System and process to ensure performance of mandated safety and maintenance inspections

A handheld, portable device is used to store data that indicates an operator was sufficiently close to each of a plurality of components during a safety inspection to actually inspect the components. The portable device includes a sensor that detects tokens, such as radio frequency identification tags, which are affixed adjacent to the components. Messages appearing on a display of the portable device prompt the operator to proceed to each checkpoint, determine a state of the component disposed there, and if the component is not operating properly, indicate a plurality of predefined conditions from which the operator can choose to identify the observed condition of the component. The state and condition of each component entered during the safety inspection are stored as data that are subsequently transferred to a remote data storage site over a wire or wireless link.

BACKGROUND

It is widely accepted that a significant reduction in accidents involving commercial trucks and trailers is likely to be achieved by ensuring that key components of such equipment are inspected on a regular basis. Such inspections can detect worn tires and brakes before they cause an accident.

To avoid accidents caused by defective equipment, Federal law presently requires that commercial drivers make a visual inspection of specific components on a truck (i.e., tractor and trailer), such as the brake system, fuel system, warning lights, tires, etc., performing pre- and post-trip inspections of these basic, but critical components. An exemplary vehicle inspection report listing the components and systems that must be inspected by a driver to satisfy the DOT regulations is illustrated inFIG. 7. However, under the current system, a driver is only required to fill out a paper log and keep it on file for 90 days. Many experts report that less than half of the drivers ever perform the check. Instead, many drivers simply fill out the report while seated in the cab of the truck or in a coffee shop. The report is meaningless unless the listed components and systems have actually been inspected. For example, a driver who fails to actually inspect components on his vehicle will fail to detect that brake fluid is leaking from a hydraulic master brake cylinder. As a result, the brakes on the driver's truck may fail, potentially causing a serious accident.

A signed inspection report does not provide any assurance that a driver actually inspected the components included on the report. It would be desirable to provide technology to at least ensure that a driver (or other person doing an inspection) was physically present in the vicinity of each component requiring inspection, even if the driver is not compelled to affirmatively inspect all of the components. Most people, if required to actually walk to a component such as a tire of a truck, will then be more willing to at least look at the condition of the component, particularly if the task of indicating the condition of the component if there is a problem, is made relatively simple and efficient.

Encouraging safety inspections of equipment by creating a record providing evidence that a person doing the inspection actually visited each component that must be inspected has utility in many other applications and for many other types of equipment than trucks in the transportation industry. The concept is also useful in confirming the safe operating condition of machinery and components in other systems in which accidents related to equipment malfunction and failure must be avoided. For example, such a need exists in high-risk chemical and petrochemical operations, where periodic inspections of valves, pressure vessels, gages, and other components must be carried out to avoid potentially disastrous and costly accidents in which significant loss of life and property might occur.

SUMMARY

This application specifically incorporates by reference the disclosures and drawings of each patent application and issued patent identified above as a related application.

Disclosed herein are a method is defined for providing a record indicating that a location or component of a vehicle or other type of apparatus or system was visited during an inspection. In this method, a portable device is provided for use in recording data related to the inspection. The portable device includes a sensor that produces a signal indicative that an operator has positioned the portable device proximate a location or component. A record of the signal produced by the sensor is made and is stored within the portable device, providing evidence that the operator was sufficiently close to the location or component to make an inspection of the location or component.

The method further includes the step of enabling the operator to store an indication of a condition of the location or component in the portable device. Preferably, the portable device provides a prompt that indicates the location or component the operator is to inspect. After the operator has inspected the location or component, a plurality of different states of the location or component are displayed to the operator, enabling the operator to select the state observed during the inspection. If the location or component needs servicing or is unusable, the operator can select one of a plurality of different possible conditions to indicate an observed condition of the location or component. A record of the condition selected by the operator is then stored in the portable device. The record of the signal, the state, and any condition selected by the operator are transferred from the portable device to a more permanent storage at a remote site that is separate from the portable device, either immediately after the inspection or at a later time. Preferably, each record is transmitted to the remote site using a data signal conveyed over a wire network and/or a wireless network.

