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Introduction
Challenges in Chennai’s Mining Operations
Why IoT Is a Game Changer for the Mining Sector
Tech4LYF’s Vision for Mining Automation
Project Overview: Scraper Blade Angle Monitoring System
Hardware Architecture Used
Firmware and Sensor Calibration
Cloud Integration and Real-Time Dashboard
Alerts, Thresholds, and Safety Logic
Results Achieved in the Mining Field
Benefits of Using IoT for Mining Equipment
ROI and Cost Reduction for Chennai Mines
Feedback from Field Engineers
Future Scope: Predictive Maintenance & AI Integration
Final Thoughts on IoT for Mining in India
IoT for mining has emerged as a powerful solution for operational safety, performance tracking, and predictive maintenance. Chennai-based Tech4LYF has pioneered a real-time scraper blade monitoring system that’s currently deployed in active mines across Tamil Nadu. This is more than a case study—it’s a blueprint for industrial transformation.
Before IoT implementation, mining firms faced:
Inaccurate blade position monitoring
Frequent breakdowns due to misalignment
No real-time alerts or condition-based insights
Safety risks due to blade tilt or failure
Manual logging prone to error and delays
These challenges resulted in downtime, higher costs, and safety violations.
With Internet of Things, mining firms can:
Monitor equipment conditions in real-time
Send automatic alerts on angle deviation
Reduce dependency on manual inspection
Collect operational data for predictive maintenance
Improve worker safety and productivity
IoT shifts mining from reactive to proactive management.
Tech4LYF envisioned a plug-and-play solution to monitor scraper blade angles using:
Wireless sensor nodes
Real-time dashboards
Custom alerts
Field-validated hardware enclosure
End-to-end control from device to cloud
Objective:
Monitor and visualize scraper blade angles in real-time to reduce wear and downtime.
Key Features:
Tilt angle detection using IMU sensors
MQTT-based data transmission
Web dashboard with threshold alerts
Offline buffering support
Waterproof and vibration-resistant hardware casing
| Component | Description |
|---|---|
| ESP32 | Wi-Fi + BLE microcontroller for edge computing |
| MPU6050 | 6-axis motion sensor for tilt and acceleration |
| SIM800L | GSM module for remote data upload (fallback) |
| Li-ion Battery | 3.7V with charging protection |
| Custom PCB | Designed in-house for rugged conditions |
| IP67 Enclosure | Dustproof and waterproof for mining environment |
Kalman Filter used for angle smoothing
Auto-calibration on startup with Z-axis alignment
Real-time sampling: 5/sec
OTA update support via HTTP
Built-in watchdog for crash recovery
| Feature | Details |
|---|---|
| Protocol | MQTT over TLS |
| Backend | Node.js + MongoDB |
| Frontend | React.js + Chart.js |
| Data History | Up to 6 months per device |
| User Roles | Admin, Field Engineer, Supervisor |
| Dashboard | Mobile + Desktop views with export to Excel |
Yellow Alert: Blade tilt exceeds 15°
Red Alert: Blade tilt exceeds 30°
Real-time SMS/email to supervisors
Daily report via WhatsApp PDF
Thresholds configurable per machine type
20% reduction in blade wear
80% drop in unplanned shutdowns
Field team saved 25 hours/month in manual checks
Safety incident probability decreased by 40%
✅ Remote visibility
✅ Predictive maintenance
✅ Data-driven decisions
✅ Reduced energy and material waste
✅ Better insurance compliance
✅ Transparent audits and documentation
Initial cost: ₹18,000 per unit (volume-based pricing)
Payback period: < 2.5 months
Estimated annual savings: ₹3.6 Lakhs per site
Additional bonus: Increased equipment lifespan by 18%
“We used to inspect manually twice a day. Now, I just open the app and get everything instantly.”
“Zero failures in 90 days.
Next upgrades include:
Vibration analytics with ML models
Blade stress estimation based on movement patterns
AI-generated maintenance predictions
Auto-ticketing when thresholds breach
Tech4LYF is setting new standards in IoT for mining with reliable, affordable, and scalable hardware + software systems. As more Indian mines explore digitization, Chennai is leading the way with homegrown innovation that fits real field conditions.
