ZIGBEE BASED WIRELESS REALTIME MONITORING

SAFETY HELMET FOR UNDERGROUND MINES

A THESIS SUBMITTED IN PARTIAL FULLFILMENT OF REQUIREMENTS FOR THE DEGREE OF

BACHELOR OF TECHNOLOGY

IN

MINING ENGINEERING

BY

BADRI.A.MEIYYAPPAN 16A91A2607

ESTRADOVE S 16A91A2611

HARI PRASATH P 16A91A2612

ANIRUDH MUTHURAMAN S P 16A91A2621

Under the guidance of

Mr. SAI KRISHNA

DEPARTMENT OF MINING ENGINEERING

ADITYA ENGINEERING COLLEGE (A)

Approved by AICTE, Affiliated to JNTUK & Accredited by NBA, NAAC with ‘A’ Grade

Recognized by UGC under the sections 2(f) & 12(B) of the UGC act 1956

Aditya Nagar, ADB Road, Surampalem – 533437, E.G.Dist., A.P.

2016-2020

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 DEPARTMENT OF MINING ENGINEERING

ADITYA ENGINEERING COLLEGE (A)

Approved by AICTE, Affiliated to JNTUK & Accredited by NBA, NAAC with ‘A’ Grade

Recognized by UGC under the sections 2(f) & 12(B) of the UGC act 1956

Aditya Nagar, ADB Road, Surampalem – 533437, E.G.Dist., A.P.

Certificate
This is to certify that the thesis entitled “Zigbee Based Wireless Real Time Monitoring
Safety Helmet for Underground Mines” submitted by

BADRI.A.MEIYYAPPAN 16A91A2607

ESTRADOVE S 16A91A2611

HARI PRASATH P 16A91A2612

ANIRUDH MUTHURAMAN S P 16A91A2621

to the Aditya Engineering College (A), Surampalem for the partial fulfillment of the reward
of the degree of Bachelor of Technology in Mining Engineering is an authentic work carried
out by him under our guidance and supervision. The thesis in our opinion, is worthy of
consideration for the award of the degree of Bachelor of Technology in accordance with the
regulations of the institute. To the best of our knowledge, the matter embodied in the thesis
has not been submitted to any other University/Institute for the award of any Degree or
Diploma.

Date:

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 Mr. SAI KRISHNA

Asst. professor

DEPARTMENT OF MINING ENGINEERING

ADITYA ENGINEERING COLLEGE (A)

Acknowledgement

We wish to express our profound gratitude and indebtedness to Mr. Sai Krishna, Asst.
Professor, Department of Mining Engineering, and Aditya Engineering College (A),
Surapalem who gave me the golden opportunity to do this wonderful project on the topic
“.ZIGBEE BASED WIRELESS REALTIME MONITORING SAFETY HELMET FOR

UNDERGROUND MINES” We find words inadequate to thank him for his encouragement and
valuable suggestions during the course of this work. We are also grateful to all faculty
members and staff of Mining Department, Aditya Engineering College (A), Surampalem. We
express our special thanks to Mr. Satyajeet Parida, HOD, Department of Mining Engineering
for their assistance. We would take the opportunity to thank our friends for helping us in
conduction of experiment. We acknowledge my indebtedness to all of them whose works
have been referred in understanding and completion of this project. We also thank to all our
well-wishers who have patiently extended all sorts of help and moral support for
accomplishing this dissertation.

Date: Badri. A. Meiyyappan

S.Estradove

P.Hari Prasath

S.P. Anirudh Muthuraman

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 ABSTRACT

Safety is a very crucial part in mining workings both underground and opencast. And so, the
aim of this project is to design a Safety Wireless Helmet for miners in coal mines which is
based on Zigbee wireless technology. The system provides a quick and wireless coal mine
supervising system. The device uses ZigBee’s WI-FI technology to build a network of
wireless sensors. This safety helmet is used for monitoring and measuring abnormal
temperatures and presence of harmful & inflammable gases at levels beyond the prescribed
standards. The safety helmet consists of a circuit with 3 wireless sensors. One sensor for
detecting temperature and other 2 for detecting carbon monoxide & methane gases. If there is
an increase in any of the following factors, mentioned before, above the permissible levels,
which are already incorporated within the code of system’s software, the helmet passes the
acquired data by using the ZigBee transmitter to the nearest control station which is equipped
with a ZigBee receiver module. Apart from this the helmet is also equipped with an LCD
display which displays the detected quantitative results of the various factors.

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 CONTENTS

Description Page no
ABSTRACT 3
LIST OF FIGURES 5
LIST OF TABLES 6
Chapter 1 INTRODUCTION
1.1 Introduction 7
1.2 History of the Zigbee 8
1.3 Objectives 9
1.4 Problem statement 9
1.5 Organization of the thesis work 9
Chapter 2 LITERATURE REVIEW
Literature review 10-14
Chapter 3 MINE GASES 15-18
Chapter 4 SYSTEM HARDWARE
4.1.1 Arduino UNO 18-20
4.1.2 Carbon Monoxide sensor(MQ7) 21-23
4.1.3 Methane sensor(MQ4) 23-26
4.1.4 Temperature sensor(LM35) 26-27
4.1.5 Voltage Regulator 27
4.1.6 Battery 28
4.1.7 Zigbee Transmitter / Receiver 28
4.1.8 LCD display 29
4.2 SOFTWARE USED
4.2.1 Arduino IDE 30
4.2.2 Hyper Terminal Software 31-33
4.3 SYSTEM ARCHITECTURE
4.3.1 Flow Chart for Smart Helmet Working 33-34
4.3.2 Flowchart for Mining and Monitoring Section 34-35
4.3.3 Electronic Circuit Layout 37
Chapter 5 METHODOLOGY
5.1 Mining System 38-39
5.2 Monitoring Section 39-40
Chapter 6 RESULTS 40-42
Chapter 7 CONCLUSION 43
REFERENCE 44

