A multifunction gate with an innovative bactericidal disinfection system

Gate|0 is a unique multifunctional disinfectant system for crowded places, offices, and mobile hospitals, providing an overhead shower of disinfectant solution for a few seconds as individuals pass through the gate.

Industry:

Medical Devices

IoT

Smart Manufacturing

Equipment & Tools

TRL:

1 → 8

Project duration:

4 months

Challenge

The COVID-19 pandemic is having a devastating impact on public health, societies, and economies around the world. Because an effective vaccine was unavailable just within a year ago, disinfection, sanitization, and distancing were considered the most appropriate measures to mitigate virus transmission. As the pandemic continues to gain momentum, several measures are being put in place to control its spread. One such effort includes the installation of walkthrough sanitization gates to disinfect passersby and prevent cross infection.

Given EnCata’s capabilities and realizing the urgent need for help as well as the fact there were very few non-tech products against covid-19 on the market in early spring of 2020, we decided to join the fight and came up with a totally new disinfectant solution for various purposes and scales in frames of virus protection.

Therefore, the major challenges we faced while working on such an extremely important project were:

  • Providing corrosion resistance of components and materials used in the structure as corrosion products are clogging the nozzles (sprayers).
  • Selection of disinfectant liquids (solutions) that are not aggressive to the materials and components used.
  • And opposite, selection of components and materials resistant to disinfectant solutions.

Our Role

  • Requirements Analysis
  • Concept Development
  • Industrial Design
  • Architecture Design
  • Functional System Design
  • Multi-layer PCB Design
  • 2D Drafting
  • 3D Modeling
  • Mechanical Engineering
  • Electrical Engineering
  • Embedded Software (Firmware) Development
  • PCB Prototype & Assembly
  • Alfa & Beta Testing
  • Design for Manufacturing (DFM)
  • Manufacturing
  • Web, Photo, Video production
  • Technical Support
  • Customer After-sale Service

Technologies Used

Engineering R&D

Engineering R&D

CAD Design

CAD Design

Multilayers PCB stack

Multilayers PCB Stack

FreeRTOS

FreeRTOS

Wi-Fi onboard

Wi-Fi Onboard

BOM Development

BOM Development

LED Display

LED Display

Thermographic camera

Thermographic Camera

Face recognition system

Face Recognition System

CNC Machining

CNC Machining

Laser cutting

Laser Cutting

EnCata offers comprehensive hardware and IoT product development services at a fraction of the cost

For Enterprises

R&D + design + manufacturing under ONE roof
Scale up and down your team
Intergrated hardware + software development
New technologies and research 

CORPORATIONS click HERE for more info

For Startups

MVP and POC prototypes
Affordable consultancy rates
All IP is yours
In-house batch production

STARTUPS click HERE for more info

Approach & Solution

EnCata didn't want to wait for the pandemic to evolve so we chose to join the fight instead, especially since most of EnCata’s staff are designers and manufacturing engineers, the method of remote work is simply impossible for the company.

This way, our design and manufacturing team has quickly adapted and shifted gears to developing a multifunctional walkthrough gate with an innovative bactericidal disinfectant system ideal for crowded places (airports, train stations, administrative buildings, industrial enterprises, shopping centers, cafes, bars, restaurants, etc.) that helps to recognize symptoms of viral diseases in advance and prevent their further spread.

The gate has a robust, corrosion-resistant stainless steel design that is easy to refill and to perform maintenance and equipped with large disinfectant tanks with a total volume of 90 L.

The Premium configuration was developed with the 'modularity' approach in mind to let Customers decide which options to add to the Basic version of Gate|0 while adding or canceling additional modules does not require the involvement of engineers to revise the product.

The disinfectant fluid is an aqueous solution of antivirus silver citrate that automatically sprays onto a person passing through the gate in 15 ml doses. A low pressure pipeline with 20 fogging nozzles is installed inside the frame.

