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Smart Industrial Monitoring and Alert System Using Arduino

Authors:

Palli Kushal Kumar, Chaitanya, K Bhuvan Sai, Harsh Kumar, Dr P Srinivasa Rao

Abstract—Industrial environments demand continuous, reliable monitoring to safeguard personnel and assets against hazards such as gas leaks, overheating, flooding, and equipment malfunctions. This paper presents a cost-effective, IoT-enabled monitoring and alert system built around an Arduino UNO, integrating six environmental sensors (temperature & humidity, gas, vibration, light, water level) with both Wi-Fi and GSM connectivity. Sensor data are transmitted every ten seconds to ThingSpeak for real-time visualization and historical logging, while a MATLAB Analysis script applies exponential smoothing to vibration time series for predictive-maintenance forecasting. Upon detecting threshold breaches or forecasted anomalies, the system triggers on-site alarms (LEDs, buzzer) and issues remote notifications via SMS and email. Experimental validation under controlled conditions demonstrated on-site alarm latencies under 3.2 s, SMS delivery within 15 s, cloud-update delays under 20 s, and vibration-based fault forecasts up to 21 h in advance. The unified platform offers small to medium enterprises an accessible solution for real-time hazard detection, proactive maintenance scheduling, and rapid emergency response.

Index Terms—Arduino UNO; IoT Monitoring; Predictive Maintenance; ThingSpeak; GSM Alerts; Environmental Sensors; Exponential Smoothing; Industrial Safety; Real-Time Analytics; Alerting & Actuation.