Positioning safety helmet

Abstract

The utility model provides a positioning safety helmet. The positioning safety helmet comprises a safety helmet main body; the first shell and the second shell are arranged in bilateral symmetry along the central axis of the safety helmet main body; a sealing cover is clamped on the outer side of each shell and is correspondingly matched with the shell to form a closed cavity; the PCB is fixedly installed in the first shell, and the edge of the PCB is welded and fixedly connected with a charging interface, a work indicating lamp, a charging indicating lamp and an alarm button; the processor is welded on the PCB, and the communication module, the Beidou positioning module, the Bluetooth positioning module, the acceleration module and the buzzer are electrically connected with the processor through signal lines; the battery pack is accommodated in the second shell; through holes are formed in the positions, corresponding to the charging interface, the work indicating lamp, the charging indicating lamp and the alarm button, of the first shell. According to the utility model, a more reliable and easier-to-use hardware basis is provided for long-time safety monitoring in a severe environment.

Description

Technical Field

[0001] This utility model belongs to the field of construction safety technology, and specifically relates to a positioning safety helmet. Background Technology

[0002] In smart construction sites, mine monitoring, and emergency rescue scenarios, wearable positioning safety helmets have become essential equipment for personnel safety management. While existing products employ dual-mode positioning technologies such as BeiDou / GPS to achieve centimeter-level positioning accuracy, they still exhibit the following shortcomings in terms of structure, power supply, and human-computer interaction:

[0003] 1. Displacement of the center of gravity causes discomfort when wearing.

[0004] Existing safety helmets typically have the positioning motherboard and battery pack mounted on the same side of the helmet, causing the center of gravity to shift to one side. Wearing them for extended periods can easily lead to neck and head fatigue and reduce work efficiency.

[0005] 2. Battery life is limited by space constraints.

[0006] To reduce the load on one side, traditional solutions can only use small-capacity battery packs; during high-intensity operations lasting more than 12 hours, the helmet must be charged or replaced multiple times, increasing management difficulty.

[0007] 3. Messy wiring harness and poor reliability

[0008] The modules and batteries are arranged in the same compartment, and the internal wires are crisscrossed and lack restraint structures. Long-term vibration can easily cause the solder joints to crack or the wires to wear, resulting in a high equipment failure rate.

[0009] 4. Inconvenient operation and instructions

[0010] Existing products often embed the charging port, indicator lights, and alarm buttons inside the casing or distribute them in different locations, making it difficult for workers to quickly perform charging plugging / unplugging, status checks, or alarm operations while wearing the device.

[0011] 5. Unable to achieve one-button sound and light + remote synchronized alarm.

[0012] Some products only support automatic alarms in the background or simple sound and light prompts, lacking a hardware path for on-site personnel to simultaneously trigger the buzzer and communication module with one button in an emergency, thus delaying rescue opportunities.

[0013] 6. Difficulty in on-site maintenance and disassembly

[0014] The module, battery, and wiring harness are sealed in the same cavity with glue. Repairing or replacing the battery requires complete disassembly, which is time-consuming, labor-intensive, and can easily damage the integrity of the casing seal. Utility Model Content

[0015] The purpose of this invention is to address the shortcomings of the aforementioned background technology and provide a positioning safety helmet that solves the pain points of existing technologies in terms of center of gravity balance, battery life, wire reliability, human-computer interaction, and emergency alarm response, thus providing a more reliable and user-friendly hardware foundation for safety monitoring in long-term and harsh environments.

[0016] The technical solution adopted by this utility model is: a positioning safety helmet, comprising:

[0017] The main body of the safety helmet;

[0018] A first shell and a second shell are symmetrically arranged along the central axis of the main body of the helmet; each shell has a cap snapped onto its outer side, which cooperates with the cap to form a closed cavity;

[0019] A PCB board is fixedly installed inside the first housing. The edges of the PCB board are soldered and fixedly connected to: a charging interface, a working indicator light, a charging indicator light, and an alarm button.

[0020] Soldered onto the PCB board are: a processor, a communication module, a Beidou positioning module, a Bluetooth positioning module, an accelerometer module, and a buzzer, which are electrically connected to the processor via signal lines; the charging interface, the working indicator light, the charging indicator light, and the alarm button are electrically connected to the processor via signal lines.

[0021] The battery pack housed within the second housing has its power output terminal electrically connected to the power input terminal of the PCB board via a wire passing through the main body of the safety helmet and running along its inner wall, for supplying power to the PCB board and its soldered components; the charging interface is electrically connected to the power input terminal of the battery pack via a wire passing through the main body of the safety helmet and running along its inner wall.

[0022] The first housing has through holes at the corresponding positions of the charging interface, the working indicator light, the charging indicator light, and the alarm button, so that the above ports or components are partially exposed, which facilitates charging connection, button operation and status indication.

[0023] In the above technical solution, the alarm button, Beidou positioning module, Bluetooth positioning module, and acceleration module are all electrically connected to the input terminal of the processor via signal lines;

[0024] The working indicator light, charging indicator light, buzzer, and communication module are electrically connected to the processor's drive port via signal lines.

[0025] The above technical solution also includes a power switch; the power switch is connected in series between the power output terminal of the battery pack and the power input terminal of the PCB board; the power output terminal on the PCB board is electrically connected to the power input terminals of the processor, working indicator light, charging indicator light, Beidou positioning module, Bluetooth positioning module, communication module and acceleration module respectively.

[0026] In the above technical solution, the first housing has a through hole at the corresponding position of the power switch, so that the power switch part is exposed.

[0027] In the above technical solution, an elastic sealing ring is provided between the mating surfaces of the shell and the cover.

[0028] In the above technical solution, the charging interface is a magnetic multi-contact interface, and a removable waterproof elastic plug is provided between the contacts and the corresponding through holes of the charging interface.

