Description:FIELD OF THE INVENTION

[0001] The present invention relates to a head-wearable safety device for hazardous workplaces that is capable of ensuring user safety in dangerous workplaces by using responsive methods that reduce injury risks from falls, collisions, or external threats.

BACKGROUND OF THE INVENTION

[0002] In hazardous work environments such as construction sites, mining operations, chemical plants, and disaster response zones, workers are frequently exposed to a range of life-threatening risks. These include falling debris, exposure to toxic gases, structural collapses, extreme temperatures, poor visibility, and unforeseen accidents like falls or seismic disturbances. Despite strict regulatory protocols and the use of traditional personal protective equipment (PPE), injuries and fatalities continue to occur due to the limitations of conventional safety gear in adapting to dynamic and unpredictable environments.

[0003] In the past, personal protective equipment (PPE) was primarily designed to offer passive protection, relying on rigid materials and standardized structures to guard against impacts, penetration, and hazardous exposure. While effective to a degree, such equipment often lacked adaptability, comfort, and real-time responsiveness to changing environmental conditions. Moreover, traditional helmets and safety gear typically do not provide any form of hazard detection, active threat response, or communication capabilities, leaving the wearer dependent on external monitoring or manual intervention during emergencies.

[0004] EP0815754A1 discloses about an invention that has an industrial safety helmet comprises a shell of a semioval shape, a cradle, and a chin strap. The shell has one or more flexures capable of strengthening the shell and of promoting air circulation of the shell. The flexures are provided respectively at the front end thereof with an air inlet while at least one of the flexures is provided at the rear end thereof with an air outlet. The cradle has an energy-absorbing mechanism. The chin strap is provided with a detachable adhesive buckling mechanism.

[0005] US6609254B2 discloses about a protective helmet includes: a shell, a headband with an absorbent brow pad, and a suspension. A key is secured to each end of each of the straps of the suspension for insertion into respective key sockets spaced about the periphery of the shell of the protective helmet along its lower edge. Of particular importance to the protective helmet of the present invention, many (if not all) of the keys are molded directly to and around a strap, rather than sewn to the strap. In the method of the present invention, lengths of strap material are positioned in a mold, and plastic is injected into the mold cavity to encapsulate the straps and form the plastic component, e.g., a key for the suspension of the protective helmet. A trimming die is used to trim any webbing scrap between parts or other extraneous materials resulting from the molding of the plastic component to the straps.

[0006] Conventionally, many means are available for providing protection in hazardous environments. However, the cited invention lacks in combining real-time hazard detection, emergency response, environmental monitoring, user comfort adjustments, and communication capabilities within a single means, thereby limiting its effectiveness in dynamic and high-risk environments.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that is capable of providing protection to workers in hazardous environments by integrating multiple safety functionalities. Such a device should not only offer physical protection from impacts and debris but also incorporate means like real-time hazard detection, fall response, environmental monitoring, and efficient communication capabilities. The device should ensure user safety through proactive alerts, automated emergency support, and continuous situational awareness, thereby enhancing both safety standards and operational efficiency at the workplace.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of ensuring a secure and comfortable fit on the user's head by automatically adjusting to pressure variations.

[0010] Another object of the present invention is to develop a device that is capable of enhancing user protection by absorbing shock from external impacts and reducing the risk of injury in the event of a fall typically encountered in hazardous workplaces.

[0011] Another object of the present invention is to develop a device that is capable of guiding the user to safety during emergencies by delivering real-time visual and audio navigation based on detected hazards.

[0012] Another object of the present invention is to develop a device that is capable of alerting the user about the presence of harmful gases in the surrounding environment and facilitate access to clean air for safe breathing.

[0013] Another object of the present invention is to develop a device that is capable of maintaining the user comfort by regulating temperature based on external thermal conditions.

[0014] Yet another object of the present invention is to develop a device that is capable of enabling early hazard detection and communication with relevant personnel to ensure swift emergency response and enhanced situational awareness.

[0015] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0016] The present invention relates to head-wearable safety device for hazardous workplaces that maintain user comfort and health by adjusting fit and temperature while detecting harmful environmental changes in real-time.

