Design and Implementation of an IoT-Based Conveyor Safety System Using ESP32
Keywords:
Conveyor safety, ESP32, Fault detection, INA219, IoT, IR sensor, Overload protection, ThingSpeakAbstract
The increasing use of conveyor systems in industrial applications has significantly improved material handling efficiency; however, it also introduces safety challenges such as belt overload, object blockage, and unexpected system failures. This paper presents the design and implementation of an IoT-based conveyor safety system using the ESP32 microcontroller for real-time fault detection and monitoring. The proposed system utilizes an INA219 current sensor to monitor motor parameters such as current, voltage, and power, along with an IR sensor for object detection. A threshold-based approach is used to detect abnormal conditions such as overload and blockage. Upon fault detection, the system automatically stops the conveyor motor using a relay, activates an audible alarm, and displays the fault status on a 16×2 LCD. Additionally, real-time system data is transmitted to the ThingSpeak cloud platform for remote monitoring and analysis. The developed system provides a low-cost, reliable, and efficient solution to enhance safety in conveyor operations. Experimental results demonstrate that the system responds quickly to fault conditions and effectively prevents potential damage and hazards, making it suitable for small and medium-scale industrial applications.
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