• sipha siddiqui
• Yaseen Ansari
• Daniyal Shaikh
• Asad Shaikh
• Ashwini Mhatre

Industrial electrical safety is a critical requirement in environments where machinery and equipment depend on stable power supply. This project presents a 1-Phase Industrial Safety Device featuring automatic fault cut-off protection and a real-time IoT monitoring system. The system is built around the ESP8266 NodeMCU microcontroller and the PZEM-004T v3 energy monitoring sensor to continuously measure vital electrical parameters such as voltage, current, power, energy consumption, power factor, and frequency. The device is engineered to protect industrial loads from electrical abnormalities including overvoltage, undervoltage, and overcurrent conditions. When any parameter exceeds predefined safe thresholds, the system instantly activates an auto cut-off mechanism using relays, isolating the connected load. This rapid response prevents equipment damage, reduces the risk of electrical fires, and enhances operator safety. For real-time visibility, the system integrates with the ThingSpeak IoT cloud platform, where electrical data is uploaded at regular intervals. This cloud integration allows continuous logging and remote access to system performance metrics. Operators and maintenance personnel can monitor live and historical data trends through an intuitive mobile interface developed using Kodular, enabling remote supervision from anywhere with internet access. The ESP8266 acts as the central controller, executing protection algorithms, managing Wi-Fi communication, and sending sensor data to the cloud. The PZEM-004T sensor ensures accurate electrical measurement, making the system reliable for industrial safety applications. A local I2C LCD display further enhances usability by showing real-time electrical values and relay status directly on the device. By leveraging IoT technology, this solution delivers a cost-effective, scalable, and intelligent industrial safety system. Key benefits include reduced equipment failure, improved safety compliance, minimized downtime, remote diagnostics capability, and enhanced preventive maintenance planning. The system provides a proactive approach to industrial power protection by combining automated electrical fault response with modern cloud-based monitoring. Overall, this project demonstrates how embedded systems and IoT platforms can be integrated to create a smart industrial electrical protection device that ensures continuous monitoring, rapid fault isolation, and improved operational reliability in demanding industrial environments.

IoT (Internet of Things) Industrial Safety Fault Detection Auto Cut-Off System ESP8266 NodeMCU PZEM-004T Sensor Power Monitoring Overvoltage Protection Overcurrent Protection ThingSpeak Cloud Remote Monitoring Electrical Protection System

"Fault Detection and self-isolation in power distribution network ", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.13, Issue 3, page no.f161-f168, March-2026, Available :http://www.jetir.org/papers/JETIR2603521.pdf

"Fault Detection and self-isolation in power distribution network ", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.13, Issue 3, page no. ppf161-f168, March-2026, Available at : http://www.jetir.org/papers/JETIR2603521.pdf