Abstract:
A high voltage proximity warning system, precise, easy to use, easy to install, rugged and weatherproof, has a control panel which is located in the cab of an excavator, other heavy equipment or vehicle, such that it is readily accessible to the operator during equipment operation and is connected to one or more strategically located sensor antenna(s). The control panel is designed to be used with or without gloves, in a position where it is readily visible. It is electrically connected to the equipment&#39;s power source. At least one high voltage proximity sensor is mountable to the vehicle and is in wired or wireless communication with the control panel.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit under 35 U.S.C. 119(e) to U.S. Provisional Application Ser. No. 61/136,253 entitled “High Voltage Proximity Warning Alarm System”, filed Aug. 21, 2008. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to a high voltage proximity warning alarm system particularly useful when installed on heavy equipment. 
       BACKGROUND OF THE INVENTION 
       [0003]    Contact of high power lines by vehicles continues to be a safety concern for equipment operators as well as persons coming to their rescue. In addition to the dangers of contact with high voltage power lines, damage to the power lines also causes inconvenience to users of electricity and increased economic costs to power companies which supply electricity and maintain the electrical distribution systems. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention is directed to a high voltage proximity warning system. High voltage is considered to be any voltage that can cause injury or harm to a person. It is an object of this invention to provide a warning device that senses a proximity to high voltage power lines. The sensor provides enhanced safety to operators of heavy equipment by sensing a proximity of a vehicle including heavy equipment and any other vehicle that may come in contact with a high voltage power line during regular work routines. 
         [0005]    In one aspect, the present invention resides in high voltage proximity warning alarm system comprising: a controller having a user interface and at least one audio and/or visual warning indicator; and one or more proximity sensors in electrical communication with the controller by at least one cable, the one or more proximity sensors capable of sensing a proximity to high voltage. More preferably, the one or more proximity sensors are in wireless communication with the controller. 
         [0006]    In another aspect, the present invention resides in a high voltage proximity warning alarm system comprising a controller and at least one voltage proximity sensor mountable to a vehicle and in communication with the controller, wherein: the controller has a user interface and at least one warning indicator which alerts a user when a voltage sensed by the at least one proximity sensor is above a user specified threshold value and each of the at least one voltage proximity sensor has a sensor housing having a front surface and a back surface, the front surface having a sensor plate connected to a voltage sensor positioned in the housing, and the sensor housing having side surfaces connecting the front surface to the back surface, the side surfaces being chamfered as sloping outwardly from the front surface to the back surface when the sensor housing is viewed from a side view, the back surface being planar so as to be mountable flat against a planar surface of the vehicle. 
         [0007]    In yet another aspect, the present invention resides in a high voltage proximity warning alarm system comprising a controller and at least one voltage proximity sensor mountable to a vehicle and in communication with the controller, wherein: the controller has a user interface and at least one warning indicator which alerts a user when a voltage sensed by the at least one proximity sensor is above a user specified threshold value and each of the at least one voltage proximity sensor has a sensor housing having a front surface and a back surface, the front surface having a sensor plate connected to a voltage sensor positioned in the housing, and the sensor housing having side surfaces connecting the front surface to the back surface, the side surfaces being chamfered as sloping outwardly from the front surface to the back surface when the sensor housing is viewed from a side view, the back surface being planar so as to be mountable flat against a planar top surface of a sensor mounting plate which is fixed to a flat surface of the vehicle. 
