Smart Transformer Health Monitoring System
About the Smart Transformer Health Monitoring System PCB
Smart Transformer Health Monitoring System is an open source ESP32 PCB design by jsitech4, published on GitHub. It is a 2-layer board measuring 108.8 × 83.6 mm, with 81 components from 64 distinct parts.
Its main chip is the LM2596S-12V, from the ESP32 family. Other key parts include the LM2596S-3.3V, ESP32-WROOM, LM2596S-5V and AMS1117-3.3. By type, the board carries 25 capacitors, 16 resistors, 13 diodes, 9 connectors, 5 ICs and 3 switches.
It belongs with the displays & leds and sensors designs in this gallery.
From the project
This project is an ESP32-S3 based smart transformer health monitoring system. It monitors transformer temperature, load current, AC voltage, vibration, relay status, storage status, and predictive maintenance condition from a local web dashboard.
This project is an ESP32-S3 based smart transformer health monitoring system. It monitors transformer temperature, load current, AC voltage, vibration, relay status, storage status, and predictive maintenance condition from a local web dashboard.
- Smart transformer health monitoring with temperature, current, voltage, and vibration analysis - Predictive maintenance risk score and transformer health score - Future fault estimate based on changing temperature, current, voltage, and vibration trends - Local web dashboard hosted directly by the ESP32-S3 - SD card backend for transformer logs…
Main components on the Smart Transformer Health Monitoring System
Smart Transformer Health Monitoring System bill of materials (BOM)
81 components, 64 distinct parts — part numbers from the project's BOM.
| Qty | Part | Footprint | Refs |
|---|---|---|---|
| 1 | LM2596S-3.3V AMS1117-3.3 | SOT-223-3_TabPin2 | U1 |
| 1 | LM2596S-12V ESP32-S3-WROOM-1U-N16R8 | ESP32-S3-WROOM-1U-N16R8 | U2 |
| 1 | ESP32-WROOM LM2596S-3.3V | TO-263-5_TabPin6 | U3 |
| 1 | LM2596S-5V | TO-263-5_TabPin6 | U4 |
| 1 | AMS1117-3.3 CH340C | SOIC-16_3.9x9.9mm_P1.27mm | U5 |
| 1 | UMH3N | SOT-363_SC-70-6 | Q1 |
| 1 | 12MHZ 12MHz | Crystal_HC49-4H_Vertical | Y1 |
| 1 | DS18B20 | PinHeader_1x03_P2.54mm_Vertical | J1 |
| 1 | CURRENT SENSOR | PinSocket_1x04_P2.54mm_Vertical | J2 |
| 1 | OLED SCREEN | PinSocket_1x04_P2.54mm_Vertical | J3 |
| 1 | LOAD | TerminalBlock_Phoenix_MKDS-1,5-2_1x02_P5.00mm_Horizontal | J4 |
| 1 | 220VAC | TerminalBlock_Phoenix_MKDS-1,5-2_1x02_P5.00mm_Horizontal | J5 |
| 1 | MPU6050 | PinHeader_1x08_P2.54mm_Vertical | J6 |
| 1 | SD MODULE | PinHeader_1x06_P2.54mm_Vertical | J7 |
| 1 | USB_C Conn | PinHeader_1x04_P2.54mm_Vertical | J8 |
| 1 | 12VAC | TerminalBlock_Phoenix_MKDS-1,5-2_1x02_P5.00mm_Horizontal | J9 |
| 1 | Buzzer | Buzzer_15x7.5RM7.6 | BZ1 |
| 1 | CMZ12 | D_SOD-123 | DZ1 |
| 1 | ~ | SolderJumper-2_P1.3mm_Open_Pad1.0x1.5mm | JP1 |
| 1 | 10A/12V FINDER-36.11 | Relay_SPDT_Finder_36.11 | K1 |
Show 44 more
| Qty | Part | Footprint | Refs |
|---|---|---|---|
| 2 | PC817XFP PC817XI | DIP-4_W7.62mm_SMDSocket_SmallPads | OC1, OC2 |
| 1 | RotaryEncoder | PinHeader_1x06_P2.54mm_Vertical | SW1 |
| 1 | SPST_CK_KXT3 RESET | SW_SPST_CK_KXT3 | SW2 |
| 1 | SPST_CK_KXT3 FLASH | SW_SPST_CK_KXT3 | SW3 |
| 1 | 1N4007 | D_SMA | D1 |
| 2 | 1N5824 SM4001 | D_SMA | D2, D3 |
| 1 | Red | LED_D3.0mm | D4 |
| 2 | SM4001 | D_SMA | D5, D6 |
| 1 | SM4001 1N5819 | D_SMA | D7 |
| 1 | GBU8M | Diode_Bridge_Vishay_GBU | D8 |
| 1 | 1N5819 | D_SMA | D9 |
| 1 | SM4001 Red | LED_D3.0mm | D10 |
| 1 | SM4001 Green | LED_D3.0mm | D11 |
| 1 | 1N5824 | D_SMA | D12 |
| 1 | 1N5819 1N5824 | D_SMA | D13 |
| 2 | 33UH 33uH | L_12x12mm_H6mm | L1, L2 |
