⚙️ CONVEY X

Intelligent Conveyor Belt Joint Rupture & Damage Monitoring System

Production-grade IoT + AI safety platform for iron ore mining operations.
Real-time multi-sensor fusion · Predictive risk scoring · Hardware-honest SCADA UI

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🎯 Problem Statement

Enterprise Industrial Safety Challenge

"Intelligent Monitoring and Prediction of Conveyor Belt Joint Rupture and Damages in Iron Ore Mining Industry"

Conveyor belt failures in iron ore beneficiation plants cause millions in downtime. CONVEY X provides continuous sensor-based monitoring with predictive risk scoring to prevent joint ruptures, misalignment, and mechanical failures before they occur.

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🏗️ System Architecture

┌─────────────────────────────────────────────────────────┐
│                  CONVEY X Platform                      │
├──────────────────┬──────────────────────────────────────┤
│   Hardware Layer │   Software Platform                  │
│                  │                                      │
│  MPU6050 ────────┤──► ESP32 SmartPod ──► Wi-Fi / MQTT    │
│  ACS712  ────────┤          │                           │
│  IR Left ────────┤          ▼                           │
│  IR Right ───────┤     Raspberry Pi 3B+ ──► POST /api/device-data
│  Relay ──────────┤     Edge AI Node         │           │
│  5V Motor ───────┤                 Node.js Backend      │
│                  │                 WebSocket Server     │
│                  │                      │               │
│                  │               React Frontend         │
│                  │               SCADA Dashboard        │
└─────────────────────────────────────────────────────────┘

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🔧 Hardware Components

Component	Role	Interface
Raspberry Pi 3B+	Edge AI gateway + OpenCV camera inference	MQTT / HTTP (Local Server)
ESP32 Microcontroller	Telemetry collector & local safety cutoff	Wi-Fi / I2C / Analog
MPU6050	3-axis accelerometer — vibration RMS	I2C (0x68)
ACS712 (20A)	DC/AC motor current — jam/stall detection	Analog A0
IR Sensor (Left)	Belt left-edge drift detection	Digital D2
IR Sensor (Right)	Belt right-edge drift detection	Digital D3
Relay Module	Normally-closed safety interlock	Digital D4
5V DC Motor	Drive pulley + belt prototype	PWM

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🧠 Risk Engine

Multi-sensor fusion scoring model (0–100 risk score):

Contributor	Max Points	Trigger Condition
Vibration (MPU6050)	35 pts	RMS > 2.8g = WARNING; > 4.0g = CRITICAL
Motor Current (ACS712)	35 pts	> 150% baseline = OVERLOAD; > 200% = STALL
Belt Alignment (IR)	25 pts	Left or Right sensor triggered
Vision (Camera AI)	20 pts	Future module — crack/splice detection

Risk Levels: NORMAL → WARNING → HIGH_RISK → CRITICAL

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🖥️ Platform Features

• Real-time SVG Digital Twin — Live conveyor visualizer with sensor node overlays
• Hardware-honest Status — Shows DISCONNECTED until real data arrives; no fake data
• 6-Scenario Test Bench — Simulate Normal / Misalignment / High Vibration / Motor Overload / Stall / Joint Rupture
• Predictive Maintenance — Risk score, failure probability, recommended action
• Alert Engine — Severity-classified alerts with acknowledge/resolve
• Maintenance Scheduler — Track upcoming service intervals
• Event Log — Full timestamped sensor event history
• Live Charts — Real-time telemetry sparklines (Recharts)
• Device Registry — All hardware nodes with connectivity status

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📡 Hardware Integration (ESP32 Firmware)

Send JSON packets to the backend every 500ms:

POST http://<server-ip>:4000/api/device-data
Content-Type: application/json

{
  "deviceId": "ESP32-001",
  "timestamp": 1725123456789,
  "vibration": { "x": 0.12, "y": 0.08, "z": 9.81 },
  "motor": { "current": 1.45, "rpm": 1420 },
  "alignment": { "leftSensor": false, "rightSensor": false },
  "relay": { "tripped": false }
}

The backend automatically transitions from DISCONNECTED → LIVE_HARDWARE on first packet.

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🚀 Quick Start

Prerequisites

• Node.js 18+
• npm 9+

1. Install Dependencies

# Backend
cd backend && npm install

# Frontend
cd frontend && npm install

2. Start Backend

cd backend
npm run dev          # Development (ts-node)
# OR
npm run build && npm start   # Production

Backend runs on port 4000

3. Start Frontend

cd frontend
npm run dev          # Vite dev server

Frontend runs on port 3000 (or 5173)

4. Login Credentials

Role	Username	Password
Supervisor	admin	conveyX@2026
Engineer	engineer	engineer123
Viewer	viewer	viewer123

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📁 Project Structure

conveyX/
├── backend/                    # Node.js + Express + TypeScript
│   └── src/
│       ├── index.ts            # Server entrypoint
│       ├── config.ts           # Environment config
│       ├── models/db.ts        # In-memory state store
│       ├── routes/api.routes.ts
│       └── services/
│           ├── websocket.service.ts    # Socket.IO + hardware watchdog
│           ├── riskEngine.service.ts   # Multi-sensor fusion scoring
│           ├── alertEngine.service.ts  # Alert lifecycle management
│           └── demoSimulator.service.ts # 6-scenario test bench
│
├── frontend/                   # React 18 + Vite + Tailwind
│   └── src/
│       ├── context/
│       │   ├── TelemetryContext.tsx    # WebSocket client + state
│       │   └── AuthContext.tsx
│       ├── pages/              # 15+ route pages
│       ├── components/
│       │   ├── digital-twin/   # ConveyorGraphic SVG, ControlPanel
│       │   ├── charts/         # RiskScoreGauge, TelemetryLineChart
│       │   ├── common/         # KPIBox, StatusBadge, PipelineVisualizer
│       │   └── layout/         # Header, Sidebar, Layout
│       └── index.css           # SCADA design system tokens
│
└── shared/types.ts             # Shared TypeScript interfaces

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🔌 API Reference

Endpoint	Method	Description
/api/device-data	POST	Receive hardware packet from ESP32
/api/hardware/status	GET	Hardware connectivity + device list
/api/hardware/simulate	POST	Activate simulation mode
/api/hardware/deactivate	POST	Stop simulation
/api/alerts	GET	All alerts
/api/alerts/:id/acknowledge	POST	Acknowledge alert
/api/conveyor/command	POST	Motor start/stop/emergency
/api/history	GET	Telemetry history (last 200 pts)
/api/maintenance	GET/POST	Maintenance schedule
/api/events	GET	Event log

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🏅 Built For

Smart India Hackathon 2026
Ministry / Organization: Ministry of Mines
Problem Category: Hardware
Team: CONVEY X

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📄 License

MIT © 2026 CONVEY X Team