[0017] According to an embodiment of the present invention, a head-wearable safety device for hazardous workplaces, comprises a hemispherical dual-layer shell consisting of a rigid outer layer and a cushioned inner layer, adapted to be worn over the user’s head. A transparent face shield is integrated into the front portion of the shell, and a head-up display (HUD) is embedded within it to deliver visual alerts and navigation. The shell houses a motorized shaft on one lateral side, which contains a spool of strap that electromagnetically connects to the opposing side for securing the helmet. A pressure sensor embedded in the shell continuously monitors the contact pressure between the shell and the user’s head, activating the motorized shaft to loosen or tighten the strap for optimal comfort. Shock absorption is achieved through a plurality of pneumatic actuators placed between the two shell layers, which cushion impacts from falling debris. An air cushion lining the inner surface of the shell inflates upon detection of a fall, identified by a gyroscope, using an inflator installed on the shell. Multiple motorized rollers are mounted along the bottom periphery of the shell, each containing spools of inflatable strips that deploy and extend along the user's body. A connected compressor inflates these strips to provide fall protection.

[0018] An artificial intelligence-based imaging unit installed on the shell captures and processes real-time visuals of the surroundings, detecting hazardous events. The imaging unit integrated with a processor, works in synchronization with the HUD and an internal speaker to guide the user to safety. Navigation is further supported by a GPS unit and an ultra-wideband (UWB) module for precise location tracking. A communication unit is embedded within the shell to transmit hazard alerts to a supervisor or control center.

[0019] The shell also includes a gas sensor to detect the presence of hazardous gases near the user, triggering an audio alert via the speaker and prompting the use of an attachable gas mask with air filters, which is connected to the shell through a hinge mechanism. To further support environmental adaptation, a temperature sensor is embedded in the shell to activate a Peltier unit, which regulates the internal temperature for user comfort.

[0020] The imaging unit also performs facial recognition to identify the user, enabling a microcontroller to log attendance data such as punch-in and punch-out times based on the wearing and removal of the shell. Illumination is provided by a set of LEDs triggered by an LDR (light-dependent resistor) when ambient light drops below a certain threshold. A user interface, connected to a computing unit, allows the user to upload personal medical information and issue an SOS alert in emergencies.

[0021] Additionally, a ground penetrating radar (GPR) installed in the shell assesses the thickness of overhead structures to identify weak spots, activating a projection unit to visually highlight these zones. An acoustic sensor detects distant explosions, seismic events, or industrial accidents, triggering both audio and visual alerts for user safety via the speaker and the projection unit.

[0022] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a head-wearable safety device for hazardous workplaces.

DETAILED DESCRIPTION OF THE INVENTION

[0024] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0025] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0026] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0027] The present invention relates to a head-wearable safety device for hazardous workplaces that empower the user with hazard detection, navigation assistance, and instant emergency communication for timely and informed responses during critical incidents in hazardous workplaces.

[0028] Referring to Figure 1, an isometric view of a head-wearable safety device for hazardous workplaces is illustrated, comprising a hemispherical dual-layer shell 101 having a first layer 102 and a cushioned second layer 103 adapted to be worn over a head of a user, a face shield 104 is provided at a front portion of the shell 101, a motorized shaft 105 provided at a lateral portion of the shell 101, containing a spool 106 of a strap 107, a plurality of pneumatic actuators 108 arranged between the first layer 102 and the second layer 103, a plurality of motorised rollers 109 arranged along a bottom periphery of the shell 101, each containing a spool of inflatable strips 110, an (head up display) HUD 111 embedded in the face shield 104, an artificial intelligence-based imaging unit 112 installed on the shell 101, a gas mask 113 attached with the shell 101 in a hinged manner, a plurality of LEDs (light emitting diodes) 114 mounted on the shell 101 and a projection unit 115 mounted on the shell 101.

[0029] The device disclosed herein includes a hemispherical dual-layer shell 101, which serves as the primary housing and the hemispherical shape to conform to the natural curvature of the human head for ensuring a snug yet comfortable fit. The dual-layer configuration consists of two distinct yet interdependent layers: a first layer 102 which is the outermost shell 101, and a second layer 103, positioned internally, which is cushioned to provide comfort and additional safety.

