Machine Maintenance Monitoring System

An IoT-based machine condition monitoring system using ESP32, AHT20 (temperature & humidity), and MPU6050 (3-axis vibration). Designed for predictive maintenance in smart factory environments with ultra-low power consumption for long-term battery operation.

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Features

• Real-time vibration monitoring — 3-axis acceleration (X/Y/Z) via MPU6050
• Environmental monitoring — Temperature & humidity via AHT20
• Deep Sleep + Motion Interrupt — ESP32 sleeps at ~55µA, wakes only on vibration or timer
• Battery life ~260 days using 2× 18650 cells (6000mAh)
• WiFi TCP transmission — JSON data streamed to C# dashboard
• Anomaly detection — Configurable WARN / ALARM thresholds
• Adaptive sampling — Burst mode on motion event, periodic status on timer

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System Architecture

┌─────────────────────────────────────────────────────┐
│              ESP32-WROOM-32U                        │
│                                                     │
│  AHT20 ──I2C──► Temp / Humidity                    │
│  MPU6050 ─I2C──► Accel X/Y/Z  ──► Motion INT       │
│                                        │            │
│  Deep Sleep ◄──────────────────────────┘            │
│       │                                             │
│       └──► WiFi TCP ──► JSON ──► C# Dashboard       │
└─────────────────────────────────────────────────────┘

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Hardware

Component	Description
ESP32-WROOM-32U	Main MCU with external antenna
AHT20	Temperature (±0.3°C) & Humidity (±2% RH), I2C 0x38
MPU6050	3-axis accelerometer + gyroscope, I2C 0x68
2× 18650 Li-ion	3.7V / 6000mAh (parallel), ~260 days battery life

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Wiring

AHT20 / MPU6050          ESP32-WROOM-32U
────────────────         ───────────────
VCC             ──────►  3.3V
GND             ──────►  GND
SDA             ──────►  GPIO 21
SCL             ──────►  GPIO 22
MPU6050 INT     ──────►  GPIO 33    ← Motion wakeup
MPU6050 AD0     ──────►  GND       ← I2C address 0x68

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JSON Output Format

Vibration packet (on motion event, 20 samples burst)

{
  "type": "vib",
  "boot": 12,
  "idx": 1,
  "wake": "MOTION",
  "ax": 1.234,
  "ay": 0.521,
  "az": 9.812,
  "mag": 9.957,
  "status": "OK",
  "temp": 28.50,
  "hum": 65.30
}

Status packet (every 60 seconds via timer)

{
  "type": "status",
  "boot": 12,
  "totalWakes": 45,
  "motionWakes": 8,
  "temp": 28.50,
  "hum": 65.30
}

status field values: OK · WARN (≥ 2 m/s²) · ALARM (≥ 5 m/s²)

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Power Consumption

Mode	Current
ESP32 deep sleep	~10 µA
MPU6050 cycle mode	~20 µA
AHT20 idle	~25 µA
Total sleep	~55 µA
Active (wake)	~80 mA

Estimated battery life with 2× 18650 (6000mAh), assuming 10 motion events/hour:

• Timer wakes: 1/min × 0.4s active
• Motion wakes: 10/hour × 1.7s active
• ~260 days (~8.6 months)

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Getting Started

1. Clone the repository

git clone https://github.com/phandienxauxa/Machine-Maintenance-Monitoring-System-.git
cd Machine-Maintenance-Monitoring-System-

2. Configure credentials

cp include/config.example.h include/config.h

Edit include/config.h and fill in your WiFi SSID, password, and C# server IP.

3. Open in VS Code with PlatformIO

code .

PlatformIO will automatically install required libraries on first build.

4. Build & Upload

Click Build (✓) then Upload (→) in the PlatformIO toolbar, or:

pio run --target upload

5. Monitor output

pio device monitor

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Libraries

Library	Version	Purpose
Adafruit AHTX0	^2.0.5	AHT20 sensor driver
Adafruit Unified Sensor	^1.1.14	Sensor abstraction layer
ArduinoJson	^7.0.0	JSON serialization

MPU6050 communicates directly via Wire.h (no extra library needed).

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Configuration

Key parameters in src/main.cpp:

Parameter	Default	Description
TIMER_SLEEP_SEC	60	Timer wakeup interval (seconds)
VIB_BURST_SAMPLES	20	Samples per motion wakeup
VIB_BURST_DELAY	100	ms between burst samples
MOTION_THRESHOLD	15	MPU6050 motion sensitivity (1 unit ≈ 2mg)
THR_WARN	2.0	Warning threshold (m/s²)
THR_ALARM	5.0	Alarm threshold (m/s²)

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Project Structure

Machine-Maintenance-Monitoring-System/
├── src/
│   └── main.cpp              # Main firmware (ESP32 deep sleep logic)
├── include/
│   ├── config.example.h      # WiFi & TCP config template (safe to push)
│   └── config.h              # Your actual credentials (gitignored)
├── platformio.ini            # PlatformIO build configuration
└── README.md

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License

MIT License — feel free to use and modify for your own projects.