Smart Welding Fume Monitoring and Automated Safety Alert System Using IoT

  • Unique Paper ID: 198898
  • Volume: 12
  • Issue: 11
  • PageNo: 10928-10933
  • Abstract:
  • The welding process generates dangerous gases and fine particulates that are harmful to workers and may cause respiratory disorders, eye irritation, and occupational diseases. Prolonged exposure to these gases in an unmonitored environment may lead to accidents and health issues. This paper introduces a smart real-time welding fume monitoring and alert system that aims to enhance workplace safety by detecting dangerous gases during welding processes. The proposed system uses an MQ-135 gas sensor to detect dangerous gases and an ESP32 microcontroller to analyze sensor data and manage safety responses. The gas concentration values are locally displayed using a 16×2 LCD display, allowing workers to monitor air quality levels in real time. When gas concentration values exceed safety limits, the system automatically triggers multiple safety alerts, such as LED lights, buzzer alarms, and a ventilation fan using a relay module, ensuring immediate safety action. The system is developed with a modular and cost-effective design, making it ideal for small and medium-scale workshops where expensive monitoring systems may not be economically viable. The prototype system was tested, and the results showed effective real-time gas detection, accurate gas concentration level display, and timely activation of safety alerts, proving its efficacy in protecting workers

Copyright & License

Copyright © 2026 Authors retain the copyright of this article. This article is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

BibTeX

@article{198898,
        author = {Prachi R. Ayate and Prof. Akshay A. Manikjade and Pragati G. Bhople and Pranjal S. Aware},
        title = {Smart Welding Fume Monitoring and Automated Safety Alert System Using IoT},
        journal = {International Journal of Innovative Research in Technology},
        year = {2026},
        volume = {12},
        number = {11},
        pages = {10928-10933},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=198898},
        abstract = {The welding process generates dangerous gases and fine particulates that are harmful to workers and may cause respiratory disorders, eye irritation, and occupational diseases. Prolonged exposure to these gases in an unmonitored environment may lead to accidents and health issues. This paper introduces a smart real-time welding fume monitoring and alert system that aims to enhance workplace safety by detecting dangerous gases during welding processes. The proposed system uses an MQ-135 gas sensor to detect dangerous gases and an ESP32 microcontroller to analyze sensor data and manage safety responses. The gas concentration values are locally displayed using a 16×2 LCD display, allowing workers to monitor air quality levels in real time. When gas concentration values exceed safety limits, the system automatically triggers multiple safety alerts, such as LED lights, buzzer alarms, and a ventilation fan using a relay module, ensuring immediate safety action. The system is developed with a modular and cost-effective design, making it ideal for small and medium-scale workshops where expensive monitoring systems may not be economically viable. The prototype system was tested, and the results showed effective real-time gas detection, accurate gas concentration level display, and timely activation of safety alerts, proving its efficacy in protecting workers},
        keywords = {IoT-based safety system, ESP32 microcontroller, MQ-135 gas sensor, Real-time detection, Occupational health, Ventilation control, Sensor-based monitoring, Cloud data logging},
        month = {April},
        }

Cite This Article

Ayate, P. R., & Manikjade, P. A. A., & Bhople, P. G., & Aware, P. S. (2026). Smart Welding Fume Monitoring and Automated Safety Alert System Using IoT. International Journal of Innovative Research in Technology (IJIRT), 12(11), 10928–10933.

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