Protective Engineered Safety is breaking new ground by integrating world-first direct current (DC) hazard detection into its flagship GoUpSafely system – which Protective’s Managing Director Karl Rosewarne said will deliver “true end-to-end protection” for rail, tram and light rail operators.
GoUpSafely is a unique product capable of sensing electrical fields, invented by Perth-based engineer Rosewarne after he witnessed the aftermath of several fatal electrical accidents and decided he needed to do something to stop this avoidable loss of life.
The product can be installed in most types of aerial machines working on construction sites and near rail lines. When it senses a live power line within the machine’s pre-programmed danger zone, it sends a warning to the operator, while also preventing the machine from contacting the power source and allowing it to move out of harm’s way.
Now, Protective is taking GoUpSafely to the next level – and addressing a “dangerous blind spot” in Australia’s rail industry.
Closing the safety gap
Electrical hazards are one of the leading causes of serious injury and death on worksites worldwide.
While overhead alternating current (AC) power lines have become the focus of detection technology and new regulations, Rosewarne said DC-powered rail corridors – common in tram, light rail, and private rail networks – have long been overlooked.
“Until now, there has been no automated, machine-mountable solution that reliably detects the presence of live DC lines and can actively prevent accidents,” he said.
“Building on the success of GoUpSafely’s globally deployed AC detection, Protective’s engineering team has achieved what no one else has: combining high-voltage AC and DC detection into a single, integrated safety system for mobile machinery.”
The result is a durable, permanently installed sensor that can alert operators and stop a machine if it approaches a live overhead line, whether it’s carrying AC or DC voltage.
Rosewarne explained that traditional DC detection has relied on field mill technology, which uses exposed plates to sense static electric fields but is inherently vulnerable to weather, dust, and physical wear.
“These devices are suited only for laboratory or hand-held use – not for the harsh and variable environments of rail corridors,” he said. “Protective’s breakthrough is a fully sealed, weatherproof static detection system, designed specifically for permanent mounting on rail vehicles and mobile equipment.”
How does It work?
The new GoUpSafely system combines proven AC electric field and frequency sensing, already in use across cranes, tippers, concrete pumps, and more, with static electric field sensing for DC voltage and machine motion awareness.
“The AC electric field and frequency sensors we already have on the market detect AC lines with pinpoint accuracy, filtering out nuisance alarms,” Rosewarne said.
“Meanwhile the new sealed sensor technology enables detection of DC lines, even in tough rail and tram environments.
“In addition, by integrating motion data, GoUpSafely can distinguish real hazards from background noise, dramatically reducing false alarms and providing actionable alerts.”
To power these new capabilities, the DC sensors are hardwired to the host machine, due to the increased energy demands of static field and motion sensing.
However, all operator notifications and controls remain wireless and compatible with existing GoUpSafely panels, preserving a seamless user experience.
Designed for the real world
Protective’s design team has reimagined the GoUpSafely sensor housing, eliminating the solar panel to make room for the new detection components, and adding advanced electromagnetic shielding to ensure accuracy.
“The entire package is engineered to meet stringent IP68 ingress protection standards, suitable for the scorching heat of an Australian summer or the freezing winters of Europe,” Rosewarne noted.
Just as importantly, the system is designed for permanent installation, so there is no frequent calibration or ongoing sensor protection required.
“Once installed, operators and site managers can have confidence that GoUpSafely will keep working day after day, regardless of weather, vibration, or grime.”
Bridging the industry gap
Rosewarne said that with no commercial DC detection systems currently on the market that offer a rugged, sealed sensor suitable for mobile applications, or one that can integrate with machine controls to stop movement when a hazard is detected, most operators are still relying on human spotters.
“Human spotters are looking for an electric field – which is something you can’t really see.
“There are also a lot of factors at play, from fatigue to poor eyesight, that means this approach can lead to errors and missed hazards.”
He said Protective’s updated AC/DC GoUpSafely system fills this critical industry gap, providing rail maintenance vehicles, emergency response machines, and other mobile platforms with a solution that brings DC corridors into the fold of modern safety.
Testing and validation
Due to the complexities of DC detection, Protective has built a DC rail simulation environment in-house, which reproduces live DC overhead conditions.
Rosewarne said this has allowed the engineering team to carry out “robust, repeatable testing and rapid iteration”.
Tests will continue throughout 2025, and once the team is happy with the lab test results, they will move on to field validation – paving the way for commercial rollout of the integrated AC/DC GoUpSafely product.
Looking ahead, GoUpSafely’s AC/DC capability will support mixed-voltage sites and evolving rail infrastructure, including battery and renewable integrations.
“This is a future-proof solution, designed to keep pace with the changing landscape of transport and energy,” Rosewarne said.
“Protective’s commitment remains clear: close the last major gap in electrical safety for rail and give every worker the best chance of going home safe.
“Protective’s AC/DC GoUpSafely system isn’t just ‘on track’ – it’s redefining the track for safety, innovation, and peace of mind in the rail sector.”
