IoT-Based Motor Protection and Control System Using PLC and ESP8266

Notice

This is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.

Year : 2026 | Volume : 04 | 01 | Page :
    By

    Harikrishna Prakash,

  • Aswin N.S,

  • Krishnadas P.M,

  • Mahesh M,

  • Soumya K.G,

  • Sonima M.P,

  1. Student, Department of Electrical and Electronics Engineering, College of Engineering Kidangoor, Kerala, India
  2. Student, Department of Electrical and Electronics Engineering, College of Engineering Kidangoor, Kerala, India
  3. Student, Department of Electrical and Electronics Engineering, College of Engineering Kidangoor, Kerala, India
  4. Student, Department of Electrical and Electronics Engineering, College of Engineering Kidangoor, Kerala, India
  5. Head of the Department, Department of Electrical and Electronics Engineering, College of Engineering Kidangoor, Kerala, India
  6. Assistant Professor, Department of Electrical and Electronics Engineering, College of Engineering Kidangoor, Kerala, India

Abstract

Because of their straightforward design and affordable price, single-phase induction motors are frequently utilized in residential and small-scale industrial settings. However, conventional direct-on-line (DOL) control provides fixed-speed operation and offers limited protection against thermal overload and fault conditions. This article describes the design and implementation of an ESP8266 Node MCU-based PLC- based closed-loop motor control system with Internet of Things features. To increase operating flexibility and maintenance efficiency, the suggested system also incorporates sensor-based feedback control, wireless connection, and remote accessibility capabilities. Through a web-based interface, the suggested system allows for the continuous monitoring of motor temperature and operating status. To assist with predictive maintenance and improve system dependability, cloud-based data recording and trouble notification systems are also included. It also implements automatic thermal derating and shutdown mechanisms to prevent damage. Experimental results indicate a reduction in temperature rise by approximately 12–15%. The system also achieves an efficiency improvement of about 10–12% compared to conventional DOL control. During continuous operation, the developed prototype exhibits consistent performance, lower energy consumption, and enhanced protection against electrical failures and overheating. The suggested approach is affordable, scalable, and appropriate for Industry 4.0 applications provide improved long-term operating stability, sustainability, flexibility, safety, dependability, and connection.

Keywords: PLC, ESP8266, IoT, Induction Motor, Thermal Protection, Speed Control

How to cite this article:
Harikrishna Prakash, Aswin N.S, Krishnadas P.M, Mahesh M, Soumya K.G, Sonima M.P. IoT-Based Motor Protection and Control System Using PLC and ESP8266. International Journal of Electrical Power and Machine Systems. 2026; 04(01):-.
How to cite this URL:
Harikrishna Prakash, Aswin N.S, Krishnadas P.M, Mahesh M, Soumya K.G, Sonima M.P. IoT-Based Motor Protection and Control System Using PLC and ESP8266. International Journal of Electrical Power and Machine Systems. 2026; 04(01):-. Available from: https://journals.stmjournals.com/ijepms/article=2026/view=245079


References

  1.  Haq S, Biswas SP, Hosain MK, Rahman MA, Islam MR, Elavarasan RM, Muttaqi KM. A modified PWM scheme to improve the power quality of NPC inverter based solar PV fed induction motor drive for water pumping. IEEE Transactions on Industry Applications. 2023 Feb 16;59(3):3019-30.
  2. Tiwari S, Sujith M. Analysis Of closed loop control of matrix converter for capacitorless single phase induction motor for variable speed operation. In2017 International Conference On Smart Technologies For Smart Nation (SmartTechCon) 2017 Aug 17 (pp. 766-771). IEEE.
  3. Colak I, Bayindir RA, Bektas A, Sefa I, Bal GÜ. Protection of induction motor using PLC. In2007 International Conference on Power Engineering, Energy and Electrical Drives 2007 Apr 12 (pp. 96-99). IEEE.
  4. Parameshwari V, Dinesh P. An IoT Enabled PLC Based Multichannel Temperature Monitoring and Controlling System. In2025 International Conference on Emerging Technologies in Engineering Applications (ICETEA) 2025 Jun 5 (pp. 1-5). IEEE.
  5. Al-Fuqaha A, Guizani M, Mohammadi M, Aledhari M, Ayyash M. Internet of things: A survey on enabling technologies, protocols, and applications. IEEE communications surveys & tutorials. 2015 Jun 15;17(4):2347-76.
  6. Ashton K. That ‘internet of things’ thing. RFID journal. 2009 Jun 22;22(7):97-114.
  7. Alphonsus ER, Abdullah MO. A review on the applications of programmable logic controllers (PLCs). Renewable and Sustainable Energy Reviews. 2016 Jul 1;60:1185-205.
  8. Singh J, Banerjee C, Pandey SK. Smart automation in manufacturing process using industrial internet of things (IIoT) architecture. Innov. Syst. Softw. Eng.. 2023 Mar 1;19(1):15-22.
  9. Lyon WV. Heat losses in the conductors of alternating-current machines. Transactions of the American Institute of Electrical Engineers. 2009 Jun 2;40:1361-409.
  10. Herbert W. Totally enclosed fan cooled (TEFC) squirrel cage induction motor options. InConference Record of 2013 Annual IEEE Pulp and Paper Industry Technical Conference (PPIC) 2013 Jun 23 (pp. 17-25). IEEE.
Ahead of Print Subscription Review Article
Volume 04
01
Received 27/04/2026
Accepted 07/05/2026
Published 25/05/2026
Publication Time 28 Days
1

Login


My IP

PlumX Metrics