Biometric control system and method for machinery

The present invention is a system and method that allows only authorized users to turn on specific equipment they are approved to use and maintains a record of the name of the user, date, time and length of operating time. In one embodiment, the system comprises an AMS unit in communication with a BCS unit located at and connected to the machine. AMS comprises a computing device, a biometric reader connected with the computing device, a storage device connected with the computing device, a program module stored on the storage unit, and a communication module connected to the computing device. The program module has sets of code configured to instruct the biometric reader to scan the biometric feature of the operator and to create a digitized biometric signature. The program module is further configured to store the biometric signature on the storage device. The BCS unit comprises a computing device, a biometric reader connected with the computing device, a storage device connected to the computing device, a program module stored within the storage device, and a communication module connected with the computing device and in communication with the communication module of the AMS. The biometric reader of the AMS unit is adapted to detect the presence of the biometric feature of the operator and to scan and create a digitized biometric signature. The program module of the BCS unit is configured allow the user to turn-on the machine if the user's biometric signature matches the authorized biometric signature.

BACKGROUND OF THE INVENTION

Safety is a major concern with machinery used in the manufacturing industry. Employees using equipment they are not properly trained in the use of exposes the employee to potential peril, as well as exposing the company to potential lawsuits, higher accident and workers compensation rates.

SUMMARY OF THE INVENTION

The present invention is a system and method that allows only authorized operators to turn on specific equipment they are approved to use. The system and method maintains a record of the operator's identification, date, time, and length of operating time. In one embodiment, the system comprises an access management system (AMS) in communication with one or more machines each equipped with a biometric control switch (BCS) unit. The AMS comprises a computing device, a biometric reader connected with the computing device, a storage device connected with the computing device, a program module stored on the storage unit, and a communication module connected to the computing device. The program module has sets of code configured to instruct the biometric reader to scan the biometric feature of the operator and to create a digitized biometric signature. The program module is further configured to store the biometric signature on the storage device. The BCS unit comprises a computing device, a biometric reader connected with the computing device, a storage device connected to the computing device, a program module stored on the storage device, and a communication module connected with the computing device and capable of communication with the communication module of the AMS. The biometric reader of the BCS unit is adapted to detect the presence of the biometric feature of the operator and to scan and create a digitized biometric signature. The program module of the BCS unit is configured to allow the operator to turn-on the machine if the biometric signature matches the authorized biometric signature.

DESCRIPTION OF THE INVENTION

Referring toFIG. 1, the present invention is a system10that allows only authorized users to turn on specific equipment they are approved to use. System10maintains a record of the name of the user, date, time, and length of operating time. System10may store other information relating to the user and machines4,6, and/or8. System10generally comprises a central access management system (AMS)12and one or more machines4,6, and8each equipped with a biometric control switch (BCS) unit30. AMS12is a special purpose computer system having a program module21(to be described) running thereon. Similarly, BCS unit30is a special purpose computer system having a program module36(to be described) running thereon. Machines4,6, and8may be any type of commercial and/or industrial machine such as manufacturing equipment used in a factory having a defined work area or construction equipment used on a construction site covering a large or undefined area. AMS12and BCS units30communicate with each other over a conventional communication network9such as a wireless network or a hard wired network. The type of communication network9employed by system10depends upon the distance between AMS12and BCS units30. In applications where AMS12and BCS units30are in relatively close proximity such as a factory, the preferred communication network9is a wireless network and more specifically a WIFI® wireless local area network (LAN) employing a router (not shown). In applications where BCS units30are a significant distance from AMS unit12, cellular and internet networks would be the preferred type of communication network9. BCS unit30may be fabricated as part of machines4,6, and/or8by an original equipment manufacturer (OEM). In another embodiment, BCS unit30may be retro-fitted to existing machines4,6, and/or8.

