Abstract:
An improved material handling system ( 15, 115 ) comprising a material lifting device ( 16 ), the material lifting device having a sensor ( 23 ) for sensing an operational parameter associated with the material lifting device, a load attachment device ( 18 ) configured and arranged to attach a load to the material lifting device, the load attachment device having a data tag ( 20 ) containing data regarding one or more parameters associated with the load attachment device, a reader ( 21 ) configured and arranged to read the data tag, a processing unit ( 22 ) communicating with the reader and the sensor, the processing unit configured and arranged to receive data from the reader and the sensor, and a material handling control device ( 19 ) configured and arranged to control operation of the material handling device.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates generally to the field of material handling systems, and more particularly to an improved material lifting monitoring and management system and a method of using such a system. 
       BACKGROUND ART 
       [0002]    U.S. Pat. No. 7,121,457, entitled “Automatically Adjusting Parameters of a Lifting Device by Identifying Objects to be Lifted,” is directed to a system having RFID tags, on which is stored a value associated with an adjustable parameter, attached to materials being lifted by a lifting device and an interrogator module linked to the lifting device that communicates with the RFID tag to obtain the value and adjust the parameter as a function of the data from the RFID tag. 
         [0003]    U.S. Pat. No. 7,825,770, entitled “System and Method of Identification, Inspection and Training for material Lifting Products,” is directed to a method that includes the steps of attaching an RFID tag to a material lifting device, the RFID tag having identification and inspection data, wherein the identification and inspection data is accessed during periodic inspections with a portable computer device having a RFID reader and the inspection data is updated on the portable computer device and also on the RFID tag during such inspections. 
         [0004]    U.S. Pat. No. 7,612,673, entitled “RFID System for Lifting Devices,” is directed to a lifting device equipped with an RFID scanning system having an article receiving area configured for receipt of a stack of articles having associated RFID tags. 
         [0005]    U.S. Pat. Publication No. 2006/0043197, entitled “Carrier Facilitating Radio-Frequency Identification (RFID) Operation in a Semiconductor Fabrication System,” is directed to a radio-frequency identification system for a semiconductor manufacturing environment. The system comprises a carrier having a carrier body and a RFID tag mounted on the carrier body, where the carrier body comprises a plate inscribed with permanent information corresponding to the carrier with the permanent information stored in the RFID tag. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    With parenthetical reference to the corresponding parts, portions or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present invention provides an improved material handling system ( 15 ,  115 ) comprising a material lifting device ( 16 ), the material lifting device having a sensor ( 23 ) for sensing an operational parameter associated with the material lifting device, a load attachment device ( 18 ) configured and arranged to attach a load to the material lifting device, the load attachment device having a data tag ( 20 ) containing data regarding one or more parameters associated with the load attachment device, a reader ( 21 ) configured and arranged to read the data tag, a processing unit ( 22 ) communicating with the reader and the sensor, the processing unit configured and arranged to receive data from the reader and the sensor, and a material handling control device ( 19 ) configured and arranged to control operation of the material handling device. 
         [0007]    The material lifting device may comprise a hoist. The operational parameter associated with the material lifting device may be selected from a group consisting of malfunction, load weight, overload, excessive jogging, starts beyond duty cycle, run time beyond duty cycle, and excessive heat. The load attachment device may comprise a below-the-hook lifting device. The load attachment device may be selected from a group consisting of a shackle, a vacuum lifting device, a magnet, a rigging hook, a sling, an eyebolt, a turnbuckle, a ring, a block, a chain, a clamp and a clip. The data tag may comprise an RFID tag. The RFID tag may comprise an active RFID tag. The data tag may comprise a writable RFID tag. The processing unit may be configured and arranged to write to the RFID tag. The parameter associated with the load attachment device may be selected from a group consisting of rated capacity, load attachment device weight, identification number, inspection status, and size. The reader may comprise an RFID tag reader. The processing unit may comprise a microprocessor. The material handling control device may comprise an operator control pendant. The microprocessor may be programmed to provide an output as a function of the received data and to communicate the output to the operator control pendant. The operator control pendant may communicate wirelessly with the processing unit. The operational parameter associated with the material lifting device may comprise load weight, the parameter associated with the load attachment device may comprise rated weight capacity, and the microprocessor may be programmed to compare the load weight and the rated weight capacity. The microprocessor output may comprise a warning signal if the load weight exceeds the rated weight capacity. The reader may be on the material handling lifting device. The reader may be on the material handling control device. 