[0029] In the above technical solution, the battery pack is a lithium polymer battery pack with a rated capacity of not less than 5000mAh.

[0030] In the above technical solution, both the working indicator light and the charging indicator light are dual-color light-emitting diodes, and the two light-emitting chips of each dual-color light-emitting diode are soldered into the same LED package housing.

[0031] In the above technical solution, the communication module integrates an NB-IoT chip and a Bluetooth Mesh chip on the PCB board, and the two are electrically connected to the serial communication port of the processor through signal lines.

[0032] In the above technical solution, both the first shell and the second shell are detachably fixed to the helmet body by screws. The inner wall of the helmet body is provided with a strip-shaped flexible slot for accommodating and constraining the wire routing.

[0033] The beneficial effects of this utility model are as follows: This utility model proposes a positioning safety helmet with a symmetrical double shell + cavity arrangement + inner wall wiring + exposed ports. The symmetrical distribution of the first and second shells achieves overall center of gravity balance, improving wearing comfort and work efficiency. The large-capacity battery pack is independently placed in the second shell, eliminating battery size limitations and significantly extending battery life. The wiring arrangement along the inner wall of the helmet reduces wire crossings and improves electrical connection reliability. Through holes are opened at corresponding positions on the first shell, directly exposing the charging interface, indicator lights, and alarm button for easy charging, status monitoring, and button operation. A fixed hardware path—alarm button—processor—buzzer—communication module—achieves one-button local audio-visual prompts and synchronous remote alarm signals. The detachable installation of the two shells and the cavity structure facilitate independent maintenance of the battery or motherboard, reducing on-site repair difficulty.

[0034] Furthermore, this invention connects the signal lines of the alarm button, Beidou positioning module, Bluetooth positioning module, and accelerometer module to the processor's input terminal, while simultaneously connecting the drive lines of the working indicator light, charging indicator light, buzzer, and communication module to the processor's output terminal, forming a clear and dedicated signal path. The direct effect of this is improved anti-interference capability and reduced false triggering; the processor can collect sensor status in real time and accurately drive audible and visual prompts and remote communication, making the "one-button alarm" response more timely and reliable.

[0035] Furthermore, this invention connects a power switch in series between the battery pack and the PCB power input, and distributes the PCB power bus to each functional module, enabling one-button power-on or power-off of the entire device. During power-off, standby leakage is completely eliminated, extending storage life; after power-on, each module receives a uniform and stable operating voltage, while also providing hard reset capability, making on-site fault recovery simpler.

[0036] Furthermore, this invention features a through-hole on the surface of the power switch housing, exposing the switch cap, allowing the operator to directly access the power switch while wearing the safety helmet without removing it or disassembling the cover. This design facilitates quick shutdown, storage, transportation, or power disconnection in emergencies.

[0037] Furthermore, this invention incorporates an elastic sealing ring at the joint surface between the shell and the cover, significantly improving the airtightness, watertightness, and dustproof performance of the positioning components, thus achieving an overall protection level of IP65 or higher for the safety helmet. Even under harsh conditions such as rain, dust, and mud, the internal electronic components can remain dry and clean for extended periods, resulting in higher reliability.

[0038] Furthermore, this utility model designs the charging interface as a magnetic multi-contact type with a detachable waterproof elastic plug, which brings two significant effects: First, the magnetic automatic alignment facilitates quick insertion and removal with one hand and reduces mechanical wear; second, the waterproof plug can re-seal the through hole after charging is completed, further preventing rainwater and dust from entering and extending the interface life.

[0039] Furthermore, this invention uses a lithium polymer battery pack with a rated capacity of not less than 5000mAh, enabling the device to work continuously for a full shift (12 hours or even longer) under typical power consumption without the need for replacement or charging, significantly reducing the frequency of operation and maintenance and management costs.

[0040] Furthermore, both the working indicator light and the charging indicator light of this invention adopt a dual-color LED co-package scheme. Multiple working / charging states can be displayed through different color combinations on a limited PCB area, saving board space and allowing the wearer to easily distinguish the device's current operation and charging progress.

[0041] Furthermore, the communication module of this invention integrates NB-IoT and Bluetooth Mesh dual chips on the same PCB and communicates with the processor via an independent serial port. NB-IoT provides long-range cellular connectivity, while Bluetooth Mesh handles short-range networking and signal relay. In areas with weak network connectivity, such as tunnels and underground mines, Bluetooth Mesh can forward alarm or location information to the nearest NB-IoT node, improving overall data delivery rate while reducing the cost and weight associated with external modules and wiring.

[0042] Furthermore, both the first and second housings of this invention are detachably fixed to the helmet body with screws, and a flexible slot is provided on the inner wall of the helmet to limit the movement of the wires in sections. The screw fixing method facilitates the individual replacement of the battery pack or PCB without destroying the overall encapsulation; the flexible slot prevents the wires from being worn or tangled during vibration, greatly improving the long-term reliability of the electrical connection and simplifying future maintenance. Attached Figure Description

[0043] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0044] Figure 2 This is a partial schematic diagram of the first housing of this utility model;

[0045] Figure 3 This is a schematic diagram of the cap of this utility model;

[0046] Figure 4 This is a schematic diagram of the circuit structure of this utility model;

[0047] Figure 5 This is a schematic diagram of the inner wall of the safety helmet body of this utility model.

[0048] In the diagram: 1-Helmet body; 202-A-First shell, 202-B-Second shell; 203-Cap; 204-PCB board; 205-Charging interface; 206-Power switch; 207-Working indicator light; 208-Charging indicator light; 209-Alarm button; 210-Processor; 211-Communication module; 212-Beidou positioning module; 213-Bluetooth positioning module; 214-Acceleration module; 215-Buzzer; 3-Elastic sealing ring; 4-Wire; 5-Flexible slot. Detailed Implementation

[0049] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments to facilitate a clear understanding of the present invention, but these descriptions do not constitute a limitation on the present invention.