Referring toFIG. 2, AMS12comprises a computer system14having a computing device16and a storage device18. In the embodiment shown, computing device16is a microprocessor that is commonly available. In the embodiment shown, storage device18is a hard disk drive that is commonly available. AMS12further comprises a database22configured and stored on storage device18. Database22may store various information or records relating to machines4,6, and8which can be updated and retrieved. This information may include, but is not limited to, the name of the authorized user or operator, date, time, and length of operating time. AMS12further comprises a program module21stored on storage device18. As will be described more fully herein, program module18comprises computer code or software used to configure and/or operate AMS unit12by providing instructions to computing device16. AMS12further comprises a communication device24for communication with BCS units30of machines4,6, and8. In a wireless WIFI® network application, communication device would be a WIFI® internal or external adapter card. In a cellular application, communication device would use data packets. AMS12further comprises a biometric device26adapted to store a unique biometric feature of an authorized employee or user of machines4,6, and/or8. In the embodiment shown, biometric device26is a fingerprint reader. Using biometric device26, the user's fingerprint is sensed, read, registered, encrypted, and digitally stored in database22. Although not shown, a system administrator has access to AMS12to specify, for example, which machines the authorized user has access to and over what time periods. In other embodiments, biometric device26may employ an iris recognition reader or system adapted to sense, read, register, encrypt, and digitally store an authorized user's iris in database22. In other embodiments, the user or operator of machines4,6, and8might be a robot rather than a person. In this situation, biometric device26would be tailored to read, register, encrypt, and digitally store in database22a feature that is unique to the robot.

Referring toFIG. 3, each BCS unit30generally comprises a computing device32and a storage device34. Each BCS unit30further comprises a database35configured and stored on storage device34. Database35may contain or store various information or records relating to the machine employing BCS unit30which can be updated during the course of the day and transmitted to AMS12over network9. This information may include, but is not limited to, the name of the authorized user or operator, date, time, and length of operating time. Each BCS unit30further comprises a program module36stored on storage device34. As will be described more fully herein, program module36comprises computer code or software used to configure and/or operate BCS unit30by instructing computing device32. In the embodiment shown, computing device32is a micro-controller that is widely available and storage device34is an EEPROM fabricated as part the micro-controller and programmed by well known means. In other embodiment, computing device32may be a microprocessor and storage device34may be a hard disk drive.

Each BCS unit30further comprises a biometric device38connected to computing device32. Biometric device38is adapted to sense and read a specific biometric feature of the user or operator. In the case of humans, the biometric feature may be a fingerprint or an eye. In the case where a user or operator is robot, the biometric feature may be some feature or code that is unique to the robot. In the embodiment shown, biometric device38has a fingerprint reader40. Fingerprint reader40reads and encrypts the user's fingerprint that is stored on fingerprint reader40. As will be described more fully herein, program module36instructs computing device32to check the user's fingerprint against authorized fingerprints stored on database35and will either signal the operator that he/she is authorized causing a signal to be sent to switching module50(to be described) turning on the machine or notify the user that she is rejected. In the embodiment shown, message notifications are conveyed to the user either by displaying a message using a display device46, status LEDs58, or generating an audible signal using an audio device54. Display device46may be take the form a variety of conventional display devices (2×16 LCS; 64×128 LCD; or 240×32 LCD) having select buttons or touch screen capability. Similarly, audio device54is commonly available.

Each BCS unit30further comprises a communication device42for communicating with AMS12over communication network9(FIG. 1). In a wireless WIFI® network application, communication device42would take the form of a WIFI® internal or external adapter card. In a cellular application, communication device42may take the form of a quad band cellular module.

Each BCS unit30further comprises a security layer device48adapted to provide an additional layer of security to biometric device38. In the embodiment shown, security layer device48may employ a radio frequency identification (RFID) reader that requires the user to present an object such as a tag or card for scanning by the reader to gain access to the machine. Security layer device48may also be a keyboard requiring the user to enter a password.

Each BCS unit30further comprises a start/stop button62connected to computing device32. Start/stop button62is adapted to allow the user to start or stop the machine after the user has been identified as an authorized user of the machine. The user is authorized if his/her fingerprint matches one of the authorized fingerprints stored in database35.

Each BCS unit30further comprises a switching module50connected to computing device32. Switching module50is also connected between an external power source2and machines4,6or8. Switching module50is adapted to receive a signal from computing device32indicative of either “turn on” or “turn off” of machine4,6, or8. Computing device32receives the “turn on” or “turn off” signal from activation of start/stop button62by the user. If switching module50receives a “turn on” signal from computing device32then external power source2is connected with the machine thereby turning it on. If switching module50receives a “turn off” signal from computing device32then external power source2is disconnected from the machine thereby turning it off. In the embodiment shown, switching module50has a power contactor or magnetic solenoid that is used to open and close an electrical connection between external power source2and the machine. In other applications, switching module50may employ a digital relay having a MOSFET diode or logic level output. The type of electro-mechanical and/or electrical circuit employed by switching module50will vary depending upon the type of machine.

