Design of Electronic Protection Modules, Voltage Monitoring, and Safe Reset for Industrial Electrical Equipment and Tools

International Journal of Electrical and Electronics Engineering

© 2025 by SSRG - IJEEE Journal

Volume 12 Issue 12

Year of Publication : 2025

Authors : Elmer Brany Ppacco Ppacco, Franklin Llamoca Sikos, Ricardo Raul Sulla Torres

10.14445/23488379/IJEEE-V12I12P110

How to Cite?

Elmer Brany Ppacco Ppacco, Franklin Llamoca Sikos, Ricardo Raul Sulla Torres, "Design of Electronic Protection Modules, Voltage Monitoring, and Safe Reset for Industrial Electrical Equipment and Tools," SSRG International Journal of Electrical and Electronics Engineering, vol. 12,  no. 12, pp. 130-139, 2025. Crossref, https://doi.org/10.14445/23488379/IJEEE-V12I12P110

Abstract:

This article presents the design and implementation of electronic modules for protection, voltage monitoring, and safe reset aimed at industrial applications that demand high reliability in terms of electrical safety. The developed system continuously monitors single-phase 220 VAC and three-phase (220 VAC, 380 VAC, and 440 VAC) voltage equipment and tools, integrating voltage measurement circuits and using an ATTiny 84 microcontroller for phase loss detection and protection processing, incorrect phase sequence in three-phase voltages, or abnormal power supply conditions with historical data in three-phase applications. It also enables safe reset reactivation, in addition to providing protection against incorrect rotation reversal in motors and faster short-circuit faults. The main objective is to prevent uncontrolled start-up when recovering a power supply lost due to external problems and to ensure that, after a power outage, power is restored only through a controlled and validated reset. The implementation of the proposed module reduces electrical incidents associated with unsafe resetting by up to 81.2%, thanks to the verification of phase failure or absence of power supply and manual validation prior to service restoration using safe resetting. In addition, the visual interface of LED indicators facilitates rapid identification of the operating status, reducing diagnostic times for problems external to the equipment. Experimental results and field tests demonstrate that the proposed solution constitutes a significant advance in the protection of industrial machinery, increasing workplace safety, the reliability of the electrical system, and the operational sustainability of power tools.

Keywords:

Safe Reclosing Module, Electrical Protection System, Industrial Safety Automation, Voltage and Phase Monitoring, ATTiny84 Microcontroller Design.

References:

[1] Mingda Zhai et al., “A Safety Evaluation method based on Gating Model and Generalized Zero-Shot Learning for Industrial Process,” Reliability Engineering & System Safety, vol. 265, 2026.
[CrossRef] [Google Scholar] [Publisher Link]
[2] Arslan Zahid et al., “Exploring the Role of Digital Twin and Industrial Metaverse Technologies in Enhancing Occupational Health and Safety in Manufacturing,” Applied Sciences, vol. 15, no. 15, pp. 1-51, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[3] Yuxuan Li et al., “A Safe and Fast Closed-Loop Start-Up Strategy for Triple-Active-Bridge Converters under DC Microgrip Application,” IEEE Transactions on Power Electronics, vol. 40, no. 9, pp. 12676-12689, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[4] Janine Hoelscher et al., “Safe Start Regions for Medical Steerable Needle Automation,” IEEE Transactions on Robotics, vol. 41, pp. 2424-2440, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[5] Dong Liu et al., “Model-Free Adaptive Optimal Control for Fast and Safe Start-Up of Pumped Storage Hydropower Units,” Journal of Energy Storage, vol. 87, pp. 1-29, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[6] Julio Garrido Campos et al., “Integrated Simulation and Control Environment for the Development and Safe Start-Up of Cable Driven Parallel Robots,” International Journal of Computer Integrated Manufacturing, vol. 38, no. 7, pp. 876-892, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[7] Rajesh Tanna et al., “Detecting Safe Operational Regimes of Synchronous Motor-Generator Pair for Wind Integration: A Non-Linear Perspective,” IET Energy Systems Integration, vol. 5, no. 4, pp. 430-443, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[8] Jiangming Jia et al., “Fault Diagnosis Analysis of Angle Grinder based on ACD-DE and SVM Hybrid Algorithm,” Mathematics, vol. 10, no. 8, pp. 1-16, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[9] Zhenyu Liu et al., “Selection of the Optimal Scheme for the Conceptual Design of a Polisher Considering Multi-Source Uncertainties,” Journal of Mechanical Science and Technology, vol. 38, no. 8, pp. 4261-4276, 2024.
[CrossRef] [Google Scholar] [Publisher Link]