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 LIST OF FIGURES

SL.NO DESCRIPTION PAGE NO

Figure 3.1 Coward diagram 17
Figure 4.1 Arduino UNO 18-19
Figure 4.2 MQ7 Gas Sensor 21
Figure 4.3 Influence of temperature and humidity on MQ7 sensor 22
Figure 4.5 MQ4 Gas Sensor
Figure 4.6 Sensitivity characteristics curve of the MQ4 gas sensor
Figure 4.7 LM35
Figure 4.8 Voltage regulator
Figure 4.9 Battery
Figure 4.10 Zigbee module
Figure 4.11 16*2 LCD display
Figure 5.1 Arduino IDE webpage
Figure 5.2 Connection description
Figure 5.3 GSM modem
Figure 5.4 Terminal emulator
Figure 5.5 Client software

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 LIST OF TABLES

SL NO DESCRIPTION PAGE NO
Table 3.1 Physiological effects of CO
Table 4.1 Technical specification of MQ7
Table 5.1 Arduino pro IDE

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 Chapter 1

Introduction
1.1 Introduction
Atmosphere has a significant impact on mine workers, instruments, and underground
equipment in underground mining. Atmosphere in mining terms is nothing but the
concentration of gases present in an underground mine and these gases include oxygen,
carbon-dioxide and even carbon-monoxide and methane etc. The permissible level of each
gas in underground mining is maintained through ventilation. In a mine ventilation system,
the surface air is pumped to the underground workings to maintain the permissible gas levels
in the underground atmosphere. So, in underground mining especially those extracting coal
and its other forms, the mine atmosphere has a significant impact.
Today in mining specially in underground mining the biggest problems faced by
miners are the problems due to gas .There are lot of dangerous gases which occur inside an
underground mine during the extraction process and these gases are commonly called as
damp, for example CO2 (Carbon-dioxide) is called as black damp, methane (CH4) is called
as fire damp, H2S is called as stink damp, CO (carbon mono oxide) is called as white damp.
The gases produced in mines are nothing, but harmful vapors produced during the formation
period of the said ore deposit/over-burden. As the rock is excavated, the pressure under which
these gases were trapped inside the rocks decreases, which in turn results in expulsion of the
gases from their rock pockets and into the underground mine atmosphere. The problem lies
with the fact that it is not possible to find the location and quantity of such harmful gases
present within the rock bodies. Due to this the only way to detect them is when they are
suspended inside the underground mine atmosphere, with the help of gas detectors and other
such devices.
These gases may also lead to explosion in a mine. For example, the lower explosible
limit of methane gas is 5.4%, similarly every inflammable gas has it’s explosible limit. And
this explosion results in accidents such as fire accidents, roof falls, road disruption etc.
Some gases present in underground mines are very harmful to the human body and
cause danger to mine workers working inside the underground mine, some gases are even
poisonous in nature and results in very critical condition even in presence of small quantity.
In underground coal mine gas leakage often happen and sometimes even ventilation system
fails to remove all the dangerous gases present in the underground mine. So, if the percentage

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of harmful gas present in underground mine is more than the safest limit it will cause many
serious issues to the mine workers health and it even causes death.
One of the most harmful gases that occur in an underground mine is carbon-monoxide (CO)
and a chief inflammable gas being methane (CH4). Both these gases are very dangerous and
cause critical health issues to mine maximum limit then the corresponding measures should
be taken immediately.

1.2 HISTORY OF THE ZIGBEE

Zigbee is a wireless communication technology where the data can be transmitted from one
place to another without using any wire, many years ago ZigBee has been established as an
IOT network which is standard for remote control and sensing. Zigbee is a commonly used
wireless data transmitting device used in many fields and ZigBee is a very popular wireless
data transferring technology. Zigbee module consist of ZigBee transmitter and ZigBee
receiver, ZigBee transmitter collects the send it to the ZigBee receiver which is on the other
place connected with a computer and the computer displays the data which is collected by
transmitter and sent to receiver.

Sensors systems used in mining industry It plays a major role in the safety of mining
industry. Gas sensing technology is very helpful to save lives and damage to the property.
The sensor shows the flammable and toxic gases and depleted oxygen levels under harsh
mine conditions, rapid humidity variations and significant pressure fluctuations. The
pellistors are utilized on the walls and machinery in mines to detect any hazardous gases.
Now UV illumination is used more than pellistors at ambient temperature. Now UV LED
activated gas sensors are alternative for current sensors. These provide the improvement of
quality, reliability and economic efficiency of sensor systems used in mining industry. Now
the Nanofabrication technology helps to fast and sensitive detection.

Advantages of ZigBee are it consumes very less electric power, cost of ZigBee is very low, In
ZigBee the rate of data transmission is very high, It is used globally all around the world,
Zigbee is based on standard wireless IOT network, The security features provided by ZigBee
is very strong and Zigbee is a open source data transferring device. Disadvantages of ZigBee
are: It has a low data transferring speed. Replacing parts which are tractable with the Zigbee
module is costly. It doesn’t have end services available yet. It has low complexity and low
data speed.

