Smart Transformer with IoT-Based Power Monitoring and Automatic Load Balancing System for Industrial Applications

The proposed Smart Transformer with IoT-Based Power Monitoring and Automatic Load Balancing System provides an integrated approach for improving transformer operation in industrial applications. The developed concept uses two 0.5 kVA, 230/12 V transformers, Arduino UNO, voltage and current sensors, a DS18B20 temperature sensor, relay modules, LCD display, cooling fan, and ESP8266 IoT connectivity. Under normal loading, Transformer 1 supplies the load while Transformer 2 remains OFF. When the load exceeds the predefined 400 VA threshold, Transformer 2 is automatically activated to share the load. For the considered 700 VA high-load condition, both transformers share approximately 350 VA each, corresponding to about 70% loading and 29.17 A secondary current per transformer. The system also provides continuous monitoring of voltage, current, power, and temperature. Automatic cooling is incorporated to respond to high-temperature conditions, while the LCD enables local observation and the IoT module supports remote monitoring through the cloud. Therefore, the proposed system demonstrates a practical framework for automatic load management, transformer protection, and real-time supervision. The calculated results support the feasibility of the proposed prototype, while actual hardware testing will be required to validate sensor accuracy, switching performance, thermal response, and IoT communication under practical operating conditions.

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