Description:Field of the Invention:

The present invention relates to an automated conveyor health monitoring system for high-temperature industrial environments, particularly in sinter plant at Durgapur Steel Plant. More specifically, the invention utilizes a thermal imaging camera (MLX90640), an edge computing device (Jetson Nano), a media converter, and a relay-controlled sprinkler system to monitor and regulate conveyor belt temperatures in real time. The system detects overheating conditions, processes thermal data, and activates cooling mechanisms to prevent fire hazards and equipment damage. It further enables predictive maintenance and remote monitoring, enhancing operational efficiency and safety in industrial material handling applications.

Description of the Related Art:

In industrial environments such as sinter plants, conveyor belts are used to transport high-temperature materials, often operating under extreme conditions with exposure to high heat, dust, and mechanical stress. Over time, these factors contribute to potential overheating, wear and tear, fire hazards, and operational failures, which can result in unplanned downtime, safety risks, and financial losses.
Traditional conveyor health monitoring systems rely on manual inspections or thermocouple-based temperature sensing, which have several limitations, including:
1. Delayed Detection: Manual inspections are periodic and may fail to detect sudden temperature spikes.
2. Limited Coverage: Thermocouples provide point-based temperature measurements, which do not offer a comprehensive view of the conveyor belt’s thermal distribution.
3. Lack of Real-time Action: Most traditional systems lack an automated response mechanism, leading to potential delays in mitigating overheating risks.
Recent advancements in thermal imaging, artificial intelligence, and IoT-based industrial monitoring have enabled real-time condition monitoring and predictive maintenance. Thermal cameras like the MLX90640 provide a wide-area temperature profile of conveyor belts, allowing for continuous, non-contact temperature measurement. Edge computing devices such as Jetson Nano can process this data locally, minimizing latency and ensuring rapid decision-making. Fiber-optic media converters allow seamless data transmission to remote control centres, ensuring centralized monitoring.
Despite these advancements, existing conveyor health monitoring solutions often lack an integrated automated response system that can take immediate action in case of overheating. The present invention addresses this gap by incorporating a relay-controlled sprinkler system, which is triggered automatically when the temperature surpasses a critical threshold, effectively preventing fires and equipment damage. Additionally, the system enables real-time alerts, remote monitoring, and predictive maintenance capabilities, making it a comprehensive solution for conveyor health management in high-temperature industrial settings.

Summary

The main objectives of our invention are as follows:
1. Real-time Temperature Monitoring
o Utilize the MLX90640 thermal camera to continuously monitor the temperature of the conveyor belt in a sinter plant.
o Provide a thermal map to detect potential overheating zones.
2. Automated Overheat Detection and Response
o Process thermal data using Jetson Nano to identify temperature anomalies.
o Automatically trigger a relay-controlled sprinkler system when the temperature exceeds a critical threshold.
3. Prevent Fire Hazards and Equipment Damage
o Reduce the risk of conveyor fires due to material ignition or belt overheating.
o Ensure longer operational life of conveyor components by preventing excessive heat exposure.
4. Seamless Data Communication and Remote Monitoring
o Use a media converter for real-time data transmission over fiber-optic or Ethernet networks.
o Enable remote monitoring via MQTT, HTTP, or MODBUS protocols for industrial integration.
5. Predictive Maintenance and Data Logging
o Store historical temperature data to predict potential failure points.
o Provide early maintenance alerts, reducing unplanned downtime and repair costs.
6. Scalability and Industrial Adaptability
o Design the system to be modular and scalable for different conveyor belt lengths and industrial settings.
o Ensure compatibility with existing plant automation systems and industrial IoT frameworks.
7. Energy-efficient and Cost-effective Operation
o Optimize power consumption by using edge computing for real-time decision-making.
o Provide a cost-effective alternative to manual inspections and expensive infrared monitoring systems.
8. Environmental Protection and Safety Compliance
o Reduce excessive water usage by activating sprinklers only when required.
9 Ensure compliance with industrial safety regulations and fire prevention standards.
This invention improves safety, enhances operational efficiency, and minimizes downtime, making it an essential solution for high-temperature industrial conveyor systems.
, C , Claims:Claim 1 A real-time conveyor health monitoring system, comprising:
• A thermal imaging sensor (MLX90640) configured to capture thermal profiles of a conveyor belt in a high-temperature industrial environment.
• An edge computing device (Jetson Nano or equivalent) configured to process the thermal image data and identify zones of overheating.
• A slave microcontroller (Arduino Uno) communicatively connected to the edge device and configured to control external actuators.
• A relay-controlled sprinkler system configured to cool the conveyor surface when activated by the microcontroller.
• A 5V cooling fan positioned near the edge computing device, configured to remove accumulated dust and reduce thermal stress.
• A media converter for transmitting monitoring data from the edge device to a remote monitoring system.
Claim 2 The system of Claim 1, wherein the thermal imaging sensor is a non-contact IR thermal sensor array capable of operating in dusty and high-ambient-temperature conditions.
Claim 3 The system of Claim 1, wherein the edge computing device processes thermal data using predefined threshold algorithms and sends appropriate control signals to the microcontroller via UART or I2C communication.
Claim 4 The system of Claim 1, wherein the Arduino Uno receives commands from the edge device and performs relay activation for sprinkler control and fan operation.
Claim 5 The system of Claim 1, wherein the cooling fan serves a dual purpose:
• (a) to cool the Jetson Nano or its enclosure; and
• (b) to prevent dust accumulation on the device.
Claim 6 The system of Claim 1, further comprising:
• A watchdog timer or fallback logic in the Arduino Uno that activates the relay automatically in case of Jetson Nano communication failure.
Claim 7 The system of Claim 1, further configured with exception handling mechanisms, wherein:
• If the thermal camera fails to respond or sends invalid data, the system retries a set number of times, logs the error, and notifies the remote-control station.
• If communication with the Arduino Uno fails, the fan is turned on by default as a failsafe.
• If network transmission fails, thermal data is logged locally and retransmitted upon reconnection.
• If an overheating condition persists, the sprinkler system remains active until manual reset or temperature stabilization is confirmed.
Claim 8 The system of Claim 1, wherein the media converter converts Ethernet signals to optical fibre signals for robust, interference-free communication to a centralized remote monitoring dashboard.
Claim 9 The system of Claim 1, wherein the system is integrated with predictive maintenance and logging features to assist in operational efficiency and downtime reduction.
Claim 10 The system of Claim 1, wherein the solution is modular, scalable, and compatible with existing automation and PLC-based plant control systems.