International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 01 | Jan 2025
p-ISSN: 2395-0072
www.irjet.net
IoT-Integrated Smart Energy Meter for Industrial Energy Monitoring Kiruthick Sundakaraipudur Maheshkumar 1, Pragatheesh Rangasamy Jagadeesan2 1 UG Student, Department of Robotics and Automation Engg, PSG College of Technology, Coimbatore, 641004, India 2 UG Student, Department of Robotics and Automation Engg, PSG College of Technology, Coimbatore, 641004, India
---------------------------------------------------------------------***----------------------------------------------------------------------
Abstract - Electric energy monitoring in industrial loads
like pressure die casting is extremely vital especially due to their energy handling requirements. This work details the conception and implementation of an Internet of Things based Smart Energy Meter designed specifically for Industrial purposes. The system can measure three-phase voltage, current (up to 100A) and furnace temperatures with the aid of Resistance Temperature detectors. Using the ESP32 microcontroller and the Blynk Internet of things platform, the meter enables the collection, storage, and displaying of the data on the Cloud in real time. In order to enhance accuracy, the hardware architecture combines ZMPT101B voltage sensors, SCT-013-000 current sensors and a MAX31865 Resistance Temperature detector module. The software part of the system uses the Open-Energy Monitor library which contains various algorithms for energy calculations and transfers data over Serial peripheral interface/Wi-Fi protocols. The system has been tested in an industrial setting and the results have shown an accuracy of measurement within a tolerance of 1% for electrical and thermal characteristics plus a normal operation for variable conditions. The presented results prove the possibility of intra- system energy optimization and the industrial prospects of its application. Promising research directions include the addition of predictive maintenance features based on machine learning as well as more efficient scaling to support many different industrial applications.
presents the development of a Smart Energy Meter tailored for industrial applications, which addresses critical challenges such as high-frequency electrical noise, harsh environmental conditions, and fluctuating energy demands. The system leverages advanced hardware components, including Resistance Temperature Detectors (RTD), ZMPT101B voltage sensors and SCT-013-000 current sensors, to ensure precise measurement of energy parameters. Furthermore, the integration of an ESP32 microcontroller enables seamless data acquisition and communication with the Blynk IoT platform, allowing for real-time data visualization and remote control. The custom-designed printed circuit board (PCB) enhances reliability by incorporating robust power management circuits and protection mechanisms. The proposed design offers a platform for future advancements, including the incorporation of three-phase energy metering Integrated Circuits (IC), predictive maintenance algorithms, and a standalone data management system to enhance scalability, security, and operational efficiency. By combining IoTbased architectures with modular hardware and software frameworks, this work paves the way for innovative energy optimization solutions, empowering industries to achieve greater sustainability and cost-effectiveness in their operations
2. HARDWARE DESIGN
The growing demand for sustainable energy management in industrial settings has intensified the need for precise, reliable, and scalable energy monitoring systems. Traditional energy meters often fall short in meeting the evolving requirements of modern industries, where realtime data acquisition, remote monitoring, and actionable insights are paramount. The advent of the Internet of Things (IoT) has revolutionized energy management by enabling the integration of intelligent monitoring devices with cloud platforms, thereby facilitating real-time decision-making and predictive analytics. This study
The hardware design of the smart energy meter that supports IoT applications is the main ingredient of the industrial design. This encompasses high-accuracy sensors, robust microcontroller unit, custom PCB layout and design, and sturdy casing. This design allows the energy parameters to be measured with precision and ensures accuracy under the industrial set- tings. For the three-phase voltage control, ZMPT101B voltage sensors are used. They give isolated voltage feedback, and they are also very accurate in terms of measurements with high sensitivity and a low error margin enabling them to be used in real-time voltage measurement. SCT-013-000 non- invasive AC current sensors are used for current monitoring which enables safe and precise measurement of up to 100A current. To interface the sensors with the Analog to Digital Converter (ADC) of the ESP32 microcontroller, a current to voltage conversion circuit is used.
© 2025, IRJET
ISO 9001:2008 Certified Journal
Key Words: Smart Energy Meter, IoT, ESP32, RTD Sensors, Energy Monitoring, Industrial Automation
1. INTRODUCTION
|
Impact Factor value: 8.315
|
|
Page 673