| 2 | 680UF/35V 100nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C1, C2 |
| 1 | 470NF 100nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C3 |
| 4 | 100NF 100nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C4, C12, C23, C24 |
| 2 | 220UF/16V 100nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C5, C11 |
| 1 | 220UF/16V 104 | C_0805_2012Metric | C6 |
| 1 | 680UF/35V 145J400V | C_Rect_L19.0mm_W6.0mm_P15.00mm_MKS4 | C7 |
| 1 | 4.7uF/16V | CP_EIA-3528-21_Kemet-B_HandSolder | C8 |
| 1 | 2200UF/35V 10uF_16V | CP_Radial_D5.0mm_P2.00mm | C9 |
| 1 | 2200UF/35V 470nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C10 |
| 2 | 100NF 4.7uF/16V | CP_EIA-3528-21_Kemet-B_HandSolder | C13, C25 |
| 1 | 470UF/25V 470uF/25V | CP_Elec_8x11.9 | C14 |
| 1 | 4.7UF/16V 680uF_35V | CP_Elec_10x12.5 | C15 |
| 1 | 680uF_35V | CP_Elec_10x12.5 | C16 |
| 1 | 22pF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C17 |
| 1 | 100NF 22pF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C18 |
| 1 | 4.7UF/16V 100nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C19 |
| 1 | 22PF 100nF | C_0805_2012Metric_Pad1.18x1.45mm_HandSolder | C20 |
| 1 | 22PF 220uF_16V | CP_Elec_6.3x7.7 | C21 |
| 1 | 100NF 220uF_16V | CP_Elec_6.3x7.7 | C22 |
| 2 | 680K 10k | R_0805_2012Metric | R1, R7 |
| 1 | 680K 1k | R_0805_2012Metric | R2 |
| 1 | 100K 2k | R_0805_2012Metric | R3 |
| 4 | 10k | R_0805_2012Metric | R4, R5, R8, R13 |
| 2 | 330R 10k | R_0805_2012Metric | R6, R9 |
| 1 | 10K 1M | R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R10 |
| 1 | 330R 330R/2W | R_Axial_DIN0309_L9.0mm_D3.2mm_P20.32mm_Horizontal | R11 |
| 3 | 10K 330R | R_0805_2012Metric | R12, R15, R16 |
| 1 | 330R/2W 10k | R_0805_2012Metric | R14 |
Smart Transformer Health Monitoring System design files
The KiCad project lives in the jsitech4/Projects repository on GitHub; these links point at the commit this page was built from.
- LayoutESP32/Smart_Transformer_Health_Monitoring_System/hardware/Smart_Transformer_Health_Monitoring_System.kicad_pcb
- SchematicESP32/Smart_Transformer_Health_Monitoring_System/hardware/Smart_Transformer_Health_Monitoring_System.kicad_sch
- BOMESP32/Smart_Hybrid_IOT_energy_management_System/production/bom/Smart_Hybrid_IOT_energy_management_System_BOM.xlsx
Smart Transformer Health Monitoring System: common questions
What microcontroller does the Smart Transformer Health Monitoring System use?
The Smart Transformer Health Monitoring System is built around the LM2596S-12V, from the ESP32 family.
How big is the Smart Transformer Health Monitoring System PCB?
The Smart Transformer Health Monitoring System measures 108.8 × 83.6 mm, has 2 copper layers and is 1.6 mm thick.
How many components are on the Smart Transformer Health Monitoring System?
81 components, from 64 distinct parts, with part numbers taken from the project's own BOM. The full bill of materials is listed on this page.
Where can I download the Smart Transformer Health Monitoring System design files?
From the jsitech4/Projects repository on GitHub, which has the KiCad layout, the schematic and the BOM; the links under Design files point to each one.
Can I use the Smart Transformer Health Monitoring System design in my own project?
The repository has no license, so all rights stay with jsitech4. Use it as a reference, and ask the author before reusing the design.
Can I test firmware for the Smart Transformer Health Monitoring System without the hardware?
Yes. HardLabs builds a simulation of the board from its netlist and BOM, so you can run and debug ESP32 firmware against it before you order a PCB.
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