The method further includes the step of affixing a token adjacent to the location or component. The sensor responds to the token to detect when the portable device is proximate the location or component. The token causes the signal produced by the sensor to identify the location or component, e.g., a specific tire on a vehicle or a specific system component of a system or other apparatus, or a particular location. In most applications, a plurality of tokens are provided, each token being associated with and affixed adjacent to a different one of the plurality of components or locations. The token then causes the signal produced by the sensor to identify the location or component when the portable device is proximate the location or component associated with the token. Also, different predetermined ranges can be specified for the plurality of location or components, so that an appropriate predetermined range can be specified for each location or component.

Another aspect of the concepts disclosed herein are directed to a system for providing evidence that a plurality of components were visited during an inspection. The system includes a plurality of tokens, each of which is associated with a different location or component that is to be checked during the inspection and affixed adjacent to the location or component. Also included in the system is the portable device, which is adapted to be transported to each location or component to be inspected during the inspection. The portable device includes a housing, a display, an operator interface, and a memory in which machine instructions and data are stored. A sensor included with the portable device detects when the portable device is proximate each of the plurality of tokens, and thus, within a predetermined maximum distance from each of the locations or components with which the plurality of tokens are separately associated. The sensor then produces a signal indicative that the portable device is within the predetermined maximum distance from the location or component. A controller is coupled to the display, the memory, the operator interface, and the sensor and executes the machine instructions causing the memory to store data indicative of each component visited during the inspection in response to the signal produced by the sensor. Other functions implemented by the system are generally consistent with the steps of the method described above.

This Summary has been provided to introduce a few concepts in a simplified form that are further described in detail below in the Description. However, this Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

DESCRIPTION

Figures and Disclosed Embodiments are not Limiting

Exemplary embodiments are illustrated in referenced Figures of the drawings. It is intended that the embodiments and Figures disclosed herein are to be considered illustrative rather than restrictive. No limitation on the scope of the technology and of the claims that follow is to be imputed to the examples shown in the drawings and discussed herein.

Utility of the Concepts Disclosed Herein

The concepts disclosed herein are applicable in recording data resulting from a safety inspection of almost any type of equipment, apparatus, or system and is applicable to other types of inspections in which it is desirable to maintain a data record as evidence that the person making the inspection was actually physically present at a checkpoint or component requiring inspection. While the data accumulated with the concepts disclosed herein are not conclusively presumptive evidence that each component of a system was indeed carefully inspected, in most cases, if a person is required to visit a checkpoint or component, it is very likely that the person will actually inspect the component. By encouraging a person making an inspection to be physically close enough to a component to carry out an inspection, and by providing evidence of that fact in the data recorded, there is at least a justifiable presumption that the person actually did the inspection.

FIG. 1illustrates a tractor-trailer10with which an embodiment of the concepts disclosed herein are usable to carry out a safety inspection. Tractor-trailer10is provided with a plurality of tokens affixed adjacent to each checkpoint or component that is to be inspected. While only a few of the tokens are illustrated inFIG. 1,FIG. 7lists all of the components or systems that should be inspected if a driver is to be in compliance with the DOT regulations regarding pre- and post-inspections of such vehicles. A token will be affixed adjacent to the components and systems listed inFIG. 7, although several components might be associated with the same token. For example, in the engine compartment, one token might be used for both the radiator and the belts. As a driver moves about the tractor and trailer, evidence that the driver or the person doing the inspection moved sufficiently close to the components being inspected so that the inspection could actually take place is recorded in a portable device20. Further details of portable device20are described below.

For the few tokens illustrated inFIG. 1, the relevance of the disposition of the token adjacent to a corresponding component of the tractor-trailer10should be evident. For example, token12is disposed adjacent to tandem dual rear tires14on the trailer. Since all the tires of the tandem dual rear wheels on the left rear of the trailer are readily visible from a position adjacent to token12, a single token is sufficient to determine that the driver was sufficiently close so that all four tires at the left rear of the trailer could be readily inspected. Similarly, tandem dual wheels18on the left rear of the tractor are readily inspected when an observer22is positioned as shown inFIG. 1. In this position, the observer moves portable device20within a maximum predefined range of token16, which is exposed above tandem dual wheels18. Portable device20, detects and responds to token16, recording data indicating that the driver was in a position to inspect tandem dual rear wheels18on the tractor. It is contemplated that the operator may initiate the recognition of a token by activating a switch, or the portable device can instead simply respond when a token is sufficiently close to the portable device.

