In the era of Industry 4.0, real-time motor monitoring is essential for preventing costly downtime. However, relying on cloud services isn't always the best move. Whether due to security concerns, high subscription costs, or unstable internet, building an edge-based monitoring system offers a robust alternative.
Why Go Cloudless?
Monitoring industrial motors without cloud dependencies ensures low latency and complete data ownership. By processing data locally via an ESP32 or Raspberry Pi, you can trigger instant alerts even if the internet goes out.
Core Components for Local Monitoring
- Vibration Sensors: To detect bearing wear (e.g., ADXL345).
- Current Transformers (CT): To monitor load and power consumption (e.g., SCT-013).
- Local Gateway: An ESP32 or PLC with a built-in web server or MQTT broker.
- Dashboard: A local Node-RED instance or a hosted HTML dashboard on the device.
Implementation: Local Web Server Code
Below is a simplified C++ code for ESP32 to host a local dashboard that displays motor status without any external cloud connection.
#include <WiFi.h>
#include <WebServer.h>
const char* ssid = "Motor_Monitor_AP";
const char* password = "password123";
WebServer server(80);
void handleRoot() {
String html = "<html><body>";
html += "<h1>Local Motor Status</h1>";
html += "<p>Vibration: <b>Normal</b></p>";
html += "<p>Current: <b>4.5 Amps</b></p>";
html += "</body></html>";
server.send(200, "text/html", html);
}
void setup() {
WiFi.softAP(ssid, password);
server.on("/", handleRoot);
server.begin();
}
void loop() {
server.handleClient();
}
The Benefits of Edge Intelligence
By implementing Local Industrial IoT (IIoT) solutions, companies can achieve Predictive Maintenance without exposing sensitive operational data to the public web. This "Off-Grid" approach is becoming the gold standard for high-security manufacturing environments.
Stay tuned for more tutorials on building secure, offline industrial systems!
Industrial IoT, Edge Computing, Motor Monitoring, ESP32, Predictive Maintenance, Offline IoT, Smart Manufacturing
