Design of Modular 4G Intelligent Safety Helmet and Communication Engineering Construction Safety Management
Design scheme of modular intelligent safety helmet
Product Name: Modular Safety Intelligent Safety Helmet
Core features:
Basic helmet body integration: Near electric alarm module, trajectory positioning module, built-in helmet body, non removable, serving as the basic base function of the safety helmet;
Video capture, auxiliary lighting, high-altitude warning, facial recognition, safety helmet buckle warning, and voice intercom are all independent and detachable functional modules, with a dual locking structure of magnetic suction and buckle, supporting on-demand assembly. Unused modules can be directly removed to reduce weight and power consumption;
Unified bus interface: A standardized universal interface slot is set on the outer side of the helmet body for unified power supply, data communication, and module plug and play recognition;
Protection level: The helmet body meets the GB2811 national standard for safety helmets, with an overall IP65 rating, suitable for high-risk work scenarios such as construction, power, mining, and tunnels;
Overall architecture: Helmet base (main control, battery, near power alarm, positioning)+pluggable functional module group+backend management platform.
Design logic: Near field alarm and trajectory positioning are basic safety requirements. Antennas, induction coils, GPS/Beidou modules require shielding protection inside the helmet and are not suitable for external disassembly and assembly. They are fixed on the base; All other functions are made into independent modules, which users can purchase, disassemble and assemble as needed.
1、 Safety helmet body base (non removable base unit)
Hardware composition
Safety helmet body: ABS high-strength engineering plastic helmet shell, national standard safety helmet lining cushioning structure, native helmet strap wearing mechanism; Reserve multiple sets of module installation slots, distributed in front of the cap, on the left and right sides of the cap, at the top of the cap, and behind the cap.
Built in main control unit: MCU main control, 4G/5G communication, local storage, module hot plug recognition, unified power management.
Built in lithium battery: large capacity detachable battery, base battery compartment, supports fast charging; All external modules are uniformly powered by the base.
Curing module 1: Near electric alarm module (built-in helmet, non removable)
Function: Non contact electric field induction, detecting high-voltage live equipment, supporting multi level voltage threshold alarm; When the distance to the high-voltage equipment reaches the warning distance, sound and light+helmet vibration alarm will be triggered; Support threshold backend configuration.
Output: Local sound and light vibration alarm, while uploading alarm events to the platform.
Solidification module 2: Beidou+GPS trajectory positioning (built-in helmet, non removable)
Function: Real time personnel location reporting, action trajectory storage and playback, electronic fence crossing alarm; Support offline trajectory caching, and supplement position data after restoring the network in areas without signal.
Standardized interface: The cap body is equipped with a unified magnetic suction spring type electrical interface at multiple locations, with physical snap locking. Each module can be connected to the interface to complete power supply and data transmission without the need for wiring.
Base software capability
Automatically identify the functional modules that are connected, and automatically block the corresponding functions for modules that are not installed;
Local edge computing: some early warnings are judged locally in the safety helmet and do not rely on the cloud network;
Unified alarm output: The helmet body integrates a buzzer, status indicator light, and built-in vibration motor, and all modules generate unified sound, light, and vibration prompts for alarms.
2、 Detachable independent functional modules (all modular, optional and detachable as needed)
Each module is an independent unit with an IP65 protective shell and comes with a fixed buckle and magnetic contacts; No need to remove directly, it does not affect the basic protection of the safety helmet; Modules are independent of each other and can be combined and matched freely.
Module 1: Video capture module (front brim installation)
Installation position: The brim slot in front of the safety helmet
Hardware: high-definition camera, infrared night vision, microphone pickup; Local TF card storage, supporting real-time video feedback, photography and recording.
Function: on-site audio and video capture, event recording, one click snapshot; Support cloud streaming.
Disassembly: Simply open the buckle outward and remove it; After removal, the video related functions fail.
Module 2: Auxiliary lighting module (optional or dual configuration on the left and right sides of the cap)
Installation position: slots on both sides of the safety helmet
Hardware: High power LED flood lighting, adjustable brightness level, flashing alarm light mode.
Function: Night/tunnel operation lighting; Alarm event linkage automatically turns on flashing lights.
Features: Can be installed on one side or both sides; No need to dismantle directly, reduce weight and save electricity.
Module 3: Climbing Warning Module (Hat Top Installation Module)
Installation position: Top slot of safety helmet
Hardware: high-precision barometric altitude sensor, three-axis accelerometer gyroscope.
Function:
Height threshold alarm for climbing, triggering local alarm when exceeding the set working height;
High altitude falling detection, identifying personnel falling impact, and automatically reporting falling alarm;
Attitude detection, serious collision warning for safety helmet.
Logic: The module is removed, and the high-altitude and fall detection functions are turned off.
Module 4: Facial recognition module (front-end, compatible with the same position as the video capture module)
Attention: Occupying the same front slot as the video capture module, choose one or stack them together (double layered slots can be designed for simultaneous assembly)
Hardware: Small facial recognition camera, supplementary infrared light.