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1.3 OBJECTIVE:
 To design a ZigBee based communication system for the detection of mine gasses and
temperature.
 Detection of mine gasses and temperature.
1.4 PROBLEM STATEMENT:

To design a safety system which detects various harmful and noxious gases present
in the underground mine atmosphere and warn the miner when such gases exceed their
permissible limits, thereby enabling the miner to escape in time.

1.5 Organization of the thesis work:

In this thesis work, Chapter One discussed about the introduction to mine gases, History of
ZigBee, objectives, and problem statement. In this thesis, Chapter Two discussed about the
literatures of different researchers regarding ZigBee. In this chapter three we discussed about
the mine gases. The Chapter Four presents the hardware components used for making the
smart helmet is based on ZigBee technology, the software used and their implementation for
working of smart helmet and the operational flow charts and electronic circuit layout of the
project. The Fifth Chapter we discussed about the methodology of the project. The Sixth
Chapter presents the results and discussion of the entire thesis work. The last chapter i.e.,
Chapter Seven gives the final conclusions of the project.

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 Chapter 2
Literature review
2.1 Previous Work: -

SL.N AUTHOR YEAR TYPE OF WORK OUTCOME

O
1 T.Pathan&Puja G Panchbuddhe 2018 Microcontroller based A small safety-
smart helmet for coal based model made
miner’s safety with
microcontroller is
fitted in the
miner’s helmet to
protect the miners
from object fall
and related
hazardous events
which cause
problems and
danger to mine
workers.
2 Sumit Kumar Srivastava 2015 Real time monitoring Detecting the toxic
system for mine gases within
safety using wireless mining
sensor network environment and
establishing
communication
between sensors
and ZigBee and
establishing the
wireless
communication
between ZigBee
transmitter and

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 receiver and
designing a
wireless
monitoring system.
3 Yu Zhang, Wei Yang, 2014 An integrated An integrated
Dongsheng Han & Young Il Kim environment environment
monitoring system for monitoring system
underground coal for underground
mines – wireless coal mines using
sensor network CMS as a
subsystem with multi- backbone network
parameter monitoring and WSN as the
supplementary
network is
proposed because
CMS alone cannot
collect all the
required
parameters and it
is difficult to
deploy complex
areas.
4 Abhishek Pal &Sachin Kumar - Health monitoring A low cost
device for prototype design
underground coal that consist of
miners. health related
sensor like pulse
sensor to measure
the pulse rate and
body conditions
and it is less in
weight and it is be
easily wearable in
hands so that
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 miners can easily
use it under the
mine.
5 Jayabharata S &Marimuthu CN 2015 Wearable real time More security is
health and security provided by GSM
monitoring scheme module, it is used
for coal mine to send message to
workers. fire and ambulance
service to evade
the damage and
then this system
has an ability to
find shortest exit
path for workers in
case of fire
accidents in
underground
mines.
6 Bonala Ashwini& D Ravi Kiran 2018 ITO based coal mine This IOT structure
Babu safety monitoring and encase the most
control automation outrageous key and
genuine part of
right currently sent
excavator security.
Since the system is
made up of low
power Wi-Fi
module and control
light with PWM
strategy degree of
force usage is cut
down.
7 Sachin M Ledange, Swarup S 2016 Robot base wireless Sensing the
Mathurkar monitoring and safety temperature,
Page | 12
 system for humidity, methane,
underground coal tint, with the
mines using Zigbee respective sensor
protocol. and will display it
in 16*2 display
and transmitting
the data to the
station present on
the surface through
ZigBee wireless
data transferring
technology.
8 Boddepati Venkata Sai Phani 2019 Design of IOT based Collected data
Gopal, PakirabadAkash, PSG coal mine safety from gas sensor,
Arun Sai system using DHT11 sensor, fire
nodemcu sensor, LDR
sensor are passed
to IO through node
MCU and then to
cloud.
9 Sneha Khanapure & Sayyadajij D 2013 Coal mine monitoring To provide safety
and security system in coal mine many
sensors are used to
sense the gasses
and transfer that
data from wireless
transmitter to
wireless receiver
which is connected
to the computer.
10 GH Raisoni college of 2017 Developing a device The pulse sensor
engineering for health monitoring sense the pulse and
and human tracking send it to Wi-Fi
in coal mine module and
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 calamities. Arduino and Wi-Fi
module send the
data to base station
and Arduino send
it to reader.

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 Chapter 3

Mine gases
3.1 MINE GASES

In general, the gases present in the atmosphere are oxygen, nitrogen, carbon dioxide and
some other inert gases. In an underground working, the gases formed during mining
operations are carbon monoxide, methane, hydrogen sulfide, hydrogen, sulfur dioxide,
nitrous fumes.

3.2 CARBON MONOXIDE (CO):

This silent killer is generated during the oxidation of coal and during mine fires or
explosions. It is extremely toxic in nature. If its levels get as high as 0.2%, death will take
place within one or two hours. It is also highly flammable and explosive. And flames won’t
extinguish in its presence as it would with carbon dioxide. It is not easy to detect.