[0030] The first layer 102, or the outer shell 101, is typically constructed from high-strength, impact-resistant materials to withstand high-energy impacts, resist penetration from falling objects, and endure harsh environmental conditions such as heat, moisture, and chemicals often encountered in industrial or construction zones. For example, a worker in a mining environment is at risk from falling rock fragments; the outer layer of the shell 101 deflects or absorb the energy of such an impact, minimizing the risk of head injury.

[0031] Beneath the outer shell 101 lies the second layer 103, which is developed with cushioning material such as expanded polystyrene (EPS), memory foam, or other viscoelastic polymers. This layer performs two critical roles: first, it acts as a shock absorber, dispersing impact forces away from the skull; and second, it provides ergonomic comfort, reducing pressure points and allowing the helmet to be worn for extended periods without discomfort. The cushion is contoured or modular, designed to adjust to different head shapes and sizes.

[0032] In an another embodiment of the present invention, the cushion may be replaceable or washable to support hygiene in high-use environments, thereby preventing chances of contamination within the cushion.

[0033] A face shield 104 is located at the front portion of the shell 101 that serves as both a protective barrier. Structurally, it is made from transparent, high-impact materials like shatterproof polycarbonate or laminated glass with anti-scratch and anti-fog coatings. Functionally, the face shield 104 is developed to protect the user’s eyes and face from flying debris, sparks, chemical splashes, dust, and other environmental hazards. In environments such as metalworking plants, where high-temperature sparks fly toward the face, or in chemical facilities where splashes are a concern, this shield 104 aids in facial protection.

[0034] The face shield 104 is usually connected to the shell 101 by hinge for enabling it to be flipped up or retracted when not needed, and locked into position during operation. In some variants, the shield 104 is modular and replaceable, allowing for different types of shields to be attached depending on the nature of the task or workplace regulations. A motorized shaft 105, housed within a lateral portion of the helmet shell 101, typically near the left or right side above the ear area. This shaft 105 serves as a rotational drive element and contains a spool 106 onto which a flexible strap 107 is wound. The strap 107 itself is made of a durable yet pliable material which is capable of withstanding wear and tension while remaining comfortable against the user’s skin.

[0035] The strap 107 extends from the spool 106 across the inner perimeter of the shell 101, with its opposite end configured to engage with the opposing lateral portion of the shell 101 using electromagnetic fastening. Instead of traditional mechanical clips or buckles, which is cumbersome or inconsistent in pressure application, the use of electromagnetic latching ensures a firm, consistent, and user-friendly locking of the helmet around the head.

[0036] A pressure sensor is installed within the shell 101 usually embedded along the inner cushioned layer or near the contact region of the strap 107. This sensor continuously monitors the contact pressure between the helmet and the user’s head. The data collected by the sensor is relayed to a microcontroller which interprets whether the fit is too tight, too loose, or within an optimal range. Based on this input, the processor actuates the motorized shaft 105 to either tighten or loosen the strap 107 by rotating the spool 106, thereby adjusting the fit dynamically.

[0037] For example, if a worker puts on the helmet and the pressure sensor detects insufficient contact pressure, indicating a loose fit, the motorized shaft 105 rotates to pull in more strap 107, tightening the shell 101 against the head. Conversely, if the helmet is squeezing too tightly, perhaps due to prolonged wear or a change in the user's headgear, the microcontroller automatically unwinds the strap 107 slightly to relieve pressure and enhance comfort. This is especially useful in dynamic environments, such as mining sites or construction zones, where workers often move between different levels of exertion and environmental conditions. For example, a miner who starts sweating inside a hot tunnel experience swelling or shifting of the helmet due to moisture.

[0038] A plurality of pneumatic actuators 108 embedded in the interstitial space between the first (outer) and second (inner cushioned) layers of the helmet shell 101. These actuators 108 are developed to mitigate the impact force caused by external shocks, particularly from falling debris, an ever-present hazard in environments such as construction sites, underground mines, or heavy industrial facilities. Pneumatic actuators 108 operate using compressed air to produce mechanical motion or cushioning. When debris falls onto the helmet, the outer shell 101 transfers the kinetic energy inward, instead of this energy directly reaching the skull, the pneumatic actuators 108 compress, converting and dissipating the force through air displacement, thereby protecting the wearer from injury.

