ISO 45001 Smart Safety Helmet

　　ISO 45001-Compliant Industrial Router: Design, Application & Safety Compliance

　　1. Core ISO 45001 Requirements for Industrial Routers

　　As core connectivity devices for the Industrial Internet of Things (IIoT), industrial routers must meet the core constraints of the ISO 45001:2018 occupational health and safety management system. Unlike commercial routers, these routers focus on addressing "industrial personnel safety risks":

　　Electrical Safety Protection: Eliminate the risks of electric shock and short-circuit fires in industrial environments and must comply with the IEC 61010-1 industrial electrical safety standard (insulation level ≥ Class II, protection against direct and indirect electrical contact).

　　Environmental Risk Adaptation: Withstand the high temperatures, vibrations, and dust/oil contamination found in industrial environments (to prevent equipment failures from exposing personnel to high-risk environments such as hot workshops and high-altitude workstations).

　　Operational and Maintenance Safety: The device's ergonomic design (lightweight and easy to install) eliminates the need to disassemble high-risk components (such as high-voltage modules) during maintenance, reducing the risk of bumps, burns, and electric shock. Emergency Response and Risk Management: Automatic fault alarms and remote diagnostics reduce the need for on-site personnel inspections (especially in high-risk environments such as explosion-proof and high-altitude environments). Emergency power outages are also supported to prevent accidents from escalating.

　　2. Key Technical Features for ISO 45001 Compliance

　　2.1 Electrical Safety Design

　　Insulation & Grounding Protection:

　　Double insulation structure (flame-retardant ABS outer shell + independent insulation of internal modules, insulation resistance ≥ 100MΩ @ 500V DC) isolates the risk of electric shock even if a single insulation failure occurs.

　　Dedicated protective grounding terminal (yellow-green two-color wire, cross-sectional area ≥ 2.5mm²) with a grounding resistance ≤ 4Ω (prevents leakage voltage exceeding the safety limit of 50V due to fluctuations in the industrial power grid). Overload & Fault Protection:

　　A 10A resettable fuse is installed on the power input (disconnects within 0.5s in the event of an overload). The ETH port has built-in surge protection (1.2/50μs surge withstand ≥6kV to protect against industrial power grid shocks).

　　High-temperature overload protection: When the internal temperature exceeds 75°C, the device automatically derates (CPU frequency drops to 50%). When the temperature exceeds 85°C, an emergency power outage is triggered to prevent overheating and burns or fire. 2.2 Industrial Environment Adaptability (Risk Reduction)

　　Harsh Environment Resistance:

　　Protection rating ≥ IP65 (dust and oil splash protection in factory workshops; weatherproof for outdoor sites), preventing liquid intrusion and short circuits, and reducing the need for personnel to enter high-risk areas for repairs due to equipment failures.

　　Wide operating temperature range (-40°C to 75°C), suitable for high-temperature metallurgical workshops and outdoor sites in northern winter, eliminating the need for frequent on-site adjustments (reducing the risk of frostbite and heatstroke).

　　Vibration resistance (10–500Hz random vibration, amplitude ≤0.8mm). Internal components are bolted and secured with shock-absorbing rubber pads to prevent loose components from falling and causing injury (e.g., when installed near a factory assembly line).

　　Explosion-Proof Design (for Hazardous Areas):

　　Explosion-proof rating ≥ Ex d IIB T4 Ga (for flammable and explosive environments such as chemical and mining environments). The housing is made of cast aluminum (no spark gap), and the internal circuitry has a current-limiting design (prevents arcing and explosions). This eliminates the need for personnel to open the cover when operating in explosion-proof areas. 2.3 Ergonomic & Maintenance Safety

　　Human-Centric Operation Design:

　　Lightweight design (≤3kg, wall-mounted/rail-mountable), single-person installation possible (avoiding bumps and muscle strains when working with multiple people, in compliance with ISO 45001 "Prevention of Musculoskeletal Injuries").

　　The operation panel is tilted 15° for easy viewing while standing, and the indicators use high-brightness LEDs (red/green/yellow for operation/fault/alarm, visible even in strong sunlight) to reduce eye fatigue.

　　Key spacing is ≥12mm, with clear Chinese labels (such as "Emergency Power Off" and "Reset") to prevent operation errors (especially when wearing gloves in industrial environments).

　　Low-Risk Maintenance:

　　Modular design (power supply and 4G/5G modules are independently pluggable and removable), eliminating the need to disconnect power or disassemble the entire system for maintenance, and module replacement requires no tools (snap-on design).

　　Safety warnings are marked on key areas (such as "Replace the power module after power is off" and "Do not open the cover in explosion-proof areas"), and the accompanying maintenance manual clearly defines "safe operating procedures" (such as grounding test procedures). 3. Scenario-Specific Safety Solutions

　　3.1 Factory Workshop Industrial Router (e.g., Automotive Assembly Line)

　　Application: Connects workshop PLCs, sensors, and AGVs for data transmission and remote control.