SOURCES OF CARBONMONOXIDE:

OXIDATION OF COAL:

Coal oxidation at low temperatures is the main reason of self-heating and spontaneous
combustion of coal. This process involves consumption of oxygen, formation of solid
oxygenated complexes and generation of gaseous oxidation products. Parameters to describe
this process are mass change, heat release, oxygen consumption, and formation of oxidation
products in the gas or solid phase. Various kinetic models have also been developed to
describe the rate of oxygen consumption. They are applicable for predicting the self-heating
and gas emission in a coal seam or stockpile.

INTERNAL COMBUSTION ENGINE:

In underground coal mines, the Internal combustion engine can be used in diesel
operated machines. It increases the percentage of carbon monoxide in an underground
working.

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SPONTANEOUS COMBUSTION:

Majority of the fires in coal mines are due to the spontaneous combustion of coal. It
is a slow process and the heat evolved is carried away by air. The process of self-heating of
coal or other carbonaceous material resulting eventually in its ignition is termed as
‘spontaneous heating’ or ‘auto oxidation’. Coal can interact with oxygen in the air at ambient
temperatures while liberating heat. It is a surface phenomenon and proceeds through a loosely
bound coal-oxygen-water complex with subsequent steps being breakdown of the complex to
simple molecules such as CO, CO2, H2O etc. Chemical inhibitors play a vital role to control
and combat fires.

Table 3.1 Physiological Effects of Carbon monoxide

PERCENTAGE OF BLOOD PHYSIOLOGICAL EFFECTS

SATURATION
5-10% Loss of concentration
10-20% Slight headache
20-30% Throbbing headache, judgment impaired
30-40% Severe headache, dizziness, vomiting, improper vision
40-60% Collapse, increase in pulse, convulsions
60-70% Coma, possible death

DETECTION OF CARBONMONOXIDE:

Some of the CO is detected by Taximeter, Multi-gas detector and Chip measurement

system.

3.3 METHANE:

It is highly inflammable and highly explosive. It is a major component of the natural

gas. It accumulates in ‘pockets’ and can be released as the coal is mined. It has a density
relative to air of 0.55. Methane is only combustible at levels between 4 and 16%. Below that
range there is not enough to be ignited, and above that range the mixture is too dense to be
explosive. The riskiest level of methane in the air is said to be 9.5%. And this makes sense to
firstly avoid the build- up of this highly flammable gas, which may result in an explosion,
provided that there is a suitable source of ignition present in the vicinity.

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  Coward diagram explains the explosibility of methane in fire damp:

Fig 3.1 Coward’s diagram of Methane

SOURCES OF METHANE:

Methane being lighter than air is found near the roof and in rise workings of a coal
mine. Fault and dykes are other places where the gas may be expected in a non-gassy coal
mine.

In a coal mine the gas may find its way into the workings in one of the following ways:

 In pre-mine drainage systems, the horizontal wells are used to recover methane in
advance of mining or after mining.
 Air ventilation dilute the concentration of methane in underground mines.
 In closed mines, methane may seep out through vent holes or through fissures or
cracks in the ground.
 In surface mines, methane is directly exposed to atmosphere.
 Fugitive emissions from post-mining operations, in which coal continues to emit
methane as it is stored in piles and transported.

PHYSIOLOGICAL EFFECTS OF METHANE:

Increase in percentage of methane reduces the percentage of oxygen in general body of air. If
oxygen percentage reduces below 12%, this may lead to the symptoms which are similar to
those of oxygen deficiency and sometimes this may lead to death of workers.

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DETECTION OF METHANE:

 Methane can be detected by using any of the following instruments/detectors:

1. Flame safety lamp, which works on principle of formation of gas caps

2. Automatic fire damp detector
3. Methane monitors MEMACS-1
4. Interference Methanometer, which works on principle of optical properties of the
methane
5. Spiral alarms
6. Multi-gas detector
7. Methane telemonitoring system.

CHAPTER 4

SYSTEM DESIGN

4.1 SYSTEM HARDWARE DESIGN:

The Smart Helmet contains several components like Arduino board, MQ4 sensor
module,MQ7 sensor module, LM35, voltage regulator, capacitor, battery, LCD
display.

4.1.1 ARDUINO UNO:

FIG 4.1 Arduino UNO

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 (https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.indiamart.com
%2Fproddetail%2Farduino-uno-board-
20238835133.html&psig=AOvVaw0QnI0QhMU66ScAQh1TJ9iv&ust=1594650969174000&source=images&cd=vfe&ved

=2ahUKEwinqt7198fqAhWo2nMBHR9bBBAQr4kDegUIARCGAg)

 Arduino is a circuit board which is programmable by using open source code. It can
be used to process data from sensors and take other inputs. It is also capable of
sending the data too LCD displays & LCD monitors.
 Arduino Uno is one of the microcontroller boards which work on ATmega328 data
sheets.
 It consists of the following: a USB connection, a Reset Button, 14 Digital pins for
input & output, a 16 MHz crystal oscillator, a Power Jack, an ICSP header, 6 analog
inputs.
 It consists of all the required supports for the microcontroller. It begins to function
upon connecting it with computer by using a USB cable or by using a battery or
adapter[AC to DC] to power it up.
 The Arduino Uno is unique as the FTDI USB-to-serial driver chip ,which is present
in its predecessors, is not made use of here.
 It makes use of Atmega8U2 programmed USB-to-serial converter.
 "Uno" refers to "one" in Italian , which denotes the Arduino 1.0.
 The most recent USB connected Arduino board is the Uno.
 Power: A USB connection or an external power supply can be used to power up the
Arduino Uno.
 Automatic selection of power source is possible.
 External (non-USB) power can come either from an AC-to-DC adapter (wall-wart)
 A 2.1mm center-positive plug is to be plugged into the power jack in the board, to
connect the adapter.

