Design of Electronic Protection Modules, Voltage Monitoring, and Safe Reset for Industrial Electrical Equipment and Tools

This article presents the design and implementation of electronic modules for protection, voltage monitoring, and safe reset aimed at industrial applications that demand high reliability in terms of electrical safety. The developed system continuously monitors single-phase 220 VAC and three-phase (220 VAC, 380 VAC, and 440 VAC) voltage equipment and tools, integrating voltage measurement circuits and using an ATTiny 84 microcontroller for phase loss detection and protection processing, incorrect phase sequence in three-phase voltages, or abnormal power supply conditions with historical data in three-phase applications. It also enables safe reset reactivation, in addition to providing protection against incorrect rotation reversal in motors and faster short-circuit faults. The main objective is to prevent uncontrolled start-up when recovering a power supply lost due to external problems and to ensure that, after a power outage, power is restored only through a controlled and validated reset. The implementation of the proposed module reduces electrical incidents associated with unsafe resetting by up to 81.2%, thanks to the verification of phase failure or absence of power supply and manual validation prior to service restoration using safe resetting. In addition, the visual interface of LED indicators facilitates rapid identification of the operating status, reducing diagnostic times for problems external to the equipment. Experimental results and field tests demonstrate that the proposed solution constitutes a significant advance in the protection of industrial machinery, increasing workplace safety, the reliability of the electrical system, and the operational sustainability of power tools.