Efficient Material Handling through Smart Hopper Level Monitoring and Conveyor Speed Control

In the fly ash bricks manufacturing industry, effective management of raw materials is essential for both economic efficiency and environmental sustainability. The project proposes a comprehensive solution utilizing advanced sensor technologies to streamline the handling of fly ash mixtures in the production process. The primary objective is to address the inefficiencies associated with traditional hopper systems, where material wastage due to overflow is a common issue. To mitigate this, ultrasonic sensors are deployed to monitor the level of the hopper continuously. Real-time data from these sensors enable precise control over the material intake, ensuring that the hopper remains at an optimal capacity, thus minimizing waste. Moreover, the project integrates humidity sensors within the hopper to monitor the moisture content of the fly ash mixture. This data is crucial for maintaining the desired consistency of the mixture, as it directly impacts the quality of the bricks produced. By automatically adjusting water spray levels based on humidity sensor feedback, the project ensures consistent and efficient mixing. Temperature sensors are also incorporated into the hopper system to monitor the thermal conditions. Maintaining the appropriate temperature range is critical for the chemical reactions involved in the brick manufacturing process. The temperature data collected by these sensors enable proactive adjustments to the production environment, optimizing the overall efficiency and quality of the process. To facilitate seamless control and automation, the project utilizes a DC motor with pulse width modulation (PWM) to regulate the speed of the conveyor belt carrying the fly ash mixture. The motor speed is dynamically adjusted based on the data received from the sensors, ensuring smooth and efficient material flow while minimizing energy consumption.