Investigation of Root Causes Analysis, Preventive Maintenance Delays & Breakdowns in Diesel Generators Using IOT Integrated Hardware & FEA Method

This study investigates the root cause of preventive maintenance in diesel generators by integrating IoT-based monitoring and Finite Element Analysis (FEA). Using an ESP8266 controller with temperature sensors, vibration sensors, and an accelerometer, real-time data is collected to analyse temperature variations, vibration occurrences, and potential misalignment effects. Additionally, FEA is performed in ANSYS for different shaft rotational speeds, evaluating frequencies with modal analysis. A 3D model is developed in CATIA to simulate modal and thermal responses, aiding in identifying breakdown causes and optimizing generator performance for enhanced reliability and lifespan.