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Electrical Hot-Spot Detection using a Low-Cost Thermal Camera

Approx. component budget: Rs. 6,000 - 11,000

Objective

Detect loose connections and overloaded parts by thermal imaging and set alarm temperature rules for a panel.

What you will build

A thermal array sensor (MLX90640) with an ESP32, a display or web view, and a test panel with loose and tight connections, overloaded wires and a warm motor.

Results you can expect

• Thermal images of good and loose joints
• Temperature rise vs current
• Alarm threshold tests
• Comparison with a contact thermometer

What you will learn

Thermography for predictive maintenance, thermal measurement accuracy and image processing basics.

Tools and notes

ESP32, MLX90640 module, thermocouple or IR thermometer for reference, Python or Excel. The test panel runs at a safe load only. Do not touch live parts, and keep the panel enclosed.

Resume points from this project

• Built and tested Electrical Hot-Spot Detection using a Low-Cost Thermal Camera; objective: detect loose connections and overloaded parts by thermal imaging and set alarm temperature rules for a panel.
• Measured and analysed thermal images of good and loose joints and temperature rise vs current; wrote the report and presented the results in a viva. Add your own numbers: [x].

Replace [x] with your own measured results. Write only what you really did.

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