         [0008]    Further and other features of the invention will be apparent to those skilled in the art from the following detailed description of the embodiments thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Reference may now be had to the following detailed description taken together with the accompanying drawings in which: 
           [0010]      FIG. 1  shows a high voltage proximity warning system in accordance with one embodiment of the present invention; 
           [0011]      FIG. 2  shows a control box of the high voltage proximity warning system shown in  FIG. 1 ; 
           [0012]      FIG. 3  shows a sensor of the high voltage proximity warning system shown in  FIG. 1 ; 
           [0013]      FIG. 4  shows a bottom side of the sensor shown in  FIG. 3 ; 
           [0014]      FIG. 5  shows a block diagram of the high voltage proximity warning system; 
           [0015]      FIG. 6  shows a block diagram of a high voltage proximity warning system with wireless communicating components; 
           [0016]      FIG. 7  shows a high voltage proximity warning system in accordance with another embodiment of the present invention; 
           [0017]      FIG. 8  shows a voltage sensor and sensor mounting plate as shown in the high voltage proximity warning system in  FIG. 7 ; 
           [0018]      FIG. 9  shows a cross-section of the voltage sensor housing and sensor mounting plate shown in  FIG. 7  through a plane extending vertically downward through cross-sectional line X-X; 
           [0019]      FIG. 10  shows the voltage sensor housing shown in  FIG. 8 ; 
           [0020]      FIG. 11  shows a back surface of the voltage sensor housing shown in  FIG. 10 ; 
           [0021]      FIG. 12  shows the sensor mounting plate as shown in  FIG. 8 ; 
           [0022]      FIG. 13  shows a wireless high voltage sensor in accordance with another embodiment of the present invention; 
           [0023]      FIG. 14  shows the controller in  FIG. 7  with a mounting base in accordance with a preferred embodiment; and 
           [0024]      FIG. 15  shows a backhoe with a wireless voltage proximity warning system connected thereto. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]      FIG. 1  shows a high voltage proximity warning system  2  in accordance with one embodiment of the present invention. The system  2  has a controller  4  electrically connected to three sensors  6 A,  6 B and  6 C. While other embodiments may include more or less than three sensors, the embodiment shown in  FIG. 1  has three sensors. The controller  4  is connected to the first sensor  6 A by cable  8 A, the first sensor  6 A is connected to the second sensor  6 B by cable  8 B, and the second sensor  6 B is connected to the third sensor  6 C by cable  8 C. 
         [0026]    In use, the controller  4  is selectively positioned in an operational, audio and visual nearness to heavy equipment or vehicle operator in the heavy equipment vehicle cab, and the electrical field proximity sensor  6 A,  6 B are fixed to the heavy equipment to sense high voltage. 
         [0027]    The controller  4  is shown in detail in  FIG. 2 . The controller  4  has a housing  10  that is constructed to be weatherproof and to resist entry of water to protect the active electronic circuitry contained within the housing. 
         [0028]    A user interface portion  12  is provided on a top side of the controller  4 . The user interface portion  12  has an on/off latching push button  14 . A green LED power indicating light  13  is positioned to a right side of the on/off push button  14 . The green LED power indicating light  13  lights up when the controller is on to inform the user. 
         [0029]    The user interface portion  12  also has an alarm LED  16 . The alarm LED  16  lights up in red if an alarm condition has been met, for example an antenna is in a predetermined proximity to high voltage cables. 
         [0030]    An error LED  18  is also provided on a user interface portion  12 . The error LED  18  lights up when an error condition has been met, for example a cable connecting the controller  4  to one or more of the sensor  6  or a cable between the sensors  6 A,  6 B, or  6 C is faulty or disconnected. 
         [0031]    The user interface portion  12  has a set push button  20  used to “set” the threshold sensitivity of the sensors in terms of sensing proximity of a source of high voltage to the sensor. A manual sensitivity increase button  22 , and a manual sensitivity decrease button  24  are also provided on the user interface portion  12 . The manual sensitivity increase button  22  is used to increase the sensitivity threshold. The manual sensitivity decrease button  24  is used to decrease the threshold sensitivity of the sensors. 
         [0032]    The manual increase button  22  has an associated red/green bicolour LED  21 . The manual decrease button  24  has an associated red/green bicolour LED  23 . The green LED indicates that the depressed up or down manual push button is increasing or decreasing the threshold, respectively. The red LEDs indicate that the end of a given adjustment range for manual control has been reached and thus can not be further increased or decreased. Once the user is satisfied with the threshold adjustment, they commence use of their heavy equipment. 
