e-ISSN: 2582-5208

International Research Journal of Modernization in Engineering Technology and Science

( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com

APPROACH TO DESIGN IOT BASED SMART HELMET FOR COAL MINERS

Ayush Kadukar*1, Mansi Lad*2, Harsh Adyalkar*3, Yamini Pardhi*4, Jayant Hande*5
*1,2,3,4Research Students, Electronics Of Telecommunication, P. J. L. C. E. Nagpur, India.
*5Assitant Professor, Electronics Of Telecommunication, P. J. L. C. E. Nagpur, India.
DOI : https://www.doi.org/10.56726/IRJMETS52730
ABSTRACT
Coal mining operations present numerous challenges related to safety and efficiency, particularly in hazardous
underground environments. In response, this research proposes the development and implementation of an
IoT-based smart helmet designed specifically for coal miners. The smart helmet integrates various sensors to
monitor environmental conditions such as gas levels, temperature, humidity, air quality, and presence of toxic
substances like methane and carbon monoxide. Real-time data collected by these sensors is transmitted
wirelessly to a central control system, enabling continuous monitoring by supervisors and timely response to
potential hazards. The proposed smart helmet integrates various sensors, communication modules, and data
processing techniques to monitor environmental conditions, detect hazardous gases, track miner location, and
provide real time communication capabilities. By leveraging Internet of Things (IoT) technologies, this smart
helmet aims to enhance safety measures, improve emergency response times, and optimize productivity in
underground coal mining environments. The paper discusses the system architecture, sensor integration,
communication protocols, data processing algorithms, and the overall impact of the IoT based smart helmet on
coal mining operations. Additionally, the paper explores potential challenges, future research directions, and the
scalability of the proposed solution in other industrial sectors.
Keywords: IOT, Smart Helmet, Coal Mining, Safety, Sensors, Communication, Environmental Monitoring, Data
Processing.
I. INTRODUCTION
IoT-based smart helmet include alert systems utilizing visual indicators, audible alarms, and vibration alerts to
notify miners about dangerous conditions or when they are nearing restricted areas. Communication modules
such as Wi-Fi, Bluetooth, or radio frequency enable seamless communication among miners and with surface
personnel, facilitating coordination and swift response during emergencies. Additionally, GPS tracking
functionality allows supervisors to monitor the location of miners within the mine, enhancing overall safety and
enabling prompt assistance in case of accidents or emergencies. Furthermore, this research explores the
application of data analytics and predictive maintenance algorithms to analyze collected data, identify patterns,
predict potential hazards, and optimize maintenance schedules for mining equipment. The design of the smart
helmet emphasizes comfort, durability, and usability in the harsh mining environment, with a focus on
regulatory compliance and cost-effectiveness. Field trials involving actual miners are conducted to evaluate the
effectiveness and usability of the IoT-based smart helmet in real-world conditions. Feedback from miners
informs iterative improvements in the technology, paving the way for widespread adoption in the mining
industry. By enhancing safety measures and operational efficiency, the IoT-based smart helmet promises to
significantly mitigate risks and improve the working conditions of coal miners, thereby advancing the
sustainability and profitability of coal mining operations. Coal mining remains a vital industry, providing a
significant portion of the world's energy needs. However, it also presents inherent risks to miners, particularly
in underground environments where hazards like gas leaks, collapses, and poor air quality pose constant
threats to safety. In response to these challenges, there has been a growing interest in leveraging technology to
enhance safety measures and improve the efficiency of coal mining operations. One promising avenue of
technological innovation is the development of IoT-based smart helmets designed specifically for coal miners.
These smart helmets integrate a variety of sensors, communication modules, and data analytics capabilities to
provide real-time monitoring of environmental conditions, facilitate communication among miners, and enable
swift response to emergencies. By harnessing the power of IoT technology, these smart helmets have the
potential to revolutionize safety practices in coal mining and mitigate the inherent risks faced by miners on a
daily basis. This research paper explores the design, development, and implementation of IoT-based smart
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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com
helmets for coal miners. It investigates the key features and functionalities of these smart helmets, including
sensor integration, real-time monitoring, alert systems, communication capabilities, and data analytics.
Furthermore, the paper examines the implications of this technology for improving safety measures, enhancing
operational efficiency, and advancing sustainability in the coal mining industry. Through field trials and
evaluations involving actual miners, the effectiveness and usability of IoT based smart helmets are assessed,
with a focus on regulatory compliance, cost-effectiveness, and user feedback. By addressing the unique
challenges of the coal mining environment and leveraging the capabilities of IoT technology, these smart
helmets have the potential to significantly reduce accidents, injuries, and fatalities among coal miners, while
also improving productivity and profitability for mining companies. Overall, this research paper aims to provide
insights into the development and implementation of IoT-based smart helmets for coal miners, highlighting
their role in transforming safety practices and shaping the future of the coal mining industry.
II. BLOCK DIAGRAM

