Development of a Real-Time IoT-Based Monitoring System for 3-Phase Industrial Machines

Authors

  • Yohanes Sugiarto Teknik Mekatronika, Politeknik ATMI Surakarta
  • Fenty Pandansari Teknik Rekayasa Mekatronika, Politeknik ATMI Surakarta
  • Hilarius Prin Pujianto Teknik Mekatronika, Politeknik ATMI Surakarta
  • Dionisius Alviano Yustama Teknik Mekatronika, Politeknik ATMI Surakarta
  • Maria Mige Kusuma Teknik Mekatronika, Politeknik ATMI Surakarta
  • Nemesio Tito Abi Darmawan Teknik Mekatronika, Politeknik ATMI Surakarta
  • Nicholas Amon Teknik Mekatronika, Politeknik ATMI Surakarta

DOI:

https://doi.org/10.46984/sebatik.v29i2.2709

Keywords:

Real-Time Monitoring, Internet of Things, 3-Phase Industrial Machine, Digital Manufacturing, Condition Monitoring

Abstract

This study addresses the urgent need for timely and accurate information regarding manufacturing resources by developing a cost-effective, real-time Internet of Things (IoT)-based monitoring system for 3-phase industrial machines, such as milling, turning, and grinding equipment. The primary objective is to enhance operational efficiency, minimize downtime, and support manufacturing digitalization. The methodology employed a mixed-methods approach and utilizes a hybrid microcontroller architecture, featuring low-cost SCT-013 current sensors and ZMPT-101B voltage sensors for data capture. An Arduino Mega performs high-speed data acquisition and complex measurement calculations, while an ESP32 module handles dedicated wireless communication and transmission. The system monitors crucial electrical parameters, including phase voltage, current, active and reactive power, and energy cost, while explicitly classifying the machine state (ON/OFF/STANDBY). A MySQL database ensures reliable data storage, and a Nextion display and web interface provide real-time visualization and user control. Rigorous quantitative testing validated the implementation: the fidelity of data transfer to the database was confirmed to be 100%. Sensor readings were successfully validated against a reference AC Clamp Meter. The system efficiently supports early anomaly detection using residual analysis. However, the end-to-end system latency was measured between 5 and 6 seconds consistently. This prototype delivers an effective and reliable solution for industrial online monitoring, providing a robust, data-driven foundation for future predictive maintenance and energy efficiency strategies

References

Aiman, M. A., Hussian, A. H., Ibrahim, M. T., & Pambudi, S. (2025). IoT implementation based on power quality network analyzer for 3-phase induction motor control. Teknika, 10(2), 46–56. https://doi.org/10.52561/teknika.v10i2.612

Arifianto, M. J. F., & Prasetyani, L. (2022). Sistem pemantauan dan kontrol energi listrik menggunakan platform Node-RED, Influxdb dan Grafana melalui jaringan WiFi dan Lora. Jurnal Fokus Elektroda, 7(1), 61–67. https://doi.org/10.33772/jfe.v7i1.23440

Azizi, A. (2023). Sistem monitoring daya listrik berbasis IoT dan aplikasi mobile untuk efisiensi energi. Jurnal Indonesia: Manajemen Informatika dan Komunikasi, 4(3), 1809–1814. https://doi.org/10.35870/jimik.v4i3.409

Bachri, A., Laksono, A. B., & Adams, B. (2025). Design and build an IoT-based 3-phase electric motor protection system. JEEMECS (Journal of Electrical Engineering, Mechatronic and Computer Science, 8(1), 1–16. https://doi.org/10.26905/jeemecs.v8i1.13666

Chanda, A., & Gudipalli, A. (2024). Current measurement and fault detection based on the non-invasive smart Internet of Things technique. Engineering Proceedings, 59(174), 1–10. https://doi.org/10.3390/engproc2023059174

Ciancetta, F., Fiorucci, E., Ometto, A., Fioravanti, A., Mari, S., & Segreto, M.-A. (2021). A low-cost IoT sensors network for monitoring three-phase induction motor mechanical power adopting an indirect measuring method. Sensors, 21(3), 754. https://doi.org/10.3390/s21030754

