Energy Monitoring System - IoT-Based Industrial Monitoring

🚀 Energy Monitoring System is a reliable and scalable solution for real-time monitoring of energy consumption in industrial environments. It utilizes Modbus RTU (RS-485) for data acquisition, and transmits critical parameters such as voltage, current, power, and energy usage to a cloud server via Wi-Fi or Ethernet for remote monitoring and analysis.

📌 Features

✅ Modbus RTU (RS-485) for real-time data collection
✅ Wi-Fi & Ethernet support for cloud connectivity
✅ Live dashboard for remote monitoring
✅ Real-time fault detection and diagnostics
✅ Scalable solution supporting up to 45 energy meters
✅ Secure and reliable industrial-grade solution

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📡 System Overview

The Energy Monitoring System architecture consists of:

1️⃣ ESP32 Microcontroller – Handles data acquisition & communication
2️⃣ Modbus RTU (RS-485) – Reads energy parameters from meters
3️⃣ Ethernet & Wi-Fi Modules – Provides internet connectivity
4️⃣ Cloud API Server – Stores & visualizes real-time data

🛠 How It Works

📊 Step 1: Data Collection – ESP32 reads energy data using Modbus RTU protocol
🔄 Step 2: Data Processing – Formats data for transmission to the cloud
🌐 Step 3: Data Transmission – Sends data to the cloud via HTTP GET request
📈 Step 4: Cloud Visualization – Logs data for real-time monitoring on a cloud dashboard

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⚙️ Technologies Used

1️⃣ Modbus RTU (RS-485) Communication

• Purpose: Fetches real-time energy data from energy meters
• Why RS-485? ✔ Long-distance communication
  ✔ Supports multiple devices on a single bus
  ✔ Reliable and noise-resistant

2️⃣ Ethernet Communication (W5500 Module)

• Purpose: Provides stable and high-speed cloud connectivity
• Advantage: More reliable than Wi-Fi in industrial environments

3️⃣ Wi-Fi Communication (ESP32 Built-in Wi-Fi)

• Fallback option when Ethernet is unavailable
• Security: WPA2-PSK encryption for secure connectivity

4️⃣ HTTP API for Cloud Communication

• Data is sent to a REST API endpoint via an HTTP GET request
• Example API Format:

  https://serverurl?data=P101,parameter1,parameter2,...
  

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📊 Data Acquisition via Modbus

The ESP32 reads the following energy parameters using Modbus RTU:

Parameter	Modbus Address
Power Factor Average	43907
Line-to-Line Voltage Avg	43909
Line-to-Neutral Voltage Avg	43911
Energy (Wh)	43961
Current Average	43913
Watts R Phase	40103
Watts Y Phase	40105
Watts B Phase	40107
Frequency (Hz)	43110

📟 Modbus Read Code Example (ESP32 + ModbusMaster Library)

float modbus_read(int addr, int sm) {
    delay(100);
    int result = node.readHoldingRegisters(addr, sm);
    uint data;
    float flt = 0;
    
    if (result == node.ku8MBSuccess) {
        data = node.getResponseBuffer(0);
        Serial.print(id);
        Serial.print(": ");
        Serial.println("response: " + String(data));
    } else {
        Serial.print(id);
        Serial.print(": Failed, Response Code: ");
        Serial.println(result, HEX);
    }
    return flt;
}

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📡 Data Transmission to Cloud (HTTP GET Request)

1️⃣ Formatting Data for Transmission

The retrieved data is formatted as a comma-separated string before sending:

data = String(PFAverage) + "," + String(VLLAverage) + "," + 
       String(VLNAverage) + "," + String(wh) + "," + 
       String(current) + "," + String(wattsrphase) + "," + 
       String(wattsyphase) + "," + String(wattsbphase) + "," + 
       String(frequency);

2️⃣ Sending Data to Cloud API

bool push_data() {
    String lnk = endpoint + data;
    HTTPClient http;
    http.begin(lnk);
    int httpCode = http.GET();

    if (httpCode > 0) {
        String res = http.getString();
        Serial.println(res);
        return true;
    } else {
        Serial.print("GET err: ");
        Serial.println(httpCode);
        return false;
    }
}

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🌍 Network Configuration

📶 Wi-Fi Setup (ESP32)

WiFi.begin(SSID, PASS);
while (WiFi.status() != WL_CONNECTED) {
    delay(1000);
    Serial.println("Connecting to Wi-Fi...");
}
Serial.println("Connected to Wi-Fi");

🌐 Ethernet Setup (W5500)

Ethernet.begin(mac, ip);
if (Ethernet.hardwareStatus() == EthernetNoHardware) {
    Serial.println("Ethernet shield not found.");
}

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🚨 Error Handling & Fault Detection

1️⃣ Modbus Communication Failure

If ESP32 fails to read Modbus registers, it logs an error:

Serial.print(id);
Serial.print(": Failed, Response Code: ");
Serial.println(result, HEX);

2️⃣ HTTP GET Request Failure

If the API request fails, it prints an error message:

Serial.print("GET err: ");
Serial.println(httpCode);

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📌 Summary & Conclusion

The Energy Monitoring System is an IoT-based industrial monitoring system designed to:

✅ Continuously monitor energy parameters like voltage, current, and power
✅ Detect faults and improve operational efficiency
✅ Enable remote diagnostics & predictive maintenance

This system ensures improved efficiency, reduced downtime, and enhanced reliability in industrial environments. 🚀

💡 Contributions & Feedback are Welcome!

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📧 Contact: mdriyas1607@gmail.com

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