[0039] For example, if a heavy tool accidentally falls from scaffolding and strikes the helmet, the sensors trigger rapid inflation of specific actuators 108 to blunt the impact. In essence, the pneumatic actuators 108 serve as a multi-layered shock-absorbing barrier, greatly enhancing cranial safety and reducing the risk of traumatic brain injury in high-risk occupational settings. Herein, a gyroscope sensor, mounted securely within the shell 101 structure, typically adjacent to the helmet’s internal electronics bay. The gyroscope is capable of detecting angular velocity and orientation changes in real-time. The gyroscope continuously monitors the spatial orientation of the helmet relative to the vertical axis. When it detects abrupt deviations consistent with free-fall or unbalanced body movement, such as a sharp downward pitch or a sideways rotation exceeding a predetermined threshold, it interprets the event as a potential fall.

[0040] Once a fall is detected, the gyroscope sends an immediate signal to the microcontroller, which then triggers an inflator attached to the outer shell 101 of the helmet. This inflator is connected via flexible tubing or direct injection ports to an air cushion that is layered along the inner surface of the shell 101. The air cushion itself is fabricated from high-strength, lightweight, inflatable polymer materials such as TPU (thermoplastic polyurethane) or Kevlar-reinforced nylon, capable of rapid inflation and pressure containment. Upon activation, the inflator releases compressed gas often CO₂ or ambient air from a micro-compressor into the cushion chambers within milliseconds, expanding them between the helmet and the user's head. This inflation creates a buffering air layer that significantly reduces the transmission of impact forces from the outer shell 101 to the skull, particularly in the crown, side, and occipital regions where head trauma is most likely during a fall.

[0041] To illustrate, consider a technician servicing a transmission tower who loses footing and begins to fall. In such a scenario, the gyroscope detects the unnatural angular momentum and sudden acceleration. Before the user even hits the ground, the microcontroller activates the inflator, and the air cushion inflates around the skull, absorbing and dispersing impact energy. This proactive safety means drastically lowers the likelihood of concussions or skull fractures. Additionally, since the air cushion is internally layered, it maintains helmet integrity and does not interfere with external protective elements or vision fields.

[0042] The safety means is designed to provide full-body fall protection by deploying and inflating protective strips 110 that cover the entire vertical length of the user's body from head to lower limbs within seconds of detecting a fall. The safety means comprises multiple motorized rollers 109, uniformly distributed along the bottom rim of the helmet shell 101, each housing a spool of inflatable protective strips 110. These strips 110 are made of flexible, high-strength, puncture-resistant materials such as coated Kevlar, TPU (thermoplastic polyurethane), or layered synthetic fabric designed to withstand both rapid inflation and high-impact energy without tearing.

[0043] In operation, once a fall is detected, the motorized rollers 109 are triggered by the microcontroller embedded in the helmet. These rollers 109 then begin to unspool the inflatable strips 110 downward in a controlled and rapid manner, covering the user’s shoulders, torso, hips, and legs. Simultaneously, a miniature compressor or gas inflator, linked to the deployed strips 110 via small-diameter hoses or integrated valves, is activated. This compressor rapidly inflates the strips 110 with compressed air or gas, giving them structural rigidity and energy-absorbing capability. The inflated strips 110 act as vertical shock absorbers along the user’s body, particularly protecting vital areas like the spine, hips, and limbs from blunt trauma. For example, if a worker on a scaffold platform loses balance and falls, within a second the rollers 109 deploy the strips 110, and the compressor inflates them into cylindrical air chambers that run along the user’s sides and back. Upon ground contact, the air-filled cushions compress to absorb and dissipate kinetic energy, reducing the risk of broken bones, spinal injuries, or other critical trauma.

[0044] A central visual interface is a head-up display (HUD) 111, which is embedded directly into the transparent face shield 104 of the helmet. This HUD 111 is designed to project critical information within the user's field of view without obstructing vision for allowing the user to maintain full spatial awareness while being guided or alerted. Synchronized with this HUD 111 is a speaker integrated inside the shell 101, which delivers audio cues, warnings, or navigational instructions to the wearer in noisy or low-visibility environments.

