Open-Source Data Logger System for Real-Time Monitoring and Fault Detection in Bench Testing

This paper presents the design and development of a proof of concept (PoC) open-source data logger system for wireless data acquisition via Wi-Fi aimed at bench testing and fault detection in combustion and electric engines. The system integrates multiple sensors, including accelerometers, microphones, thermocouples, and gas sensors, to monitor critical parameters, such as vibration, sound, temperature, and CO₂ levels. These measurements are crucial for detecting anomalies in engine performance, such as ignition and combustion faults. For combustion engines, temperature sensors detect operational anomalies, including diesel engines operating beyond the normal range of 80 °C to 95 °C and gasoline engines between 90 °C and 110 °C. These readings help identify failures in cooling systems, thermostat valves, or potential coolant leaks. Acoustic sensors identify abnormal noises indicative of issues such as belt misalignment, valve knocking, timing irregularities, or loose parts. Vibration sensors detect displacement issues caused by engine mount failures, cracks in the engine block, or defects in pistons and valves. These sensors can work synergistically with acoustic sensors to enhance fault detection. Additionally, CO₂ and organic compound sensors monitor fuel combustion efficiency and detect failures in the exhaust system. For electric motors, temperature sensors help identify anomalies, such as overloads, bearing problems, or excessive shaft load. Acoustic sensors diagnose coil issues, phase imbalances, bearing defects, and faults in chain or belt systems. Vibration sensors detect shaft and bearing problems, inadequate motor mounting, or overload conditions. The collected data are processed and analyzed to improve engine performance, contributing to reduced greenhouse gas (GHG) emissions and enhanced energy efficiency. This PoC system leverages open-source technology to provide a cost-effective and versatile solution for both research and practical applications. Initial laboratory tests validate its feasibility for real-time data acquisition and highlight its potential for creating datasets to support advanced diagnostic algorithms. Future work will focus on enhancing telemetry capabilities, improving Wi-Fi and cloud integration, and developing machine learning-based diagnostic methodologies for combustion and electric engines.