Abstract:
An apparatus and method for controlling equipment in response to a proximity signal from one or more chips and sensors for detecting proximity of an individual with respect to a manufacturing device. A chip can be retained by an individual and a sensor can be mounted on the manufacturing device. When the individual retaining the chip comes into a predetermined proximity with the sensor, the sensor can emit a signal. The signal can be received by an electric control device for disengaging operation of the machine or for placing the machine in a safe mode in response to the signal. The chip and the signal can interact in a first manner where the chip emits a signal receivable by the sensor. Alternatively, the chip and sensor can interact where the sensor emits a signal creating a field for identifying when a chip enters the signal generated field.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This Application is a continuation of U.S. Provisional Patent Application Ser. No. 60/268,982 filed Feb. 15, 2001. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The invention relates to a system for controlling operation of equipment in response to the monitored position of individuals within a manufacturing facility and, more specifically, to a system of chips and sensors for controlling automated equipment in response to the detected proximity of an individual retaining a chip relative to a sensor positioned within the facility.  
         BACKGROUND OF THE INVENTION  
         [0003]    Many devices have been developed to prevent machine operators from being injured in the performance of jobs around automated equipment. For example, fencing can be placed around a machine to prevent an operator or another individual from moving too close to the device. Another example of a safety feature is a double button assembly. In a double button assembly, the operator is required to press two different buttons to operate the machine. The two buttons are placed spaced apart from the machine so that the operator cannot be too close to the machine while the machine is running. Another example of a safety device is a light screen. Light screens can be positioned around a machine. When the light screen is pierced, the manufacturing device can be stopped or further automatic operation can be disengaged. Generally, a shortcoming of presently known safety devices is that each device is either too easily circumvented or is extremely costly.  
         SUMMARY OF THE INVENTION  
         [0004]    The present invention provides a system for controlling the operation of equipment in response to detected proximity of an individual to a location in a manufacturing facility, such as the location of a manufacturing device. The system can include chips retained by one or more individuals within the manufacturing facility and sensors positionable at any desired location in the manufacturing facility. In particular, the sensors can be positioned at a machine and can detect when an individual retaining a chip moves relatively close to the machine. The chips can be active or passive relative to the sensor and the sensor can be active or passive relative to the chips. The invention can also include control means for controlling the operation of a machine in response to a signal received from the sensor. Specifically, the control means can receive a signal from the sensor indicating that a chip has moved in relatively close proximity to a machine. The control means can disengage, stop or place the machine in a safe mode in response to the signal. A manufacturing facility can include a plurality of sensors located at various locations in the manufacturing facility. Chips can be retained by each individual in the manufacturing facility. Each chip can be uniquely configured for each individual, or for a group of individuals, or can be similarly configured for all individuals. The invention can also include data storage means for collecting data relating to the position of individuals in the manufacturing facility. 
       
    
    
       [0005]    Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]    The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:  
         [0007]    [0007]FIG. 1 is a schematic overhead view of a system according to the present invention having a passive chip and an active sensor;  
         [0008]    [0008]FIG. 2 is a schematic overhead view of a system according to the present invention having an active chip and a passive sensor;  
         [0009]    [0009]FIG. 3 is a schematic overhead view of a manufacturing facility having a plurality of sensors, data storage means and monitoring means;  
         [0010]    [0010]FIG. 4A is a flow chart illustrating the logic applied by control means for placing an operating machine in safe mode in response to a pulse signal from a proximity sensor according to the present invention; and  
         [0011]    [0011]FIG. 4B is a flow chart illustrating the logic applied by control means for placing an operating machine in safe mode in response to a continuous signal from a proximity sensor according to the present invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0012]    The present invention provides a system for detecting the proximity of an individual relative to a position within a manufacturing facility. The system  10  includes at least one chip  12  and at least one sensor  14 . A chip  12  is retained by an individual in the manufacturing facility. The sensor  14  detects the proximity of the chip  12  with a specified range and can emit a signal in response to detection of one or more chips  12  within the specified range. By way of example and not limitation, when a chip  12 , retained by an individual, is detected by a sensor  14  operably engaged, directly or indirectly, with a manufacturing device  22 , the sensor  14  can emit a signal that results in the device  22  ceasing operations or entering a safe mode.  