Each BCS unit30further comprises a power supply52connected to computing device32. Power supply52provides an independent power source to the various components of BCS unit30. For applications where only an external AC power source is available, as might be typical in a factory, power supply52may take the form of an AC/DC converter. For applications where only a DC power source is available, as might be typical in farming equipment, power supply52may take the form of a DC/DC converter. In other embodiments, power supply52may take the form of a battery or a solar power supply. Power supply52is commonly available.

Each BCS unit30further comprises a download port56connected to computing device32. Port56may be used by an authorized person such as an administrator to download information stored in database35to an external storage device (not shown) for subsequent uploading to AMS12or for general back-up. Download port56is commonly available.

Each BCS unit30further comprises a LED module58connected to computing device32. LED module58provides the user with a visual color display of the status of a given function or operation of the machine such as “on”; “off”; “authorized”; or “unauthorized.” LED module58is activated by a signal from computing device32. LED module58is widely available.

Each BCS unit30further comprises a key switch60connected to computing device32. Key switch60allows the person to over ride biometric device38and/or security layer device48to gain access to the machine. In the embodiment shown, key switch60is adapted to receive a master mechanical key (not shown). When the master key (not shown) is inserted into key switch60and turned one way (for example clockwise) the person may power the machine by-passing biometric device38and security layer device48. Additionally, if BCS unit30is used as a stand-alone unit (i.e., without any AMS12) then the key (not shown) may be turned counter-clockwise causing fingerprint reader40to read, encrypt, and store a master fingerprint of the person on database35. Thereafter, the person having the master fingerprint may use the fingerprint reader40to gain access to BCS unit30and software stored on program module36may cause a menu to appear on display device46allowing the person to add additional authorized users by having their fingerprints read and encrypted by the fingerprint reader40and stored on database35.

Referring toFIG. 4, BCS unit30may configured as a retro-fit or add on to an existing machine rather than built as part of the machine by the OEM as depicted inFIG. 3. In the retrofit embodiment of the invention, BCS unit30comprises all of the same components as the OEM embodiment ofFIG. 3except for an internal switching module50or a start/stop button62. In the retrofit embodiment, start/stop button62is not employed as the user would utilize the existing start and stop buttons70of machine4. In the retrofit embodiment of the invention, each BCS unit30further comprises an amperage detection circuit64connected to computing device32and to a power switching unit (PSU)66(to be described). Detection circuit64is constructed of conventional circuitry to sense whether or not there is current draw or flow thru a switching module68(to be described) of PSU66and to send a steady-state digital or analog signal to computing device32indicative of whether or not a current is flowing thru switching module68. PSU66is physically separate from BCS unit30and is also directly connected to computing device32. Switching module68operates similar to switching module50for an OEM machine having a BCS unit30(FIG. 3). PSU66is installed to interrupt the power flow, such as in the power cord, such that switching module68is located between external power source2and machine4. Upon receipt of a signal from computing device32, switching module68is adapted to connect or disconnect machine4from external power source2. If switching module68is in a state where machine4is connected to external power source2then amperage detection circuit64will sense a current flow. If switching module68is in a state where machine4is disconnected from external power source2then amperage detection circuit64will not sense any current draw. As will be described more fully herein, if the machine switch happens to be in the “on” position, then BCS unit30will signal the operator to turn off the machine thereby reinitializing BCS unit30. This reduces the possibility of an unexpected machine start up giving an extra layer of safety. If the machine switch is in the “off” position, switching module68is then energized allowing the power to flow to the machine for normal operation. BCS unit30will allow a set number of seconds to start up the machine, after which time BSC unit30will disconnect PSU66. When the operator is finished running the machine, BCS unit30will sense there is no longer current to the machine and log the user, date, time, and amount of time the machine ran. This information is uploaded to AMS12when available or stored in database35until manually downloaded via port56.