         [0008]    The system may further comprise a data processing platform ( 25 ) configured and arranged to collect data via a wireless network from the processing unit. The wireless network may comprise a WiFi network ( 24 / 30 ). The wireless network may comprise a cellular network ( 136 ). The system may further comprise a data processing center ( 37 ) configured and arranged to collect data via the internet from the data processing platform. The data processing center may be configured to communicate with a remote user interface ( 38 ,  39 ). The user interface may comprise a customer computer or a distributor computer and the communication may be via the internet. The user interface may comprise a display screen and a keyboard. The processing unit may be connected to a wireless interface ( 24 ). The system may further comprise a data processing platform ( 25 ) having a wireless interface ( 30 ) configured to receive data transmitted from the processing unit. The data processing platform may comprise a data storage device ( 32 ) configured to store data received from the processing center. The data processing platform may comprise a computer. The data processing platform may be connected ( 40 ) to the internet. 
         [0009]    The system may further comprise a data processing center connected to the internet and configured and arranged to process data received from the data processing platform. The data processing center may be configured and arranged to provide a report of the processed data received from the data processing platform. The report may provide information on operating mode, predictive maintenance, operator training or safety with respect to the material lifting device. The report may be provided via a website. 
         [0010]    In another aspect, a material handling system is provided comprising a hoist, a reader connected to the hoist and configured and arranged to read a data tag, and a processing unit communicating with the reader and configured and arranged to receive data from the reader. 
         [0011]    In another aspect, a method of monitoring a material handling system is provided comprising the steps of providing a material handling system comprising a material lifting device, the material lifting device having a sensor for sensing an operational parameter associated with the material lifting device, a load attachment device configured and arranged to attach a load to the material lifting device, the load attachment device having a data tag containing data regarding one or more parameters associated with the load attachment device, a reader configured and arranged to read the data tag, a processing unit communicating with the reader and the sensor, the processing unit configured and arranged to receive data from the reader and the sensor, and a material handling control device configured and arranged to control operation of the material handling device, read the data tag of the load attachment device, and transmit the data to a processing platform. 
         [0012]    The processing unit may be programmed to provide an output as a function of the received data and to communicate the output to the operator control pendant. The operational parameter associated with the material lifting device may comprise load weight, the parameter associated with the load attachment device may comprise rated weight capacity, and the processing unit may be programmed to compare the load weight and the rated weight capacity. The output may be a warning signal if the load weight exceeds the rated weight capacity. 
         [0013]    The processing platform may be programmed to provide an output as a function of the received data and to communicate the output to the operator control pendant. The operational parameter associated with the material lifting device may comprise load weight, the parameter associated with the load attachment device may comprise rated weight capacity, and the processing unit may be programmed to compare the load weight and the rated weight capacity. The output may be a warning signal if the load weight exceeds the rated weight capacity. 
         [0014]    The processing platform may be programmed to provide an output as a function of the received data and to communicate the output to a user interface. The output may be communicated to the user interface via the internet. The output may be communicated to the user interface via a cellular network. The data may be transmitted via a wireless network from the processing unit to the processing platform. The wireless network may comprise a WiFi network. The wireless network may comprise a cellular network. The method may further comprise the step of storing the data on a data storage device. The method may further comprise the step of transmitting the data from the data processing platform to a data processing center via the internet. The method may further comprise the step of generating a report from the data. The report may provide information on operating mode, predictive maintenance, operator training or safety with respect to the material lifting device. The method may further comprise the step of providing the report on a website accessible via the internet. 