         [0033]    The user interface portion  12  also has a volume increase push button  26  and a volume decrease push button  28 . A speaker (not shown) is provided within the housing  10  as a audio alarm signal when an alarm condition has been met, for example the sensors  6 A,  6 B or  6 C are in a threshold proximity high voltage power lines. The volume of the audio alarm can be set using the volume increase button  26  or volume decrease button  28 . 
         [0034]    The audio alarm is designed such that it can be adjusted to be heard above the loud background noise that may be present in heavy equipment or other vehicle environments. 
         [0035]    Each of the push buttons provided on the user interface portion  12  are operable conveniently by a user with or without gloved hands. The controller  4  can be provided near the operator of heavy equipment in a location that is readily visible and audible and easily connectable electrically to the proximity sensors  6 A,  6 B and  6 C. 
         [0036]    A sensor  6  is shown in perspective view in  FIG. 3 . The sensor  6  has a sensor housing  30 . The sensor housing  30  has a front surface  31  and a back surface  40 , shown in  FIG. 4 . The sensor housing  30  has chamfered edges  33 A and  33 B which slant outwardly from the front surface  31  to the back surface  40  when the sensor housing  30  is viewed from a side view. Similar chamfered edges  33 C and  33 D (not shown) are provided on the other two sides of the sensor housing  30 . The chamfered edges  33 A,  33 B,  33 C and  33 D advantageously prevent the housing from catching on branches or debris which may be encountered when using heavy equipment to which the sensor is attached. Preferably, the sensor housing  30  is made of a durable material such as ultra high modular weight polyethylene (“UHMW”) and powder coated steel, which protect the sensor from physical damage and resist damage caused by weather conditions. The sensor housing  30  could also be made of polycarbonate or acrylic material. 
         [0037]    The sensor housing  30  has wire channels  32 A,  32 B provided so that a wire connecting the sensor to the controller  4  or an additional sensor  6  fits within the channel  32 A or  32 B, so that the sensor housing  30  can be mounted flush against a planar surface of the vehicle or heavy equipment. 
         [0038]    As shown in  FIG. 3 , the sensor plate housing is mountable to the vehicle or heavy equipment using mechanical mounting fasteners such as bolts  34 A,  34 B,  34 C and  34 D. The mounting fasteners  34 A,  34 B,  34 C and  34 D are fitted through respective bore holes  35 A,  35 B,  35 C and  35 D shown in  FIG. 4 . 
         [0039]    A sensor plate  36  is provided on a top surface of the sensor housing  30 . The sensor plate  36  and active circuitry provide precise detection of high voltage electricity lines. The sensitivity of voltage detection can be adjusted using the controller  4  as described above. 
         [0040]    A name plate  38  is also provided on the top surface of the sensor housing  30 . 
         [0041]      FIG. 4  shows a bottom surface  40  of the sensor housing  30 . Cable channels  42 A,  42 B,  42 C and  42 D are provided on the bottom surface  40  to provide space for a cable to run to an outer perimeter of the bottom surface  40  and facilitate a flush mounting of the sensor  6 . As shown, cable  8  is positioned in channel  42 D and passes through an orifice  41  through a middle of the back surface  40  to connect to a voltage sensor (not shown) positioned within the sensor housing  30 . 
         [0042]      FIG. 5  shows a schematic block diagram of the sensor and control box including the interior components. The control box  50  has a power supply  52 . The power supply  52  preferably is 12 to 24 volts direct current. The power supply  52  is connected to hardware/software  54 . The hardware/software  54  receives inputs from pushbuttons  56 , for example which are depressed by a user. The hardware/software  54  is connected to LEDs  58 , which provide visual indication to the user in response to activation of the pushbuttons  56  through the software  54  and from output commands from the software in relation to inputs from a sensor  60 . 
