-conditioned voltage outputs. circuit is utilized to obtain the requisite voltage of 5 V, which
It has a 3 g range and measures full scale acceleration. Both is then fed into the ESP32.
static and dynamic accelerations are measured. This is where
the dynamic acceleration caused by motion, shock, or vibra- 4.1.5. Temperature Sensor. The DHT11 is a temperature and
tions is monitored. Different bandwidths for three axes can humidity sensor that is widely used. The sensor includes a
be chosen depending on the application [30]. The X and Y dedicated NTC for temperature measurement and an 8-bit
axes have bandwidths ranging from 0.5 Hz to 1600 Hz, while microprocessor for serial data output of temperature and
the Z axis has bandwidths ranging from 0.5 Hz to 550 Hz. It humidity values.
displays three values for each of the three axes that represent
motor vibrations. Vibrations are measured based on the 4.1.6. Single Phase Induction Motor. A single-phase squirrel
values acquired in three axes. cage induction motor for testing purposes and its rating is
shown in Table 1.
4.1.4. Voltage Sensor. A voltage sensing circuit measures the
voltage and creates an output voltage that meets the Wi-Fi 4.2. Technology Used. In this research, the Internet of Things
board’s requirements. A 230 V/12 V potential transformer technology (IoT) is used to monitor an induction motor. In
is employed, and the output is converted to DC via a rectifier IoT (Internet of Things), the Internet of Things (IoT) is a
when needed. The rectifier output is rippled out using a network of smart devices and things that are equipped with
Journal of Sensors 5

Figure 7: Current intake graph of motor.

Figure 8: Humidity graph of motor.

various sensors and network to gather and transmit data. In induction motor is done by continuously monitoring the
IoT/cloud platform, the IoT platform is the heart of the parameters with the use of different sensors [25]. Current
Internet of Things architecture, as it connects the physical sensor ACS 712, ADXL acceleration sensor, DHT 11 tem-
and virtual worlds, allowing items to communicate with perature sensor, and voltage sensor circuit are used to sense
one another [32]. Thing speak is a cloud platform by Math parameters RMS current, vibration, temperature, and volt-
Works. It has been used as the IoT platform in this research. age, respectively. All the data sensed will be in accordance
It generates graphical displays for data uploaded to the plat- with the instruction coded to ESP32 module.
form by devices in real time. Thing speak is frequently used The ESP32 module has fifteen ADC pins, and it can
for prototyping and proof of concept IoT applications. sense voltage between 0 volt to 3.3 volt. Corresponding to
this range value can be assigned between zero to 4095. The
5. Experimental Setup and Assembly analog input has 12-bit resolution. The data collected can
be analyzed and stored in cloud using ESP32 module [17].
Figure 3 shows the experimental set up developed in this There are various general purpose input output pins in
research work. The goal of real time monitoring of 1-pH ESP32 module which can be used for reading and writing
6 Journal of Sensors

Figure 9: Temperature graph of motor body.

data. For storing the data in things speak platform account is sensitivity of 330 mV per G. The formula used for calcula-
to be created, and a new channel is generated. Number of tion of acceleration is given below.
fields has to be chosen proportional to the number of  
parameters under monitoring. Each field is being given with ððsensor output × 3:23Þ/4095 − 1:47Þ
Acceleration = M/S2 :
its own parameter and then it can be visualized using various 0:33
graphical forms. In this work, parameters of healthy motor
ð2Þ
and abnormal motor have been shown and compared. User
with this system can visit things speak website and can mon-
6.3. Sampling of Temperature and Humidity Data. The
itor the motor anytime from anywhere [18, 19]. In case of
instruction code uploaded to ESP32 uses DHT 11 library
any abnormal operation, emergency protocol can be imple-
for getting data values and for updating it in regular inter-
mented and motor can be turned off [22]. Hence, such sys-
vals. DHT-11 sensor provides temperature and humidity
tems can improve the longevity and reliability of rotating
data using its data output pin [11]. The single wire two-
machines.
way communications are used for data retrieval process.
6. Formula Used for Data Sampling 6.4. Sampling of Voltage Data. The output of voltage sensor
circuit is given to ESP32 module. The ESP32 module reads
6.1. Sampling of AC Current Data. AC current withdrawn
the output from sensor within the scale of resolution from
from induction motor is sensed using hall effect current sen-
0 to 4095, and the reference voltage is 3.3 volt. The trans-
sor. The output voltage coming from sensor is converted to
former converts 240 V to 12 V, and the secondary is con-
voltage under 3.3 volts. Signal conditioning circuit for the
nected to arrangement of rectifier with zener diode. Five-
reference voltage conversion is shown in Figure 4.This is
volt logic across zener diode is reduced to proportional
done because the reference voltage for ESP32 for reading
3.3 V, and the logic is given to ESP32 module ADC pin
analog values is 3.3 volt only. As mentioned, ESP32 is a
[9]. As the single-phase supply varies, the logic level to
12-bit ADC hence scale for resolution is kept from 0 to
ESP32 module also changes in reference to 3.3 V. As per
4095. ACS 712 05B module has sensitivity of around
the formula given in the code single phase voltage gets
185 mV. The formula used for calculation of RMS current
recorded and stored in cloud IoT platform.
is mentioned below.
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 7. Experimental Results
ðI SUM /Measurement CountÞ
I RMS = Amps: ð1Þ Figures 3 and 5 show the entire assembled circuit set up. The
4095 × ð3:3/0:185Þ
developed code is uploaded to module. Sensors are inter-
faced to ESP32 board. Once the module is powered up, it
6.2. Sampling of Vibration Data. ADXL 335 GY-61 sensor is gets connected to internet, and sensors start accumulating
used to detect vibration in motor. Initially, the sensor is cal- the data. All the data is sent to things speak IoT platform
ibrated, and the error is subtracted from the expression of and user can monitor the parameters with the help of graphs
main equation. The GY-61 sensor used in this work has a and widgets. From Figures 4–8, various graphs are shown
Journal of Sensors 7

below, and the parameters that can be monitored are cur- Acronyms
rent, temperature, humidity, vibration, and power. From
the graphs, it can assessed that x axis comprises of date, IoT: Internet of Things
and y axis comprises of the magnitude of the parameter. MCSA: Motor Current Signature Analysis
When the system turns on, the dark red dotted points on ANN: Artificial neural network
the graph show present value of the parameter. The RMS: Root mean square
straight-line which traces with in the various dates shows DHT: Digital temperature and humidity sensor.
the changes by comparing the present-day status with the
last period when system was turned on. Hence, it should Data Availability
not be concluded that graphs are linear in nature. The pres-
All data used to support the findings of this study are
ent value of parameter can be seen by tracing the latest entry
included in the article.
of red dark dot and by double clicking with in it the graph-
ical display becomes more dynamic as it shows minute by
minute entry of data from the sensors. Conflicts of Interest
With all these parameters, any threshold limit can be set The authors declare that they have no conflicts of interest.
and if the set limit for any required parameter is crossed then
notification or alert can be sent to the operator using IoT plat- References
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