[Link]
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International Journal of Innovations in Engineering and Science, [Link]
IOT Based Smart Industrial Fault Monitoring
System Using Raspberry Pi
Himali Chaudhari1*, Neha Chaudhari2, Konika Patil3, Hemakshi Rane4,
Pranav Gond5, Dr Hemant T Ingale6 Smita k chaudhari7
1,2,3,4,5
UG students, Dept of Electronic and Telecommunication Engineering, Godavari Collage of Engineering,
Jalgaon, Maharashtra, India.
6
Professor, ::0000-0003-2464-3353
himalichaudhari2004@[Link], chaudharin08@[Link], konikapatil47369@[Link],
pranavgond43@[Link], hetui@[Link], [Link]
Received on: 13 March,2025 Revised on: 16 April,2025 Published on: 18 April,2025
Abstract- Internet of Things (IoT) is rapidly increasing Internet of Things (IoT) devices are controlled by web
technology. IOT is the network of physical objects or controller or E- controller which is a bunch of embedded
things embedded with electronic software, sensors, and system and software stack, Technology development is an
network connectivity which enables these objects to
unending process and hence it is necessary for us to be
collect and exchange data. IOT then deals with bringing
control of physical devices over the internet. In this well equipped and aware of the new upgrades in the
project, we are developing a system which will technology. These technological changes have thus
automatically monitor the industrial applications and brought ease in the daily human life. Automation has
generate Alerts/Alarms or make intelligent decisions become the need of the day. Today all the data, system is
using the concept of IoT. A number of sensors are available on internet and the web technology is growing
deployed in our project to monitor industrial parameters very fast.
like temperature, pressure, gas, etc. These parameters
were carefully selected on the basis of the potential
hazards they can cause to the normal working of the .
industry machine. The sensors used in our project are
sensor Temperature DHT11, Gas sensor MQ9, Flame
sensor LM393, Accelerometer ADxL335, Ultrasonic
sensor HC-SR04, and PIR sensor.
Keywords – Internet of Things (IoT), industrial safety,
sensors, Raspberry Pi, fault monitoring, Wi-Fi module
INTRODUCTION
Technology development is an unending process and Figure 1. Internet of Thing
hence it is necessary for us to be well equipped and aware
LITERATURE SURVEY
of the new upgrades in the technology. These
technological changes have thus brought ease in the daily
Previous studies have extensively explored various aspects
human life. Automation has become the need of the day.
of industrial safety and IoT integration. Research by
Today all the data, system is available on internet and the
Zheng et al. (2018) delves into smart manufacturing
web technology is growing very fast. Embedded system
systems, emphasizing IoT's role in enhancing safety and
with web technology provides remote management
efficiency. Similarly,Glória et al. (2017) discuss IoT
and controlling of embedded device via network interface
gateway
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implementation for smart environments, providing Pi controller has built-in WiFi, USB, and A/V ports. The
insights into sensor integration and data management. programming of the Raspberry Pi controller is done is
Other studies, such as Rigelsford (2003), focus on GSM Python scripting language. The Raspberry Pi controller
network applications in remote monitoring, while Dinardo runs the Raspbian OS which is a distribution of Linux OS.
et al. (2018) examine machine condition monitoring in There are four relays connected to the output pins of the
Industry 4.0 scenarios. These works underscore the Raspberry Pi controller. Four different industrial devices
importance of real-time data transmission and predictive These commands are then communicated to the
maintenance facilitated by IoT technologies. Wang et al. Raspberry Pi controller over the WiFi using IOT
(2018) demonstrated the use of wireless sensor networks protocols. According to these commands, the Raspberry
for real-time fault detection in rotating machinery. Their Pi controller turns the relays on and off. An LCD is also
work emphasized the need for low-power, robust sensor connected to the Raspberry Pi controller which is used to
nodes to operate in harsh industrial environments. As per display the device statuses as well as other messages.
Singh and Roy (2019), integrating machine learning Block Diagram
algorithms such as SVM and Random Forests has
improved the fault detection accuracy by over 90%.
