A Cyber-Physical IoT Architecture for Secure Fuel Dispensing with DualFactor Authentication and Real-Time Volumetric Monitoring

Abstract

This project presents the design and implementation of an IoT-based Automatic Fuel Dispensing System aimed at enhancing security, transparency, and efficiency in fuel management. Traditional fuel stations often face challenges such as manual errors, fuel theft, and lack of real-time monitoring. To address these issues, the proposed system utilizes an ESP32 microcontroller integrated with RFID technology, an ultrasonic sensor, and a GSM module. The system operates through a multi-layer authentication process. Users must first present a valid RFID card; upon successful identification, the system prompts for a secondary 4-digit security PIN via a keypad interface. Once authenticated, the user enters the desired fuel amount. The system automatically calculates the balance, deducts the cost from the digital wallet, and activates a relay-driven pump for a precise duration to dispense the fuel. Simultaneously, an ultrasonic sensor provides continuous monitoring of the fuel storage tank level. If the fuel falls below a critical threshold, the system triggers a local buzzer and sends immediate SMS alerts via the GSM module to the administrator. All transaction data including user ID, timestamps, and tank levels are uploaded to a cloud server via Wi-Fi, allowing for remote data logging and realtime inventory tracking through a web interface. By replacing manual intervention with automated precision and IoT connectivity, this system ensures a secure, tamper-proof, and user-friendly solution for modern fuel stations and private industrial fuel reserves