Volume: 2 Issue: 2
Year: 2025, Page: 81-85, Doi: https://doi.org/10.70968/ijeaca.v2i2.E117
Received: July 20, 2025 Accepted: Nov. 15, 2025 Published: Dec. 10, 2025
Traditional R&D setups of electrical/electronics like Robotics, Automotive, Aerospace, etc involve extensive wiring and multiple equipment interfaces, making debugging difficult, time-consuming and less efficient. The proposed novel product addresses these issues by reducing setup complexity and improving ease of testing and debugging by remote monitoring, automated safety and modular expansion features which are absent in traditional setups. The design and implementation of an Internet of Things-based isolated AC load control and energy monitoring test bench utilizing ESP32(micro controller) and phase-angle TRIAC control with the option of switching between random phase firing and zero cross firing are presented in this paper. The developed system integrates three regulated DC outputs (12 V, 5 V, and 3.3 V), two independent AC control channels for dimming and switching, high-side energy measurement using the HLW8032, wireless monitoring via Wi-Fi and automatic protection logic for enhanced safety and reliability.
Keywords: Form Factor Reduction of an Industrial Research and Development Test Setup with IoT Integration
1. Cena G, Valenzano A, Scanzio S, Zunino C. Evaluation of Response Times in Industrial IoT Applications. <I>IEEE Transactions on Industrial Informatics</I>. 2017, 13(2), pp. 828–837
2. Alheraish A. Design and implementation of home automation system. IEEE Transactions on Consumer Electronics. 2004; 50 (4). Available from: https://doi.org/10.1109/tce.2004.1362503
3. Chau KT, Yang H. Recent Developments in AC Lamp Dimming and Control. <I>IEEE Transactions on Industrial Electronics</I>. 2020, 67(5). pp. 3820–3830.
4. Wang Y, Zhang Z, Li J, Shahidehpour M. Smart Residential Energy Management System Considering RealTime Load Control and Monitoring. <I>IEEE Transactions on Smart Grid</I>. 2021, 12(3). pp. 2157–2167.
5. STMicroelectronics. <I>BTA16 TRIAC Datasheet</I>. STMicroelectronics, Geneva, 2006.
6. Rashid MH. <I>Power Electronics: Circuits, Devices and Applications</I>. Upper Saddle River, NJ: Pearson, 2014.
7. Mirani M, Awasthi R, Singh AK. Industrial IoT-Based Energy Monitoring System: Using Data Processing at Edge. IoT. 2024; 5 (4). Available from: https://doi.org/10.3390/iot5040027
8. Wadhwa CL. <I>Electrical Power Systems</I>. New Delhi: New Age International Publishers, 2017.
9. Hannan MA, Faisal M, Ker PJ, Hussain A. A review of internet of energy based smart metering systems. <I>Renewable and Sustainable Energy Reviews</I>. 2019, 107. pp. 1–15.
10. Espressif Systems. <I>ESP32 Technical Reference Manual</I>. Espressif Systems, Shanghai, 2023.
11. HLW. <I>HLW8032 Energy Metering IC Datasheet</I>. HLW, Shenzhen, 2022.
12. ON Semiconductor. <I>MOC3041M Zero-Cross Triac Driver Output Optocoupler Datasheet</I>. ON Semiconductor, Phoenix, AZ, 2022.
13. Pawar V, Phule A, Metkari A, Takale SR. Review of Smart Energy Meter Implementations Using ESP32 Microcontroller and IoT Platforms. International Journal of Advanced Research in Science, Communication and Technology. 2025; Available from: https://doi.org/10.48175/ijarsct-29423
14. Somantri M, <I>et al.</I>. Optimization of IoT-based monitoring system for automatic power factor correction using PZEM-004T sensor. Indonesian Journal of Electrical Engineering and Computer Science. 2025; 39 (2). Available from: https://doi.org/10.11591/ijeecs.v39.i2.pp860-873
15. Salcedo JG, Obispo KGM, Rojas JJH. Development of an Automated Testing System for Alternators with Real-Time Monitoring Based on IoT and Electrical Analysis. International Journal of Electrical and Electronics Engineering. 2025; 12 (6). Available from: https://doi.org/10.14445/23488379/ijeee-v12i6p102
© 2025 Vangury, et al. This is an open access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.
Vangury PS, Pandji S, Dhegaskar P, Amrutkar P, Kelapure R. Form Factor Reduction of an Industrial Research and Development Test Setup with IoT Integration. 2025; 2(2):81-85. https://doi.org/10.70968/ijeaca.v2i2.E117