         [0013]    The chip  12  can be active or passive. An active chip  12   b  can emit an inaudible wave signal receivable by a sensor  14   b  over a range  16 , as shown in FIG. 2. As shown in FIG. 1, a passive chip  12   a  does not emit a signal. The chip  12  can be retained by an individual in a badge, a hat, safety glasses or be maintained as a distinct item. The chip  12  can be uniquely configured, allowing a sensor  14  to detect and identify specific chips  12  when multiple chips  12  are functioning within a single manufacturing facility. For example, a chip  126  can emit an encoded, unique identification signal. The invention can be practiced with multiple chips  12  and multiple sensors  14  in a single manufacturing facility. Individual chips  12  can be distributed to different individuals operating in the manufacturing facility with unique individual or group identification characteristics. Each individual can be assigned a specific unique identification code associated with the corresponding chip  12  so that the location of each individual can be determined at any specific time when the individual is within range to be detected by any one of the multiple sensors  14 . In such an embodiment of the invention, the system of chips  12  and sensors  14  can be used to track the movements of individuals within the manufacturing facility to teach one or more groups of workers having predefined job characteristics, such as a member of the plumbers group, engineering group, electrician group or the like. Alternatively, more than one similarly configured chips  12  can be used in a single manufacturing facility to track one or more groups of workers having predefined job characteristics, such as a member of the plumbers group, engineering group, electricians group or the like. For example, all maintenance workers can retain a first configuration of chip  12  and all machine operators can retain a second configuration of chip  12 . Alternatively, a combination of similarly configured chips  12  and uniquely configured chips  12  can be used in a single manufacturing facility. For example, each maintenance personnel of a manufacturing facility can retain uniquely configured chips  12  while all machine operators can retain similarly configured chips  12 . In this embodiment of the invention, the location of maintenance personnel can be detected with greater accuracy relative to determining the location of any particular machine operator. The uniquely configured chips  12  can also be used in the present invention to enhance the security of the manufacturing facility. For example, plant management can be equipped with uniquely configured chips  12 . Access to certain areas of the manufacturing facility can be controlled by gates or doors that respond only to a uniquely configured chip  12 . Another use for uniquely configured chips  12  can be for non-employees such as contractors that enter the manufacturing facility. Non-employees can be equipped with uniquely configured chips  12  to track movement within the manufacturing facility and to prevent access to certain areas of the manufacturing facility.  
         [0014]    Each of the sensors  14  can be active or passive. As shown in FIG. 1, an active sensor  14   a  can detect the proximity of a chip  12   a  over a range  18 . The sensor  14   a  can produce an inaudible wave signal having the range  18 . A passive sensor  14   b  is shown in FIG. 2. A passive sensor  14   b  can receive a signal emitted by the chip  12   b . The sensor  14  can be positioned on a manufacturing device such as a stamping press, a lathe, or a welding machine. The sensor  14  can also be positioned adjacent to a manufacturing device if the range  16  or  18  encompasses a desired zone of safety around the manufacturing device  22   b  or  22   a , respectively. One or more sensors  14   a  can be positioned on a single manufacturing device  22   a  to provide an array of ranges  18 . The invention can also be practiced with a chip  12   b  operable to emit a signal having a range  16  and a sensor  14   a  operable to emit a signal having a range  18 . In such an embodiment of the invention, the ranges  16  and  18  can be configured as desired. The ranges  16  and  18  should contemplate a desired distance between a chip  12  and a sensor  14  to ensure that a signal is emitted from the sensor  14  in adequate time to perform a subsequent function, such as the disengagement of a manufacturing device or the opening of a door. Sensors  14   a  or  14   b  can detect and distinguish between a plurality of different encoded, unique identification codes. As shown in FIG. 3, a manufacturing facility can be equipped with