         [0043]    The sensor  60  is connected to the control box  50  with power supply line  62  and a software communication line  64 . The sensor has sensor hardware/software  66  which communicates with the control box hardware/software  54  via the software communication line  64 . The sensor  60  has an antenna  68  which is capable of sensing the proximity to high voltage. The antenna  68  is connected to the sensor hardware/software  66 . The sensor hardware/software  66  receives inputs from the antenna  68  with respect to a voltage sensing and communicates the inputs via outputs to the control box hardware/software  54  via the software communication line  64 . A high impedance buffer  70  is provided between the antenna  68  and sensor hardware/software  66 . The high impedance buffer  70  provides a stable signal for the sensor hardware/software  66 . It does this by effectively isolating the signal on the antenna from any loading effect that the hardware/software  66  might otherwise have on this signal. 
         [0044]    As shown in  FIG. 5 , the sensor  60  can be connected in series to an additional sensor via a continuation of the software communication line  64 . It is appreciated that an extension of the power supply line  62  can also be provided for additional sensors. 
         [0045]      FIG. 6  shows a similar block diagram as shown in  FIG. 5 . In  FIG. 6 , the control box  100  has a power supply  102  preferably having an input voltage of 12 to 24 volts DC. The power supply  102  is connected to control box hardware/software  104  to provide power thereto. Pushbuttons  106  are provided on the control box  100  and are connected to the control box hardware/software  104 . Pushbuttons  106  are actuated by a user to effect commands which are in turn inputted to the hardware/software  104 . The hardware/software  104  communicates to the user via visual LEDs  108  in response to the user actuation of the pushbuttons  106 . The hardware/software also communicates via LEDs  108  to indicate conditions communicated from a sensor  110 . The sensor  110  has a transceiver and battery pack  112  which sends wireless signals which are received by a control box transceiver  114 , and vice versa. As such, the sensor transceiver  112  and the control box transceiver  114  send and receive signals so as to have bilateral communication capabilities. 
         [0046]    The sensor  110  is equipped with hardware/software  116  which is in turn connected to an antenna  118 . The antenna  118  senses proximity to a source of high voltage and communicates to the sensor hardware/software  116 . The hardware/software  116  interprets the signals received from the antenna  118  and communicates via transceiver  112  to the control box transceiver  114  and connected control box hardware/software  104 . 
         [0047]    A high impedance buffer  120  is provided between the antenna  118  and the sensor hardware/software  116 . The high impedance buffer  120  provides a stable signal for the sensor hardware/software  116 . It does this by effectively isolating the signal on the antenna from any loading effect that the hardware/software  116  might otherwise have on this signal. 
         [0048]    By the construction shown in  FIG. 6 , the control box  100  and sensor  110  can cooperate to communicate to a user when the sensor  110 , which is attached to heavy equipment, is in a specified proximity to high voltage to sound an alarm warning the user. 
         [0049]    It is also appreciated that further sensors, similar to sensor  110 , could be attached to the heavy equipment and similarly communicate with the control box transceiver  114  via sensor transceivers. Additional sensors are not shown in  FIG. 6 . 
         [0050]      FIG. 7  shows a high voltage proximity warning system  102  in accordance with another embodiment of the present invention. The high voltage proximity warning system  102  has a controller  104  connected to the sensors  106 A,  106 B and  106 C by a main cable  108  and respective lead cables  110 A,  110 B and  110 C. It is appreciated that more or less than three sensors could be connected in the high voltage proximity warning system  102 . 
         [0051]    The controller  104  is similar in design to the controller  4  shown in the high voltage proximity warning system  2  of  FIG. 1 . The controller of  104  has similar features and operates in a similar manner as the controller  4  previously described. 
