Distance-Aware Attenuation Modeling of a Helmet-Mounted Edge Thermal System Using MLX90640 and Raspberry Pi 5 for Industrial Safety Applications: Linear Regression Approach

Thermal hazards in industrial environments often remain undetected until critical failure or injury occurs. Conventional handheld infrared cameras require manual operation and limit continuous situational awareness. This study presents the design and field validation of a wearable helmet-mounted real-time thermal system based on the MLX90640 infrared array sensor and a Raspberry Pi 5 edge computing platform. Experimental validation was performed across multiple scenarios of 400 measurements based on industrial distances of 100 cm and 150 cm. The performance of the system was tested against a pre-calibrated hotspot infrared thermometer using linear regression analysis and standard error metrics to determine proportional agreement. The results indicate a strong proportional relationship between the two systems at both industrial distances, with R2 values ranging from 0.9885 to 0.9973 at 100 cm and from 0.9586 to 0.9867 at 150 cm. A moderate increase in mean absolute error (MAE) was observed as the measurement distance increased. Statistically significant increases in error were identified in mechanically dynamic scenarios where statistically significant increases in measurement error were observed (p-value < 0.05), indicating distance-dependent sensitivity under moving mechanical conditions. The higher absolute errors at longer distances mainly result from field-of-view expansion, reduced target occupancy, and mixed-pixel hotspot effects rather than weakened proportional trend stability. An industrial distance-aware linear regression model was developed to describe behavior and support calibrations under different deployment conditions. Despite minor absolute deviations during dynamic operations, the system maintained strong trend-tracking performance, suggesting suitability for daily preliminary hazard monitoring in industrial safety maintenance.