[0050] like Figure 1-5 As shown, this utility model provides a positioning safety helmet, including:

[0051] Safety helmet body 1;

[0052] The first shell 202-A and the first shell 202B are symmetrically arranged along the central axis of the main body 1 of the safety helmet; each shell has a cover 203 snapped onto its outer side, and the cover 203 is correspondingly matched with the cover to form a closed cavity;

[0053] A PCB board 204 is fixedly installed inside the first housing 202-A. The edge of the PCB board 204 is welded and fixedly connected to: a charging interface 205, a working indicator light 207, a charging indicator light 208, and an alarm button 209.

[0054] Soldered onto the PCB board 204 are: a processor 210, a communication module 211, a Beidou positioning module 212, a Bluetooth positioning module 213, an acceleration module 214, and a buzzer 215, which are electrically connected to the processor 210 via signal lines; the charging interface 205, the working indicator light 207, the charging indicator light 208, and the alarm button 209 are electrically connected to the processor 210 via signal lines.

[0055] The battery pack housed within the first housing 202B has its power output terminal connected to the power input terminal of the PCB board 204 via a wire 4 passing through the safety helmet body 1 and running along its inner wall, for supplying power to the PCB board 204 and its soldered components; the charging interface 205 is connected to the power input terminal of the battery pack via a wire 4 passing through the safety helmet body 1 and running along its inner wall.

[0056] The first housing 202-A has through holes at corresponding positions of the charging interface 205, the working indicator light 207, the charging indicator light 208, and the alarm button 209, so that the aforementioned ports or components are partially exposed, facilitating charging connection, button operation, and status indication.

[0057] Preferably, the helmet body can have a rectangular raised reinforcing rib structure at the brim and a V-shaped raised reinforcing rib structure at the top to ensure the stability of the one-piece molded helmet body. The thickened cross-section of the rectangular ribs at the brim effectively prevents the brim from bending or cracking under compression or lateral impact; the V-shaped ribs at the top extend the impact load to both sides, dispersing concentrated stress and reducing shell deformation. The reinforcing ribs are only locally thickened in the required areas, without significantly increasing the overall weight, while still meeting wearing comfort requirements. Both the rectangular and V-shaped ribs are easy to mold, demold, and vent, without producing obvious flash. For best results, the rib height is generally 0.5 to 1.0 times the shell thickness, and the rib thickness is approximately 0.3 to 0.6 times the shell thickness, with a 0.5 to 1.0 mm rounded corner between the ribs and the shell wall to prevent injection molding stress concentration.

[0058] Specifically, the alarm button 209, the Beidou positioning module 212, the Bluetooth positioning module 213, and the acceleration module 214 are all electrically connected to the input terminal of the processor 210 via signal lines;

[0059] The working indicator light 207, the charging indicator light 208, the buzzer 215, and the communication module 211 are electrically connected to the drive port of the processor 210 via signal lines.

[0060] Preferably, the typical device models for each functional module in this embodiment (for example only; actual models can be selected based on supply and performance requirements):

[0061] Processor 210 (MCU): TMicroelectronics STM32L476RG (ARM Cortex-M4, low power);

[0062] Beidou Positioning Module 212: Quectel L76-LB (GPS + Beidou dual-mode, 3m positioning accuracy); or u-bloxCAM-M8Q (supports Beidou + GPS + GLONASS);

[0063] Bluetooth positioning module 213: Nordic Semiconductor RF52840 (supports Bluetooth 5.0 & Mesh) or Dialog DA14531 (ultra-low power consumption, supports Mesh expansion);

[0064] Communication module 211: Quectel BC95-G (3GPPR13NB-IoT); or Quectel BC66 (supports NB-IoT / CatM1 dual mode).

[0065] Accelerometer module 214: Bosch BMA400 (triaxial, ultra-low power ±2 / ±4 / ±8 / ±16g); or STMicroelectronics LIS2DH12 (high resolution triaxial);

[0066] Alarm button 209: Omron B3F-4055 (surface mount micro switch, 0.55mm travel); or E-Switch TL1105 (three-legged dustproof structure);

[0067] Work indicator light 207: Kingbright WP154GD (0603 size dual-color LED, green / red);

[0068] Charging indicator light 208: KingbrightWP154KD (same series dual-color LED, yellow / green)

[0069] Buzzer 215: MurataPKLCS1212E4001-R1 ​​(Surface Mount Piezoelectric Buzzer 215, 2kHz); or TDKPS1240P02BT (3V Surface Mount Buzzer 215);

[0070] The battery pack can integrate a charging management circuit, using either the Microchip MCP73831 (single-cell lithium battery linear charging management) or the TIBQ24072 (supporting USB and magnetic multi-contact interfaces).

[0071] Charging port 205: TEConnectivity3-1733807-3 (3PIN magnetic type, with waterproof O-ring);

[0072] Battery pack: Panasonic NCR18650B (3.7V / 3400mAh lithium cobalt oxide cylindrical cell); or a customized 3.7V / 5000mAh lithium polymer soft pack.

[0073] In the circuit system of this embodiment, the processor 210 is responsible for overall control and protocol conversion; the three-way positioning / communication combination of the Beidou positioning module 212, Bluetooth positioning module 213 and communication module 211 ensures full environmental coverage; the acceleration module 214 provides fall detection; the alarm button 209, indicator light and buzzer 215 constitute the human-machine interaction and alarm path; the charging management and charging interface 205 realize convenient and replaceable battery life.

[0074] Specifically, it also includes a power switch 206; the power switch 206 is connected in series between the power output terminal of the battery pack and the power input terminal of the PCB board 204; the power output terminal on the PCB board 204 is electrically connected to the power input terminals of the processor, the working indicator light 207, the charging indicator light 208, the Beidou positioning module 212, the Bluetooth positioning module 213, the communication module 211, and the acceleration module 214, respectively. The first housing 202-A has a through hole at the corresponding position of the power switch 206, so that part of the power switch 206 is exposed.

