MONITORING TEMPERATURE HYDRAULIC CYLINDER EXCAVATOR TO PREDICTIVE FAILURE USING IOT

Abstract

Unscheduled hydraulic cylinder replacements in Komatsu PC2000-8 excavators, reaching 75% between 2021–2024, have disrupted operations due to the lack of early warning. This study develops an Internet of Things (IoT)–based system for real-time temperature monitoring to support predictive maintenance. Using the DMAIC framework, the prototype integrates DS18B20 sensors, an ESP8266 microcontroller, and the Blynk 2.0 dashboard to provide alerts when abnormal temperature differences occur. Conventional decision-making required 6–7 days, and up to 14 days under anomalies, while the IoT system enables detection within seconds, significantly reducing cycle time. User Acceptance Qualification (UAQ) results show 85% of users rated the system user-friendly and 80% validated alert accuracy, highlighting its practicality. The findings demonstrate that IoT monitoring can reduce unscheduled replacements, enhance decision-making efficiency, and support scheduled maintenance strategies for heavy equipment.