[0045] An artificial intelligence-based imaging unit 112 installed on the shell 101, typically on the front or lateral portion. This imaging unit 112 includes cameras capable of capturing live images or video of the surrounding environment. These visual feeds are processed in real-time by an on-board processor which uses trained AI protocols such as object detection, motion tracking, thermal anomalies to identify hazardous incidents such as fires, gas leaks, structural cracks, moving machinery, or blocked evacuation routes. For example, in an underground mining site, the AI detect a fire igniting from electrical equipment or observe unusual smoke patterns near chemical storage and immediately flag it as a hazard.

[0046] Once a hazard is detected, the processor activates a navigation protocol that utilizes a GPS (Global Positioning System) unit for outdoor, satellite-based positioning and UWB (ultra-wide band) for highly accurate indoor location tracking, especially useful in industrial buildings, tunnels, or confined spaces where GPS signals may be weak or unavailable. Using this positioning data, the microcontroller calculates the safest and quickest evacuation route from the user's current location to a pre-mapped safety zone. This route is then projected onto the HUD 111 in the form of arrows, distance markers, or visual beacons, while the speaker simultaneously provides step-by-step verbal guidance (e.g., “Turn left in 5 meters, exit ahead”).

[0047] Crucially, the helmet includes a wireless communication unit (e.g., LTE, Wi-Fi, or mesh network capable), which is automatically triggered to send alerts and real-time incident data to a remote supervisor or control room. This includes video footage, location, environmental metrics, and user status. For example, in the event of a fire breakout in a chemical factory, not only is the wearer guided out, but the supervisor immediately receives information such as: "Worker ID 104 – Fire detected near Section B3 – Navigating to Safety Zone C – Time to exit: 32 seconds." This bi-directional communication ensures that emergency response teams are fully informed and act accordingly, even before the worker reaches safety.

[0048] A gas sensor is embedded in the shell 101 to continuously monitor the air quality surrounding the user in real time. The sensor is capable of detecting a wide range of harmful gases and vapors, including carbon monoxide (CO), methane (CH₄), hydrogen sulfide (H₂S), ammonia (NH₃), chlorine gas, and volatile organic compounds (VOCs), which are commonly found in hazardous industrial, mining, chemical, and fire-risk environments. These gases are lethal even in low concentrations and are not easily detectable by human senses alone.

[0049] When the gas sensor detects the presence of a harmful gas exceeding a preset safety threshold, it immediately sends a signal to the microcontroller which then triggers the integrated speaker. The speaker emits a clear, loud audio alert, notifying the user of the detected hazard. More importantly, the speaker issues specific verbal instructions through the speaker, such as “Toxic gas detected – Wear gas mask now,” thereby minimizing the time taken for the user to recognize and respond to the danger. This is especially vital in environments with high ambient noise or low visibility, where visual warnings go unnoticed.

[0050] To facilitate immediate respiratory protection, the helmet includes a gas mask 113 that is physically attached to the shell 101 via a hinge, usually positioned on the side or lower front of the shell 101. The hinged design allows the gas mask 113 to swing into place quickly and securely over the user’s mouth and nose area. The mask 113 is equipped with high-efficiency air filters such as activated carbon or HEPA-grade filters capable of neutralizing or filtering out the specific gases detected by the sensor. This ensures that the air being inhaled by the user is purified and safe, even when the surrounding environment is contaminated.

[0051] For example, consider a worker entering a confined underground chamber for inspection work. If a pocket of methane gas is unexpectedly released due to structural shifts, the sensor detects the abnormal concentration in the air. Without requiring any user input, the helmet issues a verbal warning "Methane gas detected, activate mask 113", while the worker quickly lower the hinged gas mask 113 into position and continue breathing safely, potentially buying crucial seconds or minutes before full evacuation. Similarly, in a chemical storage facility, if there is a leak of chlorine gas, the helmet alerts the user before physical symptoms occur, preventing respiratory distress or unconsciousness.