         [0015]    Accordingly, an object of the present invention is to provide an improved material handling system which is adapted to be used to monitor material handling operations. 
         [0016]    Another object is to provide an improved material handling system which is adapted to be used to managing material handling operations. 
         [0017]    Another object is to provide an improved material handling system which is adapted to be used to report material handling operations data to users. 
         [0018]    Another object is to provide an improved material handling system which is adapted to be used to collect, analyze and display data regarding material handling operations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is a schematic of a first embodiment of the improved material handling system. 
           [0020]      FIG. 2  is a schematic of a second embodiment of the improved material handling system. 
           [0021]      FIG. 3  is a schematic of an expanded embodiment of the improved material handling system shown in  FIG. 1 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, debris, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof, (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or of rotation, as appropriate. 
         [0023]    Referring now to the drawings, and more particularly to  FIG. 1  thereof, this invention provides an improved material handling system, of which a first embodiment is generally indicated at  15 . System  15  is shown as broadly including hoist  16 , load attachment device  18 , operator control pendant  19 , local computer  25 , and server  37 . 
         [0024]    As shown in  FIG. 1 , load attachment hardware/device  18 , such as a below-the-hook (BTH) lifting device, is provided for attachment of a load to hoist  16 . In this embodiment, load attachment device  18  is a shackle. While shackle  18  is shown and described, other load attachment devices may be used. For example, the load attachment device may comprise a vacuum lifting device, a magnet, a rigging hook, a sling, an eyebolt, a turnbuckle, a ring, a clip, a block, a chain, a clamp or a clip. 
         [0025]    Shackle  18  includes radio frequency identification (RFID) chip or tag  20 . RFID tag  20  may be attached to shackle  18  adhesively and/or may be recessed in a hole on the end of the shackle bolt. As another alternative, RFID tag  20  may be formed in a portion of shackle  18  during manufacturing. Thus, shackle  18  may be retrofit with RFID tag  20  or manufactured at the factory with RFID tag  20 . 
         [0026]    RFID tags of any known type may be used, including active RFID tags, passive RFID tags, semi-passive RFID tags, read only RFID tags, and read/write RFID tags. Active RFID tags are battery-powered devices that transmit a signal to a reader and typically have long ranges such as 100 feet or more. Passive RFID tags are not battery powered but rather draw energy from electromagnetic waves provided from an RFID reader. Passive RFID tags often have a range of about 10 feet or less. Semi-passive RFID tags employ a battery to run the circuitry of a chip but rely on an electromagnetic wave from a reader to power the transmitted signal. Read-only RFID tags have a serial number that is used in connection with a corresponding database. With a read/write RFID tag, data can be written into the tag by the user. The RFID tag includes an antenna for receiving and transmitting the signal, with the type of antenna generally a function of the operating frequency and desired range of the system. 
         [0027]    In this embodiment, hoist  16  is a wire rope hoist with a five ton capacity. Hoist  16  includes a deep grooved heavy duty rope drum, a heavy duty DC disk brake, motors designed for hoisting service, triple reduction hoist gearing and an oil tight gear case, a heavy duty steel frame, a trolley that is easily adjustable to handle a wide range of beam flange widths, an upper and lower geared limit switch, and a two-speed hoist and trolley control. The hoist motor is two-speed with a 4:1 ratio from high to low speed. The wire rope drum is deep grooved with a rope guide and is machined from steel. The wire rope is secured to the drum with three heavy deck tile iron clamps and is designed to have three extra wraps of wire rope on the drum with the rope at full extension. The hoist is provided with a bearing mounted trunnion hook that rotates 360-degrees and swings back and forth 180-degrees for easier load adjustment. The Yale Global King Monorail Wire Rope Hoist, manufactured by Yale of Wadesboro, N.C., may be used in this embodiment. Other types of electrically power hoist may be used as alternatives, including without limitation other sized and types of wire rope hoists or chain hoists. 
