Intelligent Monitoring of BECS Conveyors via Vision and the IoT for Safety and Separation Efficiency

Conveyor belts are critical in various industries, particularly in the barrier eddy current separator systems used in recycling processes. However, hidden issues, such as belt misalignment, excessive heat that can lead to fire hazards, and the presence of sharp or irregularly shaped materials, reduce operational efficiency and pose serious threats to the health and safety of personnel on the production floor. This study presents an intelligent monitoring and protection system for barrier eddy current separator conveyor belts designed to safeguard machinery and human workers simultaneously. In this system, a thermal camera continuously monitors the surface temperature of the conveyor belt, especially in the area above the magnetic drum—where unwanted ferromagnetic materials can lead to abnormal heating and potential fire risks. The system detects temperature anomalies in this critical zone. The early detection of these risks triggers audio–visual alerts and IoT-based warning messages that are sent to technicians, which is vital in preventing fire-related injuries and minimizing emergency response time. Simultaneously, a machine vision module autonomously detects and corrects belt misalignment, eliminating the need for manual intervention and reducing the risk of worker exposure to moving mechanical parts. Additionally, a line-scan camera integrated with the YOLOv11 AI model analyses the shape of materials on the conveyor belt, distinguishing between rounded and sharp-edged objects. This system enhances the accuracy of material separation and reduces the likelihood of injuries caused by the impact or ejection of sharp fragments during maintenance or handling. The YOLOv11n-seg model implemented in this system achieved a segmentation mask precision of 84.8 percent and a recall of 84.5 percent in industry evaluations. Based on this high segmentation accuracy and consistent detection of sharp particles, the system is expected to substantially reduce the frequency of sharp object collisions with the BECS conveyor belt, thereby minimizing mechanical wear and potential safety hazards. By integrating these intelligent capabilities into a compact, cost-effective solution suitable for real-world recycling environments, the proposed system contributes significantly to improving workplace safety and equipment longevity. This project demonstrates how digital transformation and artificial intelligence can play a pivotal role in advancing occupational health and safety in modern industrial production.