Predictive Maintenance: Industry IoT Monitoring

Standard Arduino sensors are meant for clean desks. The Monitoring Industries Using IoT project adapts these components for the harsh realities of factories. It focuses on using sensors to detect mechanical failures before they happen, transmitting the data wirelessly over heavily insulated networks.

The Sensor Suite for Machinery

You do not measure the air; you measure the steel.

1. The Thermocouple: You bolt an MAX6675 K-Type Thermocouple directly to the engine block. Unlike a DHT11, this probe can measure up to 1024°C without melting!
2. The Vibrational Analysis: You attach an MPU6050 Accelerometer to the motor housing.
3. The ESP32 doesn't care about the angle of the motor; it runs high-speed math to measure the frequency of the vibrations. If the motor suddenly starts rattling violently due to a broken bearing, the accelerometer registers a massive spike in g-force!
4. Current Sensing: An SCT-013 Non-Invasive Current Sensor is clamped around the main 220V power cable of the machine. The Arduino calculates exactly how many Amps the machine is drawing.

Modbus to Cloud Transmission

An ESP32 sits in a heavy IP67 waterproof enclosure.

• The ESP gathers the heat, vibration, and amp data.
• It cannot use standard Wi-Fi (factories have terrible signal). It uses an RS485 transceiver to push the data across 1,000 feet of twisted-pair copper wire to a central Gateway Node.
• The Gateway Node pushes the aggregated factory data to an enterprise cloud platform (like AWS IoT or Ubidots).

Essential Industrial Hardware

• ESP32 Dev Module or Arduino Pro Mini (For battery nodes).
• MAX6675 Thermocouple Module.
• SCT-013 100A Current Clamp.
• RS485/Modbus TTL Converters.
• Heavy IP67 NEMA Enclosures to protect against oil and dust.