Design and Implementation of a Microcontroller-Based Monitoring System for Early Fault Detection in Three-Phase Induction Motors

Abstract

Three-phase induction motors play a critical role in industrial systems, where unexpected failures can significantly disrupt operations and increase maintenance costs. Among various fault conditions, voltage imbalance, overcurrent, and overheating are the most common factors that accelerate motor degradation. However, existing monitoring systems are often limited to single-parameter detection or lack integrated protection mechanisms, reducing their effectiveness in early fault mitigation. This study proposes the design and implementation of a microcontroller-based monitoring and protection system for early fault detection in three-phase induction motors. The system integrates a PZEM-004T sensor for real-time voltage and current measurements and a MAX6675 sensor for temperature monitoring. All data are processed using an Arduino Mega microcontroller and displayed via a TFT LCD, while a buzzer and relay provide a two-level response mechanism, consisting of early warning and automatic protection. Experimental results demonstrate that the system achieves accurate parameter measurement and effectively distinguishes between normal and fault conditions. The system successfully detects voltage imbalance, overcurrent, and overheating, and responds with timely warning and protective actions. The proposed system offers a low-cost, reliable, and real-time solution for multi-parameter monitoring and condition-based maintenance of induction motors, with strong potential for industrial applications.