         [0028]    Pendant  19  is connected to hoist  16  so that a user can remotely control operation of hoist  16 . Pendant  19  generally includes a number of control buttons, including a button for immediately stopping the hoist and a speed control button. In this embodiment, pendant  19  also includes at least one colored warning indicator. Alternatively, pendant  19  may include a digital display for providing information and warnings to the user and/or an audio warning system. 
         [0029]    Hoist  16  includes RFID reader or interrogator  21 . Reader  21  is a two-way radio transmitter/receiver that sends a signal to RFID tag  20  and reads RFID tag  20 ′s response. Reader  21  includes an RFID writer, which can write data to the data tag. Data written to the tag may include parameter data, including an indicator that the hook device has been operated beyond its capability and should be examined before further use. Other parameters that may be written to the data tag include a variable which is a function of the operation time of the below the hook device since the its last maintenance, the record of any emergency or warning conditions during operation, a record of which user IDs were operating the system, maintenance related data, and other similar information. 
         [0030]    In this embodiment, pendant  19  also includes RFID reader  29 . Thus, pendant  19  may be used to read and write to RFID tag  20  on shackle  18  and to communicate such data wirelessly with both hoist  16 , via interface  42 , and local computer  25 , via interface  26 . 
         [0031]    While an RFID reader and an RFID tag are described, various alternative reader-tag technologies may be used for the reader-tag interface, including a single wire interface, a multiwire interface, or other wireless interfaces. By way of example, a single wire interface such as the Dallas Semiconductor 1-wire microlan found in automobile transponder keys may be used. Viable multi-wire interfaces for reading electronic codes include the I 2 C interface, the SPI bus interface, or the CAN bus interface. Other wireless interfaces include Bluetooth, or an optical reader-coded tag interface such as a bar code reader or QR code reader. 
         [0032]    Hoist  16  also includes PC interface  24  for communication with computer  25 , which in this embodiment is located near or on the same premises as hoist  16 . In this embodiment, interface  24  is an IEEE 802.11x WiFi data communication transceiver device. Data is transmitted wirelessly, preferably in a real-time and continuous manner, to and from PC  25 . Transceiver  24  may alternatively be a Bluetooth wireless device, which affords good data transmission rates and the ability to ensure such data transmissions are properly encrypted and secure. Transceiver  24  may also be an Ethernet connection transceiver. Alternatively, a point to point protocol (PPP) connection or other similar connection may also be used for the interface with PC  25 . 
         [0033]    Hoist  16  includes pendant communication interface  41 . In this embodiment, interface  41  is an IEEE 802.11x WiFi data communication device. Data is transmitted wirelessly, preferably in a real-time and continuous manner, between pendant  19  and hoist  16 . Alternatively, pendant communication interface  41  may be a 1-wire microlan interface, an I 2 C two wire interface, a CAN bus, a USB interface, a Bluetooth connection, an infrared line of sight remote control interface, or any other similar wired or wireless interface. Interface  41  may be further configured to receive user data from pendant  19 , such as a user ID, a user finger print, a user voice identification phrase, a user iris scan, or other similar user data. 
         [0034]    As shown in  FIG. 1 , hoist  16  includes smart card  22 . Card  22  implements and handles the interface with RFID tag  20 , the interface with local PC  25 , and the interface with pendant  19 . Card  22  also controls monitoring and operation of hoist  16 . Thus, smart card controller  22  handles data flow between each of the interfaces as well as sensors or other controls within hoist  16 . In this embodiment, smart card controller  22  is a microcontroller having its own internal flash memory. Alternative controllers may be used, such as a CPU, a system on a chip, or a programmable logic device such as an FPGA (field programmable gate array) or a PLD (programmable logic device). A memory device may be included with the controller, such as flash memory, a hard disk drive, or other solid state memory device. In this embodiment, software is provided in the microcontroller&#39;s flash memory. The software implements communication protocols for each of the interfaces as well as the processing logic for operation of smart card  22 . Smart card  22  may be configured to also allow control of the lifting device through local computer network interface  24 . 
