IoT-Based Predictive Machine Health & Safety Monitoring System

IoT-Based Predictive Machine Health & Safety Monitoring System ¹Md Hefjur Rahaman, ²Manisankar Hira, ³Razia Sultana, 4Sayani Ghosh 1,2UG Student, Department of ECE, Haldia Institute of Technology, Haldia, Purba Medinipur, West Bengal 3,4Assistant Professor, Department of ECE, Haldia Institute of Technology, West Bengal, India ABSTRACT Industrial machines often exhibit warning signs such as excessive temperature and abnormal vibration before failure. This work presents a low-cost IoT-based machine health and safety monitoring system using an ESP32 controller. DHT22 and MPU6050 sensors monitor temperature/humidity and vibration, respectively. The data are processed locally and displayed on a 0.96-inch SSD1306 OLED, while LEDs and a buzzer indicate NORMAL, WARNING, and DANGER conditions. The system also supports Wi-Fi-based remote monitoring and can be extended with relay-based machine shutdown. Prototype readings demonstrate the transition from normal to hazardous conditions, establishing the system as a practical condition-monitoring and early-warning platform with scope for future predictive-maintenance development.