Other tokens24,26,30, and32are illustrated adjacent other components of the tractor that are part of the safety inspection. For example, token26is affixed adjacent a tire28on the right front of the tractor, while tokens30and32are accessible if the front hood of the tractor is opened and are disposed adjacent the hydraulic brake master cylinder and the engine belts/radiator, respectively (not shown separately).

For each token there is a predetermined maximum distance that portable device20can be held from the token that will enable the portable device to detect the token, and thus the component that is associated with it in order to produce a record as evidence that the person holding the portable device was in a position to inspect the component. Depending upon the component to be inspected and the type of token, different predetermined maximum distances may be assigned to the various components. The different predetermined maximum distances might be implemented by partially shielding a token to vary the distance at which the portable device can detect the token.

Operator20is prompted to approach the next component in a series of components that must be checked during the safety inspection by a message58appearing on a display40of portable device20, as shown inFIG. 2. For example, if operator22has just completed the inspection of tandem dual tires14on the left rear of the truck, display40provides a prompt58indicating that the operator should “verify tire condition—left rear of tractor.” A sensor46on portable device20responds to token16when the portable device is held less than the predetermined maximum distance from token16by producing a signal indicating that the portable device was within the required range of tandem dual tires18to enable the operator to inspect the tires. Display40also provides a prompt60to operator22requesting that the operator indicate whether the tire condition is okay. If so, the operator presses a green control button52corresponding to the message “YES, OK.” However, if during the visual inspection of the tires the operator determines that they require servicing, the operator is prompted to depress a yellow control button54on the portable device. Certain conditions such as a tread separation or a nail or other sharp object lodged in the tire would likely lead the person doing the inspection to depress a red control button56, indicating a safety problem that requires the operator to refer to a supervisor who will likely elect to delay the trip until the tire is repaired and/or replaced or take other appropriate action depending upon the nature of the component and the type of problem that makes the component unsafe to use. Portable device20also includes a cursor control50, which is a four-position switch that enables a cursor (not shown in this figure) to be moved up or down, and left or right. Cursor control50, green, yellow, and red control buttons52,54, and56and display40are all disposed on a front surface of a housing42of portable device20. Sensor46is disposed on the top edge of housing42, while an optional universal serial bus (USB) port48is disposed on the edge of housing42, opposite from sensor46.

An antenna44is also disposed on the top edge of the housing for transmitting radio frequency (RF) transmissions to a remote data storage site61that is used for long-term storage of data resulting from safety inspections. The data produced by a safety inspection indicates each of the components of the vehicle (or other system or apparatus being inspected) that were visited by the operator, so that the portable device was positioned within the predetermined maximum distance from the token associated with the component, and also indicates the status of the component. In the event that the component appears to need service or represents a safety problem (as would be evident if the operator depressed yellow control button54or red control button56, respectively), the operator is prompted to select one of a plurality of predefined conditions that justify the state of the component determined by the operator and best represent its observed condition.

If the state of the component is okay so that green control button52is depressed, i.e., if the component does not require any service and is usable or otherwise within its nominal operating parameters, there is no need to provide an indication of the condition of the component. The condition need only be recorded as part of the data stored in the portable device if either yellow control button54or red control button56is depressed by the operator to indicate the state of the component being other than “OK.”

A further example illustrating the selection of a condition relating to the example shown inFIG. 2is included inFIG. 4. As shown inFIG. 4, if the operator has indicated that the state of the tires is such that they need service by pressing yellow control button54, portable device20automatically displays several possible conditions that would have led an operator to indicate that state. In the example shown, message58prompts the operator to use the arrow button (i.e., cursor control50) to select a possible condition from among the listed options that best describes the observed condition of the tires. Display40includes five possible conditions, the last of which covers any condition that might not be included among the first four that are listed. Using cursor control50, the operator can move the cursor to the displayed statement that best describes the observed condition of the tire and then can depress red control56, which corresponds to an “Enter” menu option70on display40for this screen. Green control52can be depressed to select a “Previous” display, if the operator elects to reconsider the state of the component that was previously selected.

