Retrofit Sensor Module for Protective Head Tops
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Solution Overview
Problem
Existing personal protective equipment (PPE) systems, such as respirators and self-contained breathing apparatuses, lack efficient and user-friendly methods for confirming proper usage and detecting potential hazards like dusts, fumes, and gases, especially in environments where workers need reliable and durable solutions.
Innovation Solution
A retrofit sensor module is designed for easy installation on protective head tops, featuring a sensor housing with a head presence sensor, position sensor, accelerometer, temperature sensor, and audio transducer, along with a Bluetooth communication component, which can be installed without tools and provides Ingress Protection (IP) rating for durability, allowing for real-time monitoring of visor position, temperature, and user safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor module is integrated into the protective head top, then monitoring capability is improved, but device complexity increases
Solution Approach 1:
The sensor module is designed as a separate, modular component that can be independently installed and removed from the protective head top. This segmentation allows the monitoring functionality to be added without permanently complicating the base head top structure, enabling users to attach sensors only when needed for specific monitoring purposes.
Solution Approach 2:
The sensor module serves multiple functions including monitoring visor position, detecting head presence, tracking movement via accelerometer, and sensing temperature. By consolidating these diverse sensing capabilities into a single universal module, the system achieves comprehensive monitoring without proportionally increasing overall device complexity.
2Ease of operation
If the sensor module is made removable for easy installation and removal, then ease of operation is improved, but reliability may worsen due to potential dislodgement
Solution Approach 1:
The attachment mechanism features a dynamic design with movable components including a spring-loaded clip and cam-actuated locking system. These dynamic elements enable the user to easily attach and detach the sensor module through simple manual operations, while the spring mechanism maintains constant securing force during normal use to prevent accidental dislodgement.
Solution Approach 2:
The sensor module is designed as a completely removable component that can be extracted from the protective head top without tools or damage to either component. This extraction capability provides ease of operation for installation and removal, while the dedicated attachment interface ensures reliable connection when installed.
3Measurement precision
If the sensor module includes multiple sensors for comprehensive monitoring, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Multiple independent sensors including position sensors, head presence sensors, accelerometers, and temperature sensors are merged into a single integrated sensor module. This consolidation provides comprehensive monitoring capabilities across multiple parameters while managing complexity by housing all sensors within one unified structure that attaches to the protective head top as a single unit.
Data Source
AI summary
The present disclosure includes a retrofit sensor module for use with a protective head top with a helmet and a visor. The sensor module includes a sensor housing and an attachment mechanism. The sensor housing encloses a head presence sensor to sense when the protective head top is being worn. The sensor housing also encloses a position sensor to sense the position of the visor relative to the helmet. The retrofit sensor module further comprises an attachment mechanism secured to the housing. The attachment mechanism mates with a first hinge component of a hinge assembly in the protective head top to removably install the sensor module into the protective head top, wherein the hinge assembly allows the visor to move relative to the helmet.