OPTIMISING ELECTRIC MOTOR EFFICIENCY THROUGH IOT

A Technical Paper Presentation Report

Submitted in partial fulfillment of the
Requirements for the award of the Degree of

BACHELOR OF TEHNOLOGY
IN
ELECTRICAL AND ELECTRONICS ENGINEERING

By
B. Bhanu Prakash
(20P61A0206)

DEPARTMENT OF ELECTRICAL & ELCTRONICS ENGINEERING

VIGNANA BHARATHI INSTITUTE OF TECHNOLOGY

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING
(An Autonomous Institution, Accredited by NBA and NAAC, New Delhi)
Aushapur (v), Ghatkesar (m), R.R Dist, Hyderabad-501301

2022-23

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 Aushapur (v), Ghatkesar (m), R.R Dist, Hyderabad-501301

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

CERTIFICATE

This is to certify that technical presentation report entitles, “OPTIMISING ELECTRIC

MOTOR EFFICIENCY THROUGH IOT”, done by B. Bhanu Prakash bearing Admn.
No: (20P61A0206) submitted to the faculty of Electrical Engineering, in partial fulfillment
of the requirements for the Degree of BACHELOR OF TECHNOLOGY from VBIT,
Aushapur, Hyderabad.

Coordinator Head of the Deparment

Dr.K.Neelima
Technical Presentation professor & HOD

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 Aushapur (v), Ghatkesar (m), R.R Dist, Hyderabad-501301

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

DECLARATION

We hereby declare that the project entitled “OPTIMISING ELECTRIC MOTOR

EFFICIENCY THROUGH IOT” is carried out during 2020-2024 in a partial fulfillment
for the award of Bachelor of Technology Degree in Electrical and Electronics Engineering.
We have not submitted this dissertation to any other University or Organization for the award
of any other Degree.

By

B.Bhanu Prakash (20P61A0206)

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 ACKNOWLEDGMENT

I take the opportunity to acknowledgement with thanks and deep sense of gratitude towards
our principal Dr. P.V.S. SRINIVAS, who extended his whole hearted co- operation and
encouragement in the successful completion of our Technical Presentation .

I express our sincere thanks to Dr. K. NEELIMA, HoD , Department of Elec-

trical and Electronics Engineering who has given her invaluable suggestions and encour-
aging support and guidance in carrying out the Technical Presentation . .

I hereby, one and all who extended helping hand in the accomplishment of our project.

by

B. Bhanu Prakash (20P61A0206)

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 ABSTRACT

Interference to the three-phase electric motors often occurs in power plant, unfortunately the
interference can’t predicted and decreasing unit performance. This paper presents a system
that handling interference based on Internet of Things (IoT) for improving electric motor
perfomance. The build system can monitoring and controlling with FLM (First Line
Maintenance). FLM is a mild corrective maintenance activity that is carried out when the unit
is operating with the provision of simple equipment.Design and implementation of the device
using an ESP8266 to acquire motor’s vibration and temperature condition supporting by
application as user interface. The result is to prevent further damage to electric motor by
adding an external fan and greasing pump which serves for additional cooling on the motor.

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 TABLE OF CONTENTS

LIST OF CONTENTS PAGE NO:

ACKNOWLEDGEMENT iv

ABSTRACT v
1.0 Introduction 1
2.0 Related work 3
3.0 Methodolgy 4
4.0 Result and Discussion 7
4.1 Temperature measurements result
4.2 Vibration measurements result 8
4.3 Result comparsion between Temperature and 10
Vibration

CONCLUSION 11

REFERENCES 12

List of Figures
1.Components on the System Proposed
2.Monitoring Scheme using ESP8266 to wifi Network
3.Flowchart of System
4.Bearing Temeprature rise graph
5.Vibration graph for 30 days
6.Comparison chart between temeperature and vibration
7.Comparison temperature and vibration values for 30 days
8.Pie chart for 30 days trial period

