In today’s world of automation and smart technology, IoT-based Bluetooth pump control systems are becoming increasingly popular for home, agricultural, and industrial applications. Manual switching of pumps can be inconvenient, time-consuming, and sometimes even unsafe when dealing with high-voltage equipment. To address these challenges, we developed a smart water pump controller using ESP32 and a Bluetooth mobile app.

This project is a complete Product Design and Development journey, covering the selection of electronic components, Arduino Programming Language for coding the ESP32, and 3D Design and Modeling for creating a compact, user-friendly enclosure. By combining IoT technology with an efficient hardware design, we built a system that allows users to turn their 220V AC or 12V DC water pump ON or OFF remotely with just a tap on their smartphone.

The system is powered by a 3.7V 18650 lithium-ion cell with an integrated charging module, making it portable and convenient. A physical push button is included as a master control to switch the ESP32 system ON or OFF, ensuring additional safety. The 3D-printed casing ensures durability, portability, and neat placement of all components, with custom holes for the power supply and control button.

This project not only demonstrates how IoT can simplify everyday tasks but also shows how electronic hardware, firmware, and industrial design come together in a real-world product. Whether used for home automation, agricultural irrigation, or industrial pump systems, this solution is a practical example of how modern IoT devices can improve efficiency and convenience.

Product Design and Development Process for Bluetooth Pump Control System:

Conceptualization

• Identify the need for a remote-controlled water pump system.
• Define power requirements, safety measures, and IoT features.

Electronics Development

• Selection of ESP32 for IoT capabilities.
• Designing the battery-powered system with safe charging.
• Integration of relay module for controlling the pump.

Software Development

• Writing firmware in Arduino Programming Language.
• Implementing Bluetooth communication protocols.
• Testing system response with the relay and pump.

3D Design and Modeling

• Creating an enclosure that fits the ESP32, relay module, battery, and button.
• Ensuring ventilation and cable routing for safety.
• Adding holes for USB charging, 5V supply, and the power button.

Prototyping and Testing

• Assembling the full system in the custom 3D-printed case.
• Testing Bluetooth connectivity and pump switching reliability.
• Checking battery backup performance and safety.

Advantages of the System

• IoT-based Smart Control: Remote switching using a Bluetooth app.
• Portable Design: Battery-powered with recharging capability.
• Safety: Relay isolation prevents high-voltage risks to the ESP32.
• Custom Product Design: Professional 3D-printed casing for durability.
• Scalability: Can be expanded to Wi-Fi IoT systems for remote monitoring.

Components used in IoT Bluetooth Pump Control System:

ESP32 Development Board

• Acts as the brain of the project.
• Provides Wi-Fi and Bluetooth functionalities.
• Handles input signals and controls the relay for water pump operation.

2-Channel Relay Module

• Used to switch the 220V AC or DC Pump water pump.
• Provides electrical isolation between ESP32 (low voltage) and the pump (high voltage).

3.7V 18650 Lithium-ion Battery

• Powers the ESP32 board for portable use.
• Ensures stable operation even during temporary power fluctuations.

Battery Charging Module (TP4056 or similar chip)

• Recharges the 18650 cell through a 5V supply.
• Includes overcharge and discharge protection for battery safety.

12V DC Water Pump

• The load device being controlled through the relay.
• Can be switched ON/OFF wirelessly via the Bluetooth mobile app.

Push Button

• Works as a master switch to turn the ESP32 system ON/OFF.
• Increases user control and system safety.

3D-Printed Enclosure

• Designed using SolidWorks.
• Provides compact housing for all components.
• Includes holes for 5V input and button placement for convenient usage.

Circuit Diagram of Bluetooth Pump Control System with ESP32:

• The ESP32 connects to the relay module through digital pins.
• The relay controls the live wire of the AC 220V water pump, ensuring isolation.
• The 3.7V battery powers the ESP32, while the charging chip ensures safe recharging via a 5V adapter.
• The push button is connected in series with the battery output to the ESP32, allowing complete power cut-off when the system is turned off.

Programming the ESP32

The ESP32 was programmed using the Arduino Programming Language within the Arduino IDE.

• The code initializes Bluetooth connectivity, allowing the ESP32 to communicate with a smartphone app.
• Commands sent from the app (ON/OFF) are received by the ESP32 and translated into relay control signals.
• Relay states are toggled based on user input, thus controlling the DC or AC water pump.
• Optional safety checks can be added in the code to prevent rapid switching.

This approach demonstrates how IoT systems can be implemented in real-world applications using microcontrollers and wireless connectivity.

Code for Bluetooth Pump Control System with ESP32:

#include "BluetoothSerial.h"

// Check if Bluetooth is enabled in your ESP32 settings
#if !defined(CONFIG_BT_ENABLED) || !defined(CONFIG_BLUEDROID_ENABLED)
#error Bluetooth is not enabled! Please run `make menuconfig` to enable it
#endif

BluetoothSerial SerialBT;

#define LED_BUILTIN 32   // Built-in LED (GPIO2 on ESP32)
// You can also use another pin, e.g., #define LED_PIN 5

void setup() {
  Serial.begin(115200);
  SerialBT.begin("ESP32_LED");  // Bluetooth device name
  pinMode(LED_BUILTIN, OUTPUT);
  digitalWrite(LED_BUILTIN, LOW); // LED OFF initially
  Serial.println("Bluetooth Device Started. Connect and send '1' or '0'");
}

void loop() {
  if (SerialBT.available()) {
    char receivedChar = SerialBT.read();

    if (receivedChar == '1') {
      digitalWrite(LED_BUILTIN, HIGH);   // Turn LED ON
      Serial.println("LED ON");
      SerialBT.println("LED is ON");
    }
    else if (receivedChar == '0') {
      digitalWrite(LED_BUILTIN, LOW);    // Turn LED OFF
      Serial.println("LED OFF");
      SerialBT.println("LED is OFF");
    }
    else if (receivedChar == 'B' || receivedChar == 'b') {
      // Blink LED 5 times
      for (int i = 0; i < 5; i++) {
        digitalWrite(LED_BUILTIN, HIGH);
        delay(500);
        digitalWrite(LED_BUILTIN, LOW);
        delay(500);
      }
      Serial.println("LED Blinked 5 times");
      SerialBT.println("LED Blinked 5 times");
    }
  }
}

IoT Integration with Bluetooth

• The Bluetooth App acts as a user interface for controlling the pump.
• The app connects directly to the ESP32’s Bluetooth module, ensuring simple pairing without internet dependency.
• Future expansion can include Wi-Fi connectivity to allow cloud-based remote control, scheduling, or integration with IoT platforms.

Project Video of Bluetooth Pump Control System with ESP32:

Applications Bluetooth Pump Control System:

• Smart home automation (controlling household water pumps).
• Agricultural irrigation systems.
• Industrial water circulation control.
• Remote motor/pump operation in areas with limited manual access.

Conclusion

The IoT Water Pump Control using ESP32 and Bluetooth App project is a perfect example of integrating Product Design and Development, Arduino Programming Language, 3D Design and Modeling, and IoT concepts into one system. By combining hardware, software, and design, we created a compact, efficient, and reliable water pump controller that can be used in homes, industries, and agriculture.