Industrial machines and electrical equipment are susceptible to faults such as short circuits, overloads, and high voltage conditions, which can damage machinery, disrupt production, and pose safety hazards. This project presents a Machine Fault Detection and Alarm System using a Wecon PLC, integrated with current and voltage sensors to continuously monitor a motor representing the load. When the system detects abnormal operating conditionsโsuch as undervoltage, overvoltage and overcurrent/Overloadโthe PLC immediately triggers a buzzer alarm and disconnects the load via a relay, preventing equipment damage and ensuring operator safety. The system leverages the programmable logic of the Wecon PLC to implement real-time monitoring and decision-making with high reliability. Sensor data is continuously processed, and fault thresholds are pre-configured to respond instantly to unsafe conditions. The project demonstrates an automated, scalable solution for industrial safety, minimizing downtime and maintenance costs. By integrating PLC-based monitoring, current/voltage sensing, and protective relays, this system provides a practical and effective approach to safeguard motors and industrial loads against electrical faults.
The proposed PLC-based Machine Fault Detection System was successfully designed and experimentally implemented to monitor the voltage and current of a machine load. The system effectively detected abnormal conditions such as undervoltage, overvoltage, and overcurrent using the INA219 sensor and Arduino Uno. The detected fault signals were transferred to the PLC through relay interfaces, where the programmed ladder logic generated the required control response. The LCD provided real-time display of electrical parameters and system status, while the buzzer provided an immediate warning during fault conditions. The experimental results confirmed the successful operation of the system under normal and abnormal conditions. Overall, the proposed system demonstrates a simple, low-cost, and effective approach for real-time machine fault monitoring and PLC-based protection, with potential for further development into a more advanced industrial condition monitoring system.
References
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๐ How to Cite This Paper
B. Vishal Sahrudhy, Y. Srinivas Rao (2026). Fault Detection in DC Motor Using a Programmable Logic Controller. International Journal of Engineering and Techniques, 12(5), 287โ296. ISSN: 2395-1303. DOI: https://doi.org/10.5281/zenodo.23034185