However, their models were mostly tested in simulated
environments. Research by Zhang et al. (2020) compared
cloud-based analytics with edge computing. Edge
computing was found to reduce latency and improve
response time in critical fault detection, although it came
at the cost of lower computational power. According to
Khan and Patel (2021), security remains a major concern
in IoT-based systems. They highlighted vulnerabilities in
MQTT and CoAP protocols, commonly used for IoT
communication Dr. Ananya Verma’s 2022 review in IEEE
Transactions on Industrial Informatics focused on the
lack of standardized communication protocols and its
impact on system scalability. She advocated for the use of Figure3 Block Diagram
OPC UA and TSN (Time Sensitive Networking) for real-
time fault diagnosis. Federated learning (FL) allows
distributed training of fault detection models without
centralized data. Wu et al. (2023) integrated FL with
blockchain to enhance data privacy and trust,
demonstrating its effectiveness in heterogeneous
industrial networks.
METHODOLOGY
Overview
The Raspberry Pi single board computer is used as the
main device controller in the project. It is used to
establish communication with the remote IOT server
using the IOT protocols over the WiFi connection. are
connected to these relays. And a four different sensors are
also connected to Raspberry pi. The Raspberry Pi board
communicates with the remote server based IOT platform
by means of built-in WiFi. The control commands are Figure 4 Raspberry Pi
provided by the user in the IOT platform.
The power supply on the circuit board provides 5VDC to The minimum power given to raspberry pi board is 5V,
the Raspberry Pi controller and the LCD.. The Raspberry
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1A. USB ports are used to connect keyboard, mouse.
Ethernet port is used for internet connection through
LAN. HDMI port for [Link] card slot is used to
handle memory of 16GB of capacity for operating system
and programming files. We read the parameters from
sensors and raspberry pi
Hardware Use:
Raspberry Pi, LCD Display, Wifi Module, Relay
Temperature sensor, Humidity sensor, Gas sensor,
Camera, Rectifier, Regulator, Resistors, Capacitors,
Transistors, Power Supply, Cables and Connectors, Figure 6 Circuit Diagram of Relay Module
Diodes, LED, Transformer/Adapter, Switch. IC, IC
Sockets, Motor, Lamps. Some of Hardware descriptions Relay
are given below: In layman terms, a relay is a switch. Technically speaking,
Raspberry Pi: relay is an electromagnetic switch where a small control
signal (usually from a microcontroller) at the input of the
Raspberry Pi is a low cost, credit- card sized computer Relay will control a high voltage supply (usually AC
that plugs into a computer monitor or TV and uses a mains). Since this is a Raspberry Pi based project, let us
standard keyboard and mouse. It is a capable little device talk with respect to Raspberry Pi. The Raspberry Pi
that enables people of all ages to explore computing and to computer, although a powerful device, works on a 3.3V
learn how to program in languages like Scratch and Logic. If you want this powerful computer to control your
Python. It is capable of doing everything you’d expect a electrical loads, like an LED strip running along your
desktop computer to do, from browsing the internet and garden or kitchen, you cannot interface them directly as
playing high-definition video, to making spreadsheets, the electrical loads work on AC Mains supply and the
word-processing, and playing games. Raspberry Pi 4 is Raspberry Pi works on 3.3V. The circuit shown above
the latest iteration of the Raspberry Pi product family and will drive a relay with minimum number of components
it offers the fastest performance when compared with the (a Transistor, a current limiting resistor, a Relay and a
previous generations. Diode). A Relay Module is a simple circuit board that
consists of the relay itself and all the necessary
3.3.3. Relay Module: components that are required to drive a relay and also the
required connectors to connect the load. I have used a four
Even though the Relay Coil needs a small current in order channel relay module in this project. It is basically, four
to get energized, driving it directly from Raspberry Pi (for relays with all the circuitry on a single board.
that matter, any Microcontroller like 8051 or Arduino) is
not a good idea. A simple way is to drive the Relay Coil
through a Transistor. The following image shows the
connections required with respect to a Relay.
