An Industry 4.0 implementation of a condition monitoring system and IoT-enabled predictive maintenance scheme for diesel generators

In most business and residential organizations, Diesel Generators (DG) is a viable supplementary power source for ensuring an undisturbed power supply. The DG is a hybrid machine that generates electrical energy using a Diesel Engine (DE) and an Electric Generator (EG). By routinely monitoring crucial machine parameters, alternative power source efficiency can be improved. Furthermore, Condition Monitoring Systems (CMS) based on the Internet of Things (IoT) have supplanted the traditional equipment maintenance method. Predictive maintenance is also an important building block of Industry 4.0, whose entire process and performance can be fully understood by using IoT-enabled Remote Monitoring (RM) schemes. Firstly, this paper introduces a remote monitoring and data acquisition scheme to realize the concept of predictive maintenance. Secondly, this article discusses a strategy for real-time observation of DG parameters as well as a comprehensive analysis of various metrics. Thirdly, this research article includes a monitoring and analysis scheme of crucial factors in a DG, like the speed of an engine, voltage output, the current produced, power factor, coolant required, fuel consumption, and battery health. Different mathematical models are formulated by correlating experimental data and estimating the coefficients. Finally, to create suitable real-time warnings under critical circumstances, a fuzzy logic-based Decision Support System (DSS) and web-based integration elements are presented.