Smart Pump PDH30 - IoT-Based Industrial Monitoring System

🚀 Smart Pump PDH30 is an advanced IoT-based system designed for real-time monitoring of industrial pumps. It utilizes Modbus RTU (RS-485) for data acquisition and transmits pump performance data to a cloud dashboard via Wi-Fi or Ethernet.

This system enhances fault detection, remote diagnostics, and predictive maintenance, ensuring improved efficiency and reduced downtime for industrial applications.

📌 Features

✅ Modbus RTU (RS-485) for real-time data collection
✅ Wi-Fi & Ethernet support for cloud connectivity
✅ Live dashboard for remote monitoring
✅ Fault detection & predictive maintenance
✅ Secure & reliable industrial-grade solution

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📡 System Overview

The Smart Pump PDH30 architecture consists of:

1️⃣ ESP32 Microcontroller – Handles data acquisition & communication
2️⃣ Modbus RTU (RS-485) – Reads pump parameters
3️⃣ Ethernet & Wi-Fi Modules – Provides internet connectivity
4️⃣ Cloud API Server – Stores & visualizes real-time data

🛠 How It Works

📊 Step 1: Data Collection – ESP32 reads pump parameters via Modbus RTU
🔄 Step 2: Data Processing – Formats the data for transmission
🌐 Step 3: Data Transmission – Sends data to the cloud using HTTP GET
📈 Step 4: Cloud Visualization – Logs data for real-time monitoring

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⚙️ Technologies Used

1️⃣ Modbus RTU (RS-485) Communication

• Purpose: Fetches real-time pump data
• Why RS-485?
  ✔ Long-distance communication
  ✔ Supports multiple devices on a single bus
  ✔ Reliable and noise-resistant

2️⃣ Ethernet Communication (W5500 Module)

• Purpose: Provides stable, high-speed cloud connectivity
• Advantage: More reliable than Wi-Fi in industrial environments

3️⃣ Wi-Fi Communication (ESP32 Built-in Wi-Fi)

• Fallback option when Ethernet is unavailable
• Security: WPA2-PSK encryption for secure connectivity

4️⃣ HTTP API for Cloud Communication

• Data is sent to a REST API endpoint via an HTTP GET request
• Example API Format:

  https:Serverurl?data=P101,parameter1,parameter2,...
  

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📊 Data Acquisition via Modbus

The ESP32 reads the following pump parameters using Modbus RTU:

Parameter	Modbus Address
Running Frequency	4097
Bus Voltage	4098
Output Voltage	4099
Output Current	4100
Output Power	4101
Output Torque	4102
Running Speed	4103
Cumulative Power On	4108
Cumulative Running Time	4109
Cumulative Consumption	4110
Target Pressure	4111
Setting Pressure	4112

📟 Modbus Read Code Example (ESP32 + ModbusMaster Library)

float modbus_read(int addr, int sm) {
    delay(100);
    int result = node.readHoldingRegisters(addr, sm);
    uint data;
    float flt = 0;
    
    if (result == node.ku8MBSuccess) {
        data = node.getResponseBuffer(0);
        Serial.print(id);
        Serial.print(": ");
        Serial.println("response: " + String(data));
    } else {
        Serial.print(id);
        Serial.print(": Failed, Response Code: ");
        Serial.println(result, HEX);
    }
    return flt;
}

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📡 Data Transmission to Cloud (HTTP GET Request)

1️⃣ Formatting Data for Transmission

The retrieved data is formatted as a comma-separated string before sending:

data = String(runningfreq) + "," + String(runningspeed) + "," + 
       String(outtorque) + "," + String(busvoltage) + "," + 
       String(outputvoltage) + "," + String(outputcurrent) + "," + 
       String(outpower) + "," + String(cumpoweron) + "," + 
       String(cumrunning) + "," + String(cumconsumption) + "," + 
       String(settingpressure) + "," + String(targetpressure);

2️⃣ Sending Data to Cloud API

bool push_data() {
    String lnk = endpoint + data;
    HTTPClient http;
    http.begin(lnk);
    int httpCode = http.GET();

    if (httpCode > 0) {
        String res = http.getString();
        Serial.println(res);
        return true;
    } else {
        Serial.print("GET err: ");
        Serial.println(httpCode);
        return false;
    }
}

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🌍 Network Configuration

📶 Wi-Fi Setup (ESP32)

WiFi.begin(SSID, PASS);
while (WiFi.status() != WL_CONNECTED) {
    delay(1000);
    Serial.println("Connecting to Wi-Fi...");
}
Serial.println("Connected to Wi-Fi");

🌐 Ethernet Setup (W5500)

Ethernet.begin(mac, ip);
if (Ethernet.hardwareStatus() == EthernetNoHardware) {
    Serial.println("Ethernet shield not found.");
}

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🚨 Error Handling & Fault Detection

1️⃣ Modbus Communication Failure

If ESP32 fails to read Modbus registers, it logs an error:

Serial.print(id);
Serial.print(": Failed, Response Code: ");
Serial.println(result, HEX);

2️⃣ HTTP GET Request Failure

If the API request fails, it prints an error message:

Serial.print("GET err: ");
Serial.println(httpCode);

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📌 Summary & Conclusion

The Smart Pump PDH30 is an IoT-based industrial monitoring system designed to:

✅ Continuously monitor critical pump parameters
✅ Detect faults and improve operational efficiency
✅ Enable remote diagnostics & predictive maintenance

This system ensures improved efficiency, reduced downtime, and enhanced reliability in industrial environments. 🚀

💡 Contributions & Feedback are Welcome!

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📧 Contact: mdriyas1607@gmail.com

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