[0052] To enhance the comfort of the user in extreme working environments, the safety helmet is equipped with a temperature sensor embedded within the shell 101. This sensor is designed to continuously monitor the ambient and internal temperature of the shell 101, particularly in regions where direct contact with the user's head occurs. The sensor detects when the temperature rises above or falls below a predetermined threshold which is set, for example, between 18°C and 30°C for optimal human comfort. Once the detected temperature deviates from this range, the sensor relays a signal to a thermoelectric Peltier unit also embedded in the shell 101 structure. The Peltier module, which operates based on the thermoelectric effect, then initiates a heating or cooling process depending on the requirement. If the temperature is too high, the Peltier unit draws heat away from the shell 101’s interior surface, creating a cooling effect. Conversely, during colder conditions, the unit generates heat to maintain a warm environment inside the shell 101

[0053] The thermal regulation is especially useful in scenarios where workers are exposed to intense outdoor heat, freezing cold, or thermally unstable indoor environments. For example, workers at desert-based construction sites face prolonged exposure to sunlight, leading to rapid heating of conventional safety gear. In such cases, once the shell 101 temperature exceeds the comfort limit, the Peltier unit kicks in to cool the interior surface, allowing the user to continue working without discomfort or risk of heatstroke.

[0054] Similarly, in cold storage warehouses or alpine rescue missions, where ambient temperatures drop significantly, the temperature sensor detects the cold conditions and activates the heating mode of the Peltier unit, preventing hypothermia or discomfort. This automated thermal regulation not only enhances the usability of the safety helmet across diverse climates but also ensures that the user's focus and productivity are not hampered by thermal stress.

[0055] A facial recognition-based attendance tracking means within the helmet using imaging unit 112, which is configured to capture the face of the user upon wearing the shell 101. As soon as the helmet is placed on the head, the imaging unit 112 scans the user’s facial features and compares them against a pre-stored database to accurately determine the identity of the wearer. Once a match is confirmed, the microcontroller then records the “punch in” time, effectively marking the beginning of the user’s work shift. This eliminates the need for separate biometric scanners or manual check-ins, thus improving security and operational efficiency.

[0056] Similarly, when the helmet is removed, detected either by the imaging unit 112 ceasing to see the user’s face or by pressure sensors recognizing disengagement, the microcontroller automatically logs the “punch out” time. This is especially valuable in large-scale industrial, mining, or construction environments, where accurate timekeeping and personnel tracking are critical for safety audits and productivity analysis. For example, in a mining operation with hundreds of workers entering at different intervals, the helmet ensures that each worker’s active time within hazardous zones is precisely monitored without delays or crowding at manual attendance stations. It also allows supervisors to maintain real-time logs of who is currently active within a danger zone, enabling faster emergency response and evacuation coordination when necessary.

[0057] The helmet incorporates a light-dependent resistor (LDR) strategically embedded on the outer surface of the shell 101 to continuously monitor the ambient light intensity in the surrounding environment. The LDR functions as a sensor that changes its electrical resistance based on the amount of light falling on it decreasing resistance in bright conditions and increasing it in low light. This change in resistance is analyzed by the microcontroller which compares it against a predefined threshold value. When the detected ambient light level falls below this threshold, for example, in dimly lit tunnels, foggy environments, or during nighttime operations, the microcontroller actuates a plurality of energy-efficient LEDs 114 mounted on various sections of the helmet to provide focused and uniform illumination around the user's immediate vicinity.

[0058] These LEDs 114 are placed along the front brim, sides, or even the lower edge of the helmet to offer 360-degree visibility. The lighting ensures that the user maintain visibility in hazardous or visually restricted environments, thereby preventing accidents or missteps. For example, a utility worker repairing underground cables at night or a rescue operator navigating through smoke-filled or collapsed buildings greatly benefit from this hands-free lighting, thus eliminating the need for external flashlights or headlamps and enhancing both safety and efficiency.

[0059] A user interface designed to be compatible with an external computing unit such as a smartphone, tablet, or workstation for allowing the user to access and interact with the helmet’s digital platform. Through this interface, the user securely upload personal medical details, such as blood type, allergies, chronic conditions, and emergency contact numbers, which are stored in the memory and linked to the individual user profile identified via facial recognition. This interface also enables the user to configure and update emergency response settings, including predefined SOS protocols.