　　ISO 45001 Safety Design:

　　IP65 protection (protects against welding fumes and coolant splashes), preventing personnel from entering high-risk areas near the assembly line (such as AGV driveways) for repairs due to equipment failures;

　　Din-rail mounting (DIN 35mm standard rail), installation height 1.5–1.8m (for easy access without bending or climbing);

　　Remote diagnostics (check device status and restart/configure via the cloud platform), reducing the frequency of personnel entering noisy areas (above 85dB) in the workshop (protecting hearing health).

　　Use Case: In an automotive welding workshop, the router is installed in a control cabinet away from the welding stations, with a radiation intensity of less than 2W/m² (no electromagnetic radiation health risk). In the event of a fault, the cloud platform automatically issues an alarm, allowing personnel to conduct remote troubleshooting (without having to approach the high-temperature welding area). 3.2 Outdoor Industrial Site Router (e.g., Photovoltaic Power Station)

　　Application: Transmits photovoltaic inverter data and monitors equipment status, suitable for outdoor high-altitude and remote sites.

　　ISO 45001 Safety Design:

　　IP67 protection + lightning protection design (8/20μs lightning surge withstand ≥10kV) reduces equipment failures caused by heavy rain and lightning (avoiding personnel performing maintenance work in thunderstorms or at heights);

　　Low-temperature self-heating function (automatically activates the heater at -30°C), eliminating the need for on-site preheating in winter (preventing frostbite);

　　Equipped with a safety bracket for high-altitude installation (supports ≥10 times the equipment weight) and an anti-fall hook (for personnel to attach a safety rope during installation to reduce the risk of falls).

　　Use Case: Desert photovoltaic power station. The router is installed on top of the inverter control cabinet (2.5m above the ground). It supports solar power (12–48V DC). Signal strength is remotely monitored on the cloud platform, requiring only one on-site inspection per quarter (reducing the risk of exposure to high desert temperatures). 3.3 Hazardous Area Router (e.g., Chemical Plant)

　　Application: Connects chemical storage tank level sensors and toxic gas detectors, suitable for data transmission in explosion-proof areas.

　　ISO 45001 Safety Design:

　　Explosion-proof rating: Ex d IIB T4 Ga. The housing is screwless (welded and sealed), and all interfaces utilize explosion-proof cable glands (to prevent spark leakage).

　　Fully remote operation and maintenance (no local operation buttons, configuration is performed only via the cloud platform). Personnel are prohibited from opening the cover in the explosion-proof area to prevent the detonation of flammable gases.

　　In the event of a fault, non-critical circuits are automatically disconnected (only alarm signal transmission is retained), preventing equipment abnormalities from causing chain reactions.

　　Use Case: In a chemical solvent storage tank area, the router is installed in an explosion-proof control cabinet and linked to a toxic gas detector. When the detector alarms, the router prioritizes transmission of the alarm data, eliminating the need for personnel to enter the explosion-proof area to handle the situation (to protect respiratory health). 4. ISO 45001 Compliance & Operational Management

　　4.1 Certification & Safety Standards

　　System Certification: Equipment manufacturers must obtain ISO 45001 system certification to ensure that the entire design and production process complies with occupational health and safety requirements (such as collision prevention in the production workshop workstation layout and pre-job safety training for employees).

　　Product Certification: Products must comply with IEC 61010-1 (electrical safety), IEC 60068 (environmental compatibility), and ATEX/IECEx (explosion-proof certification, if required). Third-party test reports (such as insulation resistance and vibration test data) must be provided. 4.2 Safe Operation & Maintenance

　　Installation: Operated by a certified industrial electrician. Post-installation ground resistance (≤4Ω) and insulation performance (≥100MΩ) must be tested, and test records must be maintained (ISO 45001 audit traceability).

　　Maintenance: Develop "Industrial Router Safety Maintenance Procedures," clearly defining the "power-off test → grounding test → module replacement" process. Maintenance personnel must wear insulating gloves (voltage resistance ≥1000V) and goggles (to protect against component splashing).

　　Training: Operators and maintenance personnel must undergo ISO 45001 safety training (e.g., industrial environment risk identification and operating restrictions in explosion-proof areas). Only qualified personnel can begin work (training records must be retained for ≥3 years). 5. Selection Checklist

　　Electrical Safety: Verify insulation class (≥Class II), ground resistance (≤4Ω), overload protection (resettable fuse + high-temperature power-off), and provide an IEC 61010 test report.

　　Environmental Adaptability: Protection level (≥IP65), wide operating temperature range (-40°C to 75°C), and vibration resistance (10–500Hz). For explosion-proof applications, Ex d IIB T4 Ga or higher must be confirmed.

　　Ergonomics & Maintenance: Weight (≤3kg), modular design (tool-free replacement), safety warning signs, and a safety manual.

　　Certifications: Enterprise ISO 45001 system certification and product CE (EN 61010)/UL (UL 60950) certification. For explosion-proof applications, ATEX/IECEx certification is required.

　　Emergency Functions: Remote diagnostics, emergency power off, and fault alarms (audio/visual/cloud platform) reduce on-site personnel risks.