A Review on Wireless Industrial Safety Helmet Using ESP32 with IoT

Industrial worksites such as mines, construction sites, and manufacturing plants expose workers to hazards including toxic gas leakage, extreme temperature, falls, and head injuries. Conventional safety helmets provide only passive mechanical protection and cannot alert supervisors in real time when a worker is in danger. This paper presents a review of a Wireless Industrial Safety Helmet built around the ESP32 microcontroller and integrated with Internet of Things (IoT) technology. The helmet continuously monitors ambient gas concentration, temperature, humidity, helmet-wearing status, and worker movement using an MQ-135 gas sensor, DHT11 temperature and humidity sensor, MPU6050 accelerometer-gyroscope module, and a helmet-wearing detection switch. Upon detecting an unsafe condition or upon manual panic activation, the system triggers local audio-visual alerts through a buzzer, LED, and OLED display, while simultaneously transmitting sensor data over Wi-Fi to a cloud IoT platform for real-time supervisor monitoring. The system is powered by a rechargeable Li-ion battery with a regulated charging and power-distribution circuit. The proposed architecture and workflow are presented ahead of full hardware validation.