08 / 09Device-first safety monitoring
RoboFusion Monitor
A resilient ESP32 safety monitoring system that keeps camera, sensor, storage, synchronization, and alert status understandable from one live dashboard.
The problem
The challenge
A safety system cannot rely on perfect connectivity.
Camera, sensor, alarm, and history data must remain trustworthy when the network drops or power is interrupted. The dashboard also needs to explain offline and recovery states without contradicting the physical device.
What we changed
The key decision
Keep safety decisions with the device.
We made the ESP32 the authority for sensing, alerts, local history, and acknowledgement. The web platform mirrors that ordered state and makes disconnection, catch-up, and recovery visible to operators.
The product
The experience
One operational view, even through interruptions.
RoboFusion combines camera presence, climate and obstacle readings, overall safety, storage health, synchronisation, history, and alert acknowledgement. A device-hosted fallback keeps essential information available when the cloud cannot be reached.
What it enables
Useful outcomes for the people using it.
- 01
Understand camera and sensor status in one live operational view
- 02
Keep safety decisions working when the internet is unavailable
- 03
See offline recovery and history synchronisation clearly
- 04
Acknowledge alerts from the dashboard or the physical device
Under the hoodTechnical details
- Stable event IDs and sequence numbers preserve order during offline catch-up.
- A bounded on-device store keeps recent history without uncontrolled storage growth.
- Server validation and deduplication protect the MongoDB mirror during recovery.
Results
Project evidence