Referring toFIG. 5, wherein a high level flow chart shows the process of program module21and AMS12. As shown by block102, an administrator logs into AMS12. The log in procedure may be accomplished by the administrator entering a username and password and/or using a biometric feature. Control is then passed to block104where an employee to be designated an authorized user of one or more machines4,6, and8places his/her finger (index finger or thumb) on fingerprint reader28of biometric device26where the fingerprint is read. Control is passed to block106where the fingerprint is digitized and saved in database22. Control is passed to block108where the administrator assigns or designates the user to one or more approved machines4,6, and/or8thereby becoming an authorized user of the assigned machine. Although not shown, software module21may be configured to allow the administrator to designate specific times of day, or number of times, that the user is an authorized user of one or more machines4,6, and/or8. Control is passed to block110where software module21is configured to instruct computing device16to transmit the updated user data from database22to BCS units30of machines4,6, or8. Although not shown, software module21may be programmed to provide transmission of updated user data each time an existing user's information is changed and/or a new user is added to database22or at specific times of the day or week. Control is passed to block112, where database22of AMS12is updated with new information transmitted by one or more BCS units30of machines4,6, and/or8. Control is passed to block114where the administrator logs out of AMS12. Although not shown, once the administrator does a change, it will send and receive whether or not the administrator is logged in. Updates will be program selectable, usually once a day during non-operating hours to collect data.

Referring toFIG. 6, wherein a high level flow chart shows the method or process of program module36and BCS unit30in the OEM embodiment (FIG. 3). Although applicable to any machine having BCS unit30, for ease of description, this process will be described with reference to machine4. As shown by block202, a prospective user of a machine such an employee places a finger (typically, an index finger or thumb) on finger print reader40associated with machine4. Control is passed to block204where a sensor (not shown) of fingerprint reader40detects that a finger has been placed on the reader for reading. Control is passed to block206where the user's fingerprint is digitized. Control is passed to block208where program module36instructs computing device32to compare the digitized fingerprint against authorized digitized fingerprints stored in database35of BCS unit30. Control is passed to a decisional block210where program module36instructs BCS unit30decide whether the digitized fingerprint matches one of the authorized fingerprints stored in database35. If the digitized fingerprint does not match one of the authorized fingerprints stored in database35then the user is not authorized and control is passed to block212where program module36instructs computing device32to activate display device46to display a message such as “User Denied.” Alternatively, or in conjunction therewith, program module36may instruct computing device32to activate LED module58to illuminate a red LED. Alternatively, or in conjunction therewith, program module36may instruct computing device32to activate audio device54where a beeper is sounded. Control is passed to block214where program module36instructs computing device32to reset all components of BCS unit30after a set period of time such as eight (8) seconds. Returning to decisional block210, if the digitized fingerprint matches one of the authorized fingerprints stored in database35then the user is authorized and control is passed to block216where display device46displays a message such as “User Approved” or LED Module58is activated to illuminate a green LED light and beeper54is activated. Control is passed to a decisional block220. As indicated by block220, BCS unit30determines if the user has activated start button62within a set period of time such as fifteen (15) seconds. This time period can be any given duration as dictated by, for example, the type of machine4. If the user has not activated start button62with the fifteen (15) second time period then control is passed to block222where the system is reset and control is returned to block202wherein BCS unit30waits to sense the presence of an user's finger. If the user has activated start button62with the fifteen (15) second time period then control is passed to block226where a signal is sent to computing device32which in turn activates switching module50thereby connecting external power source power2to machine4. Control is passed to block228where the user activates or pushes stop button62of BCS unit30which might occur when the user has completed a task or wishes to take a break or at the end of a complete work period on the machine. Control is passed to block229where activation of stop button62causes a signal to be sent to computing device32which in turn activates switching module50thereby disconnecting external power source power2from machine4. Control is then passed to a decisional block230where BCS unit30determines if a given time period, such as fifteen (15) seconds, has elapsed since activation of stop button62. This time period can be any given duration as dictated by, for example, the type of machine4. If the fifteen (15) second time period has not elapsed then control is passed to block232where BCS unit30determines whether or not start button62has been activated. If start button62has been activated within the fifteen (15) second time period then control is returned to block226where switching module50is activated thereby providing power back to the machine for continued operation by the same user. Returning to block232, if start button62has not been activated within the fifteen (15) second time period then control is returned to block230where the time period continues to be counted. As shown by decisional block230, if the fifteen (15) seconds has elapsed since stop button62was activated then control is passed to block236where the name of the user, date, time and length of operating time is recorded in database35of BCS unit30. Control is then passed to blocks238and242. As shown by block242, BCS unit30is reset and control is returned to block202where BCS unit30waits for another or the same user to place his/her finger on finger print reader40. As shown by block238, BCS unit30operates to send or otherwise transmit data to AMS12on the next network request or update. As shown by block240, if BCS unit30is used as a stand-alone unit then the data may be downloaded via port56.

