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Remotely Accessible IoT Monitoring of a Programmable Logic Controller-controlled AC Motor System with Embedded AI Using ESP32.

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Title: Remotely Accessible IoT Monitoring of a Programmable Logic Controller-controlled AC Motor System with Embedded AI Using ESP32.
Authors: Pratikto, Pratikto, Fitriani, Raydha Zul, Kuan, Yean-Der, Julianto, Muhammad Nadzarridho, Utari, Listya, Khakim, Nur, Latif, Muhammad, Falahuddin, Muhamad Anda
Source: Sensors & Materials; 2025, Vol. 37 Issue 11,Part 2, p4941-4954, 14p
Subject Terms: INTERNET of things, PROGRAMMABLE controllers, ALTERNATING current electric motors, FAULT diagnosis, COMPUTER network protocols, COMPUTER network monitoring, INDUSTRIAL robots, MICROCONTROLLERS
Abstract: We present the development of a programmable logic controller (PLC) system designed for three-phase motor applications, incorporating a web-based monitoring system using the ESP32 microcontroller and Modbus transmission control protocol/internet protocol (TCP/IP). It supports six different motor starting methods: direct on line (DOL), on delay, off delay, sequential, alternating, and star-delta. Communication between PLC and ESP32 utilizes Modbus TCP/IP for reliable data exchange, and the web interface displays operational modes, PLC output status, and live data logging with export functionality. Additionally, the system also includes an embedded AI module for wiring fault detection, which improves safety and allows for offline documentation through local SD card storage. The results confirm that ESP32 has been successfully implemented as a central platform that functions simultaneously as a Modbus TCP/ IP client, web server, data logger, and AI processor. It communicates with PLC in under 200 ms, while its data logging capabilities provide accurate and reliable information for analysis. The developed system thus provides an effective platform for industrial automation, modern IoTbased monitoring, and intelligent fault detection capabilities. [ABSTRACT FROM AUTHOR]
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Database: Complementary Index
Description
Abstract:We present the development of a programmable logic controller (PLC) system designed for three-phase motor applications, incorporating a web-based monitoring system using the ESP32 microcontroller and Modbus transmission control protocol/internet protocol (TCP/IP). It supports six different motor starting methods: direct on line (DOL), on delay, off delay, sequential, alternating, and star-delta. Communication between PLC and ESP32 utilizes Modbus TCP/IP for reliable data exchange, and the web interface displays operational modes, PLC output status, and live data logging with export functionality. Additionally, the system also includes an embedded AI module for wiring fault detection, which improves safety and allows for offline documentation through local SD card storage. The results confirm that ESP32 has been successfully implemented as a central platform that functions simultaneously as a Modbus TCP/ IP client, web server, data logger, and AI processor. It communicates with PLC in under 200 ms, while its data logging capabilities provide accurate and reliable information for analysis. The developed system thus provides an effective platform for industrial automation, modern IoTbased monitoring, and intelligent fault detection capabilities. [ABSTRACT FROM AUTHOR]
ISSN:09144935
DOI:10.18494/SAM5889