The document describes a new hands-free thermal imaging device called the FLIR Inferno for firefighters. It consists of a ruggedized camera mounted in a firefighter's helmet connected to a wireless heads-up display in the breathing apparatus. Simulations and testing showed it can withstand high temperatures, impacts, water submersion, and flames while providing thermal video to allow firefighters to have both hands free during rescues. A working prototype was created and tested, demonstrating it meets NFPA standards for firefighter equipment.

1. Hands-Free Thermal Imager for Firefighters
Acknowledgments
Marcel Tremblay, Kai Moncino, David Bothman, Stephen Laguette,
Greg Dahlen, Brian Gibson, ECE team, Machine Shop staff
Kyle Boswell (Team Leader) • Paul Doran • Petros Serbana • Michael Friedman • Xiaojun Li
ME 189 • June 5th, 2015
Abstract
Current firefighter thermal imagers are bulky, hand
held devices that pose problems during fire and rescue
missions. Not only can the display screen be blocked by
smoke, but it also limits the firefighter to having only
one free hand to save a victims life. The cutting-edge
FLIR inferno is an innovative solution to this problem. It
is a ruggedized helmet mounted camera coupled with a
wireless heads-up display (HUD) system mounted inside
the self-contained breathing apparatus (SCBA). This
product is the first of its kind and can change the
dynamic of firefighter efficiency.
Simulations and Analysis
Technical analysis and SolidWorks simulations
were repeatedly conducted to validate design features
and performance capabilities. Various high-profile
s i m u l a t i o n s w e r e r a n , i n c l u d i n g t h e r m a l
considerations, housing impact stress, and gasket
compression to ensure a watertight housing cavity.
Table 1. Mechanical Performance Specifications
Figure 1. Current technology (top) w/ proposed solution (bottom)
Figure 2. Camera housing (top) & electronic assembly (bottom)
Figure 3. Drop test graph (left) with FEA impact simulation (right)
Prototype
Our team was able to create a fully functional
prototype that has a complete wireless (Wi-Fi) video
stream to the Recon Snow 2 HUD2. It also consists of a
single multipurpose button with an integrated micro
USB for easy charging access. This system is both
heat and flame resistant with a low-profile stature
weighing in at a sleek 0.79 lbs.
Figure 4. Fully functional prototype with Recon Snow 2 HUD
Testing and Results
Multiple tests were conducted on our prototype to
solidify performance proficiencies. It is completely
functional for the NFPA1 2 hour operational requirement
and yielded extremely promising results to pass the 5
minute heat oven test at 260°C. The versatile inferno
housing is also watertight for small submersion depths
and can withstand a rigorous 10 second direct flame
exposure at 950°C.
References
1) National Fire Protection Association
2) Recon Instruments
Product Design Specifications
Product design specifications were generated based
on low cost goals and National Fire Protection
Association (NFPA)1 standards. These standards are the
backbone for the inferno design which guarantee
reliability during harsh firefighter environments.
Description Performance Specification
Low manufacturing cost < $300
NFPA 1801 - Drop test 2 meters on concrete
NFPA 1801 - Thermal test 260°C for 5 minutes
NFPA 1801 - Thermal test (non operating) 95°C for 15 minutes
NFPA 1801 - Direct Flame 10 s
NFPA 1801 - Water submersion test 1 meter for 30 minutes
NFPA 1801 - Operational time 120 minutes
Figure 5. Heat oven test at various temperatures
Thermal pad
Elastomer Cover
2.4 in (61 mm)
2.4 in
(61 mm)
3.7 in (95 mm)
Problem
Solution
Gasket
Insulation
Layers
Design Features
Our design is a multi-layered, compact structure
made out of Radel 5100 PPSU that is light weight and
thermally resistant for high heat and direct flame
conditions. Additionally, our camera is completely
waterproof and shockproof to protect the tightly packed
internal electronics from reaching their maximum
physical limitations.
Lepton Camera
Battery
Sheet Metal
Pushbutton
Edison Processor
Safety Factor: 2.1
Micro
USB
0 0.5 1 1.5 2 2.5 3 3.5
40
45
50
55
60
65
70
75
80
Thickness (mm)
Acceleration(gload)
Rubber Thickness vs. Acceleration
0 0.5 1 1.5 2 2.5 3 3.5
0
20
40
DecelerationReduction(%)
0 50 100 150 200 250 300
20
25
30
35
40
45
50
55
60
65
70
75
Electronic Temp vs. Oven Temp
Oven Temperature (C)
ElectronicTemperature(C)
Edison Core
Shutter Surface
Predicted Future
Student Version of MATLAB