[0060] In case of an emergency, such as a fall, exposure to toxic gases, or injury, the user or the helmet generates an SOS signal, which is transmitted via the onboard communication unit to designated emergency contacts, supervisors, or medical personnel. The interface also offers a manual SOS button for the user to activate distress calls in real time. For example, if a construction worker is trapped under debris or a chemical plant employee feels symptoms of gas poisoning, the SOS feature is instantly triggered to send their location (via GPS/UWB), identity, and medical history to response teams, significantly reducing reaction time and ensuring targeted medical assistance.

[0061] A Ground Penetrating Radar (GPR) module is embedded within the shell 101 to perform real-time structural analysis of the environment, particularly focusing on the roof or overhead structures in hazardous workspaces such as mines, tunnels, or construction sites. The GPR operates by emitting high-frequency radio waves into the structure above the user; when these waves encounter materials of differing dielectric properties such as air pockets, cracks, or voids they are reflected back to the sensor. By analyzing the time delay and amplitude of the returning signals, the microcontroller effectively calculates the thickness and density of the roof layers.

[0062] The data is processed by an onboard computational unit which determines whether there are weak spots, thinning sections, or areas with structural instability that are prone to collapse. Once identified, these zones are visually communicated to the user through a projection unit 115 mounted on the via a detachable projector which projects real-time images or colored overlays onto the roof surface, highlighting safe zones and danger zones for easy visual identification. For example, in an underground coal mine, if a section of the roof is found to be unusually thin or riddled with voids, the helmet project a red warning highlight over that area, allowing the user to evade collapse-prone regions without needing any separate scanning equipment or expert interpretation.

[0063] In addition to the GPR, the helmet is also equipped with a highly sensitive acoustic sensor that continuously monitors the sound environment for abnormal acoustic events. These include distant explosions, equipment malfunctions, collapsing structures, or seismic vibrations that are often inaudible to the human ear but indicate impending danger. The sensor processes these sounds and distinguishes between normal operational noise and potential threats using pre-trained sound profiles. When such hazardous audio patterns are detected, the microcontroller automatically activates both the speaker and the projection unit 115.

[0064] The speaker delivers a clear, loud audio warning such as sirens or voice alerts while the projection unit 115 reinforces the message visually by displaying alert symbols, evacuation arrows, or color-coded warnings directly in the user’s field of vision. For example, if a faint seismic tremor is detected in a deep tunnel, the helmet issue a voice alert instructing immediate evacuation while simultaneously projecting directional guidance to the nearest exit.

[0065] The present invention works best in the following manner, where the user dons the device, which automatically adjusts for a secure and comfortable fit using the motorized shaft 105 and strap 107, controlled by the pressure sensor embedded within the shell 101. Once worn, the imaging unit 112 identifies the user’s face to log attendance via microcontroller. During usage, the gyroscope continuously monitors the user’s orientation; in the event of fall, it triggers the inflator to deploy internal air cushion lining the shell 101 for head protection. Simultaneously, motorized rollers 109 located around the lower periphery of the shell 101 release inflatable strips 110 that extend along the user's body, which are then inflated by connected compressor to cushion the fall and minimize injury.

[0066] In continuation, In the event of impact from overhead debris, pneumatic actuators 108 situated between the shell 101’s dual layers absorb shock to protect the user. The temperature sensor ensures thermal comfort by activating Peltier unit to heat or cool the interior of the shell 101 within predefined range. If hazardous gases are detected by the gas sensor, the speaker issues audio alert, prompting the user to wear the gas mask 113, which is hinged to the shell 101 and equipped with air filters. In low-light conditions, the LDR activates LEDs 114 mounted on the shell 101 to provide visibility. The imaging unit 112, aided by the processor, GPS unit, and UWB modules, continuously monitors the surrounding environment for hazards. Upon detection of hazardous incident, the HUD 111 and speaker work in conjunction to guide the user to safe location while simultaneously sending alerts to remote supervisor through the communication module.

