DC Motor Health Monitoring

Dr.Prof. S. V. Phakde
Professor

Dept. of Electronics & Telecommunication Engg.

P. V. P. I. T Budhgaon

Yash R.Balurgi
Student

Dept. of Electronics & Telecommunication Engg.

P. V. P. I. T Budhgaon

Sakshi J.Karanje
Student

Dept. of Electronics & Telecommunication Engg.

P. V. P. I. T Budhgaon

Chaitanya A. Kulkarni
Student

Dept. of Electronics & Telecommunication Engg.

P. V. P. I. T Budhgaon

Varad U. Chavan
Student

Dept. of Electronics & Telecommunication Engg.

P. V. P. I. T Budhgaon

ABSTRACT

Abstract—The DC Motor Health Monitoring System using ESP32 and IoT is designed to monitor the operational condition of a DC motor in real time and provide protection against abnormal operating conditions. In industrial environments, continuous operation of motors may lead to faults such as overheating, excessive vibration, overload current, and voltage fluctuations, which can reduce motor efficiency and cause unexpected failures. To overcome these issues, an IoT-based monitoring and protection system has been developed.

The proposed system uses an ESP32 microcontroller as the main processing unit along with various sensors including a vibration sensor, temperature sensor, current sensor, and voltage sensing circuit to continuously measure important motor health parameters. The collected sensor data is processed by the ESP32 and transmitted wirelessly to the Blynk IoT platform through Wi-Fi communication for remote monitoring and real-time visualization.

A relay module is integrated into the system to control the operation of the motor. Whenever abnormal

conditions such as high temperature, excessive vibration, abnormal current, or voltage variations are detected, the ESP32 activates the relay protection mechanism to automatically stop the motor and prevent damage. The system also provides warning notifications through the IoT platform to improve fault detection and maintenance efficiency.

The developed system successfully achieves real-time monitoring, early fault detection, remote accessibility, and automatic motor protection. The project provides a reliable, cost-effective, and efficient solution for predictive maintenance and industrial motor monitoring applications.

Keywords— DC Motor Health Monitoring, ESP32, Internet of Things (IoT), Blynk IoT Platform, Real-Time Monitoring, Temperature Sensor, Vibration Sensor, Current Sensor, Voltage Sensing Circuit, Relay Protection, Fault Detection, Predictive Maintenance, Remote Monitoring, Industrial Automation, Smart Monitoring System.