         [0035]    Sensors  23  are configured to provide operating data and other parameters with respect to hoist  16 . Such parameters may include drum speed, phase-loss detection and protection, motion monitoring, motor thermal overload sensing, hoist over-capacity sensing, malfunction, load weight, excessive jogging, starts beyond duty cycle, and run time beyond duty cycle. Other sensors, systems or controllers may be used to monitor operation of hoist  16 . Thus, microprocessor  22  controls and combines operational data from sensors  23  and reader  21 , as well as ensures a continuous second-by-second stream of information through transmitter  24  to local PC  25 . 
         [0036]    As shown in  FIG. 1 , local computer  25  generally includes interface  30  for communicating wirelessly with hoist  16  and pendant  19 , processor  31  and data storage  32 . PC  25  also includes a user interface, namely a display  33  and keyboard  34 , for displaying and manipulating data and any reports of the data. As mentioned above, in this embodiment transceiver  30  is an IEEE 802.11x wireless transceiver. In this embodiment, data storage  32  is a hard drive. However, other similar non-volatile memory storage devices may be used. 
         [0037]    PC  25  continually monitors data received and stores this data locally in data storage  32 . This data is then relayed via interne interface  40  and internet  35  to remote server or CPU  37 . 
         [0038]    Processor  31  executes software to receive incoming data from smart card  22 . The data may be tagged with user input information, such as hoist identification data and BTH device identification data, for future reference. At one second intervals, PC  25  creates and stores a single data record. Each data record comprises one second of captured data from each sensor as well as related “housekeeping” information for keeping track of such data. Upon processing, the data record is then stored in data storage  32 . 
         [0039]    In this embodiment, server  37  is programmed to communicate with PC  25  to receive and analyze data stored on PC  25 . Server  37  then provides information about the operation of hoist  16  to end user computers  38 ,  39  and/or back to local PC  25 . Such information may be provided in the form of periodic reports or, in the case of a malfunction or safety issue for example, in the form of an immediate warning or other signal. End user  38  may be the owner of hoist  16  and end user  39  may be the distributor of hoist  16 . Thus, for example, a malfunction would be automatically reported via the internet to owner  38  and distributor  39 . 
         [0040]    In the event of lost or otherwise dropped data, linear interpolation can optionally be performed to fill in the missing data provided such missing data does not exceed a predetermined number of consecutive missed samples, such as, for example, 3 samples. In the event that more than 3 samples are missed consecutively, an error condition may be indicated and user intervention may be required to investigate the cause of the error. 
         [0041]    Alternatively to programming processor  25  to manipulate received data, raw data may be relayed from PC  25  to remote CPU  37 , which may include a processor for manipulating and processing the transmitted data. Server  37  may also include a user interface, such as a display and/or keyboard. 
         [0042]    System  15  provides a number of improved functionalities. For example, in normal operation mode smart card  22  in the control panel of hoist  16  identifies the BTH device being used with hoist  16  from RFID chip  20  on device  18 . Such identification may include serial number, type of device, inspection status, and safe working load (SWL). Card  22  is programmed to determine if device  18  is compatible with hoist  16 . If not, card  22  sends a warning signal to the hoist operator via pendant  19 . For example, such a warning would be provided if a 2-ton BTH device is identified from RFID chip  20  for use on a 5-ton hoist. Smartcard  22  then monitors hoist operation, records data, and communicates such data to local PC  25  via WiFi and to the operator via pendant  19 . 
         [0043]    Local PC  25  collects the data and sends packets of data to server  37  via internet  35  at specified time intervals. Server  37  analyzes and mines the data to produce operational information on hoist  16 , such as operating mode, predicted maintenance, operator training needs and safety. Server  37  then sends reports to end user contact  38  and distributor contact  39  via internet  35 . Server  37  also populates a website with this data, and the websites is accessible to authorized users via internet  35 . 
