Abstract: Electric motors play a crucial role in industrial applications, but their efficiency is often limited to 75%–85% due to excessive heat generation. Overheating leads to increased energy losses, reduced lifespan, and higher maintenance costs. To address this issue, this study proposes an innovative Phase Change Material (PCM)-based Thermal Energy Storage (TES) system combined with IoT-based real-time temperature monitoring to enhance motor cooling performance and efficiency. The system incorporates paraffin wax (PCM) within a specially designed Al6061 aluminum casing that encloses the motor. The casing is fabricated using sheet rolling, laser cutting, and welding to create a hollow chamber for PCM storage. Paraffin wax, with its high latent heat capacity, absorbs excess heat and regulates temperature fluctuations effectively. Additionally, an Arduino Uno-based IoT system is integrated, featuring a temperature sensor and a GSM module for real-time temperature tracking and remote alerts. A 75W, 900 RPM AC motor is tested under two conditions: without PCM (conventional cooling) and with PCM (TES-based cooling + IoT monitoring). Performance is evaluated based on temperature variations, motor efficiency, and thermal stability, with data transmitted via GSM for analysis. The expected results indicate that the PCM-based system significantly reduces motor temperature, thereby enhancing efficiency, reducing energy losses, and extending motor lifespan. The IoT integration enables remote monitoring and predictive maintenance, making this approach a cost-effective, scalable solution for industrial motor cooling applications.

Keywords: Phase Change Material, Thermal Energy Storage, Paraffin Wax, Motor Cooling, IoT Monitoring, Efficiency Enhancement

| DOI: 10.17148/IARJSET.2025.12332