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The problem
Workshop managers usually discover machine utilization from gut feel or manual logbooks — both unreliable. Knowing which lathe sits idle 60% of the shift, or which grinder draws current all night because nobody switched it off, is the difference between buying a new machine and simply scheduling better. This project makes that visibility cheap and safe: a split-core current transformer clamps around each machine's supply cable without touching live wiring, an ESP32 samples the current, and a dashboard turns the raw amps into utilization percentages, run/idle timelines and energy totals. The hardware is deliberately non-invasive so it can be fitted to any existing machine in minutes, and the dashboard answers the one question that matters: where is capacity being wasted.
Current transformer clamp producing a small AC voltage proportional to machine current.
Follow the working sequence
How it works
- The SCT-013 clamp around the machine's live cable produces a small AC voltage proportional to the load current.
- The ESP32 samples this signal, computes true RMS current, and smooths it to reject motor start-up inrush spikes.
- A calibrated threshold with hysteresis decides running vs idle; state changes are timestamped and published over MQTT.
- The dashboard backend accumulates run/idle seconds into utilization percentages and integrates current into kWh.
- Every few seconds the dashboard redraws machine cards, the hourly chart and the event log from the latest telemetry.
- If a machine stays idle past the configured limit during shift hours, an idle alert is raised on the dashboard.
Tech stack:
- ESP32 + SCT-013 current transformer + ACS712 (DC/low-current option)
- 0.96" OLED per node, MQTT (Mosquitto) telemetry
- Python/Flask or Node.js dashboard backend
- HTML/CSS/JS live dashboard (single-file demo included)
- SQLite for shift history
| Parameter | Value |
|---|---|
| Sensor | SCT-013-000 split-core CT, 100 A max (datasheet) |
| Controller | ESP32 per machine node |
| Sampling | RMS current computed per AC cycle, smoothed (design target) |
| Run/idle threshold | Calibrated per machine, hysteresis ±10% (design target) |
| Telemetry | MQTT, JSON payloads every 5 s (design target) |
| Dashboard | Live web app: status, charts, events, alerts |
| Energy calc. | kWh = Σ(I_rms × 230 V × Δt), per machine per day (expected) |
| Idle alert | Configurable, default 45 min in shift hours |
| Installation | Clamp-on, no wiring changes, no downtime |
Project features
- [Non-invasive current sensing] SCT-013 split-core CT clamps around the supply cable — no wire cutting, no electrician, no machine downtime for installation.
- [Run/idle detection] Load-current thresholds with hysteresis classify each machine as running or idle, debounced against motor inrush spikes.
- [Live utilization dashboard] Per-machine utilization bars, running/idle status pills, shift totals and an 8-hour utilization chart update every few seconds.
- [Idle-time alerts] Configurable alerts fire when a machine sits idle beyond a threshold (e.g. 45 minutes) during shift hours.
- [Energy accounting] Current × nominal voltage accumulates into kWh per machine per day, with shift and weekly summaries.
- [MQTT telemetry] Nodes publish to a local MQTT broker; the dashboard subscribes in real time and the design supports cloud bridging later.
- [OLED node display] Each sensor node shows its own machine's current and utilization on a local OLED for shop-floor visibility.
What is included
- Sensor node hardware per machine (ESP32 + SCT-013 + OLED)
- Node firmware (sampling, RMS, run/idle logic, MQTT)
- Central dashboard web application (live view, charts, alerts, history)
- Single-file dashboard demo for presentation
- Wiring diagram and per-machine calibration guide
- Project report PDF (background, sensing method, methodology, calibration procedure, results)
- PPT presentation for final review
- Viva Q&A preparation document (CT sensors, RMS, MQTT, utilization math)
Limitations & prerequisites
- Utilization figures are design targets until the buyer's calibration run — thresholds must be tuned per machine, and the report includes that procedure.
- Energy is estimated from current × nominal 230 V, not true power metering — power factor is not measured, stated plainly.
- Single-phase sensing per node in the base build; three-phase machines need one CT per phase (documented as an extension).
- MQTT broker and dashboard need a local always-on host (a Pi or PC) — not included as a cloud service.
- Very low standby currents (VFD-driven machines at idle) may sit below the noise floor; the calibration guide covers this.
- Not a certified energy-measurement instrument — a prototype for utilization insight, not for billing or compliance.
Frequently Asked Questions
Does installation need an electrician?
No. The split-core CT simply clamps around the existing supply cable — no wires are cut and no terminals are touched, so fitting takes minutes per machine.
How does it know a machine is idle?
It watches the load current: above a calibrated threshold the machine counts as running, below it as idle, with hysteresis and debouncing so motor inrush doesn't cause flicker.
Is the energy figure accurate enough for billing?
No — and it doesn't claim to be. Energy is estimated from current times nominal voltage without power-factor measurement, so it is for utilization insight, not billing or compliance.
Can it handle three-phase machines?
The base build senses one phase per node. Three-phase coverage needs one CT per phase and is documented as an extension.
Where does the data go?
To a local MQTT broker and dashboard on your own network. Nothing is sent to any cloud service in the base build.
Is this project suitable for a final-year project?
Yes — for IoT & Embedded, Electrical and Mechanical programs. It combines non-invasive sensing, embedded firmware, telemetry and a data dashboard around a real industrial problem. Suitable for B.E./B.Tech final-year projects in IoT & Embedded Systems, Electrical and Mechanical.
Components & software requirements
- ESP32 + SCT-013 current transformer + ACS712 (DC/low-current option)
- 0.96" OLED per node, MQTT (Mosquitto) telemetry
- Python/Flask or Node.js dashboard backend
- HTML/CSS/JS live dashboard (single-file demo included)
- SQLite for shift history
Delivery information
Built-to-order project. Delivery timeline is shared after order confirmation based on current queue.
Support terms
Complete documentation, setup guide, and viva preparation included. Support for setup and explanation provided.
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