Fig 1: Block Diagram

III. WORKING PRINCIPLE
The IoT-based smart helmet for coal miners using ESP8266 typically works by integrating various sensors to
monitor environmental conditions such as temperature, humidity, gas levels, and even detect harmful
substances like carbon monoxide. These sensors collect data and transmit it wirelessly to a central server or
cloud platform using the ESP8266 module. Miners can then access this data in real-time through a mobile app
or web interface to ensure their safety and well-being. Additionally, features like GPS tracking and
communication systems can be included for further safety measures.
Step 1: A 3.3V Li ion battery is attached to esp32 which provides power to whole system . As li ion is
rechargeable battery it can be use multiple times.
Step2: Various sensors and modules are mounted on helmet for various purposes. Such as temperature sensor,
gas sensor, vibration sensor , etc. These components helps the helmet to sense and judge the environment
weather it is feasible for the user or not. This can protect the user form many seen and unseen threats it also
helps in emergency situations as well.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com
Step 3: The environmental information collected by the components is gathered at ESP32 which is connected to
WIFI network. The collected information is shared to cloud database using WIFI which can be monitored by
authorised individual on web portal.
Step 4: Collected information is monitored and certain limits are set on those parameters, if the parameters
crosses the limit emergency alert is activated that generates the SMS which contain the coordinates of the user
(Miner) sensed by GPS module is send to the registered contacts through gsm module.

Fig 2: Flow of Software Section

HARDWARE USED
 ESP32
The ESP32 is a series of low-cost, low-power system-on-chip (SoC) microcontrollers with integrated Wi-Fi and
dual-mode Bluetooth. It is a versatile and robust device that offers a wide range of features, including a dual-
core processor, a large memory capacity, and a rich set of peripherals. The ESP32 WiFi module is a key feature
of the ESP32. It provides robust, reliable, and flexible Wi-Fi connectivity, making the ESP32 an excellent choice
for a wide range of Internet of Things (IoT) applications
 GSM
A GSM module is a device that allows electronic devices to communicate with each other over the GSM network.
GSM is a standard for digital cellular communications, which means that it provides a platform for mobile
devices to communicate with each other wirelessly. The GSM module is a specialized device that enables a
device to send and receive data over the GSM network. The GSM network is an essential component of modern
communication systems. It is a standard used by mobile devices to communicate with each other wirelessly. The
GSM module plays a crucial role in the communication between devices and the GSM network. It is responsible
for establishing and maintaining the communication link between the device and the network. The module also
handles the encryption and decryption of data, which ensures the security of the communication.
 GPS
The NEO-6M is a GPS module that is commonly used in various electronic projects and devices. It is a compact
and cost-effective module that provides accurate positioning and timing information. Here are some key
specifications and features of the NEO-6M GPS module:
1. GPS Chipset: u-blox NEO-6M

