Alarm when entering restricted zones in workshops
A danger zone is defined around a machine or electrical panel; when anyone crosses its boundary an alarm sounds and the machine stops. The boundary is drawn with laser distance sensors forming an invisible curtain, rather than a floor line that can fade or be ignored.
The problem
Safety lines painted on the floor wear away and get ignored, and workshop accidents usually happen because someone stands for a few seconds where they shouldn't. Physical barriers get in the way of work, so they're removed a few days after installation.
How it works
- Defining the zoneLaser distance sensors draw the boundaries of the restricted zone.
- MonitoringAny object crossing the reference distance is detected instantly.
- RecognitionThe detection duration determines whether it's a quick crossing or actually standing inside the zone.
- ResponseAn audible and visual alarm sounds, and the relay cuts power to the machine.
Project features
- A laser curtain defines the zone with centimeter precision, instead of a painted line.
- Instantly cutting the machine's power, not just sounding an alarm.
- Telling a quick crossing from standing inside the zone.
- A log of every breach with its time, useful for safety reports.
Preparing the interactive model…
Part models from the libraries KiCad andEspressif (CC-BY-SA 4.0), lighting from Poly Haven. Click any part's name to zoom in on it.
Parts
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Expected challenges
These are the main obstacles to expect during the build, laid out clearly so you know them before you start.
- The distance sensor is affected by shiny and black surfaces, so it needs on-site calibration.
- Suddenly cutting the machine's power can damage the work in progress, so a carefully staged response is needed.
- Workshop dust covers the sensor lens and causes false alarms.
- The number of sensors grows with the zone's size, so full coverage is expensive.
The consultation gives you a solution for each one.
Similar projects
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Students' experiences
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Need solutions to the challenges and a complete technical path?
In the consultation we give you a solution for each challenge above, plus a practical build plan from the first step to the last: technologies, libraries, wiring diagram, timeline, and tips for the defense.
- Consultation session
- PDF with solutions and a plan
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