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  The Gnd &Vin pin headers in the POWER connector are inserted with leads from a
battery.
 An external supply range of about 6 to 20 volts is used by the board. However, the
board becomes unstable if less than 7 volts is supplied.
 At the same time a charge exceeding 12 volts may overheat the voltage regulator
which results in damaging of the board.
 The designations are as follows:
Power Source:
 The required voltage can be supplied through this pin or while supplying through
power jack.
 The microcontroller & other components receive power from the regulated power
supply.
 The power can be from either the VIN through the on-board regulator or by 5V
supply or by a USB.
 The on-board regulator generates a 3.3 V supply. A maximum of 50mA current can
be drawn.
 The ATmega328 has a memory of 32KB along with 2 KB of SRAM and 1 KB of
EEPROM.
 Input / Output functions can be carried out using each of the Uno's 14 Digital pins.
 A maximum of 40mA can be sustained by each pin. It is also provided with an
internal pull-up resistor of about 20 - 50 kOhms.
 Additional special functions are also available:
 Serial: 0 [RX] & 1 [TX]. Serial data can be received by RX and transmitted through
TX.
 The corresponding ATmega8U2 USB to TTL serial chip pins is connected to these
pins.
 External Interrupts: 2 and 3. An interrupt can be triggered at a low value, change in
value, or a rising / falling edge by using these pins.
 PWM: 3,5,6,9,10,11. These provide a 8-bit PWM output along with analog function
Write().
 SPI: 13 , 12 , 11 [MOSI], 10 [SS] .These pins use the SPI library and thereby enable
SPI communication.

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  LED: 13. A built-in LED is connected to pin 13. A HIGH pin value causes LED to
switch on , while it switches off for a LOW pin value.

4.1.2 MQ7 SENSOR:

 MQ7 is a sensor which detects the Carbon Monoxide [CO] concentration in the mine
atmosphere at wide range from 20 to 200ppm.
 Power required for this carbon monoxide sensor is 3.3V to 5V.
 For output we use digital pin to accomplish the digital output.
 After the CO is detected within the detection range of 20ppm to 2000ppm a digital
output will be displayed in the LCD screen by using a microcontroller.
 Inside the sensor CO is absorbed by the SnO2 sensor. It results in the separation of sn
from SnO2 & it is formed the CO2 gas and it is released in the atmosphere.
SnO2+2CO  Sn+2CO2

FIG 4.2 MQ7 SENSOR

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TABLE 4.1 Technical specification of MQ7:

(https://www.google.com/url?sa=i&url=https%3A%2F%2Fosoyoo.com%2F2018%2F11%2F15%2Farduino-lesson-mq-7-
gas-sensor%2F&psig=AOvVaw3ML-
AhBPG6YiGScD6H8s_N&ust=1594724551913000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCKjxioiKyuoCFQAAAA

AdAAAAABAu)

SENSOR WORKING PROCESS:

It consists of two circuits. One is the Heating Circuit which consists of heater and the
other one is Signal Output Circuit, where the detection of gas occurs.

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 FIG:4.3 INFLUENCE OF TEMPRATURE AND HUMIDITY ON MQ7 SENSOR

(https://linksprite.com/wiki/images/thumb/7/7f/MQ2_E.jpg/500px-MQ2_E.jpg)

FEATURES:
 Onboard holes for easy installation.
 Compatible with Arduino and microcontroller.
 High sensitivity to natural gas.
 It has long life and low cost.
 Adjustable sensitivity.
 TTL compatible.
 Sensors are easily available in the market.
APPLICATION:
 Domestic gas leakage.
 Consumer electronics.
 Industrial CO detector.
 Portable gas detector.[10]

4.1.3 METHANE (MQ4) SENSOR:

 MQ4 gas sensor is a sensor which detects the methane concentration in the mine
atmosphere in a wide range of 300ppm to 5000ppm
 Power requirement for methane gas sensor is 5V and it consumes less than 150MA at
5V and this 5V may be AC or DC
 For getting output we can either use the digital pin or the analog pin can be used. If
the digital pin is used, then the digital output will be displayed in the LCD screen. If
an analog pin is used analog values (0-5V) will be displayed using a microcontroller.

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 FIG:4.5 MQ4 GAS SENSOR
(https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.indiamart.com%2Fproddetail%2Fmq4-methane-gas-sensor-
17521476362.html&psig=AOvVaw2giAE7szgkZE6s1dM9G9C0&ust=1594650700239000&source=images&cd=vfe&ved=2ah

UKEwjV6L_19sfqAhUH1HMBHStPAvoQr4kDegUIARDSAQ)

PINS FOR MODULE:

 VCC: This pin powers the module typically the operating voltage is +5V.
 GND: It is used to module to system ground.
 DIGITAL OUT (DO): You can also use this sensor to get digital output from this
pin, by setting a threshold value using the potentiometer.
 ANALOG OUT (AO): This pin outputs 0-5V analog voltage based on the intensity
of the gas.

