Find the faulty load with fewer sensors.

Challenge title and domain

Intelligent Electrical Fault Detection and Localisation Using Minimal Sensors

Domain: Industrial IoT | Embedded Systems | Intelligent Fault Diagnosis | Condition Monitoring. PlantLens is the industry problem statement partner and technical sponsor.

Objective

Develop a functional, low-cost intelligent monitoring system capable of detecting and localising electrical abnormalities in a multi-load system while minimising sensing hardware requirements.

The solution should demonstrate an effective balance between detection accuracy, fault localisation, response time, reliability, cost efficiency and engineering innovation.

Minimum technical requirements

• Multi-load monitoring: monitor a minimum of three independently controllable, low-voltage electrical loads.
• Electrical data acquisition: continuously or periodically measure relevant electrical parameters using suitable sensors.
• Fault detection: automatically identify abnormal electrical conditions and distinguish them from normal operational changes.
• Fault localisation: identify the likely affected load or subsystem when the measured signals contain sufficient information.
• Real-time alerting: notify the operator when a fault or abnormal condition is detected.
• Digital monitoring: provide an interface displaying the system’s operating condition, measured parameters and detected faults.
• Event logging: keep digital records of detected abnormalities, including the affected load, fault status and event time.
• Sensor optimisation: demonstrate an approach that reduces dependence on individual sensors for every monitored load.

Expected prototype

A working embedded-system prototype consisting of a low-voltage power source, at least three independently controllable electrical loads, an electrical sensing arrangement, a microcontroller or suitable processing system, an automated fault-detection and localisation mechanism, and a visual, audible or digital fault-indication interface.

Suitable loads include low-voltage DC motors, fans, LED lighting circuits or other safe electrical devices. Participants must demonstrate the system under normal operating conditions and introduce controlled abnormalities, such as load disconnection, unexpected load variation, intermittent operation or changes in supply conditions, to validate fault detection.

Key constraints

• The prototype must operate from a safe low-voltage DC supply, preferably 5 V or 12 V.
• A minimum of three electrical loads must be independently operable.
• Fault detection must be automatic, without continuous manual interpretation.
• Prioritise a minimal, cost-effective sensing architecture.
• Demonstrate the difference between normal load switching and abnormal operating conditions.
• The prototype must be suitable for demonstration in a school environment.
• Basic monitoring, detection and alerting must work without continuous internet connectivity.
• Explain the engineering principles and decision-making methods used.

Suggested hardware (indicative, not mandatory)

• ESP32, Arduino or equivalent microcontroller
• INA219, ACS712 or other suitable electrical sensors
• Low-voltage DC electrical loads
• Power supply and appropriate protection circuitry
• Switching devices and controlled fault-simulation arrangements
• LEDs, buzzer, LCD or OLED display
• Optional wireless communication modules

Suggested software (indicative, not mandatory)

Participants are encouraged to develop innovative alternatives to the suggested architecture.

• Arduino IDE, MicroPython, Python or equivalent; embedded C/C++
• Signal-processing and statistical-analysis methods
• Rule-based or machine-learning fault classification
• Local or IoT-enabled monitoring dashboard
• Digital event logging and visualisation

Safety

All prototypes must use appropriately protected, low-voltage electrical systems. Fault conditions must be introduced through controlled and reversible methods. Exposed mains electricity, intentional short circuits, destructive component testing and unsafe operating conditions are prohibited.

Use suitable current limiting, circuit protection and safe wiring practices. The prototype should be capable of repeated fault demonstrations without damaging components or creating safety hazards.

Evaluation parameters for this challenge

Evaluation may include normal operating transitions, different load combinations and controlled fault conditions. Teams are assessed on their ability to tell genuine faults from expected operating changes and to identify the source of detectable abnormalities.

Round 1: concept and proposed solution

• Problem understanding and proposed engineering approach
• System architecture or functional block diagram
• Proposed sensing and fault-detection methodology
• Hardware and software requirements
• Preliminary cost estimation

Round 2: prototype development

• Functional prototype demonstration video
• Electrical data acquisition and monitoring
• Demonstration of fault-detection functionality
• Explanation of the fault-localisation methodology
• Preliminary test results

Grand Finale: working prototype

• Fully operational embedded-system prototype
• Live monitoring of multiple electrical loads
• Demonstration of normal and abnormal operating conditions
• Automatic fault detection and localisation
• Operator alert and digital event records
• Supporting test data and performance observations
• Technical presentation explaining system operation and design decisions

Challenge objective

Develop an innovative intelligent electrical monitoring system that can determine when and where a fault occurs within a multi-load network using the minimum practical number of sensors.

The ultimate goal is to demonstrate how embedded intelligence, electrical measurements and connected technologies can enable affordable and reliable fault diagnosis for the next generation of industrial systems.