Case Study: Wearable Personal Respirable Dust Monitor
When it comes to workplace safety, monitoring respirable dust levels is crucial for protecting workers’ health across various industries. This case study delves into the creation of the DustCanary Trend 420, a state-of-the-art wearable personal respirable dust monitor that enables continuous, real-time detection of hazardous respirable dust.
This innovative product offers protection against exposure to various types of respirable dust, including silica, wood dust, metallic dust and bioaerosols, serving as a practical tool to alert workers when overall respirable dust levels become hazardous. Let’s dive in.
The Beginning
This groundbreaking device began its journey with core technology developed by our client and the University of Hertfordshire. Recognising the potential of this technology, we were approached to help transform the initial concept into a ruggedised, wearable design suitable for industrial applications.
For this project, there were three primary objectives we needed to work on:
- Develop a wearable dust monitor that could be easily carried by workers throughout their shifts
- Create a product that was capable of withstanding harsh industrial environments
- Successfully integrate the existing battery and electronics into a new, more practical internal form and appropriate enclosure.
Collaborative Development
To bring this complex product to life, we partnered with an app software and electronics development company. This collaboration allowed for a comprehensive re-development of the product, with us focusing on the mechanical design and design for assembly (DFA) and overall product integration, while the app developer handled the intricate firmware and comms integration aspects of the device.
Design Challenges and Solutions
The development process presented several unique challenges, particularly in the mechanical design of the device:
Airflow Management
The design needed to effectively manage both inlet and exhaust systems to ensure accurate dust detection. A 2L/min sampling rate from the front of the device was implemented for optimal measurement.
Waterproofing
Given the varied environments in which the device would be used, a showerproof enclosure was essential.
Sound Alert System
Integrating an audible alert system that could be heard in noisy industrial settings without compromising the device’s waterproofing.
Internal configuration & layout
Internal communications antenna placement, internal wire routing, Charging ports, airflow inlet & exhausts all had to carefully managed within a very tight compact space to consider optimal component performance for differing sub-systems.
The result was a tiny and lightweight (210g) gadget designed for all-day wear, with minimised catch hazards that could interfere with worker movement or productivity.
Key Features and Functionality
The DustCanary Trend 420 employs optical particle counting with the internal sensor module to provide optimal and reliable monitoring in workplace applications. Wide dynamic range to measure dust from 10 mg/m3 to less than 0.005 mg/m3.
- Capable of recording up to 7 days at 1-second intervals.
- Configurable audible and visual alarms.
- Bluetooth connectivity with a secure online browser application for quick configuration, live chart data, and access to alerts and dust reports.
Prototyping and Testing
The development of the DustCanary Trend 420 involved a comprehensive approach to prototyping and testing, ensuring the final product would meet the demanding requirements of its intended applications.
Low-Volume Manufacturing for Trials
We used vacuum casting techniques to create units for site trials. This strategy enabled us to reduce capital expenditure on injection mould tools during the field-testing phase, resulting in a more cost-effective alternative for generating the required prototypes.
Diverse Testing Environments
Prototypes were rigorously tested in a variety of industrial settings, including sawmills, cement plants, and grain mills. This wide set of testing locations ensured that the device could function well in a variety of environments with varying types and quantities of respirable dust.
Comprehensive Testing Protocols
To validate the product’s performance and durability, we implemented a series of thorough testing protocols:
- IP (Ingress Protection) testing to ensure the device’s waterproof capabilities
- Pre-compliance EMC (Electromagnetic Compatibility) testing to verify the device’s electrical performance
- Mechanical drop tests to confirm the ruggedised design’s ability to withstand accidental impacts
Design Optimisation
The data acquired from these pilot units was extremely useful in shaping future design optimisations and enhancements. This iterative method enabled us to fine-tune the product, resolving any flaws discovered during testing and improving its overall performance and reliability.
Recognition and Awards
The innovative design and practical application of the wearable dust monitor did not go unnoticed in the design community. In 2023, the product was awarded a Highly Commended distinction in the prestigious European Product Design Awards (EPDA), affirming its innovative approach to workplace safety.
Manufacturing Considerations
Throughout the development process, future manufacturing needs were kept in mind:
- The design was initially suitable for vacuum casting, allowing for cost-effective production of test units and small production runs.
- Importantly, the design was created with easy conversion to injection moulding in mind, facilitating a smooth transition to higher volume production when needed.
Technology Transfer and Commercialisation
The successful development of the wearable dust monitor led to the transfer of intellectual property rights. Following the transfer, the product was marketed as the DustCanary Trend 420, which is part of the AirMet Scientific product line. It is now only available from Air-Met Scientific for purchase, rental, and service, with replacement sensors accompanied by a manufacturer’s reference calibration report.
Final Thoughts
The development of the DustCanary Trend 420 wearable personal respirable dust monitor represents a significant advancement in workplace safety technology. By combining innovative design, rigorous testing and practical application, we’ve created a product that has the potential to significantly improve worker safety across numerous industries where respirable dust poses a health hazard.
This project showcases the power of collaborative development and iterative design in creating products that address real-world challenges. As this technology continues to be adopted across various sectors, it stands to make a lasting impact on occupational health and safety practices, providing workers with a crucial tool for monitoring and avoiding dangerous dust exposure in their day-to-day operations.
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