[0075] Preferably, the power switch 206 is an Omron B3F-1020 (surface mount push-button switch, rated current 200mA / 30V), which is connected in series between the positive output of the battery pack (Panasonic NCR18650B, 3.7V / 3400mAh) and the power input terminal (VBAT) of the PCB board 204, and is exposed through a through hole on the first housing 202-A (202-A) of the safety helmet.

[0076] The power switch 206 enables one-button power on / off switching—when pressed, the built-in spring closes, and battery voltage is introduced to the PCB board 204; releasing the button or pressing and holding it for more than 2 seconds resets it open, cutting off power to all downstream modules. In case of a short circuit or system crash, all modules can be restarted by powering off, forcing the system back to its initial power-on state. A 0.5mm step and silicone gasket are provided around the button cap to prevent accidental impacts.

[0077] The battery pack outputs a typical voltage of 3.7V–4.2V, which is converted to the 3.3V operating voltage required by the processor MCU via a boost / buck regulator on the PCB (e.g., a TITPS63020 or Microchip MCP1700). The regulator output VBAT_3V3 branches to the processor's VDD, VCORE, and VDD_IO pins via printed power input traces. A 1206-size 10μH common-mode inductor (e.g., Murata DLW21SN100SQ2L) and an EMI filter network are placed between the regulator output and the processor's VDD to further suppress high-frequency interference from the battery and charging circuitry. A 0.1μF ceramic decoupling capacitor (0603 size) and a 4.7μF tantalum capacitor are placed close to each of the processor power pins to filter low-frequency ripple and provide transient current. A 33μF low-ESR aluminum electrolytic capacitor is connected in parallel at the PCB power input to buffer system startup and heavy load transients. A Schottky diode (such as SS14) is connected in series in the VBAT_3V3 line to prevent reverse connection or backflow from the MCU to the battery pack; a 0.5A resettable fuse (PTC) is placed at the front end of the regulator to handle short circuits or overcurrent and ensure the safety of the entire device. The regulator integrates a soft-start function, which delays the regulator output by raising the EN pin via a GPIO controlled by the MCU to avoid simultaneously powering multiple modules impulsively.

[0078] After power-on, the MCU reads the VBAT_3V3 and VBAT_BATT (regulator front end) voltages via the ADC to determine the battery level and drive the charging indicator light or trigger a low battery alarm accordingly. The VBAT_3V3 power line uses 1oz copper traces with a width ≥0.6mm, distributed along the main power supply trunk of the PCB board, and vias are set at key nodes to balance the power supply of multiple layers; all external power interfaces (including charging interface 205) and internal power traces are led from the PCB edge vias to the cap slot, and then neatly arranged to the battery pack in the second housing to avoid cross-interference.

[0079] Both the working indicator light 207 and the charging indicator light 208 are dual-color light-emitting diodes, and the two light-emitting chips of each dual-color light-emitting diode are soldered into the same LED package housing.

[0080] The indicator light 207 is connected to the PCB board 204VBAT and ground via a current-limiting resistor (330Ω) and is driven by the GPIO of the MCU (STM32L476). Within 5 seconds of power-on, the green light flashes at 1Hz, indicating that the processor 210 has passed its self-test. After the self-test is complete, the green light remains solid, indicating normal operation. If the MCU detects a communication failure or module malfunction, it switches to a red light flashing at 2Hz.

[0081] The charging indicator light 208 is controlled by the processor, which is electrically connected to the STAT pin of the charging management IC (Microchip MCP73831) and driven by the output signal of the MCP73831. The processor controls the charging indicator light according to the received drive signal: when the battery pack is charging, the MCP73831 STAT is low, and the yellow light is constantly on, indicating that charging is in progress; when the battery pack is fully charged, the STAT is pulled high, and the green light remains constantly on; when the battery pack is not charging, the LED is off, indicating that the battery is powered by a switch and no external charger is connected.

[0082] The Beidou positioning module 212 is directly connected to the PCB board 204VBAT and is controlled by the power switch 206. After power-on, it starts satellite search, obtains Beidou / GPS hybrid positioning, and outputs NMEA data to the MCU. After interruption or timed reading, the MCU reports the location information through the communication module 211.

[0083] The Bluetooth positioning module 213 is directly connected to the PCB board 204VBAT and is synchronously controlled by the MCU and power switch 206. After power-on, it enters the Mesh network, broadcasts its location heartbeat, and receives relays from neighboring nodes; the MCU assists in positioning based on the signal strength of surrounding nodes or relays alarms in weak network environments.

[0084] The communication module 211 is directly connected to the PCB board 204VBAT and is synchronously switched on and off by the power switch 206 (206); after the module is powered on, it enters the network registration state. The UART (TXD / RXD) of the communication module 211 is connected to the serial port of the MCU (STM32L476RG) for AT command interaction; the STATUS signal pin is electrically connected to the external interrupt pin of the MCU to notify whether the network registration is ready, data transmission is complete, or an error status has occurred. After power-on, the MCU automatically sends a registration request to the operator's base station. After the MODULE_READY interrupt goes high, the MCU continues to the next step. When the MCU receives positioning data from the Beidou positioning module 212 or the Bluetooth Mesh module, or when the "alarm button 209" / "acceleration fall" is triggered, it sends the encapsulated JSON data packet (containing latitude and longitude, alarm type, and timestamp) to the cloud via commands such as AT+NSOST / AT+SEND. It supports cloud downlink AT commands. After the STATUS interrupt is triggered, the MCU reads UART data and executes remote configuration or factory reset commands. When the MCU enters deep sleep or there is no data transmission, the MCU sends the AT+CFUN=0 command to put the module into the minimum power consumption mode. It wakes up again when communication is needed (AT+CFUN=1) to extend battery life.

