Mental fatigue has a considerable influence on the completion of work as well as the safety and health of construction equipment operators who have been exposed to human–machine interaction for an extended period of time. Existing techniques of monitoring and measuring mental fatigue among construction equipment operators are either invasive or rely on subjective judgements, limiting their applicability on construction sites. Therefore, this paper developed a non-invasive smart cushion to evaluate the mental fatigue of construction equipment operators through real-time continuous monitoring of the heartbeat and respiration signals. A laboratory experiment was designed, and twelve participants were recruited to conduct the simulated excavator operation for data acquisition. First, wearable sensors were used as a reference to verify the monitoring accuracy of heartbeat and respiration signals. Excellent correlations were realized between the results of the two monitoring methods. Second, the relevant time domain and frequency domain features were extracted to construct a random forest classification model to discover the relationship between vital signs and subjectively reported mental fatigue status. The results demonstrated that the random forest model had a classification accuracy of 92%, better than other commonly used machine learning algorithms. A combination of heartbeat and respiration features is more effective than a single feature in identifying and classifying mental fatigue among construction equipment operators. The study's findings indicate that it is feasible to apply the smart cushion to identify and classify the mental fatigue of construction equipment operators, therefore contributing to the improvement of their health and safety.
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