IoT Based Condition Monitoring System for Spot Welding Machines Using Vibration and Non Contact Voltage Detection

Abstract

This study developed an Internet of Things (IoT)-based spot welding machine condition monitoring system that integrates an MPU6050 sensor, a non-contact voltage detector, an ESP32, a TFT LCD screen, and the Blynk platform. Vibration acceleration values were calculated based on changes in resultant acceleration relative to the stationary baseline and processed using an exponential moving average. Testing was conducted under normal operating conditions and increased- vibration conditions. Under normal conditions, peak vibration acceleration values ranged from 0.90 to 6.79 m/s², while under increased-vibration conditions, they ranged from 7.10 to 9.15 m/s². The response time of the system components ranged from 0.1 to 0.5 seconds. This system can display data locally and send data to Blynk. However, further validation using reference instruments is still needed to determine the measurement accuracy of the develoved monitoring system.