IoT Power Monitoring System Development
Budget: ₹12,500 – ₹37,500 INR
### **Comprehensive Functional Overview of the Power Monitoring System**
The **Power Monitoring System** is an advanced **IoT-based solution** designed to provide **real-time monitoring of electrical power consumption, phase fault detection, and alert notifications**. Built for **high reliability, efficiency, and industrial-grade performance**, the system incorporates features such as **current sensing, cloud integration, automated alerting, network connectivity management, and power backup solutions**. The system is developed using **ESP32-C3**, ensuring **low power consumption** and efficient data processing. It is designed to operate in **harsh industrial environments** and can support **multiple devices under a single MQTT communication framework**.
At its core, the system operates by **monitoring electrical parameters**, such as **current flow and phase voltages**. Using a **200A/5A split-core current transformer**, it continuously measures **power consumption** and transmits this data in real-time to **AWS IoT Core**, which acts as a cloud-based **MQTT broker**. The primary goal of this system is to **detect power failures, abnormal current variations, and phase faults** in an electrical setup and **send immediate alerts** to users. These alerts help in **preventing damage to equipment, reducing downtime, and ensuring uninterrupted operations**.
The system **fetches default threshold values from the backend API** at startup to ensure it operates with the most recent configuration. If users modify settings via the **mobile application**, the system **publishes an update** to the IoT device to **dynamically update** configurations. The **threshold mechanism** plays a crucial role in detecting abnormal power behavior.
For example, assume that:
- **Threshold value = 24A** (Set from Mobile App)
- **Minimum threshold difference = 2A** (Set from Mobile App)
- **Current flow value = 21A**
The system will evaluate:
- If **current flow < (threshold value - minimum threshold difference)**
- If **21A < (24A - 2A) → 21A < 22A**, which is **true**, the system **triggers an alert notification**.
This **real-time monitoring and alerting** mechanism ensures that power fluctuations are detected before they **cause major failures or disruptions**.
### **Communication and Cloud Integration**
The system uses **AWS IoT Core** to handle **MQTT-based communication**, ensuring **real-time, reliable, and secure data transmission** between the **IoT device and the cloud**. The ESP32-C3 device **publishes ampere readings, phase fault detections, and operational status updates** to AWS IoT Core. Users can **monitor real-time amp readings from a mobile application** or a centralized dashboard.
The **backend API** is responsible for storing **power consumption data** and managing **user preferences, device configurations, and alert triggers**. Additionally, the backend API facilitates **bidirectional communication** by **publishing updated settings to IoT devices** whenever a user changes configurations via the mobile app.
To ensure **error resilience**, the IoT device has a built-in **error handling mechanism**. If an issue arises, such as **sensor failure, missing data, or a network timeout**, the device will attempt **up to five retries** before taking corrective action. If the problem persists despite retries, the **ESP32-C3 automatically restarts**, ensuring the system **recovers and resumes operation without manual intervention**.
### **Relay-Based Wi-Fi Router Control**
Since **continuous network availability** is **critical** for **real-time data transmission and alerts**, the system features an **intelligent relay-based Wi-Fi router control mechanism**. It includes a **12-channel relay module** designed to **restart the Wi-Fi router** if network connectivity is lost.
If the IoT device **fails to establish a stable network connection after five retries**, it **triggers a relay to restart the router**. This eliminates **manual router resets**, ensuring **seamless device-to-cloud communication**.
### **Power Management and Battery Backup**
The system includes a **robust power supply design** to **ensure continuous operation**, even during **power failures**. The **power architecture** consists of:
1. **AC to DC Power Conversion** – Converts **220V AC to 12V DC**.
2. **DC-DC Step Down to 5V** – A **buck converter** reduces **12V DC to 5V DC**, which powers the **ESP32-C3**.
3. **Battery Backup System** – If AC power is lost, the system **automatically switches to battery power**, regulated via a **DC-DC inverter**.
4. **Automatic Power Switching Circuit** – Ensures a **smooth transition** between **AC and battery power** without **disrupting the IoT device’s operation**.
This ensures that **even during power outages**, the device remains **operational and continues transmitting data**.
### **Expected System Behavior and User Benefits**
The **Power Monitoring System** is designed to be **highly reliable, automated, and accurate**. It ensures:
✅ **Accurate detection of power failures and abnormalities** in real-time.
✅ **Phase fault detection** in **three-phase systems**.
✅ **Automated alerts** through API calls and MQTT messaging.
✅ **Wi-Fi router auto-restart** for **uninterrupted network connectivity**.
✅ **Battery backup for continued operation** in case of **AC power failure**.
✅ **Low power consumption**, ensuring **extended device lifespan**.