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 1.0 INTRODUCTION

Three-phase electric motor is the type of motor which is most widely used in industry and generation.
The motor converts electrical energy into the mechanical energy as the driving force. The consideration
of using the three-phase induction motor has simple construction which is easy to maintain, rotation is
relatively constant with changes in load, low cost, high reliability and has a large power factor. The
performance of three-phase motor depends on above mentioned electrical, mechanical and
environmental parameters of the motor, therefore controlling methods for high performance three-phase
motor are very sensitive to motor parameters. Disturbances in three-phase electric motors often occur
in the work system of power plants, but disruptions in three-phase electric motors are often
unpredictable and the result is decreasing the performance of the work system of power plants.
Maintenance process at a power plant can’t fast due to a very wide area causing difficulties for operators
and technicians to control the performance of the motor, hence the failure of the motor operation can
no longer be denied Damage to the electric motor can interfere with power generation equipment
systems. Disturbances in electric motor such as high temperatures on bearings or motor bearings and
motor windings. Electric motor disruption can also be sourced from vibration bearings or motor
bearings. When an increase in temperature on a bearing or winding reaches a normal limit, it can cause
damage. Electric motor vibrations also affect the performance of electric motors when there is an
increase in the vibration value that reaches the normal limit on an electric motor. The actual location
for maintenance of the power plant can’t be reach due to the large area of the plant and limited
equipment which is not standby and causes difficulties for the operator and technician to control the
performance of the motor, therefor the failure of the motor can no longer be denied. This system is
intended to facilitate monitoring, control and FLM on the performance of the motor to remain reliable
under any conditions which is the IoT is used for monitoring and controlling the three-phase motor to
handling interference and avoid the system failures.
Electric motors play a crucial role in many industrial and household applications, but they are often
subject to electromagnetic interference that can degrade their performance. Interference can cause
problems such as increased energy consumption, decreased efficiency, and reduced lifespan of the
motor. In recent years, there has been a growing interest in using Internet of Things (IoT) technology
to improve the performance of electric motors by handling interference.

IoT technology provides a means of connecting devices and sensors together in a network to share data
and information. This enables real-time monitoring and control of electric motors, allowing for the
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identification and management of sources of interference.

One way to use IoT technology to improve electric motor performance is to install sensors that can
monitor the motor's operation and collect data on its performance. This data can be analyzed to identify
patterns and trends that may indicate interference, such as changes in motor speed or energy
consumption. Machine learning algorithms can then be applied to this data to predict when interference
is likely to occur and take action to prevent it.

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2.0 Related work :

Many research correlated to this paper, the main focus in on the controlling and monitoring the motor using
Raspberry pi as the center of the main CPU has been done. Another research also building the system to
monitoring with heat and thermal sensors that aims to determine the feasibility of a motor , as well as vibration
sensors as a control media connected with Linux . An industrial wi-fi sensor community that transmits motor
currents and vibrations wirelessly was applied and its conduct at special loads examined and also indicates the
motor conditions by considering and calculating temperature and vibration data and amplified with temperature
monitoring on the motor rotor and stator . With an IoT-based monitoring system, it compare temperature, current
and vibration to normal and abnormal motors . In an electric motor working system, very accurate protection is
needed to avoid damage to the motor when the motor experiences high vibration, it can diagnose motor damage
by looking at the vibration measurement spectrum which is useful for taking appropriate corrective action when
the motor experiences high temperatures on the bearing and winding it can also be due to the wrong fan selection,
it requires a fan that matches the type of motor so that cooling can optimal , with this fan it is our point to make
paper making as the first action in overcoming if there is heat and excessive vibration. In order to observe motor
faults, an assessment was carried out underneath unloaded and fully loaded conditions, and real-time motor
currents and voltages have been examined . Research on wireless ZigBee network for monitoring motor
parameters included current, voltage and torque has been done . Motor condition was once explored each
mechanically and electrically including the lifetime power of factors . The find out that readings received with
the aid of monitoring motor parameters should expose facts about the motor.