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International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com
2. Frequency: L1 1575.42MHz
3. Channels: 50
4. Sensitivity: -161 dBm tracking, -147 dBm acquisition
5. Update Rate: Up to 5Hz
6. Accuracy: Position 2.5m CEP, Velocity 0.1m/s
7. Time-To-First-Fix (TTFF): Cold start 27s, Warm start 27s, Hot start 1s
8. Operating Voltage: 3.3V to 5V
9. Operating Current: 30mA
10. Interface: UART (TTL level)
11. Protocol Support: NMEA, UBX binary
12. Antenna: Ceramic patch antenna with LNA
The NEO-6M GPS module is easy to use and can be interfaced with microcontrollers like Arduino, Raspberry Pi,
and other development boards. It provides accurate location data that can be used for tracking, navigation,
geotagging, and other location-based applications. The module comes with an onboard antenna and can be
connected to an external active antenna for improved performance in challenging environments .Overall, the
NEO-6M GPS module is a reliable and versatile solution for adding GPS functionality to your projects or devices.
 GAS SENSORS
Gas sensors (also known as gas detectors) are electronic devices that detect and identify different types of
gasses. They are commonly used to detect toxic or explosive gasses and measure gas concentration. Gas sensors
are employed in factories and manufacturing facilities to identify gas leaks, and to detect smoke and carbon
monoxide in homes. Gas sensors vary widely in size (portable and fixed), range, and sensing ability. They are
often part of a larger embedded system, such as hazmat and security systems, and they are normally connected
to an audible alarm or interface. Because gas sensors are constantly interacting with air and other gasses.
 VIBRATION SENSORS
Vibration sensors are devices that detect vibration, shock, and sound. They can be used in machinery to detect
problems before they happen. Vibration sensors work by detecting the motion of a material or object by sensing
its frequency. The faster the movement, the higher the frequency detected on a vibration sensor. Vibration
sensors are used to: Determine when potential equipment failure will occur and can help you perform
preventative maintenance. For example, if an asset is indicating signs of wear on a part, the vibration sensors
will indicate a problem and notify you.Help you understand why a failure has occurred on an asset (if it has
broken down).Help maintenance teams with their root cause analysis (RCA). By tracking the vibrations of an
asset, you can track down the source of any damage.
 DHT11
The DHT11 is a basic, ultra low-cost digital temperature and humidity sensor. It uses a capacitive humidity
sensor and a thermistor to measure the surrounding air, and spits out a digital signal on the data pin (no analog
input pins needed). Its fairly simple to use, but requires careful timing to grab data.
SOFTWARE TOOLS
 ARDUINO IDE
The Arduino IDE (Integrated Development Environment) is used to write the computer code and upload this
code to the physical board. The Arduino IDE is very simple and this simplicity is probably one of the main
reason Arduino became so popular. We can certainly state that being compatible with the Arduino IDE is now
one of the main requirements for a new microcontroller board. Over the years, many useful features have been
added to the Arduino IDE and you can now managed third-party libraries and boards from the IDE, and still
keep the simplicity of programming the board.
To avoid any error while uploading your program to the board, you must select the correct Arduino board name,
which matches with the board connected to your computer.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com
IV. SMART HELMET DESIGN
The ESP32 has a faster Wi-Fi, a CPU core, more GPIO pins, and Bluetooth low energy capabilities. The ESP32
also has a temperature sensor, touch-sensitive pins, and a hall effect sensor built in. Both boards are very cost-
effective. The ESP32 has more pins than the ESP8266, and you can pick whether the pins are UART, SPI, or I2C
about we have to specify this in the code. This is feasible because to the multiplexing feature of the ESP32
