International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 13 Issue: 01 | Jan 2026
p-ISSN: 2395-0072
www.irjet.net
Design and Development of IoT Network for Motor Monitoring in Industrial and Agricultural Systems Mr. S. R. Pandit1, Mr. Kshitij Patil2, Mr. Vedant Vaidya3 1Assistant Professor, Department Of Instrumentation And Control, MVPS’s KBTCOE, Nashik,
Maharashtra, India
2Student, Department Of Instrumentation And Control, MVPS’s KBTCOE, Nashik, Maharashtra, India
3Student, Department Of Instrumentation And Control, MVPS’s KBTCOE, Nashik, Maharashtra, India
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Abstract - This paper details the hardware design and
architectural implementation of a low-cost, wireless Condition Monitoring System (CMS) for induction motors. addressing the limitations of expensive, wired legacy systems, we propose a distributed dual-microcontroller architecture. The system utilizes an ESP32 based transmitter node to acquire real-time vibration, temperature, and current data, and transmits it via the ESPNOW protocol to a central receiver. This paper focuses on the sensor integration, signal conditioning circuits, and the robust wireless communication framework required for reliable industrial telemetry
The Receiver Node (Base Station): Responsible for data aggregation, display, and logging.
This physical separation ensures that the critical sensing timing remains deterministic, unaffected by the latency of user interface operations.
3. HARDWARE IMPLEMENTATION The core of the transmitter node is the ESP32 microcontroller, selected for its high-performance dualcore architecture and multiple Analog-to-Digital Converter (ADC) channels.
Key Words: Condition Monitoring, Industrial IoT, ESP32, ESP-NOW, Vibration Analysis, Wireless Sensor Network, Predictive Maintenance, Induction Motors.
3.1 VIBRATION SENSING (ADXL345)
1.INTRODUCTION The operational reliability of induction motors is critical to industrial productivity. Failures in these machines are often preceded by gradual changes in physical parameters such as vibration intensity, surface temperature, and current consumption. While Continuous Condition Monitoring (CCM) is the industry standard for predictive maintenance, commercial solutions are often costprohibitive for small-to-medium enterprises (SMEs) and require invasive wiring. Fig -1: ADXL345
This study presents the design of a standalone Wireless Sensor Node (WSN) capable of retrofitting onto existing motors. The system prioritizes modularity, utilizing offthe-shelf components to reduce costs while maintaining sufficient accuracy for fault detection.
Vibration is the earliest indicator of mechanical faults (e.g., bearing wear, misalignment). We utilize the ADXL345, a MEMS-based 3-axis digital accelerometer. The sensor is configured for a measurement range of ±16g to capture high-intensity transient shocks. The ESP32 calculates the vibration magnitude vector (Vmag) using the Euclidean norm of the three axes (x, y, z).
2.SYSTEM ARCHITECTURE The system adopts a Master-Slave topology to ensure that data acquisition is never interrupted by data processing tasks.
The Transmitter Node (On-Field): Responsible solely for high-speed sensor sampling and data packet transmission.
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