PINS FOR SENSOR:

 H-PINS: Out of the two H-pins, one pin is connected to supply and the other to
ground.
 A-PINS: The A pins and B pins are interchangeable. These pins will be tied to
supply voltage.
 B-PINS: A pins and B pins are interchangeable. One pin will act as output while
the other will be pulled to ground.[11]

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 2D MODEL OF MQ4 GAS SENSOR:

FIG 4.6: MQ4 2D MODEL

(https://components101.com/sensors/mq-4-methane-gas-sensor-pinout-datasheet)

SENSITIVITY CHARACTERISTICS CURVE OF THE MQ4 GAS SENSOR:

Fig 4.7: Sensitivity Characteristics curve of the MQ4 gas sensor

(https://www.sparkfun.com/datasheets/Sensors/Biometric/MQ-4.pdf)

FEATURES:

 Good sensitivity to combustible gas in wide range.

 High resistivity to CH4, Natural gas.
 Small resistivity to alcohol, smoke.
 Fast response stable and long life.
 Simple drive circuit.

APPLICATION:

Page | 25
  Used in gas leakage detecting equipment for homes and industry. They are suitable
for detecting of CH4 and CNG
 Industrial combustible gas detector.
 Portable gas detector.[11]

4.1.4 TEMPRATURE SENSOR (LM35):

Fig 4.8 temperature sensor

 LM35 is a sensor used for measuring the temperature which converts analog output
voltages into the corresponding temperature value.
 The output voltage is converted to Celsius. And both the temperature & output
voltage decrease or increase correspondingly.
 It has a conversion rate of 10 mV = 1 ℃.
 For example: 250mV refers to 25 ℃.
 It had 3 terminals and is used to measure temperature ranging between 55 ℃ to 150
℃.
 And its supply voltage is 4V to30V.

PIN CONFIGURATION:

 VCC: Input voltage is +5V for typical applications.

 Analog Output: There will be increase in 10mV for raise of every 1°C can range
from -1V(-55°C) to 6V(150°C)
 Ground: Connected to ground of circuit.

FEATURES:

 ±0.5°C Accuracy

Page | 26
  Drain current is less than 60uA
 Low cost temperature sensor
 Small and hence suitable for remote applications.
 Operates from 4V to 30V

APPLICATION:

 Measuring temperature of a specific environment.

 It helps the monitoring temperature battery.
 Providing thermal shut down for a circuit.

4..1.5 VOLTAGE REGULATOR:

Fig 4.9 Voltage Regulator

Voltage Regulator is used for splitting the current, here voltage regulator
receives 15V current from battery and split it into three 5V current and send it to the three
sensors such as carbon monoxide sensor, methane sensor, temperature sensor (5V each).

APPLICATIONS:

 Adjustable output regulator.

 Current limiter for certain applications.
 Regulated dual supply.

Page | 27
4.1.6 BATTERY:

Fig 4.10: Battery

Battery is used to supply sufficient electric power to the devices.

4.1.7 ZIGBEE TRANSMITTER AND RECEIVER:

Fig 4.11 ZigBee module

(https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.indiamart.com%2Fbrainz-store
%2Fwireless-transceiver.html&psig=AOvVaw3-
WTakMN87yKocFw2_o34S&ust=1594703670966000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCLjOkZ68yeoCF

QAAAAAdAAAAABAD)

Zigbee Transmitter is used to transmit data from digital sensor data to a

remote monitoring site which is usually located at a distance from the local site and
the maximum distance is 100m.
Zigbee receiver is used to receive the data sent by transmitter and to display it
in monitor.

Page | 28
4.1.8 16*2 LCD DISPLAY:

(https://components101.com/sites/default/files/component_pin/16x2-LCD-Pinout.png )

Fig 4.12 LCD display

. This 16*2 LCD screen consist of 16 rows and 2 columns and it is used to display
the current level of Carbon monoxide (CO), Methane (CH4), and the Temperature at
that place. This 16*2 LCD screen not only displays weather the gases and temperature
are normal or abnormal, but it displays it with accurate degree value.

PIN CONFIGURATION:

 Vss (ground): This pin is connected to system ground.

 Vdd (+5 volt): powers the LCD with +5V (4.7V-5.3V).
 VE (contrast V): Decides the contrast level of display. Grounded to get maximum
contrast.
 Register select: It is connected to microcontroller to shift between command /data
register.
 Read/write: It can be read or write data. Normally grounded to write data to LCD.

FEATURES:

 Its operating voltage is 4.7V to 5.3V.

 Current consumption is 1mA without backlight.

Page | 29
  It can work on both 8-bit and 4-bit mode.[14]
 Available on blue and green back

4.2 SOFTWARE USED:

4.2.1 ARDUINO IDE:

This abbreviates to Arduino Integrated Development Environment. This application is written

using Embedded C language. It also allows to upload programs and write programs to
applications compatible with Arduino.

TABLE 4.2 : Arduino pro IDE (https://en.wikipedia.org/wiki/Arduino_IDE)

Developer’s Arduino Software

Written in C , C++
Operating system Windows, macOS, Linux
Platform IA-32, x86-64, ARM
Type Integrated development environment

FIG 4.13 :- Arduino IDE webpage

(https://www.arduino.cc/en/main/software)

Page | 30
4.2.2 HYPER TERMINAL SOFTWARE:

HYPERTERMINAL: This is a terminal emulation program which enables

communication via TCP/IP networks , serial COM ports and dial-up modems.