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3.0 Methodology:
The proposed system consists of Wi-Fi enabled microcontroller, Temperature sensor, vibration sensor,
moisture sensor, Infra red sensor, current and voltage measurement circuits and three-phase motor. The
system can monitor and control the motor through webpage or Android application using IoT. The
component and scheme of the system shows on figure 1.

Figure 1. Component on The System Proposed

The temperature sensor and vibration contained in the motor provides an analog signal on ESP 8266
which will provide information related to temperature and vibration on the motor. For the security
scheme, the motor is added to the external fan as the cooling of the motor bearing for the purposes to
monitoring the temperature does not exceed 65 ° C, and the motor vibration does not exceed 4mm/s. The
grease pump serves as motor lubrication to indicates abnormal noise in competing motors. If the motor
is at a certain temperature it will inform to mobile application via WIFI therefor the user can monitor it
immediately and controlling the fan cooler to be turn on or turn off and grease pump is added if
the temperature and lubrication are not optimal.

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 Figure 2. Monitoring Scheme using ESP8266 to Wifi Network

The three-axis accelerometer (ADXL345) is used to measure the vibration while the current sensor
(ACS712) is used to measure current and temperature sensor probe (DS18B20) is used to measure
temperature of the motor housing or in bearing areas. All three sensors are connected to an ESP8266 IoT
Wi-Fi chip powered by a small Lithium- ion battery in system diagram illustrated in Fig. 3. An ESP8266
is a singlechip device build-in 4MB of flash memory capable of connecting to the internet through build-
in Wi-Fi (IEEE 802.11 b/g/n) module. The chip is small, low cost, low power and able to make TCP/IP
connections using simple Hayesstyle commands, making it perfect for wireless batterypowered
applications. There are 16 general purpose input/output (GPIO) pins available on board which is more
than enough for our application.

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 Figure 3. Flowchart of System

The proposed system received data from sensor nodes over the internet then collected, managed and
analyzed data into profiles in cloud database. These profiles are then compared with pre-existing normal
operation profile. Any motor’s abnormality detection is then flagged then sent to operator notification
module which has a great flexibility due to numerous community-modules available in platform.

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4.0 RESULT AND DISCUSSION:

The 3 phase motor is monitored using node MCU or ESP6288 and several sensors to obtain temperature
or vibration parameter data that can be viewed via a mobile phone. The result is to prevent further damage
to electric motor by adding an external fan and greasing pump which serves for additional cooling on the
motor. The build System can improving the performance of motor drives in a generator and minimizing
the occurrence of damage or trip on the electric motor. The system is being tested in PT. Indonesia Power
UJP Jabar II Palabuahanratu as one of the steam power plants in West-Java, Indonesia. The following
data shows that the measurement results for 30 days showed some point measurement on an electric
motor.

4.1 Temperature measurements results:

From this data are divided into 3 categories i.e. the Normal value, the Alarm value and Critical value. These
data contain limitations i.e. temperature ≤ 50 ° C enter the category of normal value, 50-65 ° C alarm value
category and ≥ 66 ° C enter critical value.

Fig. 4 Bearing temperature rise graph.

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4.2 Vibration measurements results:
Vibration sensor is quite sensitive and the sampling rate of sensor node fast enough to detect potentially harmful
vibration electric motor operation. The boundaries of the safe (safety limit) when the motor is operating at
maximum 4.00 mm/s, when the vibration of the bearing of the motor exceeds the number in the prolonged
period will result in abnormal motor bearing which led to severe damage and failed surgery.