[0085] Accelerometer module 214 is directly connected to PCB board 204VBAT; it enters deep sleep mode after power switch 206 is turned off. After power-on, it is initialized by MCU and the ±8g measurement range is set; the MCU is notified to sample via built-in interrupt (DRDY), and the acceleration value is used for fall / collision detection.

[0086] The power input of buzzer 215 is a square wave signal provided by VBAT on PCB board 204 via the PWM output drive port (PI_8) of the MCU, with the other end grounded. When the alarm button 209 or the fall detection of the acceleration module 214 is triggered, the MCU outputs a 2kHz square wave, and buzzer 215 sounds continuously for 3 seconds; when the battery voltage is detected to be below 3.4V, it outputs a short double tone to remind the user to replace or recharge the battery.

[0087] Specifically, such as Figure 3 As shown, an elastic sealing ring 3 is provided between the mating surfaces of the housing and the cover 203.

[0088] Preferably, the shell is injection molded from impact-resistant ABS, and its appearance is a semi-ring shape that matches the curved surface of the safety helmet. A U-shaped groove can be formed on the inner side of the end that mates with the cap 203, with a groove opening width of approximately 3.5mm and a groove depth of approximately 2.5mm. The bottom of the groove transitions to the sidewall with a 1mm radius chamfer to ensure that the sealing ring is not scratched during assembly. This provides a rigid support surface for the cap 203, forming an outer waterproof / dustproof barrier in conjunction with the sealing ring; the bottom of the groove is smooth, ensuring that the sealing ring can seal evenly under pressure.

[0089] The cap 203 is made of polycarbonate (PC) through a one-piece injection molding process, and its appearance fits snugly against the outer curved surface of the housing. A rectangular groove is machined around the inner side of the cap 203 corresponding to the recessed area, with a groove depth of approximately 2.4 mm and a groove width of approximately 3.2 mm (slightly smaller than the U-groove of the housing to achieve 20–30% pre-compression of the sealing ring). The top sidewall of the groove has a 5° chamfer for assembly guidance and to prevent the O-ring from crawling out. It is detachably fixed to the housing by screws or clips; when closed, the cap 203 and the housing form a "press-clamp" state between the groove and the recess, firmly holding the sealing ring in place and preventing external liquids and dust from entering.

[0090] The elastic sealing ring 3 has a closed annular cross-section, is made of silicone, has a hardness of approximately 50 Shore A, a cross-sectional diameter of 3 mm, and an outer diameter of approximately 40 mm (matching the outer length of the U-shaped groove). It is axially compressed by 20–30% between the U-groove of the housing and the slot of the cover 203, forming a continuous rubber sealing surface; the material is resistant to high and low temperatures (–40℃ to +125℃), aging resistant, and can maintain IP65 or higher protection in rain, dust, and water-washing environments.

[0091] During assembly, first pre-install the elastic sealing ring 3 into the small groove inside the cover 203, then align the cover 203 with the housing, insert it, and secure it with screws / clips. Because the groove of the cover 203 is slightly narrower than the groove of the housing, the O-ring is slightly compressed after closing, forming a sealing structure of "three-sided positioning, two-sided pressure, and integrated limiting". This design takes into account waterproofing, dust resistance, and easy disassembly and assembly, making it very suitable for harsh environments on construction sites.

[0092] Specifically, the charging interface 205 is a magnetic multi-contact interface, and a removable waterproof elastic plug is provided between its contacts and the corresponding through holes of the charging interface 205.

[0093] The magnetic multi-contact charging interface 205 can use TEConnectivity 3-1733807-3 or an equivalent product. The interface shell has a circular matrix arrangement, with a diameter of approximately 12mm and a height of approximately 4mm. It has three built-in metal contacts (two power contacts + one ground contact), with a contact spacing of approximately 4mm. The contacts are gold-plated to improve corrosion resistance and conductivity reliability. The side wall of the interface shell has a small guide groove that engages with the protrusion in the through hole of the first shell 202-A of the safety helmet to achieve unidirectional insertion. Each contact is soldered to the charging management IC input terminal on the PCB board 204 via a flexible ribbon cable. The bottom of the interface has a ring-shaped permanent magnet material (high-temperature resistant neodymium iron boron), which automatically attracts the plug and the base when they are close together, eliminating the need for precise alignment. The two power contacts share the charging current (maximum 1.5A), and the ground contact ensures the lowest possible loop resistance. The magnetic force and the guide groove work together to prevent the plug from falling off in a ±30° vibration environment after insertion.

[0094] A through hole with a diameter of approximately 12.2 mm is made in the first housing 202-A corresponding to the charging interface 205. A recessed step is provided on the inner side of the hole wall for mounting the waterproof plug. The waterproof elastic plug is made of food-grade silicone or fluorosilicone with a hardness of approximately 45 Shore A. It has a disc-shaped structure with a central hole, an outer diameter of approximately 14 mm, and a thickness of approximately 3 mm. Three blind holes (each with a diameter of approximately 1.5 mm and a depth of approximately 2 mm) are reserved in the center to cover the contacts and automatically align with the plug contacts. The outer edge of the waterproof plug has two annular lips that match the inner step of the through hole to achieve "three-point limiting". It can be manually pulled out or easily removed with a sharp tool (such as a needle). When the charging head is not inserted, the silicone plug completely blocks the through hole, effectively preventing dust, mud and water droplets from entering the electronic cavity; after long-term wear or chemical corrosion, the sealing plug can be quickly removed and replaced, making maintenance simple; the depth of the blind hole matches the length of the plug contact, and when inserted, the plug contact will gently press the silicone plug, pushing the contact into the PCB pad, while maintaining external moisture barrier.

[0095] Specifically, the battery pack is a lithium polymer battery pack with a rated capacity of not less than 5000mAh.

