Design and Implementation of an ESP32-Based Electronic Module for Monitoring and Protecting Industrial Electrical Panels Using the Modbus TCP/IP Protocol

Abstract

This paper presents the design and implementation of an ESP32-based electronic module for the monitoring and preventive protection of industrial electrical panels using Modbus TCP/IP. The system integrates non-invasive sensors to measure up to 400 A, NTC thermistors for temperature in distribution bars, and sensors for detecting fine smoke and gases. In addition, it uses an analyzer to record 3rd and 5th harmonics, allowing for advanced power quality diagnostics. The ESP32 processes the information in real time. In the presence of smoke or flammable gases, it activates an actuator that triggers the “TRIP” button on the main switch to prevent fires and disable the mains voltage used. According to INDECI, OSINERGMIN, and the Peruvian Fire Department, 70% of industrial fires in the country are electrical in origin. Implementing the system can reduce the risk of fire by 52.2%, increase the timely detection of incidents by 85%, and improve automatic response by 89%. It also promotes predictive maintenance of the electrical panel by identifying excessive current, overheating, and harmonic distortions, offering a low-cost, high-efficiency, and quick-to-implement solution.