Evolv Express
Developed a first of its kind weapons detection system.
Duration: 10 months, team of 5+
Evolv Express is the first touchless weapons detection system that can scan groups of people as they naturally walk through without slowing, stopping, emptying pockets, or removing bags. Unlike conventional metal detectors, people can pass through as a continuous stream, and guards only need to intervene if a threat is detected.
When Evolv came to PA Consulting, they had an innovative electromagnetic scanning technology and a proof of principle prototype. Yet they were far from having a rugged system ready for deployment in the field. Over the span of 10 months, we developed a portable and weatherproof prototype that Evolv was able to bring to trade shows and lease to customers.
Tolerance Analysis
The straightness and plumbness of the system is key to the performance of the technology. I performed extensive statistical tolerance stack analysis to ensure positions and orientations of key sensors will remain within acceptable ranges once the bases were levelled. The system contained reaction injection moulded parts and extruded parts that had particularly large tolerance bands, which necessitated more complex analysis methods. I developed GD&T schemes to control the key features within required ranges.
Integrating Industrial Design and Sealing Features
I owned the design of the bases at bottom of the units. The bases were the entry points for IP67 rated connectors, and also had securely locked access doors to prevent tampering. The surface of the bases were key parts of the industrial design, and needed to fit the designer’s intended surface profiles. Another key feature was integrated casters that could be extended or retracted, allowing easier positioning of the systems.
Project and Task Management
To achieve all this on the tight timeframe we had, we had to employ effective project and task management strategies. We employed a system that was lightweight but allowed the team to see at a glance the current progress and individual task progresses.
Results
We were able to deliver a reliable prototype that the client was able to lease to customers. This secured them crucial funding, allowing them to become publicly listed in 2021. The prototype has far outlived its expected lifespan, and even now I’ve seen the system in the wild with our original design. As Evolv grows, I hope to see the Express system more and more. It’s a great joy to see my designs come to life and make a positive impact in the world.
