Hand Safety System for Steel Industry

The increasing demand for intelligent safety systems in industrial environments, particularly within the steel manufacturing sector, has led to the development of advanced solutions aimed at minimizing workplace hazards. This paper presents a microcontroller-based hand safety system designed to reduce the risk of hand-related injuries near industrial cutting machines. The proposed system integrates an ultrasonic sensor to detect proximity and an MLX90614 thermal sensor to confirm the presence of a human hand based on thermal signatures. Upon detecting an intrusion within a critical range, the system activates a buzzer and displays a real-time warning message on an LCD screen while simultaneously deactivating the machine using a relay switch. This layered detection mechanism significantly reduces false positives and enhances response accuracy. Powered by an Arduino microcontroller, the system ensures real-time decision-making and rapid intervention, offering improved safety without human dependency. Testing in a simulated industrial environment demonstrated high reliability, quick response, and robust performance under varying operational conditions. The system represents a low- cost, scalable solution for real-time accident prevention in hazardous workspaces and offers a foundation for future enhancements using IoT, machine learning, and predictive maintenance features for broader industrial applications.