Design and Development of an IoT-Based Integrated Multi-Hazard Detection System for Industrial Applications

Abstract

The Smart Industry Safety: An IoT-Based Multi-Hazard Detection System for Fire, Gas, and Electrical Fault Detection is developed to provide real-time monitoring and effective management of hazardous conditions in industrial environments. Industrial workplaces are often exposed to risks such as fire outbreaks, gas leaks, electrical faults, and poor air quality, which can lead to property damage, injuries, or even loss of life. This system aims to reduce such risks by integrating smart sensors and IoT technology to continuously monitor critical safety parameters. When any hazardous condition such as fire, gas leakage, or electrical fault is detected, the system immediately sends alerts to responsible personnel, enabling quick action and preventing the situation from escalating. An integrated alarm system also provides audible alerts, and these alerts can be controlled remotely through a dedicated mobile application.

Introduction

The text describes an IoT-based industrial safety monitoring system designed to improve workplace safety in modern industrial environments where hazards like fire, gas leaks, electrical faults, and extreme environmental conditions are common. Traditional safety systems rely on manual monitoring and alarms, which are slow and error-prone, creating the need for an automated, real-time solution.

The proposed system uses IoT technology with sensors and microcontrollers to continuously monitor industrial conditions such as fire, harmful gas levels, temperature, humidity, and electrical current. Key sensors include a fire sensor, MQ135 gas sensor, DHT11 temperature/humidity sensor, and current sensor, all connected to an ESP32 microcontroller. When unsafe conditions are detected, the system triggers a buzzer alarm, activates a relay to shut down power, and sends instant alerts through the ESP RainMaker cloud platform for remote monitoring via mobile or web applications.

The system architecture consists of three main layers:

• Sensor layer: collects environmental and electrical data
• Processing layer (ESP32/Arduino): analyzes data and detects hazards
• Cloud layer: stores and visualizes data for real-time and historical analysis

It also supports predictive fault detection, allowing early identification of risks through historical data trends, enabling preventive maintenance and reducing accidents.

The hardware setup includes ESP32, Arduino Uno, fire and gas sensors, current sensor, DHT11, buzzer, LCD display, relay module, power supply unit, and cooling components like an exhaust fan.

Each component plays a specific role in detecting hazards, processing data, alerting users, and ensuring system safety. For example, the ESP32 acts as the central controller with Wi-Fi connectivity, while sensors detect environmental threats and the buzzer/LCD provide immediate local alerts.

Conclusion

The Industrial Safety Monitoring System using IOT provides an effective and reliable solution for monitoring hazardous conditions in industrial environments. The system is designed to detect potential dangers such as fire, smoke, and electrical faults by using multiple sensors connected to a microcontroller. By continuously monitoring environmental conditions, the system ensures early detection of hazardous situations and helps prevent accidents that may cause damage to equipment or risk the safety of workers. The integration of sensors with the microcontroller allows the system to analyze environmental data in real time and respond immediately when abnormal conditions are detected. When the sensors detect fire, smoke, or electrical faults, the system activates the buzzer alarm and generates alerts to notify workers and supervisors. This quick response mechanism improves industrial safety and helps prevent serious incidents in workplaces where hazardous materials or electrical equipment are present. Another important feature of the system is the integration of IOT technology through the ESP RainMaker platform. This allows users to monitor the safety status of the industrial environment remotely using a mobile application. Real-time alerts and notifications enable supervisors to respond quickly to emergencies even when they are not physically present at the industrial site. The results obtained during testing demonstrate that the system is capable of detecting hazardous conditions accurately and generating immediate alerts. The system operates continuously and provides reliable monitoring of industrial environments. Therefore, the proposed Industrial Safety Monitoring System can be considered an efficient and cost-effective solution for improving workplace safety and reducing the risk of industrial accidents.

References

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Copyright

Copyright © 2026 S. B. Warkad, Shantanu Umaratkar, Gaurav Gulhane, Sopan Kirde, Aditya Bhatkar, Nishant Bhagat, Kalyani Jadhav. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.