Closed-loop IoT system for post-operative therm… — Enterprise Case Study

IOT · IoT medical devices · closed-loop control · thermal systems · edge algorithms · low-power embedded systems

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Problem context

Post-operative recovery often relies on non-controlled cooling methods such as ice packs, which provide inconsistent therapeutic results and carry risks of overcooling or insufficient temperature exposure. The challenge was to engineer a portable, connected thermal therapy device capable of maintaining precise, stable temperatures over extended periods without continuous human supervision. From an IoT perspective, the device needed to operate as an autonomous edge system: sensing, deciding, and adjusting in real time under real-world conditions.

Constraints

  • Precise temperature control within a narrow therapeutic window
  • Portable, non-industrial cooling source (ice-based system)
  • Continuous operation during patient recovery
  • Closed-loop control without manual adjustment
  • Medical-grade reliability and validation requirements
  • Compressed development timeline (12 months end-to-end)

Engineering decisions

Decision: Implement a closed-loop temperature control architecture
Reason: Open-loop cooling systems cannot maintain consistent therapeutic temperatures.
Trade-off: Required development of a custom control algorithm and real-time feedback loops.
Decision: Develop a thermal physics model as the core of device behavior
Reason: Accurate prediction of heat transfer dynamics enables proactive control instead of reactive correction.
Trade-off: Increased upfront modeling and validation effort.
Decision: Treat the device as an autonomous IoT edge system
Reason: Reliable therapy delivery must not depend on constant user input or external connectivity.
Trade-off: More complex embedded logic and on-device decision-making.
Decision: Parallelize hardware, firmware, and validation development
Reason: Reduced overall delivery time without sacrificing system robustness.
Trade-off: Required tighter cross-disciplinary coordination.

System overview

The system consists of a portable thermal exchange unit, embedded sensors, and an edge controller executing a real-time control algorithm. Temperature data is continuously monitored, processed locally, and used to adjust cooling behavior dynamically. The device maintains stable output despite variations in environment, usage patterns, and thermal load. The architecture follows IoT edge principles: continuous sensing, local decision-making, adaptive actuation, and predictable system behavior without cloud dependency.

Outcome

Temperature control accuracy within ±2°F. Fully autonomous closed-loop operation. 5 fully functional prototypes. Complete manufacturing and quality documentation. Extensive in vitro validation completed. Delivered in 12 months (3× faster than industry average).

Engagement delivered under NDA. Details anonymized.

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