[0067] For structural safety, the GPR scans overhead surfaces to identify potential weak spots, and the projection unit 115 highlights these areas visually. Meanwhile, the acoustic sensor detects distant seismic or explosion-related events and triggers combined audio-visual alerts. The user interface connected to the computing unit enables the wearer to manage medical information and initiate the SOS in emergencies.

[0068] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A head-wearable safety device for hazardous workplaces, comprising:

i) a hemispherical dual-layer shell 101 having a first layer 102 and a cushioned second layer 103 adapted to be worn over a head of a user, wherein a face shield 104 is provided at a front portion of said shell 101;
ii) a motorised shaft 105 provided at a lateral portion of said shell 101, containing a spool 106 of a strap 107, end of said connected electromagnetically with an opposing lateral portion of said shell 101 for fastening of said shell 101 over user’s head;
iii) a plurality of pneumatic actuators 108 arranged between said first layer 102 and said second layer 103, for absorbing shock generated from falling debris;
iv) a gyroscope installed in shell 101 to detect a fall of said user to actuate said inflator for inflate said air cushion for safety of said user against impact;
v) a plurality of motorised rollers 109 arranged along a bottom periphery of said shell 101, each containing a spool of inflatable strips 110, wherein said rollers 109 are actuated to deploy said strips 110 along entire height of said user, a compressor connected with said strips 110 is actuated to inflate said strips 110 to protect said user from fall;
vi) an HUD 111 (head up display) embedded in said face shield 104, in synchronisation with a speaker provided in said shell 101, navigates said user to a safe spot upon detection of hazardous incident by an artificial intelligence-based imaging unit 112, installed on said shell 101 and integrated with a processor for recording and processing images in a vicinity of said shell 101, to determine said hazardous incident, wherein navigational data is provided by a GPS (global positioning system) unit in combination with an UWB (ultra wide band) unit installed in said shell 101, wherein a communication unit provided in said shell 101 communicates said hazardous incident to a supervisor; and
vii) a gas mask 113 configured with air filters, attached with said shell 101 in a hinged manner, for safe breathing of said user.

2) The device as claimed in claim 1, wherein an air cushion is layered along inner surface of said shell 101, connected with an inflator provided on said shell 101 to inflate said air cushion for safety of said user.

3) The device as claimed in claim 1, wherein a pressure sensor is embedded in said shell 101 detects a pressure between said shell 101 and user’s head to accordingly actuate said shaft 105 to loosen/tighten said strap 107 for a comfortable wearing of said shell 101.

4) The device as claimed in claim 1, wherein a temperature sensor is embedded in said shell 101 detects temperature of said shell 101 to actuate a peltier unit to heat/cool said shell 101 to maintain a temperature of shell 101 within a predetermined temperature range for comfort of said user.

5) The device as claimed in claim 1, wherein said imaging unit 112 captures face of said user to determine identity of said user to trigger a microcontroller to record punch in time of said user upon wearing of said shell 101 and record punch out time upon removal of said shell 101.

6) The device as claimed in claim 1, wherein an LDR (light dependent resistor) is embedded on said shell 101 to detect an ambient light level, to trigger a plurality of LEDs 114 (light emitting diodes) mounted on said shell 101 to provide illumination if said detected ambient light level is below a threshold light level.

7) The device as claimed in claim 1, wherein a user interface is provided adapted to be installed with a computing unit, to enable said user to upload personal medical and emergency details via said user interface and generate an SOS call.

8) The device as claimed in claim 1, wherein a gas sensor is integrated with said shell 101 to detect hazardous gases near said user to actuate said speaker to provide an audio alert regarding wearing said gas mask 113.

9) The device as claimed in claim 1, wherein an acoustic sensor installed in said shell 101 detects distal explosions, accidents and seismic activity to actuate said speaker and said projection unit 115 to generate audio-visual alert for said user.

10) The device as claimed in claim 1, wherein a GPR (ground penetrating radar) installed in said shell 101 detects thickness of roof of hazardous workspace, to determine weak spots prone to collapsing, to actuate a projection unit 115 mounted on said shell 101 to project images and highlight portions of said roof with weak spots.