Dharmawan, A. D., Asmadi, & Raharjo, A. S. (2022). Implementasi sistem monitoring pada panel listrik. Elektriese: Jurnal Sains dan Teknologi Elektro, 12(2), 82–91. https://doi.org/10.47709/elektriese.v12i2.1685

Hadi, S., Anas, A. S., & Putra, L. G. R. (2022). Rancang bangun sistem monitoring penggunaan daya listrik berbasis Internet of Things. Circuit: Jurnal Ilmiah Pendidikan Teknik Elektro, 6(1), 54–67. https://doi.org/10.22373/crc.v6i1.10862

Hantoro, C. D. (2023). Monitoring and control 3-phase electric power using Internet of Things (IoT) based on Blynk application. Jurnal Penelitian dan Pengabdian Kepada Masyarakat UNIMED, 2(1), 159–167. https://doi.org/10.24018/ejece.2023.7.3.522

Hendrawati, D., Hakim, E. A., Dionova, B. W., Sulistyo, A. K., & Abdullah, M. I. (2025). IOT enabled real time load height monitoring and control system using PLC and HMI for smart industrial. Journal of Applied Engineering & Technological Science, 6(2), 1085–1100. https://doi.org/10.37385/jaets.v6i2.7044

Hermanto, & Agustini, A. A. (2022). Monitoring pemakaian arus listrik pada alat rumah tangga dengan menggunakan aplikasi Blynk berbasis Internet of Things. Media Informasi Analisa Dan Sistem (MEANS), 7(2), 161–168. https://doi.org/10.54367/means.v6i2.1576

Isanbaev, V., Baños, R., Martínez, F., Alcayde, A., & Gil, C. (2024). Monitoring energy and power quality of the loads in a microgrid laboratory using smart meters. Energies, 17(5), 1251. https://doi.org/10.3390/en17051251

Jokanan, J. W., Widodo, A., Kholis, N., & Mauboy, E. (2022). Rancang bangun alat monitoring daya listrik berbasis IoT menggunakan Firebase dan aplikasi Android. Jurnal Teknik Elektro, 11(1), 47–55. https://doi.org/10.26740/jte.v11n1.p47-55

Kotsilitis, S., Kalligeros, E., & Marcoulaki, E. C. (2024). A versatile low-cost monitoring device for high-frequency non-intrusive load monitoring in industrial and residential environments. Measurement: Sensors, 32, 101081. https://doi.org/10.1016/j.measen.2024.101081

Koyuncuoğlu, M. U. (2024). Most important performance evaluation methods of production lines: A comprehensive review on historical perspective and emerging trends. Computers & Industrial Engineering, 197, 110623. https://doi.org/10.1016/j.cie.2024.110623

Laksana, N., Madiun, M. B., & Susanto, R. (2024). Penerapan teknologi rumah pintar berbasis web menggunakan ESP32. Jurnal Pepadun, 5(2), 121–130. https://doi.org/10.23960/pepadun.v5i2.217

Noyjeen, A., & Noipitak, N. (2021). Monitoring parameters of three-phase induction motor using IoT technology for preventive maintenance. In 2021 International Electrical Engineering Congress (iEECON) (pp. 1–4). IEEE. https://doi.org/10.1109/iEECON52514.2021.9449033

Prasetyo, H., Sugiarto, Y., Raharja, A. B., Rachmawan, A. O., Mahadi, B. D., & Pratama, F. P. (2024). Design of IoT enabled three phase power quality monitoring unit based on EmonLibCM library. KONSTELASI: Konvergensi Teknologi dan Sistem Informasi, 4(2), 1–15. https://doi.org/10.24002/konstelasi.v4i2.10231

Rahman, F. F., Susanto, R., & Suryani, F. (2024). Implementasi smart energy meter dan controlling alat listrik pada rumah pintar berbasis IoT. JUPITER (Jurnal Pendidikan Teknik Elektro), 9(2), 64–74. https://doi.org/10.25273/jupiter.v9i2.20905

