Inductive Based Industrial Automation

• Author(s):

  Veeramani.R | Veerammal K | Kannagi K | Deivakani G | Senthamisevan.C

• Keywords:

  Industrial Internet Of Things, Hardware Interlock, Machine Protection, ESP32, Predictive Maintenance, Smart Manufacturing.

• Abstract:

  Unanticipated Machinery Failures In Industrial Environments, Arising From Overheating, Excessive Vibration, Electrical Faults, Or Fire, Can Result In Severe Equipment Damage, Operational Downtime, And Safety Hazards. This Study Presents A Novel IoT-based Hardware-interlocked Protection System Designed For Real-time Monitoring And Autonomous Fault Prevention In Industrial Machines. Central To The System Is The ESP32 Microcontroller, Selected For Its Reliable Real-time Performance And Integrated Wi-Fi Capabilities, Enabling Seamless Connectivity With IoT Platforms. A Comprehensive Network Of Sensors Including Temperature, Vibration, Fire, Voltage, And Current Detectors Continuously Assesses Critical Machine Parameters. Deviations Beyond Pre-established Safety Thresholds Automatically Activate Protective Responses, Such As Audible Alerts Via A Buzzer, Fault Notifications On An LCD Display, And Hardware Interlocking Through Relays That Immediately Interrupt Motor Supply. Simultaneously, The System Transmits Sensor Readings And Fault Occurrences To A Cloud-based Platform, Supporting Remote Monitoring, Fault Logging, And Analytical Evaluation For Maintenance Optimization. By Integrating Hardware Interlocking With IoT-driven Supervision, The Proposed Framework Reduces Dependence On Manual Observation, Ensures Rapid Response To Anomalies, And Enhances Overall Operational Safety. Its Cost-effectiveness, Adaptability, And Scalability Make It Suitable For Diverse Industrial Settings, Aligning With Smart Manufacturing And Industry 4.0 Principles. The Solution Not Only Improves Machine Reliability But Also Extends Equipment Lifespan Through Predictive Maintenance And Proactive Fault Management. This Work Demonstrates That Coupling IoT Intelligence With Tangible Interlocking Mechanisms Establishes A Robust, Proactive Strategy For Industrial Machine Protection

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Other Details

• Paper id:

  IJSARTV12I4105191

• Published in:

  Volume: 12 Issue: 4 April 2026

• Publication Date:

  2026-04-29

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