FIG. 3illustrates functional components60that are included in portable device20, either on or inside housing42. A central processing unit (CPU)62comprises the controller for portable device20and is coupled bi-directionally to a memory64that includes both random access memory (RAM) and read only memory (ROM). Memory64is used for storing data in RAM and machine instructions in ROM that control the functionality of CPU62when executed by it. CPU62is also coupled to receive operator input from controls68. Collectively, controls68include green control button52, yellow control button54, red control button56, and cursor control50. In addition, CPU62provides text and graphics to display40for the prompts and other messages, and menu items and options from which the operator can select using cursor control50.

After operator22has visited each of the checkpoints required for the safety inspection, the operator can optionally transmit the data that has been collected during the inspection to remote data storage site61through a RF transmission via antenna44. The data provide evidence that the operator has visited the components and indicate the state and condition of the components that were visited and inspected. Alternatively, optional USB port48on portable device20can be coupled to a network interface63on an external cradle (not shown), which is in communication with remote data storage65, as shown inFIG. 2. InFIG. 3, CPU62is shown communicating data to transmitter66(or through another data link) using a wire and/or wireless data communication link. The data collected and stored in memory64of portable device20during the safety inspection can thus be safely transferred to the remote data storage site and retained for as long as the data might be needed.

In some cases, it may be preferable to transmit the data to the remote site immediately after making a safety inspection to ensure that the data retained in memory64are not lost should an accident occur that destroys portable device20. An accident destroying the evidence that the safety inspection was implemented could have an adverse effect during any litigation related to the accident. However, since the risk of such an accident is relatively remote, it is contemplated that an operator may collect the data from a number of safety inspections in memory64and then subsequently upload the data to remote data storage65by coupling the data to a cradle (not shown) that includes a USB port terminal and network interface. The cradle might be maintained by a carrier at a freight terminal.

Alternatively, the cradle might be disposed at a different site and/or connect to the remote data storage site through other types of communication links. One example of such a communication system is the OMNITRACS™ satellite mobile communication system sold by Qualcomm Corporation that enables drivers on the road and carriers to remain in communication with each other and enables the carrier to monitor the location of a tractor-trailer during a trip. By linking portable device20through USB port48to such a data communication system, the data stored within memory64can readily be transmitted to a remote site maintained by the carrier for long-term storage, even while a trip is in progress.

The tokens that are affixed at various points on the tractor-trailer (or adjacent components of other types of systems or apparatus unrelated to a vehicle) can be of several different types, depending upon the type of sensor46that is included on portable device20. In a preferred embodiment, the token that is preferably employed is a radio frequency identification (RFID) tag that is attached with a fastener or an adhesive to a point on a frame or other support (not shown) adjacent to the component associated with the token. One type of RFID tag that is suitable for this purpose is the WORLDTAG™ token that is sold by Sokymat Corporation. This tag is excited by an RF transmission from portable device20via antenna44. In response to the excitation energy received, the RFID tag modifies the RF energy that is received from antenna44in a manner that specifically identifies the component associated with the RFID tag, and the modified signal is detected by sensor46.

An alternative type of token that can also be used in this invention is an IBUTTON™ computer chip, which is armored in a stainless steel housing and is readily affixed to a frame or other portion of the vehicle (or other type of apparatus or system), adjacent to the component associated with the IBUTTON chip. The IBUTTON chip is programmed with JAVA™ to provide a recognition signal when interrogated by a signal received from a nearby transmitter, such as from antenna44on portable device20. The signal produced by the IBUTTON chip is received by sensor46, which determines the type of component associated with a token. This type of token is less desirable since it is more expensive, although the program instructions that it executes can provide greater functionality.