processor, which allows various purposes to be assigned to the single pin. If you don't put them on the code,
they'll be around the pins that are defined by default. The MQ2 gas sensor can detect the presence of Hydrogen,
LPG, and Propane, as well as Methane and other combustible steam. It is low cost and suited for a variety of
applications. 5 volts Power is given for the smoke sensor. The voltage output by a smoke sensor indicates the
presence of smoke. More smoke is produced. VCC and GND provide power to the heater from the electricity
supply. A variable resistor is included in the circuit. The resistance throughout the pin is determined by the
amount of smoke in the sensor's environment. The resistance throughout the pin is determined by the amount
of smoke in the sensor's environment. If the content is more, the resistance will be lessened. In addition, the
voltage between the sensor and the load resistor is increased. The MQ-7 has six pins, four of which are used to
bring signals and two of which are used to supply heating current. Sensor module for air quality MQ135 It is a
dangerous gas detection element for the family and the environment, and it is ideal for ammonia, Sulphur,
aromatic compounds, smoke, benzene vapor, and other gases harmful gas detection, as well as the evaluation of
gas sensitive components. Nitrogen oxide, ammonia, benzene, alcohol, carbon dioxide, and smoke are among
gases that can be detected by an air quality sensor. It works well in a manufacturing or office setting with a
simple drive and monitoring circuit. This DHT11 Temperature and Humidity Sensor is equipped with a
condition and moisture sensor, as well as a survey mac cue harvest. It ensures high trustworthiness and
attractive global establishment by accepting the fashionable numerical-alarm acquisition routine as well as heat
and moisture sensing mechanization. This sensor connects to a high-speed 8-bit microcontroller and comprises
a resistive-type steaminess measurement segment and an NTC climate assessment piece, resulting in a
completed condition rapid response, anti interference strength, and cost-effectiveness. When the sensor output
exceeds the threshold quantity detected by the sensor, the buzzer will sound. It makes use of a piezoelectric
sensor. The Piezo buzzer is a handy sound generator that can be used to provide a sound indicator in digital
circuits. It's extensively utilized in digital gadgets as an alarm. A Piezo buzzer is made up of a Piezo disc and an
oscillator. A standard Piezo buzzer is powered by 3 to 12 volts DC. The safety of mine workers is assured,
according to our research, by monitoring psychological variables at high altitude. We can continuously monitor
the physical condition of the mine using sensors and inform personnel during disasters before a life is lost.
Using IoT and a wireless network, we can save the life of a coal mine worker. It will send the information about
each person to the monitoring unit. The project also assists in contacting emergency numbers in order to alert
paramedics to assist workers in the event of a tragedy. The vital amounts of these toxic gases from the mining
industry, such as CH4 (Methane), NO2 (Nitrogen Dioxide), CO (Carbon monoxide), CO2 (Carbon dioxide), were
signalled through an alerting device. Using an off-the shelf IR distance sensor, the helmet removal evaluation
was successful.
SOFTWARE development part
 BLYNK IOT
Blynk is an IoT platform for iOS or Android smartphones that is used to control Arduino, Raspberry Pi and Node
MCU via the Internet. This application is used to create a graphical interface or human machine interface (HMI)
by compiling and providing the appropriate address on the available widgets.
Blynk was designed for the Internet of Things. It can control hardware remotely, it can display sensor data, and
it can store data, visualize it and do many other cool things.
There are three major components in the platform:
Blynk App: – It allows you to create amazing interfaces for your projects using various widgets which are
provided.
Blynk Server: – It is responsible for all the communications between the smartphone and hardware.

