low cost predictive maintaince system for small scale industries

A low-cost predictive maintenance prototype using ESP32 was developed for small-scale industrial applications. The system uses an ADXL345 accelerometer to monitor machine vibration and can include an ACS712 current sensor for additional condition information. The ESP32 processes the sensor readings and gives local and remote indications through the OLED, LED, buzzer, and IoT dashboard. The prototype successfully demonstrated normal, warning, and fault conditions using different vibration levels. The proposed approach can help small industries move from breakdown-based maintenance toward condition-based maintenance without the cost and complexity of large industrial monitoring systems. The present work is a prototype, so further testing on real industrial machines is needed before using it as a safety-critical maintenance system.

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