Yet another type of token that might be used is an optical bar code in which a sequence of lines of varying width encode light reflected from the bar code tag. The encoded reflected light is received by sensor46, which is then read by an optical detector. Bar code technology is well understood in the art and readily adapted for identifying a particular type of component and location of the component on a vehicle or other system or apparatus. One drawback to the use of a bar code tag as a token is that the bar code can be covered with dirt or grime that must be cleaned before the sequence of bar code lines can be properly read. If the bar code is applied to a plasticized adhesive strip, it can readily be mounted to any surface and then easily cleaned with a rag or other appropriate material.

Yet another type of token usable in the concepts disclosed herein are a magnetic strip in which a varying magnetic flux encodes data identifying the particular component associated with the token. Such magnetic strips are often used in access cards that are read by readers mounted adjacent to doors or in an elevator that provides access to a building. However, in the concepts disclosed herein, the magnetic flux reader comprises sensor46on portable device20. The data encoded on such a token is readily read as the portable device is brought into proximity of the varying magnetic flux encoded strip comprising such a token.

As yet another alternative, an active token can be employed that conforms to the BLUETOOTH™ specification for short distance data transfer between computing devices. However, it is likely that the range of the signal transmitted by the token would need to be modified so that it is substantially less than that normally provided by a device conforming to the BLUETOOTH specification. It is important that the portable device be able to detect that it is proximate to the component only within a predetermined maximum range selected to ensure that the operator is positioned to actually carry out an inspection of the component.

Logical Steps Implemented in the Concepts Disclosed Herein

FIG. 5illustrates the logical steps implemented in connection with the concepts disclosed herein to carry out a safety inspection of a vehicle or other apparatus or system. From a start block80, a step82provides for manual entry of an operator identification (ID) into a data record, or the operator ID can already be stored in memory of the portable device, or can be automatically entered in response to a special operator ID tag disposed on the vehicle. Cursor control50is employed to sequentially select digits from a displayed list, to input the operator ID for the individual making the safety inspection. The operator ID might be a four (or more) digit number or alphanumeric code. Alternatively, a plurality of possible operator IDs might be displayed as a list on portable device20, enabling the operator to select his/her operator ID from the list using cursor control50and one of the three control buttons.

Once the operator ID is entered, portable device20prompts the operator to proceed to a first inspection point. For example, as indicated inFIG. 2, message58prompts the operator to verify the tire condition on the left rear of the tractor. A decision step85determines if the portable device has detected the token associated with the component that is next to be inspected. If not, the logic loops until the component is detected. Once sensor46on portable device20has detected the token associated with the current component to be inspected, the logic then advances to a step86in which the operator is prompted to indicate a state of the component (and possibly, its condition). In a step88, the operator performs the inspection, which may involve visually observing the state and condition of the component, or carrying out other steps that might be required to confirm the state and condition of the component. It is contemplated that in some types of inspections, a series of steps might be required to test the component to determine if it is operating properly, needs maintenance or repair, or is unusable. Again, portable device20can be programmed to provide appropriate prompts to direct the operator through a series of steps required to carry out the inspection of such a component. Accordingly, in a step90the operator selectively enters the condition of the component into portable device20using the control buttons and cursor control50.

A decision step92determines if there are further inspection points in the safety inspection being carried out. If not, a step94provides for transmitting or loading the inspection data into storage at a remote site; this step can be done immediately after the inspection is completed, or at some later time, perhaps after additional safety inspections have been completed. Once the data are transmitted to the remote site for long-term storage, the process is completed in a step96.

Assuming that further inspection points remain in the safety inspection at decision step92, a step98provides for the operator to proceed to the next inspection point, which will again be determined by a prompt displayed to the operator on display40of portable device20. The logic then loops back to decision step85, which determines if the sensor on the portable device has detected the component, indicating that the portable device is within the predefined maximum range of the token, thus ensuring that the operator is sufficiently close to the component to inspect it.

Further details of step90are illustrated inFIG. 6. From a start block100, a decision step102determines if the inspected component is okay. If so, the operator presses green control button52in a step104. Since the component is okay, nothing further is required for that component, and the logic then proceeds to a step106, which provides that the operator can continue with the inspection, i.e., proceed with decision step92inFIG. 5.

