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Background

In food processing facilities hospitals, laboratories, transportation systems, and restaurants--it is critical to maintain exact temperatures at all times.  To help meet strict regulatory compliance requirements and ensure that temperatures remain accurate, Tempsys created the CheckPoint temperature monitoring system to wirelessly track temperatures and thermal trends and other vital parameters in rooms, refrigerators, freezers, incubators, and other appliances.  The CheckPoint can also measure humidity, carbon dioxide, motion, and different air pressures. We partnered with Tempsys to design a faceplate and mounting for their wireless temperature sensor as part of the CheckPoint system.  Tempsys is the leading provider of real-time wireless monitoring and tracking solutions.  For the inner electronics of the sensor, we worked with Tehama Wireless Design Group, which provides design solutions and engineering products with a focus on wireless and wired communications technology, from broad-level to turn-key systems.

Challenge

• Withstand condensed moisture from refrigerator use and temperatures ranging from -20°F to 180°F.
• Waterproof for enduring spray cleaning, and an industrial dishwasher.
• House the temperature sensing element.
• External, removable temperature sensing probe.
• Non-obvious, simple, and tool-free wall mounting system.
• Space for cable sensor connectors that lead to the main housing unit.
• Withstand a drop of 3 feet.
• Easy access to the calibration switch and the batteries for replacement.
• Feature allowing the device to hook onto a rack.
• Discrete appearance to avoid the possibility of someone stealing or vandalizing the system.

Solution

The sensor that Tempsys was employing consisted of a device that housed a basic circuit board. One of the biggest issues with Tempsys’ old system was that it was fragile, too costly to produce, and not water tight.  In the initial phases, we addressed issues of form, basic architecture, functionality, usability, and ergonomics, while considering the manufacturing process.  We developed two-dimensional concepts that were quickly worked into scaled three-dimensional forms for evaluation.  The various designs were translated into hand-shaped models that were sculpted from a lightweight material.  We created a total of three versions of the casing that contained the circuit board and had a certain number of openings at the bottom for the sensor connectors that wirelessly transmit the temperature-related data. 

While Tehama Wireless Design Group worked on the electronics, we focused on the packaging for the sensor.  One of the primary requirements was designing a casing that could mount to virtually anything.  The casing needed to be able to mount to a pole, attach to magnetic surfaces, hang from an oven rack or cool room, and be screwed and glued to the wall.  Therefore, we researched several mounting options including adding a strap, magnet, and hook.  In designing the wall-mounting system, Speck Design needed to consider the process of removing the system from its mount in order to replace the battery.  One of our innovations included adding a coat-hanger inspired removable hook that was located on the back of the system and extended across the top of the device.  The back of the casing had grooves that locked the hook into place.  The casing also contained small well-hidden tabs that, when pushed apart, released the hook.  The hook was designed in such a way that it could be easily removed and stored in the system and could be reattached through a screw for mounting on any surface.  With the help of the ID team, the hook visually blended into the system, a vital yet now inconspicuous element. 

Designing a casing to withstand the dishwasher proved to be a bigger struggle than anticipated.  During the dishwashing cycle, the device would expand under the extreme heat and once cooled, would retain water.  In order to address the temperature requirements of the sensor, we looked into various materials and sealants, and conducted a series of waterproof tests that resulted in minor adjustments for improved functionality.

Results

Following several rounds of iterations, a combined effort from the Speck Design ME and ID team, and guiding Tempsys through the best manufacturing options, we were able to develop a plastic casing and mount within budget that aligned with Tempsys’ main goal: creating a device that was waterproof, small, and rugged.  We also researched local and international vendors, which resulted in the production of system parts at a low cost. According to Tempsys, the current CheckPoint system "fully meets the FDA 21 CFR Part 11 requirements for electronic documentation and guides the user through the corrective action process necessary to meet regulatory and auditing requirements".

PROJECT INFO

• Client:

  Tempsys

• Project:

  Temperature Monitoring System

• Industry:

  Industrial & Commercial