Referring toFIG. 7, wherein a high level flow chart shows the method or process of program module36and BCS unit30in the retro-fit embodiment (FIG. 4). Although applicable to any machine having BCS unit30, for ease of description, this process will be described with reference to machine4. The steps of blocks202,204,206,208,210,212,214, and216are the same as the method or process of the OEM embodiment ofFIG. 6. In the retro-fit embodiment, after the step of block216, control is passed to block244rather than to decisional block220ofFIG. 6. As indicated by block244, switching module68of PSU66is activated by a signal received from computing device32thereby connecting external power source2to machine4. Control is passed to a decisional block246where amperage detection circuit64operates to detect whether or not a current is flowing thru switching module68. If amperage detection circuit64detects a current flowing thru switching module68then control is passed to block248where switching module68of PSU66is activated by a signal received from computing device32thereby disconnecting external power source2from machine4. Control is then passed to block250where a message such as “Turn Power Off” is displayed on display device46instructing the user to turn the power off by activating stop button70on machine4. Alternatively, or in conjunction therewith, a red LCD light of LED module58is activated and/or an audio beeper of audio device54is sounded for a given time period such as three (3) seconds. Control is passed to block252where BCS unit30is reset after a given period of time such as eight (8) seconds and control returns to block202. Returning to decisional block246, if amperage detection circuit64does not detect a current flowing thru switching module68then control is passed to block254where a timer generated by the microprocessor and read by the program module is set for a given period of time such as fifteen (15) seconds is started. Control is then passed to a decisional block256where BCS unit30operates to determine whether amperage detection circuit64detects current flow in switching module68within the fifteen (15) second time period. If amperage detection circuit64does not detect a current flow thru switching module68with the fifteen (15) second time period then control is passed to block258where a message such as “User Timed Out” is displayed by display device46and/or an audio beeper is sounded by audio device54for a given time period such as three (3) seconds. Control is passed to block260where the system is reset. If amperage detection circuit64senses a current flow thru switching module68with the fifteen (15) second time period (indicative that the user has activated start button70of machine4) then control is passed to block262where BCS unit30waits for the user to activate stop button70of machine4which might occur when the user has completed a task or wishes to take a break or at the end of a complete work period on machine4. Control is passed to block264where BCS unit30detects a power loss as a result of stop button70being activated by the user. The loss of power to machine4is detected by amperage detection circuit64sensing a loss of current flow thru switching module68. Control is passed to a decisional block266where BCS unit30determines whether or not a current flow thru switching module68is detected by amperage detection circuit64within a given time period such as fifteen (15) seconds. This check is necessary for circumstances where the user may wish to activate stop button70for a short time without having to log off BCS unit30. The specific time period is dependent upon the type of machine4. If a current flow thru switching module68is detected within the specified time period then control is returned to block262where BCS unit30waits for the user to activate stop button70of machine4. Returning to decisional block266, if a current flow thru switching module68is not detected within the specified time period then control is passed to block234where switching module68is activated by computing device32thereby disconnecting machine4from external power source2(FIG. 4). Control is passed to block236where the name of the user, date, time and length of operating time is recorded in database35of BCS unit30. Control is then passed to blocks238and242. As shown by block242, BCS unit30is reset returning control to block202where BCS unit30waits for another or the same user to place his/her finger on finger print reader40. As shown by block238, BCS unit30operates to send or otherwise transmit data to AMS12on the next network request or update. As shown by block240, if BCS unit30is used as a stand-alone unit then the data may be downloaded via port56.

The foregoing description is intended primarily for purposes of illustration. The invention may be embodied in other forms or carried out in other ways without departing from the spirit or scope of the invention.