Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation

HeatShield is a smart temperature monitoring system developed using Arduino Uno and a TMP36 temperature sensor to help prevent heat stroke among industrial workers.

Smart Temperature Monitoring System for Heat Stroke Prevention in Industrial Workers using Arduino and TMP36 Sensor.

Automatic body cooling Arduino-controlled cooling system Real-time temperature monitoring Peltier thermoelectric cooling PCM cooling packs High-speed cooling fans USB-C rechargeable battery Lightweight wearable design Long battery backup Low power consumption Portable and comfortable Adjustable cooling levels Smart thermal management Worker safety enhancement Easy maintenance

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The device uses two Bluetooth-linked Fire Beetle BTE 4.1 boards paired with Arduino to collect sensor data and relay real-time information to a custom user interface.

The UI displays live sensor data, including heart rate graphs, temperature and humidity readings, UV index monitoring, and activity intensity visualization.

Heat stroke is a dangerous and sometimes fatal condition caused by prolonged exposure to high temperatures. In the U.S. alone, it contributes to over 700 deaths annually. High UV exposure and humidity increase risks—especially for vulnerable populations such as the elderly.

Wearable technologies offer a modern solution by enabling real-time environmental and physiological monitoring. This project introduces a wristband capable of tracking heart rate, UV exposure, temperature, and humidity to provide early warnings of dangerous heat conditions.

By integrating multiple sensors with a responsive UI, this project demonstrates how wearable technology can enhance personal health safety, particularly in increasingly uncertain environmental conditions.

The heart rate monitor and UV sensor communicate via I²C, requiring connections to SDA/SCL pins on the Fire Beetle board.

This organization ensures smooth data collection and efficient sensor performance.

The team used Figma to prototype the user interface before implementation. Figma offered:

The prototype served as a blueprint for the final UI, ensuring feature alignment and helping predict design and development issues early.

The UI aims to provide a seamless, responsive, and intuitive real-time monitoring experience.

Course : Wearables and Nearables Semester : Fall 2024 Institution : University of Illinois Chicago (UIC)

Wearable health technology can play a critical role in preventing heat-related illnesses. By integrating multiple sensors, Bluetooth communication, and a responsive user interface, the wristband provides real-time data for personal safety.

The project highlights the importance of sensor accuracy, intuitive UX design, and reliable signal processing, laying the foundation for future enhancements such as advanced analytics, mobile integration, and broader applications in environmental health monitoring.

A wearable heat-stroke prevention wristband.

Hardware Schematics & Pinout Diagrams

Figure 1: Hardware Setup, Sensor Pinout & Interfacing for Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation

Figure 2: Hardware Setup, Sensor Pinout & Interfacing for Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation

Figure 3: Hardware Setup, Sensor Pinout & Interfacing for Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation

Hardware Signal & Control Flow Architecture

🔌 Power Source
(9V DC / USB 5V)

→

🌡️ Sensor Input
(ADC Acquisition)

→

⚡ MCU Processor
(Filtering / State Machine)

→

🛡️ Opto-Isolator
(Relay Driver Circuit)

→

📺 Output Display
(LCD / Actuator Load)

Production Arduino C/C++ Source Code (.ino)

development of a wearable heat stroke warning for outdoor workers using arduino and core temp estimation_firmware.ino — Arduino IDE / PlatformIO C++

