Advanced Vision-Based Digital Twin System for Monitoring Steelworkers to Prevent Heat Stress in Manufacturing Plants

Steel manufacturing is vital to the construction industry, producing materials like structural steel and rebar. The process requires operating blast furnaces at around 3,600°F, putting steelworkers at high risk of heat stress. This study proposes a digital twinning system using a stereo camera setup to monitor workers’ proximity to heat sources. By detecting location in 2D, calculating disparity with a stereo anaglyph technique, and generating 3D point clouds, the system accurately measures distances to heat sources. Integrating environmental temperature and humidity data, it enables dynamic work schedule adjustments to mitigate heat stress and enhance worker safety. This advanced method improves real-time monitoring and management of heat exposure, providing an essential tool to safeguard steelworkers in extreme heat conditions and significantly reduce the risk of hyperthermia.