multiple sensors  14   a  positioned at spaced intervals within the manufacturing facility. Sensors  14   a  can be positioned such that the ranges  18  of each sensor  14   a  are approximately tangent or overlapping with respect to an adjacent sensor  14   a . Alternatively, sensors  14   b  can be positioned at spaced intervals such that a range  16  is detectable in the manufacturing facility by at least one sensor  14  at any time. In such embodiments of the invention, an entire manufacturing facility can be monitored, where the position of all chips  12  operating within the manufacturing facility is instantly determinable at all times. Alternatively, the invention can be practiced with sensors  14  positioned at manufacturing devices only. FIG. 3 shows a floor layout  32  of a manufacturing facility using multiple sensors  14   a . A sensor  14   a  can be positioned on each manufacturing device  22   a - g  to cover a substantial area of the floor layout  32 . Additional sensors  14   a  can be added, positioned between manufacturing devices  22   a - g  to cover a greater area of the floor layout  32 . One or more sensors  14   b  can also be used to monitor the floor of a manufacturing facility also. The sensors  14   a  can be electrically coupled to data storage means  28   c , remote from one or more of the devices  22 . Data storage means  28   c  will be discussed in greater detail below.  
         [0015]    As shown in FIG. 1, the present invention also includes control means  20   a  for receiving a chip-present output signal from one or more of the sensors  14   a  and for controlling one or more manufacturing devices  22   a  in response to the chip-present output signal from one of the sensors  14   a  depending on the particular sensor  14   a  generating the output signal. The process steps are shown in simplified flow diagrams in FIG. 4A and 4B. Query  36  or  36 A monitors whether a chip-present output signal, or proximity signal, from one of the sensors  14  has been received. Each of the sensors  14   a  and  14   b  can individually detect the proximity of one or more chips  12 . When at least one chip  12  and at least one sensor  14  jointly occupy a range  16  or  18 , the corresponding sensor  14  can emit a chip-present output signal to control means  20 . When the corresponding sensor  14  emits a chip-present output signal corresponding to proximity of at least one chip  12 , step  38  or  38 A can perform a predefined function, such as to cease continued operation of an automated device or to disengage a manufacturing device  22  from being cycled or turned on, or perform some other predefined function. Alternatively, the control means  20  can receive the chip-present output signal from one or more sensors  14  positioned at a door or a gate and control a door or a gate to open in response to at least one chip present output signal corresponding to proximity of at least one chip  12 . Each sensor  14  can emit an encoded signal corresponding to the sensed chip or chips to be sent to a remote centralized processing system or network, or to a local controller, processor or network or emit a single pulse signal corresponding to proximity or can emit a continuous signal as long as one of the chips  12  is in proximity. If the sensor  14  emits a pulse signal, as shown in FIG. 4A, query  40  requires that the control means  20  receive operator input before the device  22  can be restarted. For example, disengagement of a device  22  can require maintenance personnel to restart the device  22 . Step  42  restarts the device  22  after operator input. If the sensor  14  emits a continuous signal, query  44 , as shown in FIG. 4B, determines whether the signal is still being received by the control means  20 . If the answer query  44  is yes, query  44  is repeated. If the answer to query  44  is no, the program branches to step  46  to restart the device  22 .  
         [0016]    The control means  20  can also be operable to emit an encoded signal receivable by centralized or local data storage means  28   a  or  28   b , as shown in FIGS. 1 and 2 respectively. The data storage means  28  can record all occurrences of a manufacturing device  22  ceasing operations or occurrences of a gate or door being opened in the presence of one or more chips  12 . The data stored by data storage means  28  can be useful in accurately determining the costs of operating a particular manufacturing device, the distribution of employees&#39; time at specific locations in the manufacturing facility, the interaction among employees, and future planning of production and maintenance cycles.  
         [0017]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.