Design and Implementation of a Low-Power UWB-Enabled Smart Monitoring System for Full-Chain Electric Welding Safety Control with 10 cm-Level Positioning Accuracy

Electric welding operations pose significant fire and explosion risks due to high-temperature sparks, flammable gas accumulation, and irregular personnel behavior, which have caused numerous industrial accidents with heavy casualties and economic losses in recent years. This paper presents an integrated smart safety monitoring system for full-chain management of electric welding operations based on ESP32-UWB development board. The system integrates ultra-wideband (UWB) positioning technology, multi-type environmental sensors, and automatic power-off protection mechanisms to achieve real-time monitoring of worker positions, ambient temperature, humidity, smoke, and flammable gas concentrations. The UWB module provides 10 cm-level positioning accuracy to detect worker absence beyond safe ranges, while MQ-2, MQ-5, and DHT11 sensors monitor environmental parameters with a 5-second response time. The system triggers sound and light alarms and automatically cuts off power when abnormal conditions are detected, with all data displayed on an OLED screen for on-site supervision. Performance tests show that the system achieves 98.5% detection accuracy for hazardous conditions, with an average response time of 1.8 seconds. This low-cost, highly reliable solution addresses the limitations of traditional management systems, provides effective technical support for electric welding operation safety, and has broad application prospects in industrial safety monitoring.