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Welcome to Safe Plus

Safe Plus - Smart Safety Helmet

Introduction

Industrial workplaces, such as construction sites, factories, and mining zones, show significant safety risks to workers due to environmental hazards, heavy machinery, and unpredictable conditions. Every year, thousands of accidents occur due to falls, exposure to toxic gases, and collisions with moving equipment. These incidents not only lead to injuries and fatalities but also result in financial losses for companies due to medical costs, downtime, and legal repercussions.

To address these challenges, Safe Plus introduces an advanced smart safety helmet that integrates real-time monitoring, impact detection, and emergency alert systems. By providing cutting-edge sensor technology and wireless communication, Safe Plus ensures worker safety through immediate hazard detection, automated alerts, and connectivity with supervisors.

Objectives

Improve Worker Safety

Enhance safety by monitoring workers in real-time using advanced sensors and alerts.

Immediate Alerts

Send prompt notifications for critical events to minimize response times.

Long-term Data Storage

Store safety data securely for future analysis and regulatory compliance.

User-Friendly Apps

Develop intuitive mobile and supervisor dashboard applications for easy monitoring.

Solution Architecture

Solution Architecture

Data Flow

Data Flow

Detailed Budget

Detailed Budget

Hardware & Software

Hardware

Our hardware design focuses on integrating embedded components for accurate data acquisition, safety, and real-time processing.

Core Hardware

  • ESP32 DevKit
  • DHT22 Sensor
  • MPU6050
  • Heartbeat Sensor
  • Gas Sensor (MQ-2/MQ-135)
  • GPS Module

The harware components are reinforced with a well structured Helmet Module ,a component box designed using AutoCAD Fusion and a well structured PCB designed and manufactured by us.

CAD Model for the Hadrware encasing
3D Model of the PCB

Software

Our software system is divided into embedded firmware and cloud-based backend services.

Embedded System

Language: C / Arduino Framework

Functions:

  • Reads sensor data periodically
  • Performs data preprocessing
  • Sends data via MQTT over Wi-Fi
  • Handles emergency interrupts

Backend Platform

  • Node.js + Express.js
  • MongoDB for data storage
  • AWS IoT Core (MQTT Broker)
  • React Dashboard
  • WebSocket for real-time updates

API & Services

  • RESTful APIs for:
    • Device registration
    • Alert retrieval
    • User profiles
  • Real-time WebSocket stream
  • Authentication system
  • Access control

Data Visualization

  • Live monitoring dashboard
  • Historical data analysis
  • Real-time alert notifications
  • Worker location tracking
  • Customizable views

Testing

Unit Testing

Each component was independently tested to ensure functionality and robustness.

Integration Testing

Tested end-to-end communication between helmet hardware, backend, and frontend interfaces.

Performance Testing

Measured system response time, uptime, and scalability under varying loads and stress conditions.

Testing

Our comprehensive testing approach ensures all components of the Safe Plus system work reliably under various conditions. We conducted rigorous testing at every level from individual sensors to complete system integration.

Firmware Testing

We conducted extensive unit testing on the helmet's firmware to ensure reliable operation:

Firmware Testing Results

API Testing

API Testing Results

Our backend API was thoroughly tested using Postman and automated scripts:

Hardware Testing

Each hardware component was tested under controlled conditions to verify specifications:

Humidity Sensor Testing

Humidity Sensor Calibration

Temperature Sensor Testing

Temperature Sensor Validation

Additional hardware tests included power consumption measurements, signal integrity checks, and enclosure durability testing.

Sensor Testing

Each sensor was tested individually and in combination with other components:

MQ2 Gas Sensor Testing

Verified response to various gas concentrations and threshold detection accuracy.

MPU6050 Fall Detection Testing

Validated impact detection sensitivity and false-positive prevention.

Additional sensor tests included GPS location accuracy verification and heart rate sensor reliability under motion.

End-to-End Testing

The complete system was tested in simulated real-world conditions:

Alert delay testing

Simulated fall detection with automatic alert generation and supervisor notification. SOS alerts were manually sent by the device to the dashboard.

Result: Alert received within 1.3 seconds average

Load Testing

A simulator was created to simulate multiple devices to check the system's response to heavy load. Backend reaching was monitored using ACKs.

Result: ~99% data transmission reliability for 1000 devices

Performance Metrics

Team

Samarakoon S.M.P.H.

Samarakoon S.M.P.H.

E/20/346

Siriwardane I.A.U.

Siriwardane I.A.U.

E/20/378

Wakkumbura M.M.S.S.

Wakkumbura M.M.S.S.

E/20/419

Wickramasinghe J.M.W.G.R.L.

Wickramasinghe J.M.W.G.R.L.

E/20/439