International Journal of Scientific Research and Engineering Development

Motor monitoring and protection are essential in industrial and agricultural environments where continuous operation is critical. Motor failures caused by overheating, overcurrent, voltage fluctuations, and excessive vibration can result in significant downtime and financial losses. Conventional protection systems are typically limited to basic relay-based mechanisms or rely on costly PLC-based configurations. This paper proposes a low-cost IoT-based smart motor monitoring and protection system using the ESP32 microcontroller. The system continuously measures voltage, current, temperature, and vibration parameters of a DC 775 PMDC motor. The ESP32 serves as both a data acquisition unit and a standalone web server, hosting a real-time dashboard accessible via WiFi. A threshold-based protection algorithm identifies abnormal operating conditions and automatically disconnects the motor through a relay module. The system operates independently of cloud infrastructure, ensuring reduced latency and improved reliability. Experimental evaluation demonstrates accurate sensor readings, rapid response time, and effective fault detection. The proposed prototype provides an economical and scalable solution for real-time motor protection and preventive maintenance applications.

Nandini R. Patil, Prerna S. Wakhare, Sanskruti V. Deore, Uma Maheshwarrao, Dr. Prajakta Shirke,"AI–Assisted Motor Fault Prediction and Protection Using Esp32" International Journal of Scientific Research and Engineering Development, V9(1): Page(1988-1992) Jan-Feb 2026. ISSN: 2581-7175. www.ijsred.com. Published by Scientific and Academic Research Publishing.