Figure 7 Relay Module Plate
Figure 5 Relay Module Temperature Sensor
A temperature sensor is an electronic device that measures
the temperature of its environment and converts the input
data into electronic data to record, monitor, or signal
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temperature changes. The DS18B20 temperature sensor is
perfect for projects like weather stations and automation
systems. these sensors are easy to set up on the Raspberry
Pi. They're the same size as a transistor and use only one
wire for the data signal
Figure 10 Wifi Module
For an IoT-based Smart Industrial Fault Monitoring
System, a Wi-Fi module plays a crucial role in enabling
wireless communication between the sensors and the cloud
or central monitoring system. Among the most commonly
used Wi-Fi modules, the ESP8266 and ESP32 stand out
Figure 8 Temprature sensor
due to their affordability, reliability, and ease of
integration. The ESP8266 is a low-cost module suitable
Humidity Sensor for basic applications, offering built-in Wi-Fi and GPIO
The DHT11 is a low-cost temperature and humidity
pins for connecting sensors. For more advanced needs, the
sensor. It isn't the fastest sensor around but its cheap price
ESP32 is preferred because it features dual-core
makes it useful for experimenting or projects where you
processing, more GPIOs, and supports both Wi-Fi and
don't require new readings multiple times a second. The
Bluetooth, making it ideal for real-time fault detection
device only requires three connections to the Pi. +3.3v,
and data transmission in industrial environments.
ground and one GPIO pin.
Alternatively, a Raspberry Pi with built-in Wi-Fi can be
used for more complex systems that require local data
processing or edge computing.
3.4 Software Use
3..4.1 Raspbian OS
Raspbian is a free working framework in based on
Debian. It is based on the Raspberry Pi module. A
Figure 9 Humidity Sensor working framework is the arrangement of fundamental
programs and utilities that make your Raspberry Pi run. It
3.3.4 Wifi Module gives essentially speedier execution to applications that
make substantial utilization for floating point arithmetic
Low-power, low-cost Wi-Fi modules have changed the operations. Every single other application will likewise
landscape of wireless sensor networks. Autonomous, Wi- increase some execution speed because of advanced
Fi sensors connect to common, widely available wireless instruction of the ARM11 CPU in Raspberry Pi.
network infrastructure. They send sensor data over 3.4.2 Apache HTTP Server:
standard TCP/IP making their information anywhere in
the world from any computer or smart [Link], The Apache HTTP Server which is called as Apache is
wireless sensors networks have been built on top of the world's most famous web server software. It is based
proprietary protocols running on sub- gigahertz radios. on the NCSA HTTP server. Apache has a big role in the
These systems have the benefit of covering long distances initial growth of the World Wide Web. An open
however they are closed systems. Likewise sensors community of developers under the auspices of the
networks based Zigbee radios are also closed system. Both Apache Software Foundation have developed and
of these wireless sensor networks require additional maintained Apache. This is most commonly used on a
gateway hardware devices to get sensor data onto the Linux; this software is available for a wide variety of
internet or users LAN. Gateways introduce a single point operating systems, including UNIX, FreeBSD, Linux and
of failure and additional cost. Solaris.
3.4.3 TCP IP Protocol :
The same layered structure as used in the TCP/IP protocol
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suite is used by the software running on the embedded Step5 Update the System
web server. The TCP/IP protocol suite permits PCs of all
sizes, running distinctive operating systems to Setting up a Raspberry Pi involves several key steps to
communicate with each other. The TCP/IP protocol get it up and running. First, you'll need a Raspberry Pi
suite is a blend of various conventions at different layers board (such as the Raspberry Pi 4 or Zero), a microSD
as appeared in Figure. Figure demonstrates Layers of card (at least 8GB, Class 10 recommended), a power
TCP/IP protocol suit. Each layer is independent from each supply (5V 3A for the Raspberry Pi 4), and peripherals
other. The Link Layer generally incorporates the device like a keyboard, mouse, and monitor. Start by
driver in the operating system and corresponding network downloading the Raspberry Pi OS (formerly Raspbian)
interface (card) in the PC. An Ethernet controller driver from the official Raspberry Pi website and use a tool like
controls the Ethernet interface and the network layer Raspberry Pi Imager or Balena Etcher to flash the OS
controls the communication. onto your microSD card. Once the OS is written, insert
the microSD card into the Raspberry Pi, connect your
IMPLEMENTATION peripherals (keyboard, mouse, and display), and then plug
The first step in implementing the IoT-based Smart in the power supply. The Pi should boot up, and you'll be
Industrial Fault Monitoring System is to select and install guided through the initial setup process, which includes
appropriate sensors on the industrial equipment. These setting up your locale, time zone, Wi-Fi, and password.