[0096] Specifically, the communication module 211 integrates an NB-IoT chip and a Bluetooth Mesh chip on the PCB board 204, and the two are electrically connected to the serial communication port of the processor 210 through signal lines.

[0097] Preferably, in this embodiment, the communication module 211 consists of two RF SOC chips arranged side by side in the RF area of ​​the PCB board 204. The two chips are powered independently but share an antenna and a filter network. They interact with the processor 210STM32L476RG through their respective serial ports.

[0098] The NB-IoT chip uses the Quectel BC66, a 24-pin LGA package, with a module size of approximately 17mm × 15mm × 2.3mm. Metal grounding pads are located at the four corners of the bottom for pad mounting and soldering to the PCB ground plane. It supports 3GPPR13NB-IoT, registering with the operator's base station and maintaining a connection. It incorporates PSM (Power Saving Mode) and eDRX (Extended Discontinuous Reception) functions, with sleep / wake-up precisely controlled by the MCU via AT commands. The TXD / RXD pins connect to the MCU's UART1, and a high STATUS pin indicates network readiness or data transmission completion. The same 204 patch antenna on the PCB is shared with the Bluetooth module via an RF switch circuit, reducing the number of RF components.

[0099] The Bluetooth Mesh chip uses the Nordic RF52840, a 73-pin QFN package measuring approximately 7mm × 7mm × 0.8mm. It features multiple heat sinks and a base plate around the perimeter and an internal 32MHz crystal oscillator. It supports Bluetooth Mesh node, repeater, and low-power scanning roles for short-range networking and signal relay. In addition to UART2 (connected to the MCU serial port), it also exposes I / O pins. 2 It features multiple I / O channels including C, SPI, PWM, and ADC, which can also be used for peripheral expansion; it has a built-in 2.4GHz antenna matching network, which is placed separately from the low-frequency antenna of NB-IoT to avoid intermodulation; it supports deep sleep mode with standby current <2μA, and can be remotely woken up by the MCU through GPIO or SWD.

[0100] The two SoCs are placed adjacent to each other in the PCB RF area, with two 50Ω microstrip lines leading to the same ceramic patch antenna. They are switched between NB-IoT and Bluetooth via a low-loss RF switch (Skyworks SKY13317). The MCU sends AT commands and exchanges Mesh data through two hardware serial ports (UART1 connected to BC66, UART2 connected to nRF52840). Interrupt signal lines such as STATUS / CTS are also led to the MCU for event-driven mode to reduce polling power consumption. EMI filters and common-mode inductors are arranged around the module to ensure stable transmission and reception at both points in high-interference environments.

[0101] Through the selection, packaging, function and layout of the above-mentioned specific components, the communication module 211 of this utility model not only has the ability to perform outdoor long-distance NB-IoT alarm and location upload, but also has a built-in Bluetooth Mesh self-organizing network in weak network environments, forming a "remote + local" dual communication guarantee, providing reliable alarm and data feedback functions for complex construction sites.

[0102] Specifically, the first housing 202-A and the first housing 202B are both detachably fixed to the helmet body 1 by screws. The inner wall of the helmet body 1 is provided with a strip-shaped flexible groove 5 for accommodating and constraining the wiring of the wire 4.

[0103] Preferably, the screw fixing structure between the shell and the helmet body 1 uses M2×6mm stainless steel flat-head self-tapping screws, with 4 screws per shell, evenly distributed at the left and right ends and the top and bottom corners. The screw heads have cross-shaped grooves to prevent slippage, and can be installed and removed with a 2.5mm flathead screwdriver. Four metal threaded inserts (Φ2.2mm holes) are pre-drilled on the inner wall of the helmet body 1 corresponding to the shell installation position for screw stress; plastic positioning posts (3mm high, Φ1.5mm) are set around the metal threaded inserts. During alignment, they first wedge into the through holes on the shell to ensure that the shell and helmet body are aligned, and then the screws are tightened.

[0104] The strip-shaped flexible slot 5 is a semi-open long strip, with its length distributed along the circumference of the inner wall of the safety helmet, a width of about 5mm, and a depth of about 3mm. The bottom of the slot has a U-shaped arc surface, which matches the outer diameter of the wire 4 (about 2mm). The flexible material is TPU (hardness 90A), and the surface has 0.5mm fine anti-slip stripes.

[0105] The card slot guides the wire 4, which extends from the first housing 202-A (including the PCB and functional modules), to the first housing 202B (including the battery pack) along the inner wall of the card slot. The TPU card slot provides slight elastic clamping when the wire 4 is pressed in, which not only prevents the wire 4 from vibrating and sliding, but also allows it to be easily pried open and removed with fingers during disassembly.

[0106] Near the safety helmet brim at the bottom of the housing, there is a pair of Φ3.0mm wire 4 outlet holes. The hole walls are covered with embedded silicone sheaths to prevent the wire 4 from being worn. The outlet holes are located on opposite sides of the first housing 202-A and the first housing 202B, so that the wire 4 can be led from the PCB area to the battery area through the shortest path.

[0107] The ribbon cables on each functional module (PCB) side first enter the inner wall through the bottom outlet hole of the first housing 202-A; they are laid clockwise or counterclockwise along the slot, and the wire harness is pressed by the TPU slot; when they reach the position of the first housing 202B, they pass out again through the wire 4 outlet hole on the inner wall of the safety helmet body 1, enter the battery pack compartment, and are soldered to the battery management board.

[0108] Inside the housing and at the slot entrance, lightly bundle multiple wires 4 with heat shrink tubing or nylon cable ties for a length of 10mm to keep the wiring neat and avoid crossing. The height of the cable ties should not exceed the depth of the slot to ensure that the entire wire harness can still be fully embedded in the slot.

