An IoT-Enabled Condition Monitoring Device: Integrating Vibration Analysis and Environmental Sensing

Condition monitoring (CM) devices are crucial for predictive maintenance (PdM) across industries. Despite their commercial availability, the use of CM devices in small-to medium-scale industries remains low because of the cost of equipment and proprietary software systems. This research aims to overcome the challenge by developing an Internet of Things (IoT) enabled, portable CM device capable of monitoring machine vibrations and ambient conditions. The proposed battery-powered device integrates a commonly available microcontroller unit (MCU) with rich communication interfaces in combination with affordable and accessible sensors. The acquired data are wirelessly transmitted to a host computer via the Message Queuing Telemetry Transport (MQTT) protocol. During testing, offline frequency domain analysis of the vibration data for a faulty bearing, namely Hilbert and Envelope Spectrum Analysis revealed fault frequencies corresponding to an outer race defect. Ambient data collected over 24 hours provided supplementary insights into environmental fluctuations critical to industrial operations. In an industrial setting, the CM device was successful in performing its two main tasks of monitoring ambient conditions and bearing vibrations. The device positions itself as a proof-of-concept for a scalable, networked CM system, where multiple interconnected nodes could simultaneously monitor a range of machinery or individual components within a facility. This demonstrates its potential for industries to delve into the world of PdM, replacing traditional preventive maintenance mechanisms.