Reinard, V., Hugeng, H., & Utama, H. S. (2023). Perancangan sistem pemantauan sensor pada programmable logic controller mesin produksi berbasis Internet Of Things. Jurnal INTRO (Informatika dan Teknik Elektro), 2(2), 48–56. https://doi.org/10.51747/intro.v2i2.221

Sandira, A., Jufrizel, J., Maria, P. S., & Ullah, A. (2023). Alat monitoring dan notifikasi penggunaan daya listrik rumah tangga berbasis Internet Of Things menggunakan Blynk 2.0. Jurnal Komputer Terapan, 8(2), 408–420. https://doi.org/10.35143/jkt.v8i2.5761

Shadiq, J., & Mangani, S. A. (2021). Alat monitoring dan kontrol peralatan listrik pada ruangan berbasis Internet of Things. Informatics for Educators and Professionals, 6(1), 63–73. https://doi.org/10.51211/itbi.v6i1.1673

Siandiari, R. S., Candra, J. E., Munir, Z., & Burhan, R. M. (2024). Sistem monitoring daya listrik berbasis Internet of Things menggunakan aplikasi Blynk. Jurnal Quancom, 2(1), 30–34. https://doi.org/10.62375/jqc.v2i1.329

Singh, J., Singh, A., Singh, H., & Doyon-Poulin, P. (2025). Implementation and evaluation of a smart machine monitoring system under industry 4.0 concept. Journal of Industrial Information Integration, 43, 100746. https://doi.org/10.1016/j.jii.2024.100746

Soori, M., Arezoo, B., & Dastres, R. (2023). Internet of Things for smart factories in Industry 4.0, A review. Internet of Things and Cyber-Physical Systems, 3, 192–204. https://doi.org/10.1016/j.iotcps.2023.04.006

Varadharajan, S., Muthuramalingam, T., & Sundarraj, T. (2025). Cost-effective voltage and current sensor for IoT-based monitoring of agricultural motor loads. Computers and Electronics in Agriculture, 239, 111045. https://doi.org/10.1016/j.compag.2025.111045

Viciana, E., Arrabal-Campos, F. M., Alcayde, A., Baños, R., & Montoya, F. G. (2023). All-in-one three-phase smart meter and power quality analyzer with extended IoT capabilities. Measurement, 206, 112309. https://doi.org/10.1016/j.measurement.2022.112309

Xu, Y., Qamsane, Y., Puchala, S., Januszczak, A., Tilbury, D. M., & Barton, K. (2024). A data-driven approach toward a machine- and system-level performance monitoring digital twin for production lines. Computers in Industry, 157-158, 104086. https://doi.org/10.1016/j.compind.2024.104086

Zhang, F., Zhou, Z., & Chen, Y. (2024). Research on calibration method for measurement error of multiple rate carrier energy meter. Journal of Physics: Conference Series, 2815(1), 012032. https://doi.org/10.1088/1742-6596/2815/1/012032

Downloads

Published

2025-12-26

How to Cite

Sugiarto, Y., Pandansari, F., Pujianto, H. P., Yustama, D. A., Kusuma, M. M., Darmawan, N. T. A. and Amon, N. (2025) “Development of a Real-Time IoT-Based Monitoring System for 3-Phase Industrial Machines”, Sebatik, 29(2), pp. 278–287. doi: 10.46984/sebatik.v29i2.2709.

Issue

Vol. 29 No. 2 (2025): December 2025

Section

Articles

License

Copyright (c) 2025 Yohanes Sugiarto; Fenty Pandansari, Hilarius Prin Pujianto; Dionisius Alviano Yustama, Maria Mige Kusuma, Nemesio Tito Abi Darmawan, Nicholas Amon

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

 

Authors retain all their rights to the published works, such as (but not limited to) the following rights; Copyright and other proprietary rights relating to the article, such as patent rights, The right to use the substance of the article in own future works, including lectures and books, The right to reproduce the article for own purposes, The right to self-archive the article