Overview:

The Industrial Machine Vibration Monitor is an IoT-powered system designed to track and analyze the vibrations produced by industrial machines in real-time. Continuous vibration monitoring helps in predictive maintenance, identifying issues like misalignment, imbalance, bearing faults, or looseness in machinery before failure occurs. It reduces unplanned downtime, improves safety, and optimizes equipment life in manufacturing plants, factories, and processing units.

Key Features:

• Real-Time Vibration Tracking:
  Continuously measures vibration levels and frequency of machines using sensors.

• Data Visualization:
  Vibration trends displayed on a web dashboard with graph-based insights.

• Fault Detection & Alerts:
  Sends instant alerts via SMS/email/app when vibration exceeds predefined thresholds.

• Predictive Maintenance (AI/ML):
  Uses machine learning to predict future failures based on historical vibration patterns.

• Multiple Machine Monitoring:
  Scales to support multiple machines and sensor nodes in a large factory setup.

Technology Stack:

• IoT Hardware:

  • Microcontroller: ESP32 / Arduino with Wi-Fi or GSM module

  • Sensors: Accelerometer (e.g., ADXL345, MPU6050, or piezo sensors) to measure vibration

  • Power Supply: Battery/Power adapter depending on location

  • Connectivity: Wi-Fi or GSM (SIM800L) for remote areas

• Backend:

  • PHP / Java / Node.js REST API to store sensor readings, manage thresholds, and alerts

  • Real-time data streaming using WebSockets (Node.js) optional

• Frontend:

  • HTML, CSS, Bootstrap, JavaScript for real-time dashboard

  • Graphs and visual alerts (red/yellow/green indicators)

• Database:

  • MySQL / MongoDB to log vibration readings, machine profiles, alert history

Modules:

1. Sensor Module:
   Continuously captures vibration intensity (in Hz/g-force) and transmits to the cloud.

2. Threshold Monitoring Module:
   Set min/max vibration thresholds per machine type; flag anomalies.

3. Alert Notification Module:
   Sends automatic alerts (email/SMS/in-app) when abnormal vibration is detected.

4. Machine Profile Module:
   Manage machine-specific info: location, type, maintenance logs.

5. Visualization Module:
   Live charts, logs, and analytics for vibration trends per machine.

6. Predictive Analytics Module (Optional):
   Uses ML models to detect degradation patterns and estimate failure timelines.