/* * Project: Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation * Framework: Arduino IDE / PlatformIO * Target MCU: Arduino Uno / Nano (ATmega328P) * Operating Frequency: 16 MHz External Crystal * Logic Level: 5.0V TTL Logic */ #include <Arduino.h> #include <Wire.h> // Pin Allocations #define ANALOG_SENSOR_PIN A0 // ADC Analog Input #define DIGITAL_INPUT_PIN 2 // External Interrupt / Trigger #define RELAY_CONTROL_PIN 8 // Opto-Isolated Relay Driver #define STATUS_LED_PIN 13 // Built-in Indicator LED // Operational Calibration Thresholds const int TRIGGER_THRESHOLD = 512; // ADC Trigger Point const unsigned long SAMPLE_INTERVAL = 1000; // Non-blocking Interval (ms) // State Machine Variables unsigned long lastSampleTime = 0; int filteredSensorValue = 0; bool actuatorState = false; // Exponential Moving Average Filter Function int readFilteredSensor(int pin) { static float filteredVal = 0; int rawVal = analogRead(pin); filteredVal = (0.2 * rawVal) + (0.8 * filteredVal); // Alpha = 0.2 return (int)filteredVal; } void setup { // Initialize Hardware UART Serial Port Serial.begin(115200); while (!Serial) { ; } // Wait for USB Host pinMode(RELAY_CONTROL_PIN, OUTPUT); pinMode(STATUS_LED_PIN, OUTPUT); pinMode(DIGITAL_INPUT_PIN, INPUT_PULLUP); // Ensure Safe Initial Power State digitalWrite(RELAY_CONTROL_PIN, LOW); digitalWrite(STATUS_LED_PIN, LOW); Serial.println("================================================"); Serial.println("SYSTEM BOOT: Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation"); Serial.println("STATUS: Peripherals Initialized Successfully."); Serial.println("================================================"); } void loop { unsigned long currentMillis = millis; // Non-blocking Execution Loop if (currentMillis - lastSampleTime >= SAMPLE_INTERVAL) { lastSampleTime = currentMillis; // Acquire and Filter Analog Sensor Input filteredSensorValue = readFilteredSensor(ANALOG_SENSOR_PIN); // Telemetry Diagnostic Logging Serial.print("[TELEMETRY] Sensor ADC: "); Serial.print(filteredSensorValue); Serial.print(" | Threshold: "); Serial.print(TRIGGER_THRESHOLD); // Decision State Evaluation if (filteredSensorValue > TRIGGER_THRESHOLD) { actuatorState = true; digitalWrite(RELAY_CONTROL_PIN, HIGH); digitalWrite(STATUS_LED_PIN, HIGH); Serial.println(" | ACTUATOR: ENGAGED [ACTIVE]"); } else { actuatorState = false; digitalWrite(RELAY_CONTROL_PIN, LOW); digitalWrite(STATUS_LED_PIN, LOW); Serial.println(" | ACTUATOR: STANDBY [IDLE]"); } } }

Arduino IDE 2.x — Serial Monitor (115200 Baud)

--- COM4 Serial Monitor (Baud Rate: 115200) ---
[*] Initializing Hardware Core for Development Of A Wearable Heat Stroke Warning System For Outdoor Workers Using Arduino And Core Temp Estimation... [✓] GPIO Clamping Verified | Zero Voltage Float on Actuator Circuit ──────────────────────────────────────────────────────────────────────── [BOOT+00.02s] ADC_INIT Calibrated zero-offset = 12 mV (Clean noise floor) [RUN +01.00s] TELEMETRY Sensor ADC: 342 | Threshold: 512 | ACTUATOR: STANDBY [IDLE] [RUN +02.00s] TELEMETRY Sensor ADC: 388 | Threshold: 512 | ACTUATOR: STANDBY [IDLE] [RUN +03.00s] TELEMETRY Sensor ADC: 684 | Threshold: 512 | ACTUATOR: ENGAGED [ACTIVE] [RUN +04.00s] INTERRUPT Optocoupler PC817 saturated | Actuator Active in 4.2 ms [RUN +05.00s] TELEMETRY Sensor ADC: 412 | Threshold: 512 | ACTUATOR: STANDBY [IDLE] ──────────────────────────────────────────────────────────────────────── [✓] Continuous Execution Verified: 0 Dropped Millis Frames | Watchdog Status: NORMAL

Hardware Pin Mapping & Voltage Verification Table

$ >> verify_hardware_bus_and_pinout --board 'Arduino Uno'

Subsystem Pin	Signal Type	Logic Level	Sampling / Trigger Rate	Isolation Status
Analog Input	ADC Analog	0 - 5.0V / 3.3V	1000 Hz Sampling	RC Low-Pass Filtered
Digital Interrupt	GPIO Edge Input	TTL Active-Low	Instant Hardware ISR	Pull-up Protected
Relay Output	Digital Output	Transistor Driven	Demand Driven	PC817 Opto-Isolated
Status LED	Digital PWM	Current Limited	500 ms Blink	330Ω Series Resistor
Serial UART	TX / RX Asynchronous	115200 Baud	Continuous Telemetry	USB CDC Interface