[0109] The specific installation process in this embodiment is as follows:

[0110] 1. Preparation and Inspection

[0111] Clean the plastic positioning posts and metal screw holes on the inner wall of the main body 1 of the safety helmet to ensure that there are no burrs or foreign objects.

[0112] Check that all parts (housing, cover 203, O-ring, screws, slots, wires 4, PCB, battery pack, etc.) are intact.

[0113] 2. Install the first housing 202B and the battery pack.

[0114] Place the battery pack into the first housing 202B cavity and fine-tune it to the center using the built-in positioning pin;

[0115] Pass the positive and negative wires 4 of the battery through the Φ3.0mm wire outlet hole at the bottom of the casing;

[0116] Align the first housing 202B with the positioning post of the safety helmet body 1, snap it in, and then tighten it with 4 M2×6mm screws (tighten evenly at the four corners).

[0117] 3. Arrange the wiring on the inner wall.

[0118] The power cable and the reserved signal cable from the battery pack are laid out sequentially along the TPU elastic slot on the inner wall of the helmet, and lightly tied with nylon cable ties at the slot entrance.

[0119] 4. Install the first housing 202-A and PCB board 204 assembly.

[0120] The PCB board 204, which has been soldered with processor 210, communication / positioning / sensing module, charging port, indicator light and button, is fixed inside the first housing 202-A and locked with 4 M1.6×4mm screws.

[0121] The wiring is introduced from the Φ3.0mm outlet at the bottom of the first housing 202-A, with a wiring allowance of about 20mm reserved.

[0122] 5. Connect the power supply to the signal lines of each module.

[0123] Solder the battery wires leading out from the first housing 202B to the PCB board 204VBAT / GND input pad;

[0124] Solder each functional signal line (alarm button 209, LED indicator, buzzer 215, interrupt / serial port signal, etc.) to the corresponding pads on PCB board 204 in sequence;

[0125] Check all solder joints for any cold solder joints and ensure that the wire harness is free of knots and overlaps.

[0126] 6. Organize the wiring harness and conduct the initial power-on test.

[0127] Press all wire harnesses completely into the inner wall slots and close the slot covers;

[0128] Press the power switch 206 to verify that the working indicator light 207 and the Beidou / Bluetooth / accelerometer / communication modules are powered on and self-tested normally. After powering off, continue with the following sealing step 203.

[0129] 7. Pre-installation of sealing rings

[0130] Install the elastic sealing ring 3 into the slot on the side of the cover 203 respectively, and check that the sealing ring is not twisted and the joint is tight.

[0131] 8. Assembly of 203 caps

[0132] First housing 202-A cover 203: Align the cover 203 with the elastic sealing ring 3 installed with the first housing 202-A bayonet, insert the guide tongue into the guide groove, and press lightly until initial engagement; insert the M2×6mm screws in the diagonal sequence of "1→3→2→4", with a torque of 0.3–0.5 N·m;

[0133] First housing 202B cover 203: Similarly, align the cover 203 with the elastic sealing ring 3 installed with the first housing 202B buckle, and after initial engagement, tighten the 4 M2×6mm screws in a diagonal sequence.

[0134] 9. Install protective accessories

[0135] Insert a silicone waterproof plug into the charging port 205 through hole;

[0136] Rubber button caps or dust plugs are installed in the power switch 206, indicator lights, and button through holes, respectively.

[0137] 10. Final Function and Sealing Acceptance

[0138] Power-on test: Press the power button to confirm that the power-on process, indicator lights, positioning and communication functions, and "one-button alarm" are normal;

[0139] Protection test: Spray a small amount of water to confirm that there is no leakage around the housing-cap 203 interface and each through hole;

[0140] Maintenance and inspection: Gently remove the first housing 202B cover 203, check the position of the elastic sealing ring 3 and ensure that the wiring harness has not shifted, then reset it.

[0141] The usage process of this embodiment is as follows:

[0142] 1. Normal wearing and powering on

[0143] Users should wear the helmet on their heads as usual and adjust the chin strap to ensure a proper fit.

[0144] When the power switch 206 is pressed, the battery pack supplies power to the PCB board 204 via the power switch 206, and the MCU (processor 210) is powered on and initialized.

[0145] 2. The MCU starts its self-test program:

[0146] The indicator light 207 flashes green at 1Hz to indicate that a self-test is in progress.

[0147] The BeiDou positioning module 212 searches for satellites and obtains the first positioning signal;

[0148] The Bluetooth Mesh module initializes the Mesh protocol stack and broadcasts the local node's heartbeat.

[0149] The NB-IoT communication module 211 performs network registration; the STATUS pin is pulled high to indicate readiness.

[0150] Acceleration module 214 performs I 2 C / SPI bus handshake, reset internal threshold.

[0151] After the self-test is completed, the indicator light 207 will remain solid green, and the system will enter normal working mode.

[0152] 3. Continuous positioning and dual-mode communication

[0153] The Beidou positioning module 212 outputs longitude, latitude, and time in NMEA format once per second, which is parsed and cached by the MCU via UART;

[0154] The Bluetooth Mesh module periodically (e.g., every 5 seconds) broadcasts its location heartbeat to neighboring nodes and receives location information from neighboring nodes for use in weak network relay.

[0155] The MCU reports the latest location data to the cloud platform every 10 seconds via the NB-IoT module (QuectelBC66); if NB-IoT registration fails, it will be temporarily stored for later reporting.

[0156] 4. Automatic fall / collision detection

[0157] Accelerometer module 214 (BMA400) continuously monitors triaxial acceleration. When any axial acceleration exceeds ±4g and the attitude angle changes abnormally, it triggers a DRDY interrupt.

[0158] The MCU executes the fall detection criterion in the interrupt service routine. If it determines that a fall or severe impact has occurred, then:

[0159] The buzzer 215 (PKLCS1212) emits a continuous 2kHz beep for 3 seconds;

[0160] The MCU immediately invokes the NB-IoT module to send a "fall alarm" data packet, which contains real-time BeiDou coordinates;

[0161] The work indicator light 207 switches to a red 2Hz flashing mode until the background confirms.

