Fault Detection in DC Motor Using a Programmable Logic Controller

Industrial machines and electrical equipment are susceptible to faults such as short circuits, overloads, and high voltage conditions, which can damage machinery, disrupt production, and pose safety hazards. This project presents a Machine Fault Detection and Alarm System using a Wecon PLC, integrated with current and voltage sensors to continuously monitor a motor representing the load. When the system detects abnormal operating conditions—such as undervoltage, overvoltage and overcurrent/Overload—the PLC immediately triggers a buzzer alarm and disconnects the load via a relay, preventing equipment damage and ensuring operator safety. The system leverages the programmable logic of the Wecon PLC to implement real-time monitoring and decision-making with high reliability. Sensor data is continuously processed, and fault thresholds are pre-configured to respond instantly to unsafe conditions. The project demonstrates an automated, scalable solution for industrial safety, minimizing downtime and maintenance costs. By integrating PLC-based monitoring, current/voltage sensing, and protective relays, this system provides a practical and effective approach to safeguard motors and industrial loads against electrical faults.