This project implements an IoT-based monitoring and diagnostic system for RCBO/ELCB circuit breakers. The system measures AC current, performs RMS current calculation, and detects zero-crossing points using a microcontroller-based signal processing system. The measured data is transmitted wirelessly using an ESP32 WiFi module for remote monitoring and analysis.
The objective of this project was to develop a smart monitoring platform capable of detecting abnormal electrical conditions and enabling preventive maintenance of circuit protection devices.
The system is composed of three main layers:
Sensing Layer
Measures AC current flowing through the RCBO/ELCB using a current sensing circuit.
Processing Layer
A microcontroller processes the analog signals, calculates RMS current values, and detects zero-crossing events.
Communication Layer
ESP32 transmits sensor data wirelessly via WiFi to a remote monitoring system.
Data Flow
Current Sensor → Signal Conditioning → Microcontroller → ESP32 WiFi → Remote Monitoring
- Microcontroller for signal processing
- ESP32 WiFi module for communication
- Current sensing circuit
- Zero-cross detection circuit
- Signal conditioning circuit
- Custom-designed PCB
Supporting components:
- Operational amplifiers for signal conditioning
- Resistors and capacitors for filtering
- Power supply regulation circuit
The firmware was developed in Embedded C.
Main functionalities implemented:
- ADC-based current signal acquisition
- RMS current calculation from AC waveform samples
- Zero-cross detection for waveform synchronization
- ESP32 WiFi communication for data transmission
- Real-time monitoring capability
- Real-time current monitoring
- Accurate RMS current measurement
- Zero-cross detection of AC waveform
- Wireless data communication using ESP32 WiFi
- Custom PCB design with functional and EMC verification
- Industrial electrical protection monitoring
- Smart electrical distribution panels
- Predictive maintenance systems
- IoT-based electrical monitoring solutions
- Cloud-based data monitoring platform
- Mobile dashboard for real-time monitoring
- Integration with smart grid systems
- Voltage, power, and energy monitoring features
This repository documents the system architecture and firmware design of the project.
Hardware photographs and PCB design files are not publicly available due to company restrictions.