Smart Harness Fastener Sensor System for Fall Detection

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Solution Overview

Problem

Construction sites face high rates of fall-related accidents, leading to worker injuries and fatalities, despite compliance with safety standards, as existing fall protection systems often rely on manual checks and lack real-time monitoring capabilities.

Innovation Solution

A smart wearable system comprising fasteners with integrated sensors and a controller unit that wirelessly connects to these sensors, generating alerts if the fasteners are not locked within a predetermined time, and utilizing altimeters and accelerometers to monitor user safety and prevent falls by ensuring the harness is securely fastened and the user is tethered to a stable object.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual checks are used for fall protection, then device complexity is reduced, but reliability of safety monitoring deteriorates

Engineering Contradiction:

Improvesafety monitoring reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical checks with electronic sensor systems that automatically detect fastener status, position, and movement. Sensors embedded in harnesses and anchor points provide real-time digital monitoring, substituting human inspection with automated electronic detection to improve reliability while managing complexity through integration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements continuous feedback loops where sensors monitor fastener locked status, harness position, and movement patterns, then provide real-time alerts when anomalies are detected. This automated feedback mechanism ensures immediate response to potential hazards, significantly improving safety monitoring reliability compared to periodic manual checks.

Inventive Principle:

Principle #23Feedback

2Reliability

If real-time monitoring is implemented, then worker safety is improved, but loss of time for setup and calibration increases

Engineering Contradiction:

Improveworker safetyVSAvoidsetup and calibration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary configuration during harness manufacturing, with sensors pre-installed and calibrated. Fasteners come pre-configured with sensor integration, eliminating the need for complex on-site setup and calibration. Workers simply don the pre-configured harness, and the system begins monitoring immediately, thus improving safety without significant time loss.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If smart sensors and connectivity are added to PPE, then worker protection is enhanced, but manufacturing cost increases

Engineering Contradiction:

Improveworker protectionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent designs universal sensor modules that can be integrated into multiple types of PPE (harnesses, helmets, footwear) using standardized interfaces. The same sensor technology serves multiple functions: detecting fastener status, monitoring position, tracking movement patterns, and providing collision detection. This multi-functionality amortizes the manufacturing cost across diverse applications while enhancing protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enhances worker safety by providing real-time monitoring and alerts, reducing the risk of falls and associated injuries, while improving compliance with safety regulations and reducing costs associated with accidents.

Implementation Method 1

The first sensor unit and the second sensor unit each include a contact sensor configured to generate a signal when the corresponding fastener is in a locked position.

Methodology Applied

Scientific EffectContact sensor detection:

Implementation Method 2

a controller unit wirelessly connected to the first sensor unit and the second sensor unit, the controller unit configured to generate a third signal when the first or the second signal is not received by the controller unit within a predetermined period of time

Methodology Applied

Scientific EffectWireless signal transmission:

Data Source

PatentUS11247080B2Systems, methods, and apparatuses for ensuring worker safety

Publication Date: 2022.02.15 SAUDI ARABIAN OIL CO

AI summary

Methods, systems, and apparatuses for ensuring safety of a worker are disclosed. The system includes a first fastener configured to secure two or more ends of a harness around the user, a first sensor unit attached to the first fastener, the first sensor unit configured to generate a first signal when the first fastener is in a locked position, a tether attached to a portion of the harness, the tether configured to tether the user to a stationary or movable object, and a second fastener attached to one end of the tether, the second fastener configured to secure the one end of the tether to the stationary or movable object, a second sensor unit attached to the second fastener, the second sensor unit configured to generate a second signal when the second fastener is in a locked position, and a controller unit wirelessly connected to the first sensor unit and the second sensor unit, the controller unit configured to generate a third signal when the first or the second signal is not received by the controller unit within a predetermined period of time.