INDUSTRIAL BASED CONVEYOR BELT MONITORING AND FAULT DETECTION SYSTEM

The proposed BeltGuard system uses an ESP32 microcontroller to monitor conveyor belt conditions. It combines an ESP32-CAM module, an ACS712 current sensor, and a DS18B20 temperature sensor to identify visible belt cracks, abnormal motor current, and overheating conditions. The system provides local warnings through a buzzer and traffic-light indicators and displays sensor readings, camera results, and fault alerts on a web dashboard. Email notifications help operators respond quickly to detected problems. A suitable motor-control circuit can stop the conveyor during critical faults. The dashboard provides an affordable monitoring solution without requiring a separate display. Future improvements may include historical data storage, mobile notifications, improved image processing, and predictive maintenance. Further testing is required to evaluate detection accuracy, response time, and system reliability. The BeltGuard system can support industrial safety and maintenance when used alongside appropriate safety measures. This low-cost approach combines embedded processing, wireless communication, and web-based monitoring. Future improvements may include data storage, mobile notifications, better image processing, and predictive maintenance. Further testing is required to evaluate detection accuracy, response time, and communication reliability. The BeltGuard system can improve conveyor monitoring and support industrial safety when used alongside appropriate safety measures.

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