         [0044]    In emergency mode, such as a situation in which hoist  16  or lifting hardware  18  malfunctions, is overloaded or misapplied, starts beyond a duty cycle rating, is run beyond a duty cycle rating, experiences excessive heat build-up, or has other sensed problems, smartcard  22  sends a warning signal to the operator via pendant  19 . Smartcard  22  also sends a warning signal to server  37  through local PC  25  and internet  35 . Server  37  then immediately sends a warning to specified user contacts and specified distributor contacts, such as for example customer  38  and distributor  39 . Although in this embodiment such warnings would be sent to a computer, other user interfaces could receive the warning, such as a smart phone, tablet or other handheld device. 
         [0045]    A second embodiment  115  of the hoist system is shown in  FIG. 2 . System  115  is similar to system  15 . However, rather than communicating wirelessly with local PC  25 , hoist  16  comprises a cellular wireless interface  124 . Similarly, rather than communicating wirelessly with local PC  25 , pendant  19  may comprise a cellular wireless interface  126 . Thus, signals are sent to internet  35  via wireless cellular network  136 . Such data is then received by server  37  via wireless cellular network  136  and internet  35 . Server  37  processes the received data without any intermediate processing by local PC  25 . Warnings, reports and other information is then communicated from server  37  to end users  38  and  39  and/or back to hoist  16  and, if desired, to the operator via pendant  19 . 
         [0046]    Thus, in system  115  data is relayed by cellular wireless transceiver  124  to remote CPU  37  using a cellular network. Ideally, cellular service is continuously available and data is relayed to central server  37  on a continuous, real-time basis. If cellular service is substandard, and connections thereto are only intermittent, smart card  22  stores the data in memory and awaits a standard cellular connection and then transmits all data not yet transmitted since the last successful transmission up to and including the present data being collected and continues transmitting data as it is collected until the cellular network is no longer available. In this embodiment, hoist  16  may be provided with a large permanent, non-volatile memory capacity so that data is not totally lost. Data may be captured at any suitable rate, such as once per second, with much higher or lower sampling rates possible as limited by the maximum supported data rate of the sampling hardware. 
         [0047]    For operation where there is no cellular service, data can alternatively be transmitted using IEEE 802.11x compliant wireless networking technology. In these environments, such as at shipping ports and construction sites, wireless 802.11x networks could be established to provide coverage such that hoists would be in communication with a data repository for data transmission. Where neither cellular service nor 802.11x network capacity exists, periodic downloads of collected data could be accomplished by connecting hoist  16  with a data collection device, such as a USB drive, PDA or laptop, to download all data since the last download. 
         [0048]    Regardless of the manner in which data is ultimately relayed from hoist  16  to central CPU  37 , smart card  22  keeps track of what data has been transmitted and what data has not been transmitted and automatically knows where to resume each subsequent transmission or download. This may be accomplished by sequentially stamping each record with the date and time, by indexing or numbering each record of captured data with a sequence number and by keeping track of the last successfully transmitted sequence number for a given date. 
         [0049]      FIG. 3  shows the system with multiple hoists, all communicating with local PC  25 . As shown, a second hoist  216 , shackle  218  and pendant  219  are provided and such combination communicates with each other and local PC  25  in the same manner as hoist  16 , shackle  18  and pendant  19 . The data from hoist  16  and the data from hoist  216  are tagged with separate identification so that such data may be processed independently. In this way, data from multiple hoists can be collected and analyzed through a central processing platform. 
         [0050]    Alternatively, the multiple hoist system shown in  FIG. 3  may be configured such that hoists  16  and  216  communicate with server  37  through a cellular wireless interface  136 , as described with reference to the embodiment shown in  FIG. 2 . Thus, rather than communicating with local PC  25 , hoists  16  and  216 , and pendants  19  and  219 , may comprise cellular wireless interfaces  124  and  126 , as described with references to the embodiment shown in  FIG. 2 , such that signals are sent via wireless cellular network  126  and internet  35  to server  37 . Server  37  may then process the received data without any intermediate processing by local PC  25 . 
         [0051]    The present invention contemplates that many changes and modifications may be made. Therefore, while the presently-preferred form of the emissions measuring system has been shown and described, and several modifications and alternatives discussed, persons skilled in this art will readily appreciate that various additional changes and modifications may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.