Function:
Wear personnel identity verification and on-the-job facial recognition;
Identify unauthorized personnel wearing safety helmets and generate alarms;
The platform can be linked to record the information of personnel on duty.
Description: Removable, facial recognition function will be turned off after dismantling, without affecting other modules.
Module 5: Safety helmet buckle warning module (chin strap buckle module)
Installation location: at the buckle of the safety helmet chin strap, modular buckle component, replacing the original ordinary buckle.
Hardware: pressure sensor, Hall sensing unit.
Function: Check if the chin strap of the safety helmet is securely fastened; Unrepaired buckle, loose wearing, triggering sound and light alarm and uploading to the platform.
Disassembly and assembly: Replace the original chin buckle of the safety helmet directly, and replace it with a regular buckle without any need. Disassemble it as a whole.
Module 6: Voice intercom module (newly added, cap side card slot installation)
Installation position: The safety helmet has an independent slot on the side, which can be separated from the auxiliary lighting module on both sides without occupying the slot.
Hardware: noise cancelling MEMS microphone, high-power waterproof speaker, PTT button (press to speak button); Built in audio codec unit.
Function:
Cluster intercom: supports single call, group call, and voice intercom between safety helmets of operators; Support the dispatch console to issue voice calls in the background.
Noise reduction treatment: Industrial wind noise suppression, clear sound pickup in construction sites and strong noise environments.
Alarm linkage: When various warning events occur, the platform can directly broadcast alarm prompts to the helmet voice.
One click call: The module comes with a physical PTT button, which can be used for short press group calls and long press emergency call scheduling in the background.
Audio linkage: It can collaborate with the video capture module to record intercom audio synchronously during video recording; After removing the video module, the intercom module can still work independently.
Disassembly and assembly: quick disassembly and assembly with snap fastener and magnetic suction spring plate; After the module is removed, all voice intercom, shouting, and audio broadcasting functions will be disabled, while other modules will not be affected.
3、 Example of assembly combination scheme (free combination)
Basic version (base only): Near electric alarm+trajectory positioning; The lightest, suitable for regular inspections.
On site inspection version: base+video capture+auxiliary lighting+voice intercom.
High altitude operation version: base+high-altitude warning+buckle warning+auxiliary lighting+voice intercom.
Personnel access control version: base+facial recognition+buckle warning+voice intercom.
Fully functional top of the line version: base+video capture+auxiliary lighting+altitude warning+facial recognition+buckle warning+voice intercom.
4、 Key points of mechanical structure design
Connection method: Dual structure of mechanical buckle limit and magnetic conductive spring plate.
Magnetic attraction enables rapid alignment; Lock the buckle to prevent vibration and detachment during operation; Disassemble and press the buckle to remove the module.
Interface protection: Rubber sealing gaskets are installed at the module interface position, which automatically seals the module after installation, preventing dust and water; After removing the module, the base interface comes with a dust-proof rubber cover plate.
Weight control: Each functional module is designed to be lightweight, with a single module weight controlled between 50-80g to avoid heavy helmets and light feet, ensuring balanced wearing.
Interchangeability: All module interfaces are unified, and any module can be installed in the corresponding slot. The firmware automatically recognizes it without hardware modifications.
5、 Software and Platform Features
Safety helmet end:
Module hot plug recognition, enabled upon module installation, automatically shuts down corresponding services upon disassembly;
Local edge computing alerts the local acousto-optic vibration prompt, caches data locally when the network is poor, and makes supplementary transmission after network recovery;
The voice intercom module has independent audio processing and can work independently or be linked with the video module for recording.
Backend management platform:
Personnel positioning trajectory replay;
Unified reception of various alarms: near-field alarm, altitude exceeding limit, falling alarm, hat buckle not fastened alarm, abnormal facial recognition;
Voice scheduling: initiate single call, group call, broadcast call, intercom recording, storage and playback;
Real time video viewing and recording playback;
Device status management: Identify which functional modules are currently installed on the safety helmet and display the module configuration list on the platform.
6、 Power consumption and power supply design
The base battery provides unified power supply, and each detachable module has no independent battery;
Software strategy: Uninstalled module systems automatically power off to reduce overall power consumption;
The battery supports hot swapping and replacement, meeting the needs of long-term operations.
7、 Explanation of Key Risk Points
The induction coil of the near-field alarm electric field and the Beidou GPS antenna must be embedded in the helmet body and cannot be modularized externally. If they are made into detachable modules, the antenna position will be offset and the metal module will be obstructed, which will cause positioning drift and near-field false alarms or omissions. Therefore, the base should be solidified.
All detachable modules adopt non-metallic shells to avoid the interference of metal parts with near current alarms in high-voltage operation scenarios.
After disassembling and assembling all external modules, the impact protection performance of the safety helmet body must not be damaged. The failure and detachment of the module does not affect the basic safety protection of the safety helmet.
The speaker and microphone openings of the voice intercom module are treated with waterproof and dustproof film to meet IP65 standards, preventing rainwater and dust from entering.