Abstract
Electric vehicles (EVs) require intelligent monitoring systems to ensure safe operation and prevent unexpected failures. This project presents an Automatic Fault Detection and Clearing System in Electric Vehicles using an ESP32 microcontroller, current sensor, voltage sensor, DHT11 temperature sensor, relay, fan, buzzer, LCD display, and a DC motor used as the load. The system continuously monitors important parameters such as current, voltage, and temperature to detect abnormal operating conditions.
Sensor data collected from the current sensor, voltage sensor, and temperature sensor is processed by the ESP32 and also used as input for a Machine Learning (ML) model. The ML model analyzes real-time data patterns and predicts possible faults in advance, such as overcurrent, overheating, or abnormal voltage conditions. By learning from previous data, the model can classify the system condition as normal or faulty and provide early fault prediction.
The LCD display is used to show real-time system information such as current, voltage, temperature values, and system status (normal or fault). This helps the user easily monitor the operating condition of the EV system.
When the ML system predicts or detects a fault condition, the ESP32 automatically performs protective actions. If high current is detected, the system stops the DC motor by turning OFF the relay to prevent damage. If the temperature exceeds the safe limit, the cooling fan is activated to reduce heat, and a buzzer alert is triggered to notify the user about the fault condition.
This intelligent system improves the safety, reliability, and efficiency of electric vehicles by combining real-time monitoring, LCD-based status display, and machine learning–based fault prediction. The proposed system provides a low-cost, smart, and automated solution for detecting and clearing faults in EV systems.
Introduction
Electric vehicles (EVs) are becoming popular because they reduce pollution and improve energy efficiency compared to conventional fuel vehicles. EV systems include important electrical components such as motors, batteries, controllers, and sensors, which must operate safely and efficiently. However, during operation, faults such as high current, voltage fluctuations, and overheating may occur. These faults can damage the motor and other electrical components if they are not detected early.
To improve safety and reliability, it is necessary to continuously monitor the system parameters and detect faults at an early stage. In this project, an Automatic Fault Detection and Clearing System is developed using an ESP32 microcontroller. The system uses a current sensor, voltage sensor, and DHT11 temperature sensor to monitor the operating conditions of the EV system in real time. The sensor data is processed by the ESP32 to identify abnormal conditions.
A DC motor is used as the load to simulate the EV motor. If the system detects high current, the relay automatically stops the motor to prevent damage. If the temperature increases above the safe limit, a cooling fan is activated to reduce heat. A buzzer is used to alert the user when a fault occurs. In addition, an LCD display is used to show real-time information such as current, voltage, temperature, and system status, making it easy for the user to monitor the system.
The system also uses Machine Learning (ML) to analyze sensor data and predict possible faults. This helps in improving system safety and preventing major failures. The proposed system provides a low-cost, smart, and reliable solution for fault detection and protection in electric vehicles.


Objectives
1. To monitor current, voltage, and temperature in the EV system using sensors.
2. To develop an automatic fault detection system using the ESP32 microcontroller.
3. To display real-time sensor values such as current, voltage, and temperature on the LCD display.
4. To detect abnormal conditions like high current, abnormal voltage, and high temperature.
5. To use Machine Learning (ML) to predict possible faults from sensor data.
6. To stop the DC motor automatically using a relay when high current is detected.
7. To activate the cooling fan when the temperature exceeds the safe limit.
8. To provide a buzzer alert to notify the user when a fault occurs.
9. To improve the safety, reliability, and protection of EV systems.