Wearable IoT Devices for Decentralizing Emergency Controls in Kiln Operations

An Industrial IoT Safety Innovation

To enhance worker safety in a high-temperature manufacturing environment, we developed a wearable IoT device that provides a decentralized emergency stop mechanism for industrial kilns.

The Challenge

The Need for Decentralized Safety

In a high-temperature industrial manufacturing environment, kilns operate at temperatures exceeding 1400°C, posing serious safety risks to floor operators. The existing emergency stop mechanism was fixed at a specific location near the kiln, requiring workers to physically approach the dangerous area to stop the machine in the event of an anomaly, malfunction, or safety hazard. This system introduced multiple issues like delayed response times, exposure to heat hazards, and inaccessibility. To ensure faster, safer, and decentralized control, a new approach was required one that empowered the workers to take immediate action from their current location.

Our Solution

Wearable Emergency Stop Device

To address the risks and limitations, we designed and deployed a Wearable Emergency Stop Device integrated into an Industrial IoT (IIoT) architecture. The solution enabled operators to instantly halt kiln operations from a safe distance, improving both safety and reaction time.

Key Solution Features:

Wearable Form Factor: Rugged wristband or belt-clip with a large tactile emergency stop button.
Wireless Connectivity: Utilized LoRa for long-range, low-power signal transmission.
Redundant Communication: Dual-channel signaling for reliable performance.
Safety Feedback: LED and haptic feedback confirmed emergency activation.
Edge Gateway Integration: Signals routed through IIoT gateways to Safety PLCs
Controlled Shutdown: Safety PLC executed controlled shutdown and notified SCADA systems.
User Authentication & Logging: Authorized use with event logging for SCADA/MES.

Impact & Results

Measurable Safety Improvements

80% reduction in average response time.
Zero operator exposure to heat zones.
Increased worker confidence and safety.