Floor Sensor Mat
Category
SERVICES
Electrical Engineering
Mechanical Design
Firmware Development
Software Development
Prototyping
2021
THE CHALLENGE
Data and statistics play such an important role in the modern world that any company must be able to capture and analyze data to thrive and prosper. To keep track of data, new devices are developed every day. Despite their limitations, visitor tracking systems have existed in retail for a long time, but they are usually non-transferable and based on lasers or other intermittent tracking systems. Often, they rely on artificial intelligence cameras, which are not always accurate.
A device with reliability, portability, statistical accuracy, and cloud connectivity is the logical evolution of tracking technology.
The opportunity
AJProTech partnered with Scanalytics, an emerging U.S. provider of occupancy tracking data, to create a portable Floor Sensor Mat for retail, office, and commercial buildings.
Integrated into durable silicone mats, the floor sensors can be deployed across various flooring types. They capture up to 100% of foot traffic through a space. By recording individual footsteps and the paths they form, the software can monitor and analyze complete space usage and movement patterns.
THE SOLUTION
We delivered a fully integrated occupancy tracking mat, combining robust mechanics, custom electronics, and optimized firmware. Its two-part rubber body with cold-bonded plates protects the internal components and is secured to a durable aluminum PCB enclosure. The LoRaWAN antenna is housed inside the rubber shell for optimal signal. A custom PCBA and validation board ensured reliable hardware performance, while LoRaWAN-enabled firmware supports long-range, low-power data transmission.
Powered by a high-capacity battery and an efficient wireless LoRa interface, the system can operate for months without maintenance. With its waterproof design, low EMI, and precise pedestrian detection, this durable, portable IoT device delivers accurate occupancy data in diverse environments.
Our Approach
We began the project with a comprehensive feasibility study, evaluating multiple membrane options and defining the optimal configuration for performance and durability. During this stage, we compiled a complete list of required components to guide the next phases of development. This solid foundation enabled a smooth transition into Engineering Validation Testing (EVT) and Design Validation Testing (DVT), ensuring the design met all functional and quality requirements before moving toward production.
Mechanical design
The body features a two-part silicone assembly: a grooved upper part and a smooth lower part, with the membrane keyboard securely installed between them. These parts are joined via cold bonding, preventing damage to the sensitive membrane matrices. The silicone body interfaces with the PCBA enclosure through precision-molded spike grooves, ensuring a robust and sealed fit. Two housing materials were evaluated for the PCBA box: aluminum and SMC plastic. While SMC plastic allows the antenna to be integrated directly inside the housing, aluminum was selected for its superior strength and corrosion resistance. The trade-off of aluminum’s RF shielding effect is mitigated by relocating the antenna to a dedicated compartment within the mat’s silicone shell. The enclosure consists of a rigid box and a sealed screw-fastened lid, with an additional silicone cover protecting the control panel. This construction supports reliable triggering of the mat’s sensitive elements by pedestrians weighing 50–120 kg, wearing various types of footwear.
Electrical design
To ensure performance and functionality, a dedicated development board was tested as a validation platform. This dev board replicates the core circuitry of the custom PCBA, enabling thorough testing, firmware integration, and troubleshooting before full-scale production. Based on the results, a custom PCBA was specifically developed to meet the unique functional and form-factor requirements of the mat system. The sensor is so sensitive that it can distinguish who exactly passes over it – whether a person, a cyclist, a wheelchair user, a stroller, or even a dog. The final design integrates all necessary control, sensing, and communication circuits into a compact, application-optimized layout. This approach minimizes design risks, accelerates debugging, and ensures the final hardware meets all electrical and operational specifications.
Firmware Development
The firmware for this project was designed to ensure reliable, long-range, and energy-efficient wireless communication. To achieve these goals, the system implements the LoRaWAN protocol, enabling low-power, wide-area networking suitable for transmitting sensor data over extended distances. The firmware stack handles data acquisition from the mat’s sensing elements, packet formatting, and secure transmission via LoRaWAN gateways to the cloud or local server. Special attention was given to optimizing power consumption and ensuring robust connectivity, even in environments with significant signal interference or physical obstructions. This implementation allows the device to operate autonomously for extended periods while maintaining consistent communication performance.
Impact
The Floor Sensor Mat redefined occupancy tracking with unmatched accuracy, portability, and reliability. Capturing nearly 100% of foot traffic and operating for months without maintenance, it gave businesses powerful insights into space utilization. The successful launch positioned Scanalytics as a leader in smart occupancy solutions and showcased AJProTech’s ability to turn complex IoT concepts into market-ready products.