sensors continuously measure critical parameters such as After that, you'll have access to the desktop environment,
temperature, vibration, and electrical current, which are where you can start installing additional software and
key indicators of machine health. The sensors send raw configuring your Pi for various projects. To ensure your
data to a microcontroller unit like an Arduino or ESP32, system is up to date, it’s good practice to run sudo apt
which acts as the system’s central processing unit. update and sudo apt upgrade from the terminal after the
Next, the microcontroller processes the sensor data and initial setup.
transmits it wirelessly to a cloud-based platform using RESULT
communication protocols such as Wi-Fi or GSM. This
enables remote monitoring and data storage, allowing
authorized personnel to access machine status from
anywhere at any time. The cloud platform is
also responsible for running algorithms that analyze the
incoming data to detect any abnormalities or fault
conditions.
To ensure the system is user-friendly, a web or mobile
dashboard is developed. This dashboard visualizes real-
time data, historical trends, and fault alerts, enabling
maintenance teams to quickly understand the equipment’s
condition and take proactive actions. Additionally,
automatic alert systems send notifications via SMS or
email whenever a potential fault is detected, minimizing
the risk of unexpected breakdowns.
Finally, the entire system undergoes rigorous testing and
calibration. Fault scenarios are simulated to validate the
accuracy of sensors and the effectiveness of the fault
detection algorithms. Once validated, the system is
deployed on the industrial floor for continuous
monitoring, helping to reduce downtime, improve
maintenance scheduling, and extend the lifespan of
machinery.
Raspberry pi 5 OS Installation and setup
Step1 Prepare the microSD Card Step 2 Boot the
Raspberry Pi Step 3 Connect and Configure Step4 Basic
Configuration Figure 12 Sensor Data Chart
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industries. This system try to minimize the energy waste
A good comparison done by the author in which why to by providing sufficient information to the owner or top
use raspberry pi in industrial propose is explained. As level hierarchy persons via remotely and can be made
raspberry pi is small in size and also consumed less power appropriate decision. It also helps to analyze the overview
along with doing complex processing of collected data. consumption of power and material requirement. In this
There are lots of wastage in energy at workstation and system, blade aging of the cutter tool is monitored by
industries by hiding the real status of the installed system observing the energy consumption of cutter tools.
through workers or may be the middle hierarchy of
CONCLUSIONS [4] Hongyu Pei Breivold,Kristian Sandstrm, Internet of
Things for Industrial Automation Challenges and
As mentioned in the Section II, we get the information of Technical Solutions, 2015 IEEE International Conference
on Data Science and Data Intensive Systems,978-1-5090-
the SOA-IoT that is Service Oriented Architecture IoT.
0214-6/15 31.00 2015,IEEE,DOI
We also get the idea about the System overview of
10.1109/DSDIS.2015.11.
raspberry pi. We are aware from the new trends in the [5] S. CHARITH PERERA, CHI HAROLD LIU and MIN
Industrial automation and IoT technologies. The authors CHEN, A Surveyon Internet of Things From Industrial
also discuss the various challenges in the IoT and also in Market Perspective,2169-3536 2015 IEEE
Industrial automation constrain. How handle this [6] Li Da Xu (Senior Member, IEEE), Wu He, Shancang Li,
challenge is also discussed by the authors. The authors Internet of Things in Industries: A Survey, Citation
also survey the industrial marketplace considering the IoT information: DOI 10.1109/TII.2014.2300753, IEEE
perspective. The embedded internet network was Transactions on Industrial Informatics.
discussed by the author in which IEC 62591 that is [7] Song Han & Yi-Hung Wei,Deji Chen, Mark Nixon, Eric
wirelessHART standard was Rotvold, Aloysius K. Mok, Building Wireless Embedded
Internet for Industrial Automation.
[8] Gowrishankar.S, Madhu.N and [Link], Role of
BLE in Proximity Based Automation of IoT:A Practical
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