Hand Detection in Hazardous Zones of Frozen Tuna Cutting Machines Based on an Infrared Thermopile Sensor

To address the challenge of hand intrusion detection in frozen tuna cutting operations where operators wear thermal-insulating gloves, this study proposes a hand detection method based on dual-domain background modeling with absolute accuracy constraints. To tackle issues arising from low-resolution infrared arrays, such as defective pixels, random noise, and complex low-temperature backgrounds, a data preprocessing pipeline integrating defective pixel correction, exponential moving average (EMA), and median filtering is developed. A dual-domain background suppression (DDBS) strategy, combining spatial-domain and temporal-domain models with sensor absolute accuracy constraints, is employed to extract hand foregrounds under complex thermal conditions. Temperature thresholding, connected-component analysis, and hole-filling are further applied to effectively separate hands from frozen tuna. An experimental platform incorporating a Raspberry Pi 4B and an MLX90640 sensor was constructed, and a dataset comprising 1173 infrared frames was collected for validation purposes. Experimental results demonstrate that the proposed method achieves an accuracy of 94.12%, precision of 91.69%, recall of 97.55%, and F1-score of 94.53% for hand intrusion detection, with an average processing time of approximately 1.84 ms per frame. This provides a cost-effective, real-time solution for hand safety monitoring in frozen food processing operations.