The use of such nozzles allows disinfecting treatment even in hard-to-reach folds of clothing and also treats the feet.

On the firmware side, we designed the system architecture and developed the principles of its functioning. On the high level, the embedded system comprised with:

1. Control board.

To test and fine-tune the algorithms and system functioning for proof-of-concept prototype development of Gate|0 we used an already excited control board that is the core of the AeroCapsula product. During the firmware development, we created STM32 microcontroller under the FreeRTOS control. Then, we proceed with a serial version of the control board development.

2. Infrared (IR) sensors.

To determine the fact of a person's entry to the gate, we developed two types of infrared sensors: barrier and reflex.

3. Info displays.

We created a display based on LED technology which shows brief instructions for the users walking through the gate, it tells when to come in, asks to sanitize the walker's hands or checks out whether the face mask is on/off. The display also indicates system condition status, it alarms when the time comes to refill disinfectant tanks with liquid or launch the scheduled maintenance. The display allows applying any color graphics and text.

4. Control algorithms.

We wrote the custom algorithms so the system can automatically determine the work mode: single or group, visualize the disinfectant level of the tanks and the capacity of the spent fluid, activate voice/audio guidance. The most challenging thing at this stage was to write an algorithm for automatically determining whether 1 person or the group is walking through, which has resulted in plenty of attempts, improvements, then product trial periods, new errors, and fixes until, finally, the solution was found. The gate system thus automatically switches to single or group work mode depending on the number of individuals passing through and their movement speed at the moment.

To increase system capacity and improve product usability, we developed two work modes: single and group scenarios of use.
Thus, in a single mode, the disinfectant is sprayed on each person separately, in a group mode, spraying occurs continuously while a group of people is walking through the gate.

5.WEB UI.

Our software engineers developed a web interface to monitor and configure the system which is accessible just by connecting to a Wi-Fi module integrated into the device.

The operation principle of the product is as follows: as soon as the user enters the ramp, then the infrared sensor, which is located in the strut, identifies a person who came in and the system is in a single or group work mode. The voice-over is activated and the text instruction on the LED display is shifted from one status to another. Then, the user can use the sanitizer for hand disinfection. The infrared sensor, which is located on the inner side of the frame near the sanitizer,  identifies hands in a disinfectant zone and gives off a spray signal of disinfectant that is in a fluid tank.

The multifunctional decontamination system is produced in three configurations: Standard, Light and Premium.
Gate|0 STANDARD version goes with:

Gate|0 LIGHT includes:

Gate|0 PREMIUM configuration comprised with:

There are several additional modules that fits both Light and Premium configurations of Gate|0:

1. Standard thermographic camera
Temperature detection and face recognition system (bandwidth: 1 person per 5 seconds). In addition to determining an individual’s temperature, the module allows you to recognize faces based on an artificial intelligence system and configure the access mode using the base of employees together with the turnstile.

2. High traffic flow thermographic camera
Temperature detection and face recognition system (bandwidth: 1 person per 1 second).The system allows you to monitor body temperature of a continuous stream of people walking through the gate (is required when installing two gates in series in mode of high traffic flow disinfection).

3. Mechanical hand sanitizer

4. Automatic contactless hand sanitizer

5. Turnstile.
People only allowed entrance after completed face recognition, hand treatment, disinfection, diagnosis of smell function, determination of body temperature. A standard turnstile is installed and controlled by the electronics Gate|0 according to the specified scenario.

Drone Station case
Drone Station box
Autonomous Drone Station Box

Results

EnCata designed and manufactured the product that is head and shoulders above other disinfectant frames being a multifunctional germicidal disinfection system with a wide range of smart functionality to screen walking through it people to minimize the risk of infection and keep employees and visitors safe.

4 configs

of Gate|0 available to purchase: Premium version, Light version welded and unwelded one, Standard version

3 months

took from idea to pre-production sample

1 sec.

is the required time to determine 1 person body's temperature walking through the gate by a high traffic flow thermographic camera

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