What it does
This project focuses on designing a low-cost, self-monitoring fault detection system for automotive air-conditioning (A/C) systems to reduce fuel consumption. The system monitors key A/C components and transmits real-time data to users via an IoT platform.
Your inspiration
The inspiration for this project came from the significant impact vehicle air-conditioning systems have on fuel consumption, especially in tropical regions like Malaysia where A/C usage is constant. Despite technological advancements in A/C controls, many vehicles still suffer from undetected faults that degrade performance and increase fuel use. Recognizing the lack of accessible, affordable diagnostic tools for everyday drivers, this project set out to develop a simple, real-time monitoring system that empowers users to maintain their A/C systems, ultimately saving fuel, reducing emissions, and promoting sustainable vehicle use.
How it works
The proposed system is a low-cost solution that monitors a vehicle’s air-conditioning (A/C) system in real-time to detect faults that may increase fuel consumption. Focusing on refrigerant pressure and the condenser fan, the system uses pressure transducers and Hall effect current sensors to detect issues such as leaks, blockages, or fan malfunctions. Sensor data is processed by an ESP32 microcontroller, supported by an Arduino Uno, and transmitted via Wi-Fi to the Blynk IoT platform. The mobile app displays real-time data and sends alerts when values exceed safe thresholds, allowing users to address problems promptly. Prototyping was done on a Perodua Kancil for hardware integration, while fuel consumption tests were carried out on a Honda Jazz i-VTEC using an OBD-II scanner. Results showed that detecting A/C faults early can lead to noticeable fuel savings. Overall, the system offers an accessible way to improve vehicle efficiency.
Design process
The design process began by identifying the high fuel consumption caused by vehicle A/C systems, especially in hot climates like Malaysia, and how this worsens when components malfunction. A detailed literature review was conducted to explore A/C system faults, sensor options, microcontrollers, and IoT platforms. Based on this, pressure transducers and Hall effect current sensors were chosen to monitor refrigerant pressure and fan operation. To validate the concept, fuel data was collected from a Honda Jazz i-VTEC under both normal and faulty A/C conditions using an OBD-II scanner, confirming that faults increase fuel use. The system was built using an ESP32 microcontroller for Wi-Fi communication and an Arduino Uno for sensor handling. All components were integrated with attention to voltage compatibility and safety. Custom code was developed to detect faults and send alerts via the Blynk IoT app. A prototype was installed in a Perodua Kancil due to its accessible engine layout. After testing, the system was refined for accuracy and stability, and the project concluded with full technical documentation and performance analysis.
How it is different
Unlike most commercial diagnostic tools that focus on engine or emission faults, this system targets air-conditioning (A/C) issues, an often-overlooked factor in fuel consumption. Traditional OBD-II scanners don’t monitor refrigerant pressure or A/C component performance in real time, and built-in fault detection is typically limited to high-end vehicles. What makes this system unique is its low cost, ease of use, and real-time monitoring using pressure and current sensors connected to an ESP32 microcontroller. Data is sent to a mobile app (Blynk), which alerts users immediately when faults are detected. Designed for retrofitting into older or budget vehicles like the Perodua Kancil, the system makes advanced monitoring accessible to everyday drivers. While other research approaches that rely on expensive hardware or complex control algorithms, this solution is practical, scalable, and well-suited for broader adoption, especially in developing regions.
Future plans
In the future, the system can be expanded to monitor additional A/C components such as the compressor and evaporator. Integration with more advanced data logging and cloud storage would allow for long-term performance tracking. Next, as different car models have different designs, maybe further research and efforts can be made to come up with a universal system that works with most vehicle models.
Share this page on