Design and Implementation of an IoT-Based Coal Mine Safety and Alert System for Improved Miner Safety

Abstract

Coal mining is one of the most hazardous industrial activities, often exposing workers to life-threatening conditions such as toxic gas leaks, high temperatures, and equipment failure.To enhance miner safety and minimize accidents, this paper presents the design and development of an IoT-based coal mine safety and alert system [1]. The system integrates various sensors to monitor environmental parameters including methane gas concentration, carbon monoxide levels, temperature, and humidity [1]. Data collected from the sensors is transmitted in real-time to a central monitoring system using wireless communication modules [2].In case of abnormal conditions, immediate alerts are sent to both miners and surface control units through alarms and mobile notifications [2].The system enables early detection of potential threats, facilitating timely evacuation and response.By leveraging IoT technology, the proposed solution aims to improve operational safety, reduce manual inspections, and enhance decision-making [3].The design is cost-effective, scalable, and adaptable to various mine environments.This approach contributes significantly to building a smarter and safer mining ecosystem [3].

Introduction

The coal mining industry is one of the most hazardous sectors, with risks like gas leaks, high temperatures, and structural collapses. Traditional safety systems often fail to provide real-time alerts, resulting in delayed responses and higher accident rates.

To address this, the document proposes an IoT-based safety and alert system designed to continuously monitor underground conditions using smart sensors and microcontrollers. These systems provide automated, instant alerts for gas levels, temperature, humidity, and vibrations, helping to ensure miner safety and reduce accident-related costs.

Key Components & Methodology

• Sensors used:

  • MQ-2, MQ-7 for gas detection

  • DHT11 for temperature and humidity

  • Vibration sensors for structural monitoring

• Microcontrollers like Arduino or Raspberry Pi serve as the central units for processing and communication.

• Data transmission via Wi-Fi, Zigbee, or LoRa to a cloud or local server enables remote monitoring.

• Alert systems include alarms, warning lights, and mobile notifications when unsafe conditions are detected.

• Backup systems (batteries and communication modules) ensure operation during power failures.

• Testing and validation are performed under simulated mining conditions to ensure accuracy, fast response, and stability.

Results & Discussion

• The system successfully monitored environmental conditions such as methane, CO, O? levels, temperature, humidity, and vibrations.

• Real-time alerts allowed faster responses, reducing risk to miners.

• Wireless communication and system integration were stable and efficient.

• Challenges remain in areas like underground connectivity, power management, and sensor calibration.

• The system demonstrated that automated alerts and environmental tracking significantly enhance mine safety.

Future Scope

1. AI-Powered Hazard Prediction – Use of machine learning for predicting gas leaks or structural failures in advance.

2. Wearable Safety Devices – Smart helmets or vests that monitor miner vitals and environmental conditions.

3. Drone Surveillance – UAVs with gas sensors and thermal cameras for remote inspection and emergency support.

4. Smart Rescue Robots – AI-powered autonomous robots for navigating hazardous zones and aiding in rescue.

5. Real-Time Miner Tracking – Indoor positioning systems (Bluetooth, RFID, UWB) to locate miners in emergencies.

6. Predictive Maintenance – IoT-based monitoring of mining equipment to anticipate and prevent machinery failures.

Conclusion

The Design and Implementation of IoT Based Alarm Systems and Security Camera Framework fosters mineworker security solutons by providing real time monitoring and early warnings. Conventional coal mining operations face numerous hazardous conditions for example, toxic gas exposure, structural failure, and poor ventilation which are dangerous to mineworkers. Combination of IoT technology with this system provides environment monitoring, immediate danger identification and computerized alarming, thereby reducing mishaps and improving emergency response times. The use of smart sensors, AI analytics, remote sentry guns, and military grade defense systems further enhance security making coal mines safer and more efficient. Moreover, other advancements like smart enabling wearables, predictive maintenance, and AI powered threat detection help improve the safety of workers. As technology continues to grow, this IoT based system has limitless possibilities to revolutionize mining security and create an economical working environment for mineworkers globally. As technology continues to evolve, this IoT based system stands limitless possibilities to revolutionize mining security and create a cost effective working environment for miners around the globe. The combination of having a blockchain technology for secure information logging, along with automated response systems, can enhance security measures.

References

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Copyright

Copyright © 2025 Prof. Paritosh Nagarnaik, Damini Talmale, Priyanka Meshram, Kashish Kesharwani, Sujal Musale. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.