✅ **Scalability**, allowing **multiple IoT devices per user**.
including all development hardware, code and PCB design
The **Power Monitoring System** is an advanced **IoT-based solution** designed to provide **real-time monitoring of electrical power consumption, phase fault detection, and alert notifications**. Built for **high reliability, efficiency, and industrial-grade performance**, the system incorporates features such as **current sensing, cloud integration, automated alerting, network connectivity management, and power backup solutions**. The system is developed using **ESP32-C3**, ensuring **low power consumption** and efficient data processing. It is designed to operate in **harsh industrial environments** and can support **multiple devices under a single MQTT communication framework**.
At its core, the system operates by **monitoring electrical parameters**, such as **current flow and phase voltages**. Using a **200A/5A split-core current transformer**, it continuously measures **power consumption** and transmits this data in real-time to **AWS IoT Core**, which acts as a cloud-based **MQTT broker**. The primary goal of this system is to **detect power failures, abnormal current variations, and phase faults** in an electrical setup and **send immediate alerts** to users. These alerts help in **preventing damage to equipment, reducing downtime, and ensuring uninterrupted operations**.
The system **fetches default threshold values from the backend API** at startup to ensure it operates with the most recent configuration. If users modify settings via the **mobile application**, the system **publishes an update** to the IoT device to **dynamically update** configurations. The **threshold mechanism** plays a crucial role in detecting abnormal power behavior.
For example, assume that:
- **Threshold value = 24A** (Set from Mobile App)
- **Minimum threshold difference = 2A** (Set from Mobile App)
- **Current flow value = 21A**
The system will evaluate:
- If **current flow < (threshold value - minimum threshold difference)**
- If **21A < (24A - 2A) → 21A < 22A**, which is **true**, the system **triggers an alert notification**.
This **real-time monitoring and alerting** mechanism ensures that power fluctuations are detected before they **cause major failures or disruptions**.
### **Communication and Cloud Integration**
The system uses **AWS IoT Core** to handle **MQTT-based communication**, ensuring **real-time, reliable, and secure data transmission** between the **IoT device and the cloud**. The ESP32-C3 device **publishes ampere readings, phase fault detections, and operational status updates** to AWS IoT Core. Users can **monitor real-time amp readings from a mobile application** or a centralized dashboard.
The **backend API** is responsible for storing **power consumption data** and managing **user preferences, device configurations, and alert triggers**. Additionally, the backend API facilitates **bidirectional communication** by **publishing updated settings to IoT devices** whenever a user changes configurations via the mobile app.
To ensure **error resilience**, the IoT device has a built-in **error handling mechanism**. If an issue arises, such as **sensor failure, missing data, or a network timeout**, the device will attempt **up to five retries** before taking corrective action. If the problem persists despite retries, the **ESP32-C3 automatically restarts**, ensuring the system **recovers and resumes operation without manual intervention**.
### **Relay-Based Wi-Fi Router Control**
Since **continuous network availability** is **critical** for **real-time data transmission and alerts**, the system features an **intelligent relay-based Wi-Fi router control mechanism**. It includes a **12-channel relay module** designed to **restart the Wi-Fi router** if network connectivity is lost.
If the IoT device **fails to establish a stable network connection after five retries**, it **triggers a relay to restart the router**. This eliminates **manual router resets**, ensuring **seamless device-to-cloud communication**.
### **Power Management and Battery Backup**
The system includes a **robust power supply design** to **ensure continuous operation**, even during **power failures**. The **power architecture** consists of:
1. **AC to DC Power Conversion** – Converts **220V AC to 12V DC**.
2. **DC-DC Step Down to 5V** – A **buck converter** reduces **12V DC to 5V DC**, which powers the **ESP32-C3**.
3. **Battery Backup System** – If AC power is lost, the system **automatically switches to battery power**, regulated via a **DC-DC inverter**.
4. **Automatic Power Switching Circuit** – Ensures a **smooth transition** between **AC and battery power** without **disrupting the IoT device’s operation**.
This ensures that **even during power outages**, the device remains **operational and continues transmitting data**.
### **Expected System Behavior and User Benefits**
The **Power Monitoring System** is designed to be **highly reliable, automated, and accurate**. It ensures:
✅ **Accurate detection of power failures and abnormalities** in real-time.
✅ **Phase fault detection** in **three-phase systems**.
✅ **Automated alerts** through API calls and MQTT messaging.
✅ **Wi-Fi router auto-restart** for **uninterrupted network connectivity**.
✅ **Battery backup for continued operation** in case of **AC power failure**.
✅ **Low power consumption**, ensuring **extended device lifespan**.
✅ **Scalability**, allowing **multiple IoT devices per user**.
including all development hardware, code and PCB design