Industrial Safety & Monitoring System (IoT | ESP32)

This project is a real-time Industrial Safety and Environmental Monitoring System built using ESP32, designed to detect hazardous conditions such as gas leakage, fire, and abnormal temperature or humidity. The system automatically activates safety mechanisms (fan, buzzer alert) and provides a live monitoring dashboard accessible on any browser on the same network.

Hardware Components Used

• ESP32 Wi-Fi Microcontroller
• DHT11 Temperature & Humidity Sensor
• MQ-2 Gas Leak Sensor
• Flame Sensor Module
• Relay Module (2-channel)
• Active Buzzer for alert
• LED Indicators
• Cooling Fan

Software & Features

• ESP32 Web Server for live dashboard
• Auto-mode safety system
• Manual / Auto Fan Control
• Real-time readings of:
  • 🌡 Temperature
  • 💧 Humidity
  • 💨 Gas Leakage
  • 🔥 Flame Detection
• JSON API output
• Mobile-friendly UI

Working Principle

The ESP32 reads sensor data every 1.5 seconds. When readings exceed safety limits:

• Fan turns ON automatically
• Buzzer sounds alert
• Dashboard shows ⚠️ UNSAFE CONDITION
• LED turns RED

When normal, the system switches back to safe mode.

Web Dashboard Features

• Live sensor display
• Green/Red safety indicators
• Fan toggle buttons
• Responsive UI
• AJAX updates

Applications

• Industrial safety
• Chemical plants
• Fire monitoring
• Smart factories
• Warehouse safety

Future Enhancements

• Firebase / Cloud integration
• SMS / WhatsApp Alerts
• Android App
• Machine Learning prediction
• Solar + Battery backup

• To watch the demo video:

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Source Code

You can download the code for this project from the below.

📥 Download Source Code (.ino)