Introduction

Various industrial equipment is essential for the adequate production of products, parts and other services. Ensuring the proper functioning of this equipment is essential to maintain production quality, reduce material losses and costs of manufacturing processes.

Machines are subject to excessive vibration, misalignment and other types of mechanical stress during operation. Equipment that operates outside of ideal vibration and alignment parameters is more likely to experience unexpected failures.

Without proper monitoring, these issues can go unnoticed until they cause significant failures. Problems not detected early can lead to more severe damage to equipment and every hour of machine downtime not only represents an immediate loss of production, but also affects the overall efficiency of the production line.

And this has major impacts and consequences, such as:

• This results in unplanned production stoppages, leading to significant downtime while equipment is repaired or replaced.
• The costs associated with repairs can be substantial depending on the extent of the damage. In extreme cases, complete replacement of damaged equipment may be necessary, resulting in high additional costs.
• This can result in products that are defective or below expected quality standards, leading to additional rework costs, product rejection and potential loss of customers due to dissatisfaction.

To solve these problems and reduce impacts on manufacturing processes, we developed an electronic board with ESP32 and the MPU6050 sensor. The ESP32 is the heart of the project and will be able to read data from the MPU6050 sensor, process it and send this information to some service over the internet.

With real-time data provided by the MPU6050, operators and technicians can be alerted to abnormal conditions. This allows for rapid, scheduled interventions to prevent catastrophic failures and reduce unplanned downtime. By optimizing equipment maintenance and operation, the MPU6050 can help increase overall production efficiency, reducing operating costs and improving the reliability of manufactured products.

Implementing technologies like the MPU6050 not only helps avoid the high costs associated with industrial equipment failures, but also contributes to the operational and financial sustainability of companies, ensuring more efficient and profitable operations. Next, we will present the complete design of the printed circuit board presented below.

Electronic Schematic of the Project

The electronic circuit of the printed circuit board is divided into 6 electronic blocks. All of them are presented in the figure below.

The heart of this project is the ESP32. It will be responsible for reading the signals from the MPU6050 sensor and transferring this data over the internet. Its basic operating circuit is shown in the electronic schematic above. It consists of a set of buttons, decoupling capacitor and pins for code transfer (+3V3, TXD, RXD, and GND).

This electronic board aimed to be small, easy to attach anywhere and operate with low energy consumption using a Li-Ion battery. Below we have the connector for connecting a Li-Ion battery cell.

To ensure adequate power supply to the system, we used a DC-DC boost converter to raise the voltage to 5V and we used a +3V3 voltage regulator to regulate the voltage to power the ESP32. In future updates, if necessary, we will use the 5V voltage to power other circuits.

Below we present the circuit block of the DC-DC boost converter. We use the TPS61023 CHIP to supply +5V from the Li-Ion battery input voltage.

In various battery-powered electronic projects, it is essential to ensure that the battery can power the device for an extended period. This aims to provide a long operating time for the application. To ensure this, we include a circuit for monitoring the battery's voltage and current using the INA219 sensor.

What is the purpose of the INA219 sensor?

The INA219 sensor is a crucial tool for monitoring batteries and assessing current consumption in electronic circuits, especially in field applications. It measures both the battery voltage and the current flowing through it, providing essential data to evaluate system performance and efficiency. By keeping track of battery voltage, operators can effectively monitor charging and discharging status, which is key for proper energy management.

Additionally, by analyzing the current consumption of the circuit, operators can identify usage patterns, detect anomalies, and optimize energy consumption. This data is vital for extending battery life and enhancing energy efficiency in various applications, from portable devices to remote monitoring systems. The INA219 sensor circuit, shown below, communicates with the ESP32 via I2C.

Next, we have the MPU6050 gyroscope sensor circuit. This sensor will be responsible for sending vibration and vibration signals to the system.

MPU6050 Gyroscope Sensor Circuit

The gyroscope sensor circuit is shown below. It is a very simple circuit to assemble and all electronic component references are obtained from the values ​​indicated in the manufacturer's datasheet. Communication between the MPU6050 sensor and the ESP32 is through I2C.

The development of the electronic board with the ESP32 and the MPU6050 sensor proves to be an effective solution for monitoring vibrations in machines and equipment. With this approach, it is possible to obtain accurate, real-time data on the operating status of equipment, allowing preventive and corrective actions that can increase the useful life and efficiency of machines, in addition to reducing maintenance costs.

However, the application possibilities of this technology are not limited to vibration monitoring. The MPU6050 sensor, in combination with the ESP32, opens up a range of opportunities for several other areas. Among the possible applications, the following stand out:

• Movement and Posture Monitoring: In areas such as health and sports, where monitoring body movements and postures is essential for preventing injuries and optimizing performance.
• Drone Navigation and Control Systems: Using acceleration and gyroscope data from the MPU6050 to stabilize and control drones, improving flight accuracy and response to commands.
• Augmented and Virtual Reality: Integrating sensor data to create more immersive and interactive experiences in augmented and virtual reality applications.
• Robotics: In robotics projects, where precise control of movements is crucial, the MPU6050 can be used to improve the stability and precision of robots.

In summary, using the MPU6050 sensor with the ESP32 not only enables effective vibration monitoring, but also proves to be a versatile and powerful tool for a wide range of technological applications. Innovation and creativity in the use of these technologies can open new paths and opportunities in different areas of knowledge and industry.

Acknowledgments

We would like to thank PCBWAY for supportting the creation of this project and made some units available for you to earn for free and receive 5 units at your home.

To receive them, access this link, create an account on the website and receive coupons for you to win right now.