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International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com
You can use the Blynk Cloud or run your private Blynk server locally. It's open-source, could easily handle
thousands of devices and can even be launched on a Raspberry Pi.
Blynk Libraries: – It enables communication, for all the popular hardware platforms, with the server and
processes all the incoming and outcoming commands. The process that occurs when someone presses the
Button in the Blynk application is that the data will move to Blynk Cloud, where data magically finds its way to
the hardware that has been installed. It works in the opposite direction and everything happens in a blink of an
eye.

Fig 3: Blynk IOT

FLOW CHART

Fig 4: Flow Chart of IOT Based Smart Helmet For Coal Miners.
V. RESULTS ANALYSIS

Fig 5:

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International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com

Fig 6: Dashboard of Blynk IOT

VI. FUTURE SCOPE
Scope for IoT-based smart helmets for coal miners is promising, with potential advancements in technology and
application. Here are some areas of future development.
Enhanced Sensor Technology: Continued advancements in sensor technology will enable more precise and
comprehensive monitoring of environmental conditions, health parameters, and safety hazards. This could
include sensors capable of detecting a wider range of gases, improved accuracy in measuring vital signs, and
more robust tracking capabilities.
Integration with AI and Machine Learning: Integration of artificial intelligence (AI) and machine learning
algorithms will enable predictive analytics to anticipate potential hazards and optimize safety protocols. AI can
also be used for real-time decision-making and automatic response systems in emergency situations.
Augmented Reality (AR) Integration: AR technology can provide miners with real-time visual overlays of critical
information, such as navigation directions, equipment status, and safety guidelines, directly within their field of
view. This can enhance situational awareness and streamline workflow processes.
IoT Ecosystem Integration: Smart helmets can be integrated into broader IoT ecosystems within mining
operations, connecting with other devices and systems such as drones, autonomous vehicles, and centralized
control centers. This seamless integration enables comprehensive data sharing and coordinated responses
across various components of the mining operation.
Wearable Technology Advancements: Advances in wearable technology will lead to lighter, more comfortable,
and durable smart helmet designs. This includes improvements in battery life, connectivity options, and user
interface features to enhance usability and acceptance among miners.
Regulatory Compliance and Industry Standards: Future developments in IoT-based smart helmets will likely
align with evolving regulatory standards and industry best practices for occupational safety in mining.
Compliance with these standards will drive innovation and adoption of new technologies to ensure the well-
being of coal miners. Environmental Sustainability: There will be a growing focus on integrating environmental
monitoring capabilities into smart helmets to track and mitigate the impact of mining activities on the
surrounding ecosystem. This includes monitoring air and water quality, noise levels, and wildlife habitats
VII. CONCLUSION
A clever mining helmet has been designed that can detect two types of potentially dangerous events: toxic gas
levels, mining helmet collision, and effect. Another dangerous event is when miners are struck by an object that
is opposed to their will and has a force greater than 1000 on the HIC (Head Injury Criteria). It's also possible to
measure gas concentrations.

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 e-ISSN: 2582-5208
International Research Journal of Modernization in Engineering Technology and Science
( Peer-Reviewed, Open Access, Fully Refereed International Journal )
Volume:06/Issue:04/April-2024 Impact Factor- 7.868 www.irjmets.com
VIII. REFERENCE
[1] Ayush Kadukar, Harsh Adyalkar.” REVIEW ANALYSIS ON IOT BASED SMART HELMET FOR COAL
MINERS”. International Research Journal of Modernization in Engineering Technology and Science.
Volume:06/Issue:03/March-2024
[2] Sajjad Hussain Talpur, Amjad Chohan. “SMART HELMET FOR COAL MINERS SAFETY MONITORING
WITH MOBILE APP”. International Journal of Computational Intelligence in Control. Vol.13 No. 2
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[3] A.DHANALAKSHMI. “A SMART HELMET FOR IMPROVING SAFETY IN MINING INDUSTRY”. .Volume 2,
Issue 3, March – 2017.
[4] T .Sowmya, G. SrinivasaRao. “SMART HELMET FOR MINING WORKERS“. International Journal for
Research in Applied Science & Engineering (IJRASET).Vol 14 Issue 04, 2023 Technology.
[5] B. Kartik, “IOT based Smart Helmet for Hazard Detection in mining industry”. B.Tech Student, School of
Electronics and Communication (SENSE), Vellore Institute of Technology, Chennai, Tamil Nadu, India.”
[6] Deepali Shinkar, Saili S Garad. “IOT BAS ED SMART HELMET FOR COAL MININIG TRACKING”. Vol 14
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[7] “Data Security Based Routing in MANETs Using Key Management Mechanism”, Hande J.Y., Sadiwala,R.,
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1007/s42979-023-02409-5.
[8] “Optimization of energy consumption and routing in MANET using Artificial Neural Network”, Jayant Y.
Hande, and Ritesh Sadiwala Journal of Integrated Science & Technology Cite as: J. Integr. Sci. Technol.,
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[9] “A Secure Adaptive Bacterial Foraging Optimization Routing Algorithm for Mobile Ad Hoc Networks”,
Jayant Y. Hande and Dr. Ritesh Sadiwala, TELEMATIQUE, Volume 21 Issue 1, 2022

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