Fig. 5 Vibration graph for 30 days

4.3 Results Comparison between Temperature and Vibration:

The increase is detected by the sensor hot (temperature) and vibration (vibration), seen in Figure 8 can be
concluded that the increase in temperature can influence the vibration motor, at the temperature of 55 ° C
vibration rising on point 1.01 mm/s are marked with sign in the alarm value. And tends to rise to enter Critical
value i.e. at temperature of 71 ° C and vibrations 4.31 mm/s which will inform our mobile phone to
immediately run the fan (Fan cooling) and if the temperature continues to rise then pump the lubricant (grease
pump) will be executed in order to assist the process of decrease of temperature in the motor.

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Fig. 6 Comparison chart between temperature and vibration

Fig.7 Comparation Vibration and temperature value in 30 days

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 Fig.8 Pie chart for 30 days trial period

From these data it can be concluded that in the interval of the 30 day trial period percentage of obtained from the
addition of a fan cooling as well as external grease pump capable of lowering the temperature and vibration on
the motor in the event of abnormalities with the acquisition 20%.

Thus the existence of this tool will be able to prevent damage to the motor the motor even more failed
operation (break down), at least can last quite some time until the time of the inspection of the motor is
scheduled. However the data above cannot be a reference that a successful tool for securing a motor due
to differences on each motor type specification will affect the results of the works of these tools can also
be affected by external i.e. the burden on the motor move by experiencing the interference.

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CONCLUSION:
This paper proposes a device to handling interference on the three-phase motor based on IoT. The build system
using three sensor and CPU ESP8266 as central unit that can directly connected to the internet network. The
system has been designed to combine various parameter measurements in real-time, improving the delectability
of different faults. The monitoring of the motor system presents the measurement of different parameters namely
vibrations, temperature and current consumption. This system can facilitate maintenance work in controlling
efforts as well as routine maintenance of the motors in the power plant.The system has a high autonomy, easy
installation and low maintenance costs. IoT technology can play a significant role in improving electric motor
performance by handling interference. By providing real-time monitoring and control of electric motors, IoT
systems can help identify and mitigate sources of interference, increasing efficiency and reducing energy
consumption. As this technology continues to evolve, we can expect to see even greater improvements in electric
motor performance in the years ahead.

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REFERENCES

[1] Anggy Pradiftha Junfithrana1, Irfan Solikin2, Juni Kusuma Hadi3, Moch. Dedy Novianto 4,
“Improving Electric Motor Performance by Handling Interference using IOT” ,IEEE,2019.
[2] V.S.D Rekha and Dr. K.Srinivasa Ravi “Induction Motor Condition Monitoring and
Controlling Based on IoT” IJEECS,September 2017.
[3] Martin Ganchev, Bernhard Kubicek, Hansjoerg Kappeler,” Rotor Temperature Monitoring
System”, XIX International Conference on Electrical Machines - ICEM 2010, Rome,2010.
[4] D.Ganga and V. Ramachandran,”IoT based Vibration Analytics of Electrical
Machines”,IEEE,2017.
[5] H. Hafezi, A. Jalilian, “ Design and Contruction of Induction Motor Thermal Monitoring
System”, Iran University of Science and Technology, Tehran, Iran, 2006.
[6] J. Kunthong, T. Sapaklom, M. Konghirun, C. Prapanavarat, P. N. N. Ayudhya, E.
Mujjalinvimut, and S. Boonjeed, “IoT-Based Traction Motor Drive Condition Monitoring in
Electric Vehicles: Part 1”, IEEE PEDS 2017, Honolulu, USA
[7] Mehmet GUNKAS, Ramazan AKKAYA, Ali OZTURK, “Protection of AC Motors by Means
of Microcontrollers”,Student Member IEEE.
[8] Xiao Qijun, Luo Zhonghui*, “Early Fault Diagnosis of the Rolling Bearing Based on the Weak
Signal Detection Technology”, 14th International Conference on Control, Automation, Robotics
& Vision, Phuket, Thailand, 13-15th November 2016 (ICARCV 2016), 2016.

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