Abstract: The increasing use of electric motors in industrial and domestic applications has made motor monitoring and protection an important requirement for ensuring safe and efficient operation. Motors often operate under varying loads and environmental conditions, which may lead to faults such as overheating, excessive vibration, and overcurrent. If these conditions are not detected early, they can result in severe motor damage, reduced efficiency, unexpected downtime, and increased maintenance costs. Therefore, continuous monitoring of motor operating parameters is essential for preventing failures and improving system reliability.

This project presents the design and implementation of an IoT-based Motor Safety Monitoring System that continuously monitors important motor parameters and provides automatic protection against abnormal operating conditions. The system is built using the ESP32 microcontroller, which serves as the central processing unit for collecting sensor data and controlling system operations.

The proposed system utilizes multiple sensors to monitor critical parameters of the motor. A current sensor is used to measure the electrical current drawn by the motor, which helps detect overload conditions. A vibration sensor is used to identify mechanical abnormalities such as imbalance or loose components. A temperature sensor (DS18B20) is used to monitor the thermal condition of the motor to prevent overheating. These sensors continuously send data to the ESP32 microcontroller, where the values are processed and compared with predefined threshold limits.

If any parameter exceeds its safe threshold value, the system identifies it as a fault condition and automatically shuts down the motor using a relay module. This immediate response helps protect the motor from severe damage and ensures safe operation. In addition to local protection, the system also provides remote monitoring capabilities through the Blynk IoT platform.

The ESP32 connects to a WiFi network and transmits real-time sensor data to the Blynk cloud server. A mobile dashboard displays parameters such as current, vibration level, temperature, and motor status. The user can monitor the system remotely and receive alerts whenever abnormal conditions occur.

For demonstration purposes, a DC Johnson motor is used as a prototype to simulate the behavior of an industrial motor. Experimental testing shows that the system successfully detects abnormal conditions such as overcurrent, excessive vibration, and overheating, and automatically stops the motor to prevent damage.

Downloads: | DOI: 10.17148/IJIREEICE.2026.14356