1. To read the data which is uploaded in hyper terminal application

2. Install the Hyper Terminal application in your pc and open it.

3. Connection description tab opens automatically and in that enter the name and click
on OK.

Fig 4.14 Connection Description

(https://www.google.com/url?sa=i&url=https%3A%2F%2Fnetworkencyclopedia.com%2Fhyperterminal
%2F&psig=AOvVaw1A62ixCfMH-
2wQmxwIAFvj&ust=1594708855742000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCIjV0M7PyeoCFQAAAAAdAAAAAB

AV)

1.Now the new tab opens, and it consists of default details like Country, Area code and click
OK.

Page | 31
 Fig 4.14:GSM Modem

(https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.virtual-serial-port.org%2Farticles%2Falternative-to-hyperterminal
%2F&psig=AOvVaw1A62ixCfMH-
2wQmxwIAFvj&ust=1594708855742000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCIjV0M7PyeoCFQAAAAAdAAAAAB

Ab)

2. Again, a new tab opens with properties of COM35, COM35 is nothing but a machine
language. And this tab consists is entries such as Data bits, Bits per second, Stop bits etc.
Then click OK.

Fig 4.15: Terminal Emulator

(https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.cisco.com%2Fc%2Fen%2Fus%2Fsupport%2Fdocs%2Fdial-
access%2Fasynchronous-connections%2F9321-terminal-settings.html&psig=AOvVaw1A62ixCfMH-
2wQmxwIAFvj&ust=1594708855742000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCIjV0M7PyeoCFQAAAAAdAAA

AABAn)

3.Now it will display the presence of carbon-monoxide, methane, and temperature.

Page | 32
 Fig 4.16: Client Software

(https://www.google.com/url?sa=i&url=https%3A%2F%2Fwindowsshareware.com%2Fproducts
%2F10215%2F&psig=AOvVaw1A62ixCfMH-
2wQmxwIAFvj&ust=1594708855742000&source=images&cd=vfe&ved=0CAIQjRxqFwoTCIjV0M7PyeoCFQAAAAAd)

4.3 SYSTEM ARCHITECTURE:

4.3.1 FLOW CHART FOR SMART HELMET WORKING:

BATTERY

VOLTAGE REGULATOR

METHANE(MQ4) MQ7
LM35
)

ARDUINO UNO
Page | 33
 ZIIGBEE
TRANSMITTER
LCD DISPLAY

ZIGBEE
PC
RECIEVER

4.3.2 FLOWCHART FOR MINING AND MONITORING SECTION:

START

GET THE VALUES FROM SENSOR TO

MICROCONTROLLER(ARDUINO)

CONVERT THE FREQUENCY FORM DATA TO

MACHINE LANGUAGE

Page | 34
 THE CONVERTED DATA IS PASSED TO THE
ZIGBEE TRANSMITTER

TRANSMITTER TRANSFERS THE DATA TO THE

RECEIVER IN BASE STATION CONNECTED
WITH COMPUTER

IF THE RESEAVED DATA FROM SOURCES

EXCEEDS THE THRESHOLD VALUE

DANGER CONDITION

ALERTING THE MINERS

Page | 35
 Fig 4.17 Detailed Description of ARDUINO UNO Board

Page | 36
4.3.3 ELECTRONIC CIRCUIT LAYOUT:

Page | 37
 CHAPTER-5

METHODOLOGY

METHODS:

WORKING OF THE SYSTEM:

This system works based on the parameters of two sections one is mining section and the
other is monitoring system.

5.1 MINING SYSTEM:

o In the mining industry, sensors are used for measuring factors like gas & temperature.

o This is so because adverse effects of the mine environment and harmful gases such as
Carbon Monoxide & Methane may cause gas poisoning, suffocation to death, explosion,
fainting due to fatigue or absence of oxygen.

o So the project is aimed at developing a network of wireless sensors ,incorporated in a

Miner's Safety Helmet , which is based on ZigBee wireless technology.

o The helmet's main function is to reduce the potentiality of safety hazards such as
excess temperatures , presence of fire , spontaneous heating, and presence of harmful and
toxic gases.

o The helmet consists of a microcontroller known as Arduino, temperature

sensor(LM35), gas sensor for (MQ4) for sensing methane and (MQ7) for detecting CO,
voltage regulator(15V), ZigBee transmitter and receiver, 16*2 LCD screen to display the
output and a battery to sufficient electric power to the devices.

o First turn on the battery 15V current is passed to the voltage regulator there it splits or
separates 15V current into 3*5V current to provide voltage supply of 5V 3 sensors
(LM35, MQ4, MQ7).[8]

Page | 38
 o Let's say suppose the gases such as Methane & Carbon Monoxide are eliminated in
the air. If the toxic gas content is ranging from 30PPM-5000PPM the gas sensors will
sense the harmful gases present in the air and if the parameters are beyond the permissible
limits, then the sensors in the helmet detect the quantity and display it along with a
warning.

o Arduino is also known as micro controlled receiver the digital value from the sensor
in frequency form.

o If converts the frequency form data to machine language and send to machine
language and send it to ZigBee transmitter.

o Compare that value with the threshold value programmed in ARUDINO.

5.2 MONITORING SECTION:

• In third section the transmitter sends digital values from the different sensors to the
ZigBee receiver module which is connected to a computer by using a USB cable and this
computer receives the digital values.

• The information received by the ZigBee Receiver Module is sent to the administrator
via the administrator's monitor , which displays the detected data to the remote monitoring
site or the ground section.