         [0052]      FIG. 8  shows a sensor  106  having a voltage sensor housing  112  and a sensor mounting plate  114 . The voltage sensor housing  112  has a sensor plate  116  on a top surface  118  of the voltage sensor housing  112 . The voltage sensor housing  112  is mounted to the sensor mounting plate  114  by threaded mechanical fasteners or bolts  120 A,  120 B,  120 C, and  120 D. The voltage sensor housing  112  is preferably made of UHMW, powder coated steel, polycarbonate or acrylic. 
         [0053]      FIG. 9  shows the voltage sensor housing  112  and sensor mounting plate  114  in cross-sectional view taken along a plane through cross-sectional line X-X of sensor  106 A shown in  FIG. 7 . As shown, a bottom surface  122  of the voltage sensor housing  112  is secured against a top surface  124  of the sensor mounting plate  114 . An O-ring seal  126  is provided in a O-ring seal channel  128  to provide a seal against moisture and other material from entering into an inner portion of the sensor housing. 
         [0054]    Also shown, a sensor  130  is provided inside the voltage sensor housing  112  and is connected to the sensor plate  116 . 
         [0055]      FIG. 10  shows the voltage sensor housing of  FIG. 8 . The voltage sensor housing  112  has chamfered edges  132  which extend outwardly from the top surface  118  to the bottom surface  122  when viewed in a side view of the voltage sensor housing  112  for example as shown in  FIG. 9 . As shown in  FIG. 10 , a wire mounting device port  134  is provided along chamfered edge  132 B. 
         [0056]      FIG. 11  shows the voltage sensor housing  112  from a back surface  122 . The voltage sensor housing  112  has four mounting holes  136 A,  136 B,  136 C, and  136 D. The threaded fasteners  120 A,  120 B,  120 C, and  120 D shown in  FIG. 8  are inserted through the mounting holes when fixing the voltage sensor housing  112  to the sensor mounting plate  114 . 
         [0057]    Also provided on the back surface  122  are four weld clearance embossments. The weld clearance embossments  138 A,  138 B,  138 C, and  138 D provide a spacing so that excess weld material does not prevent the flush mounting of the sensor housing  112  to the mounting plate  114 . 
         [0058]    Also shown, the back surface  122  has potting material vents  140 A and  140 B which are provided to fill an air space under the sensor plate with a potting material. 
         [0059]    The lead wire  110  extends through an opening  144  through the port  134  and into an interior of the voltage sensor housing  112 . An O-ring seal is provided between the opening  144  and the lead wire  110  to prevent moisture and other materials from entering into an inner cavity of the voltage sensor housing  112 . As shown, the wire  110  extends around a strain relief post  146  and through a strain relieve groove  148 . After passing through the strain relief groove  148 , the wire  110  extends around the strain relief post  146  again in an opposite direction. The sensor wire comprises four wires which are a power wire  150 , a ground wire  152 , a first signal wire  154  and a second signal wire  156 . The power wire  150 , ground wire  152 , first signal wire  154  and second signal wire  156  are each connected to a screw terminal block connector plug  158 . The connector plug  158  is removeably insertable into a screw terminal block connector socket  160 . A sensor wire  162  has a first end  164  connected to the connector socket  160 . The sensor wire  162  has a second end  166  which passes through an orifice  168  to connect with the sensor  130 , not shown in  FIG. 11 . 
         [0060]    Connecting the lead wire  110  around the strain relief post  146  and through the strain relief groove advantageously protects the sensor cable  162  from being ripped out in the event that a force is exerted on the sensor housing  112 . For example if the sensor housing is caught on a branch of a tree the lead wire  110  should break so that the sensor wire  162  is not damaged. Further, if the strain relief post  146  and strain relief groove  148  do not provide adequate protection against the sensor wire  162  from being pulled, the screw terminal block connector plug  158  will detach from the screw terminal block connector plug  164  if sufficient force is exerted by pulling on the lead wire  110 . By preventing the sensor wire  162  from being ripped out, the repair in the event of damage to the sensor is made easier and less costly. 
