Herdiansyah Noorrizky Anggana, Moch Solikin

Development of a Real-Time Vibration Monitoring System for Drum Tester Machines Using ADXL345 Sensor and ESP32 Microcontroller

Introduction

Development of a real-time vibration monitoring system for drum tester machines using adxl345 sensor and esp32 microcontroller. Monitor drum tester machine vibrations in real-time with an ADXL345-ESP32 system. Improve industrial precision, cut inspection time, and enhance workforce efficiency. Ideal for factory operations.

Abstract

This study focuses on developing a vibration level monitoring system for a drum tester machine, utilizing the ADXL345 sensor in conjunction with the ESP32 microcontroller and a web-based monitoring platform. The system was implemented at PT Astra Daihatsu Motor's Sunter Assembly Plant (SAP) located in Jakarta, Indonesia, for large-scale industrial use. The design aimed to boost precision in vibration monitoring and elevate workforce productivity. The sensor collects data, which is then sent to a MySQL database and shown in real-time on an LCD and through a Grafana-based web interface. Functional tests verified that all components performed as specified. The ESP32 microcontroller provided reliable Wi-Fi connectivity, and the ADXL345 sensor showed impressive accuracy in detecting vibration changes in both static and dynamic situations. Performance tests conducted over eight hours, with data collected at one-minute intervals, demonstrated consistent readings across all axes (X, Y, Z), highlighting the system's reliability. The implementation of this system resulted in enhanced efficiency in machine monitoring. The inspection interval has been extended from two weeks to one month, which has reduced the workforce requirements from two workers to one. Moreover, the time required for inspection was reduced from 20 minutes to only one minute. To summarize, this vibration monitoring system enhances the accuracy of real-time data, improves workforce efficiency, and ensures reliable monitoring of machine conditions. This offers a creative approach for industrial uses, enhancing operational efficiency and ensuring workplace safety.

Review

The paper, "Development of a Real-Time Vibration Monitoring System for Drum Tester Machines Using ADXL345 Sensor and ESP32 Microcontroller," addresses a critical need in industrial maintenance by proposing an innovative and practical solution. The abstract clearly outlines the study's objective: to develop a real-time vibration monitoring system for drum tester machines using cost-effective and readily available components. The explicit mention of its implementation at PT Astra Daihatsu Motor's Sunter Assembly Plant for large-scale industrial use immediately highlights the research's significant practical relevance and potential for real-world impact, aiming to boost precision in monitoring and elevate workforce productivity. The methodology described is sound, leveraging the ADXL345 sensor for data collection, the ESP32 microcontroller for processing and Wi-Fi connectivity, and a robust data pipeline involving a MySQL database and a Grafana-based web interface for real-time visualization. The abstract provides strong evidence of the system's efficacy through functional tests confirming component performance and eight-hour performance tests demonstrating consistent readings and reliability across all axes. The most compelling aspects are the quantifiable benefits achieved: the extension of inspection intervals from two weeks to one month, a reduction in workforce from two to one, and a drastic decrease in inspection time from 20 minutes to merely one minute. These metrics powerfully illustrate the system's success in enhancing efficiency and optimizing resource allocation. In conclusion, this study presents a well-designed and thoroughly validated real-time vibration monitoring system that delivers substantial improvements in industrial operational efficiency and data accuracy. The integration of accessible technology to achieve such significant practical gains in a large-scale industrial setting makes this work highly commendable. It not only offers a creative and reliable approach for enhancing machine monitoring and ensuring workplace safety but also sets a benchmark for leveraging affordable IoT solutions for impactful industrial applications. This work represents a valuable contribution to the field, demonstrating a clear path for industries to adopt smarter, more efficient maintenance strategies.

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