• We can see the values of different sensor on computer using software

• The coding of the data of three sensors will be displayed in administrator’s computer
in case if any danger conditions found by monitoring unit the safety actions will be taken
immediately.

• This safety system changes the miner's way of working, while providing improved
safety to them.

• It also improves the decision-making system which controls the various changes in
the mine environment.

Page | 39
• ZigBee based Smart Safety Helmet is a wireless mine supervision system , which is
cost effective and includes early warning security system for the various harmful gases and
temperature in the mining environment.

CHAPTER-6

RESULTS

RESULTS:

ZIGBEE
TRANSMITTER

MQ7

TEMPERATU
RE SENSOR

ARDUINO UNO

VOLTAGE
REGULATOR

BATTERY

SAFETY HELMET

LCD DISPLAY

The circuit system connecting process of this ZigBee based safety helmet with wires,
battery, micro controller, ZigBee module and sensors are done successfully

Page | 40
TABLE 6.1:

S.NO TEMPRATURE CO
1 35 68
2 35 265
3 35 152
4 35 83
5 31 150
6 34 57
7 37 53
8 39 37
9 40 37
10 46 36
11 40 25
12 36 32
13 38 32
14 42 32
15 39 34
16 40 30
17 37 29
18 40 33
19 39 31
The readings were taken in room temperature, using Colin liquid, using Vehicle
Exhaust, in an outside environment under the Sun, etc. While taking readings under the
Sun, there was not any substantial differences in the amount of Methane and Carbon
Monoxide detected. The fluctuations in Temperature was noticeable.

If temperature rises above 50 then it indicates an abnormal temperature.

If the reading detected by the MQ7 sensor is above 150, then it will indicate carbon
monoxide level is abnormal.

Page | 41
TABLE 6.2:

S.No METHANE
1 200
2 146
3 133
4 90
5 70
6 59
7 51
8 48
9 63
10 37
11 50
12 46
13 45
14 43
15 44
16 44
17 43
18 43

As sources for methane , LPG gas and burning wood were used. The initial readings were
visibly higher due to sudden release of the LPG gas into the detecting atmosphere, but
gradually the readings started to decrease as the gas began to dissipate in the air. As this is an
uncertified project , we were unable to secure Permission for carrying out experiments inside
a mine’s premise.

Page | 42
 CHAPTER -7

CONCLUSION

CONCLUSION:

 Zigbee based wireless real time monitoring safety helmet for underground mines. It is
a safety instrument. It should be used by the underground mine workers for their
safety. This device is prescribed as the underground mine atmosphere contains
harmful and inflammable gases. Therefore, it is very important to practice the usage
of a device like this Safety Helmet. As of now this safety helmet is not widely used in
Indian mines due to its uneconomic price. More research work must be carried out to
make this safety device cheaper, more reliable and to ensure its wide availability in
the market. This device would be a reliable addition to the existing Personal
Protective Equipment (PPE’s).
 The Safety Helmet has been successfully used in detecting Temperature, Methane and
Carbon-Monoxide in a particular atmosphere.
 Although there are Rules and Regulations authorized and advised by the respective
Governmental bodies, mining accidents are still occurring. This shows that there is
more room for improvement of existing safety systems. This was the statement that
gave inspiration for proceeding with this Safety Helmet.
 It is also worth mentioning that further advancements, for this helmet, are being
researched and some waiting for patent rights ,from the U.S, by DRAGER company.
 But due to the Indian economy and large workforce present, it is not feasible to
purchase this helmet, in bulk, at high costs. This has led to the ignorance of such
safety devices which could play potential roles in saving human lives and loss of
property and machinery for the companies.

REFERENCE:

Page | 43
 1. Timko, R. J., & Derick, R. L. (1900). Methods to determine the status of mine
atmospheres-an overview.
2. https://www.britannica.com/technology/mine-gas
3. Cheng, J., Wang, C., & Zhang, S. (2012). Methods to determine the mine gas
explosibility–An overview. Journal of Loss Prevention in the Process Industries, 25(3),
425-435.
4. https://www.digi.com/solutions/by-technology/zigbee-wireless-
standard#:~:text=Zigbee%20is%20a%20wireless
%20technology,900%20MHz%20and%20868%20MHz.
5. Elements of mining technology vol-2,D.J. Deshmukh, chapter-1. Publish in
2014
6. https://nptel.ac.in/courses/123/106/123106002/lecture%202 accessed on 02-
march-2020.
7. https://miningquiz.com/download/minegases.htm accessed on 02-march-2020.
8. A handbook on gas testing by N.C.Karmakar Published in 2014.
9. https://en.wikipedia.org/wiki/Arduino_Uno
10. https://www.pololu.com/file/0J313/MQ7.pdf
11. https://components101.com/sensors/mq-4-methane-gas-sensor-pinout-
datasheet
12. https://components101.com/lm35-temperature-sensor
13. https://www.britannica.com/technology/voltage-regulator#:~:text=Voltage
%20regulator%2C%20any%20electrical%20or,electrical%20equipment
%20using%20that%20voltage.
14. https://components101.com/7805-voltage-regulator-ic-pinout-datasheet
15. https://components101.com/16x2-lcd-pinout-datasheet
16. https://en.wikipedia.org/wiki/Arduino_IDE
17. https://www.hilgraeve.com/knowledge_base/what-is-hyperterminal/

Page | 44
Page | 45