Industrial Fault Monitoring System

Nowadays, technology plays a wide role in our day to day life. Wireless technology has further reduced the human effort and invoked to adopt new, efficient, cost-effective methods, leaving behind the conventional methods. Wireless technologies like Zigbee, wifi, RF signals are used to get the right information and respond accordingly. In this article, we discuss industrial fault monitoring system.

With the rapid development of technology, everyone is addicted to modern gadgets. The aim of this project is to make an Android-based smartphone or tablet compatible to monitor and control the industrial operations and applications. Android is an operating system in Linux. It was developed from the ground to help the developers to create a mobile application for effective utilization of mobile with touch gestures. It is an open source with Java UI.


Android Applications

The Android operating system provides a platform to develop a variety of applications which run on smartphones to enhance the lives of humans.

  • Android is used to develop precise navigation, tracking system
  • It is used to develop different social media applications which provide the network of interaction.
  • It helps to develop various mobile banking, money transfer apps.
  • It facilitates easy shopping.
  • It helps to develop various safety and security apps.

Android Based Industrial Fault Monitoring System

Android-based industrial fault monitoring system detects temperature variation, over voltage, the presence of gas or smoke. This project is used to monitor the occurrence of faulty functioning without human interference.

Android Based Industrial Fault Monitoring System
Android Based Industrial Fault Monitoring System

If any fault occurs in the industries the sensors deployed at the various locations creates an alert by alarming the buzzer. The sensors produce the analog signal which is then fed to the ADC to get digital signals.

The output of the ADC is given to a Microcontroller which processes the data by comparing with the predefined threshold values. Then an alert is created using the buzzer and LEDs. At the same time, a warning is sent to the android device using Bluetooth technology.

Block Diagram Android-based Industrial Fault Monitoring System

Android-based industrial fault monitoring system has a gas sensor and a temperature sensor. If any of these sensors cross the threshold level the sensor triggers and activates the buzzer while the intimation is sent to the Android device through Bluetooth technology.

Block Diagram of Android Based Industrial Fault Monitoring System
Block Diagram of Android-Based Industrial Fault Monitoring System

LPG Gas Sensor

A gas sensor is used to detect the presence of gas in the surrounding area. This is generally used in safety systems to detect leakages. This sensor is suitable for sensing LPG gas, propane and isobutane in the air. This sensor has high sensitivity and fast response time.

Gas Sensor
Gas Sensor

The sensor module consists of steel mesh under which sensor is fixed. The sensing element has a sensing material and a heater. When the sensing element is fed with current, the sensing material gets heated up and gases coming close to it get ionized, further creating a charge difference. This changes the resistance of the sensing element which alters the value of outgoing current.

Temperature Sensor

A temperature sensor is a device which measures the temperature in the form electrical signals. The different types of temperature sensors are used in a different temperature measuring processes.

Thermistor: A thermistor is a heat sensitive resistor. It exhibits the change in electrical resistance when exposed to changes in temperature. A Negative Temperature Coefficient (NCT) thermistor exhibits the decrease in electrical resistance when exposed to increase in temperature while a Positive Temperature Coefficient (PTC) thermistor exhibits the increase in electrical resistance when subjected to decrease in temperature.

Temperature Sensor
Temperature Sensor

The thermistor with the circuit is placed on the body of whose temperature is to be measured. Then the resistance of the thermistor changes with the change in temperature.


Analog to digital converter circuits are used in digital systems to convert analog signals to digital data. An ADC0808 is an 8 bit analog to the digital controller with 8 input analog channels. The input which is to be converted to digital form can be selected by using three address lines. Generally, ADCs are interfaced with microprocessors for data conversion.

LCD Display

LCD stands for Liquid Crystal Display. It is a flat panel display used in digital data in digital watches, smartphones, display screens, monitors, etc. LCD works on the principle of blocking the light rather than emitting the light. An electrical current passing through the liquid causes the crystal to align so that the light can not pass through them. Thus, each crystal either allows the light to pass or blocks the light.



A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field that attracts a lever and changes the switch contacts. The coil current can be on or off, so relays have two switch positions and most have double throw (changeover) switch contacts. The relay allows only one circuit to switch a second circuit which can be completely separate from the first.


For example, a low voltage battery circuit can use a relay to switch a 230V AC main circuit. There is no electrical connection inside the relay between the two circuits and the link is magnetic and mechanical.


A buzzer is an audio signaling device. A piezo buzzer is connected to a digital output, which emits a beep tone when the output is HIGH. When the piezo buzzer is connected to the analog pulse modulation output, it gives varying tones and effects.



An Encoder is a device or circuit that converts the information in one format to another. In digital electronics, an encoder is a binary converter. For 2^n inputs, an encoder gives n outputs.

Bluetooth Receiver

A Bluetooth is a wireless technology that allows to transmit and receive the data wirelessly over a short distance. It covers the radius of 10meters paring with 2 to 8 devices. It is a low cost and energy efficient device with transmission speed less than WiFi. A Bluetooth receiver displays the information in an audible and visible form that the customer can listen and view it.

Bluetooth Module
Bluetooth Module

Features of Android-Based Industrial Fault Monitoring System

The message will be sent to the number of supervisors when the fault occurs.

  • Long life and negligible power consumption.
  • Easy to install with low maintenance and affordable price.


  • No need for dedicated monitoring for relay room.
  • The system can be monitored from anywhere.
  • Can be accessed from any Android device.
  • Saves time and physical work.

Applications of Android-Based Industrial Fault Monitoring System

  • The project has a major application in the power grid, factories, power plants, mines and industrial areas.
  • Fault detection through precise analysis.

This is all about Android-based industrial fault monitoring system which detects the temperature variation, over-voltage, the presence of gas or smoke. This project is used to monitor the occurrence of faulty functioning without human interference.

Do you want to design and implement electronics projects on your own using breadboards? Then, post your views, comments, ideas, suggestions in the comments section below.

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