Industrial Machine Vibration Monitoring Node

Problem statement

Unexpected failure of rotating machines in industries causes downtime and maintenance cost; routine manual checks miss early signs.

Abstract

The project uses an accelerometer attached to a motor or machine to measure vibration signatures. A microcontroller calculates RMS vibration levels and optionally applies FFT for frequency analysis. Data is sent to a central system that flags abnormal patterns, enabling predictive maintenance.

Components required

• 3-axis accelerometer (ADXL335/345 etc.)
• Microcontroller (STM32/ESP32/Arduino)
• Signal conditioning circuits
• Wireless module (Wi-Fi/LoRa)
• Central PC or server for visualization
• Machine model or motor setup

Block diagram

Working

The accelerometer measures vibration acceleration which is filtered and digitized by the microcontroller. The firmware computes RMS values over windows and may perform FFT to extract dominant frequencies. These features are transmitted to a monitoring PC where thresholds or ML models detect anomalies compared to baseline healthy signatures.

Applications

• Predictive maintenance in industries
• Motor and pump health monitoring
• Vibration analysis teaching tool
• Base for Industry 4.0 systems