Case Study

A LoRa Safety Wearable Protecting 7,000+ Workers in Hazardous Zones

The wearable moved from concept to validated, mass-manufactured product, giving safety teams live visibility of the people most at risk and a fast path to respond when something goes wrong.

Industry

Industrial IoT & OT

Time Frame

12 Months

Services We offer

Embedded & Firmware

Hardware Design

Edge AI

IIoT

Design for Manufacturing

About the client

A large industrial conglomerate operating hazardous, safety-critical worksites.

Problem Statement

Workers in hazardous areas needed continuous monitoring of critical health parameters and reliable location tracking inside the premises, on a device that could survive a full shift and beyond on a single charge.

Existing options either did not last, could not locate a person indoors, or were never designed for the range and radio conditions of a heavy-industrial site.

The Challenges

All-day battery in a watch form-factor

Fitting vitals sensing, fall detection, LoRa and BLE into a wearable that still lasts a full shift meant power budgeting every subsystem and duty-cycling the radios.

Clinically credible vitals

Heart-rate and temperature readings were validated against clinically approved devices so safety decisions could rely on them.

Approach

We owned the problem end to end, from the silicon and radio up to the manufacturing line:

Watch form-factor hardware with heart-rate and temperature sensing
Accelerometer and gyroscope fusion for fall and immobility detection
LoRa for long-range, low-power communication across the site
BLE-based indoor location so a worker can be found within the premises
Aggressive low-power design and power management for all-day battery life

The Solution

The result was, to our knowledge, the world's first LoRa-based safety wearable of its kind. It streams vitals and emits an alert the moment a fall or period of immobility is detected, while BLE beacons place the wearer inside the facility.

Sensor accuracy was validated against clinically approved reference devices, and the design was transferred to a high-volume contract manufacturer.

The impact we delivered

1+

Frontline workers protected

1 mo

From concept to volume production

Problem Statement

Existing options either did not last, could not locate a person indoors, or were never designed for the range and radio conditions of a heavy-industrial site.

The Challenges

All-day battery in a watch form-factor

Fitting vitals sensing, fall detection, LoRa and BLE into a wearable that still lasts a full shift meant power budgeting every subsystem and duty-cycling the radios.

Clinically credible vitals

Heart-rate and temperature readings were validated against clinically approved devices so safety decisions could rely on them.

Approach

We owned the problem end to end, from the silicon and radio up to the manufacturing line:

Watch form-factor hardware with heart-rate and temperature sensing
Accelerometer and gyroscope fusion for fall and immobility detection
LoRa for long-range, low-power communication across the site
BLE-based indoor location so a worker can be found within the premises
Aggressive low-power design and power management for all-day battery life

The Solution

Sensor accuracy was validated against clinically approved reference devices, and the design was transferred to a high-volume contract manufacturer.

A LoRa Safety Wearable Protecting 7,000+ Workers in Hazardous Zones

About the client

Problem Statement

The Challenges

All-day battery in a watch form-factor

Clinically credible vitals

Approach

The Solution

The impact we delivered

1+

1 mo

1+

1 mo

Read more case studies

A LoRa Safety Wearable Protecting 7,000+ Workers in Hazardous Zones

About the client

Problem Statement

The Challenges

All-day battery in a watch form-factor

Clinically credible vitals

Approach

The Solution

The impact we delivered

1+

1 mo

1+

1 mo

Read more case studies