Poxisafe Helmet: A Smart Safety Solution for Industrial Environments

In high-risk industries like mining, construction, and the chemical industry, worker safety is frequently compromised by insufficient monitoring and a delayed response to emergencies. The PoxiSafe Helmet, a wearable safety device with two communication channels and cutting-edge sensors, is discussed in this paper. Real-time monitoring is made possible by the embedded design. The PoxiSafe Helmet is based on the ESP32-S3 microcontroller. The BNO055 was used for fall detection, and the MAX30102 was used for vital signs (heart rate and SpO₂). CCS811 was used to test air quality and gas detection, while DHT22 was used to collect temperature and humidity measurements. The data was sent via Bluetooth Low Energy (BLE) for short-distance communication as well as LoRa for long-distance and power-efficient communication when signal impairments are present. The results demonstrate reliable fall detection, health monitoring accuracy within ±3 % of commercial health monitors, and stable gas detection after settling. There was reliable BLE communication up to 20 meters indoors. For the LoRa tests, there was great long-distance and power-efficient communication up to 500 meters outdoors, with packet loss of less than 5%. The findings indicate that the PoxiSafe Helmet is a viable and economical means of promoting safety in industrial occupations, enabling timely notification of supervisors who can then mitigate risks in the workplace.