         [0061]      FIG. 12  shows the sensor mounting plate  114 . The sensor mounting plate  114  has a lead wire mount  170  fixed to the top surface  124  of the sensor mounting plate  114 . The lead wire mount  170  is provided to channel the lead wire  110  into the voltage sensor housing  112  for example as shown in  FIG. 8 . 
         [0062]    The sensor mounting plate  114  has a four threaded nuts  172 A,  172 B,  172 C, and  172 D fixed to the top surface  124 . The nuts  172 A,  172 B,  172 C, and  172 D are positioned to receive the bolts  120 A,  120 B,  120 C, and  120 D, respectively, to mount the voltage sensor housing  114  to the sensor mounting plate  114 . 
         [0063]    The sensor mounting plate  114  can be fixed to a vehicle by welding. Mounting bore holes  174 A,  174 B,  174 C, and  174 D are provided through the mounting plate  114  to enable welds to be made. As such welds on the sensor mounting plate  114  can be hidden by the sensor housing  112 . Alternatively, the sensor mounting plate  114  could be fixed to the vehicle by inserting bolts through bore holes  174 A,  174 B,  174 C, and  174 D. 
         [0064]      FIG. 13  shows a wireless high voltage sensor  200  in accordance with another embodiment of the present invention. The wireless high voltage sensor  200  comprises a voltage sensor housing  202  with chamfered edges  204 A,  204 B,  204 C, and  204 D. 
         [0065]    A top surface  206  of the wireless high voltage sensor housing  202  has a sensor plate  208  thereon. 
         [0066]    The sensor plate  208  is connected to a sensor control  210  positioned within the sensor housing  202 . The sensor control is connected to a battery  212  provided inside the sensor housing  202  which provides power to the sensor control  210 . Also connected to the sensor control  210  and to the battery  212  is a radio transmitter receiver device  214 . The radio transmitter receiver device  214  is provided to communicate with a similar radio transmitter receiver device provided in a controller. As such, voltage readings sensed by the sensor plate are relayed to the sensor control and in turn to the radio transmitter/receiver device  214  for transmission to the controller. As such, the wireless high voltage sensor  200  can communicate with the controller to provide a warning in the event that a voltage above a threshold set voltage is sensed by the sensor plate  208 . 
         [0067]    A power control  216  is provided to charge the battery  212  as required. A power generation such a solar panel  218  is provided to generate power to charge the battery  212 . 
         [0068]      FIG. 14  shows the controller  220  with a mounting base  222 . The mounting base  222  has a suction cup  224  which is used to fix the controller  220  to a surface of a vehicle in proximity to a user. It is also appreciated that the controller  220  can be connected to the vehicle by other means of connection including, but not limited to, bar mount, direct mount and double sided tape. The controller  220  is similar to the controller  104  shown in  FIG. 7  except that the controller  220  has a controller radio transmitter/receiver device which is capable of wirelessly communicating with the sensor radio transmitter/receiver device  214  shown in  FIG. 13 . 
         [0069]      FIG. 15  shows a backhoe  240  with a controller  200  mounted in the cab, and three wireless voltage sensors  200 A,  200 B and  200 C attached to the arm of the backhoe  240 . It is understood that the voltage sensors  200 A,  200 B and  200 C could be attached at alternate locations on the arm of the backhoe, or other parts of the backhoe including the cab. It is also to be understood that more or less than three voltage sensors could be attached, and could be wireless or connected by wires. 
         [0070]    Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is also to be understood that the invention is not restricted to these particular embodiments rather, the invention includes all embodiments which are functional, or mechanical equivalents of the specific embodiments and features that have been described and illustrated herein. 
         [0071]    It will be understood that, although various features of the invention have been described with respect to one or another of the embodiments of the invention, the various features and embodiments of the invention may be combined or used in conjunction with other features and embodiments of the invention as described and illustrated herein.