However, if the determination in decision step102indicates that the inspected component is not okay, a decision step108enables the operator to determine if immediate attention is required. If so, the operator presses red control button56at a step110and enters the condition of the component on the handheld unit. For example, if the operator is inspecting a tire and determines that the tread of the tire is separating, the tire should not be used, but should instead be replaced, the operator would use the cursor control on the portable device to select an option for the condition “tread separating from tire” at a step112. In most inspections, the operator would be required to contact a supervisor for instructions regarding the safety condition at a step114. In the example just noted, the supervisor would likely arrange for the tire to be replaced by maintenance or repair personnel.

In some cases, a supervisor might override the operator's determination of the state of the component based upon the reported condition. Therefore, a decision step116determines if the supervisor has given authorization to the operator to make the trip, scheduling a later repair of the component. If so, the logic proceeds to step106, in which the operator continues with the inspection as described above. If not, there is no further need to inspect the remainder of the vehicle at that point, since the complete inspection will need to be carried out again after the unsafe condition has been corrected, e.g., by replacing the defective tire. The logic is then done, as indicated in step118.

In the event that the operator determines that immediate attention is not required at decision step108, at a step120, the operator presses yellow control button54on portable device20. The operator then selects and enters the condition noted on the portable device, as indicated in a step122. In the example shown inFIG. 4, six possible conditions are indicated by statements on display screen40for a tire that is still usable but needs service. In this case, the operator employs cursor control50to move the cursor to a selected statement that thus describes the observed condition of the component and then depresses red control button56to enter the condition, creating a record of the state and condition of the component currently being inspected that is retained within the memory of the portable device. Thereafter, the logic proceeds to step106, in which the operator continues with the inspection.

Alternative to Portable Device

While it is likely that an initial preferred embodiment will employ portable device20, it is also contemplated that an accessory might be provided for a personal digital assistant (PDA), such as the PALM™ PDA, that would enable the PDA to be used for the same functions as portable device20. The accessory to the PDA will include a sensor to detect when the PDA is within the predetermined maximum range from the token associated with the component currently being inspected. The conventional controls on the PDA can be used to make and enter a selection. Furthermore, instead of using a cursor control, it is also contemplated that a touch screen display might instead be used for making selections of menu items and other options presented to the operator. In addition, the PDA would need to be programmed to carry out the functions implemented by portable device20, as described above.

Other Applications of the Concepts Disclosed Herein

Although the concepts disclosed herein will initially be used in connection with safety inspections of tractors and trailers in the commercial trucking industry, there are many other types of safety inspections unrelated to vehicles in which it is equally applicable. For example, in a chemical processing plant or a petroleum refinery it is common for technicians to make periodic safety inspections of valves, gauges, reactors, pressure vessels, and other types of processing equipment and system components to ensure that they are operating properly and within nominal or acceptable limits. During an inspection, a technician may note that a valve is leaking slightly, and schedule it for repair or replacement at a later date. Clearly, if the leak is of a non-hazardous substance and is insignificant in volume, there might well be no reason to shut down the process line in which the valve is installed simply because of the leaking valve. However, if the valve is used in controlling an extremely hazardous or toxic substance, even a small leak may be unacceptable. In this case, the technician should immediately report the condition to a supervisor who would then likely shut down the process or divert the flow of hazardous substance to a different process line to enable the condition to be corrected by immediate replacement or repair of the valve. Based upon the preceding discussion that discloses how a first preferred embodiment of the concepts disclosed herein are used in recording data related to safety inspections of a vehicle, it should be evident that portable device20is also readily adapted to recording data from other inspections. In the example just noted, a technician would be prompted to inspect the valve, and once the portable unit was within a predetermined distance of the valve, would be prompted to indicate a state of the valve. If the technician depressed either yellow control button54or red control button56, the display would provide a menu of possible conditions from which the technician could select, using cursor control50and red control button56to indicate the observed condition of the valve.

Although the concepts disclosed herein have been described in connection with the preferred form of practicing them and modifications thereto, those of ordinary skill in the art will understand that many other modifications can be made thereto within the scope of the claims that follow. Accordingly, it is not intended that the scope of these concepts in any way be limited by the above description, but instead be determined entirely by reference to the claims that follow.