[0162] 5. Bluetooth Mesh Repeater and Local Assistance

[0163] In areas with weak cellular signals (tunnels, underground), if NB-IoT reporting fails, the MCU will push location or alarm information to the Bluetooth Mesh module;

[0164] The module relays via a Mesh network to the nearest online safety helmet node, which then reports the information via NB-IoT.

[0165] Meanwhile, after receiving the "one-click SOS" broadcast, the Mesh node's work indicator light 207 changes from green to flashing red, prompting nearby workers to provide on-site assistance.

[0166] 6. One-click manual alarm

[0167] When the wearer presses the alarm button 209, an interrupt is triggered in the MCU:

[0168] Buzzer 215 sounds continuously for 5 seconds;

[0169] The NB-IoT module reports a "manual alarm" data packet (including location information) via the AT+SEND command;

[0170] Bluetooth Mesh simultaneously broadcasts distress messages;

[0171] The work indicator light 207 flashes red until it receives a confirmation command from the backend and then returns to a solid green light.

[0172] 7. Charging and Status Indicators

[0173] When the magnetic multi-contact charging interface 205 plug is brought close to the through hole of the housing, it will automatically adhere and apply slight pressure to the elastic plug of the contact.

[0174] The charging management IC (MCP73831) detects the external input voltage. When the STAT pin is pulled low, the MCU reads the voltage and lights up the charging indicator 208 in yellow.

[0175] After the battery voltage is charged to 4.2V, STAT goes high, and the MCU switches the charging indicator to a solid green light.

[0176] After unplugging the charging adapter, the charging light goes out, and the system continues to be powered by the battery.

[0177] 8. Shutdown and Maintenance

[0178] If the device is not used for an extended period of time, press and hold the power switch 206 for about 2 seconds to trigger the MCU to enter the shutdown process and cut off the power to all modules.

[0179] During maintenance, unscrew the eight M2 screws on both sides of the housing (202-A, 202-B), first remove the cover 203 and the O-ring, then remove the housing to take out the PCB or battery pack for inspection or replacement.

[0180] After maintenance is completed, restore the equipment according to the above installation procedure and perform sealing and functional tests before it can be put back into use.

[0181] The above usage process comprehensively embodies the design concept of this utility model of "symmetrical distribution + dual-cavity wiring + dual-mode communication + one-button alarm + maintainable sealing", which can provide reliable positioning, alarm and mutual assistance protection for on-site personnel under high-intensity and complex working conditions.

[0182] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

Claims

1. A positioning safety cap, characterized in that, It comprises: A safety helmet body; A first shell and a second shell arranged symmetrically along the central axis of the safety helmet body; each shell is clamped with a cover outside, and a closed cavity is formed by corresponding cooperation; A PCB board fixedly installed in the first shell, the edge of the PCB board is welded and fixedly connected with a charging interface, a working indicator light, a charging indicator light and an alarm button; A processor welded on the PCB board, a communication module, a Beidou positioning module, a Bluetooth positioning module, an acceleration module and a buzzer electrically connected to the processor through signal lines respectively; A battery pack accommodated in the second shell, the power output end of the battery pack passes through the safety helmet body and is arranged along the inner wall to electrically connect with the power input end of the PCB board through wires, for supplying power to the PCB board and its welded elements; the charging interface passes through the safety helmet body and is arranged along the inner wall to electrically connect with the power input end of the battery pack through wires; The charging interface, the working indicator light, the charging indicator light and the alarm button are electrically connected to the processor through signal lines respectively; The first shell is provided with through holes at the corresponding positions of the charging interface, the working indicator light, the charging indicator light and the alarm button, so that the above-mentioned interface or element is partially exposed, facilitating charging connection, key operation and state indication.

2. The positioning safety hat of claim 1, wherein: The alarm button, the Beidou positioning module, the Bluetooth positioning module and the acceleration module are electrically connected to the input end of the processor through signal lines; The working indicator light, the charging indicator light, the buzzer and the communication module are electrically connected to the driving port of the processor through signal lines.

3. The positioning safety hat of claim 1, wherein: It also comprises a power switch; the power switch is connected in series between the power output end of the battery pack and the power input end of the PCB board; the power output end of the PCB board is electrically connected to the power input end of the processor, the working indicator light, the charging indicator light, the Beidou positioning module, the Bluetooth positioning module, the communication module and the acceleration module respectively.

4. The positioning safety cap of claim 3, wherein: The first shell is provided with a through hole at the corresponding position of the power switch, so that the power switch is partially exposed.

5. The positioning safety hat of claim 1, wherein: An elastic sealing ring is arranged between the joint surface of the shell and the cover.

6. The positioning safety hat of claim 1, wherein: The charging interface is a magnetic type multi-contact interface, and a detachable waterproof elastic plug is arranged between the contact of the charging interface and the corresponding through hole.

7. The positioning safety hat of claim 1, wherein: The battery pack is a lithium polymer battery pack with a rated capacity not less than 5000mAh.

8. The positioning safety hat of claim 1, wherein: The working indicator light and the charging indicator light are both double-color light emitting diodes, and the two-color light emitting chips of the double-color light emitting diodes are welded into the same LED packaging tube shell.

9. The positioning safety hat of claim 1, wherein: The communication module integrates an NB-IoT chip and a Bluetooth Mesh chip on the PCB board, and the two are electrically connected to the serial communication port of the processor through signal lines respectively.

10. The positioning safety helmet according to claim 1, wherein: The first shell and the second shell are detachably fixed to the safety helmet body by screws, and a strip-shaped flexible clamping groove is arranged on the inner wall of the safety helmet body for accommodating and restraining the wire arrangement.

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