Digitalization of Welding Safety Equipment for Workers Safety

Diploma Mechanical Engineering

Welding processes generate a variety of hazardous substances due to the interaction of high temperature, ultraviolet radiation, surface coatings on metals, electrode materials, shielding gases, and airborne chemicals released from cleaning agents. These factors lead to the formation of welding fumes and gases that pose serious risks to worker health. One of the most common short-term health effects is metal fume fever, which usually develops within a few hours after exposure. Symptoms may include fever, chills, muscle pain, chest tightness, coughing, fatigue, nausea, excessive thirst, and an unpleasant metallic taste. To reduce these occupational hazards, this project introduces three safety-oriented enhancements integrated into two welding protection devices. The first enhancement is a smart electronic welding helmet that incorporates an eye-blink sensing mechanism. This feature allows the welder to control the movement of the protective glass through natural eye blinking, eliminating repeated manual adjustments. The welding glass automatically changes from a clear state to a darkened state during arc initiation and returns to transparency when welding stops. The second enhancement involves the design of an intelligent welding electrode holder equipped with an arc-detection sensor. When welding begins, the sensor identifies arc radiation and instantly activates a connected fume extraction suction fan. This system removes welding fumes directly from the source, significantly limiting the amount of smoke reaching the welder’s face and body.

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