Equipment data sensor and sensing for fleet management

Embodiments of the invention are directed to an equipment data sensor arranged on a powered machine. The equipment data sensor includes a processing device coupled to one or more sensors for obtaining values of at least one parameter associated with running of the powered machine, a memory, and a short range transceiver configured for wireless short range communication arranged to receive short distance communication signals, wherein the processing device is configured to register, in the memory, one or more values of the at least one parameter and an associated operator identifier received over the short range transceiver.

BACKGROUND

Outdoor power equipment is widely used for performing maintenance operations and modifications of land areas, including landscaping, forest care, lawn mowing, etc. Examples of such equipment include string trimmers, brush cutters, chain saws, blowers, aerators, spreaders, sprinklers, edgers, dethatchers, riding lawn mowers, walk behind lawn mowers, robotic lawn mowers, other cutting machines, etc. Usually the equipment is operated and controlled by an operator performing various actions in the area being worked and, in many situations, particularly in cases of professional use, at least two operators are working together in the same land area. In cases of large scale maintenance work with a fleet comprising multiple operators, e.g., as in landscaping industries, it may be difficult to keep track of the many operators and machines involved in a maintenance operation. Likewise it may be complicated to keep informed about the status of individual machines that are part of the fleet. This can lead to a situation where it is more or less impossible to be updated on the general performance of a machine fleet (e.g., how the different machines have been handled, the amount of working hours, performance, efficiency, etc.) and it may also become difficult to know the operational status (e.g., repairs, maintenance, cost of operation) of individual machines. This may cause additional costs related to repairs and downtime.

Another challenge related to fleet management is the amount of turnover of workers and the frequency with which inexperienced newcomers are placed in charge of a machine. Often there is a start-up period during which a beginner will be relatively inefficient. It may be difficult to monitor the beginner and provide the beginner or even other workers with detailed feedback regarding technique and machine operation simply because it is very inefficient to keep a constant watch during progressing working operation. Even after finishing an activity, it may be hard to provide constructive advice. Therefore worker training often takes much longer than desired. This may lead to inefficient and unsafe use of the machine, increased emission and fuel consumption, and increased wear and tear on the equipment.

Large-scale maintenance work such as landscaping, foresting, and ground care often involves a number of operators working in parallel leading to a very dynamic and continuously changing operative situation. Such a situation can easily get complex and may even involve a safety risk. For example, when several persons are spread out in an area it may be difficult for the individual person to keep track of surrounding co-workers due to characteristics of the landscape, noise levels, and reduced visibility. Under these conditions, two or more operators may accidentally get too close and interfere with each others work. This could lead to damage to the equipment and, in a worst case scenario, injury to the personnel.

SUMMARY OF SOME EMBODIMENTS OF THE INVENTION

Some embodiments of the present invention provide a fleet management system which is cost efficient, intuitive and easy to implement, and which is suitable for a dynamic fleet comprising often a plurality of operators handling a plurality of powered machines, such as in the case of professional grounds care, landscaping, forest work, etc. It is, therefore, an object of some embodiments of the invention to provide a system that assists with collection of informative data related to the running of individual powered machines, and to use this collected data to evaluate the performance and status of the machine. It is a further object of some embodiments of the invention to provide a quick, efficient, and automated way of pairing a specific machine to a specific operator who has been running the machine, thereby being able to match the performance of the machine to the behavior of a specific operator and evaluate the operator's performance, e.g. for training purposes. It is a further object of some embodiments of the invention to provide a fleet management system for monitoring a fleet comprising a plurality of operators handling a plurality of powered machines, where the fleet management system provides a situational awareness regarding productivity, efficiency, health, safety, service status, quality, location, etc., of the fleet including the fleet's equipment, operators, teams, customers, jobs, etc. Another object of some embodiments of the invention includes achieving one or more of the above objects in a more cost effective manner. Other objects of various embodiments of the invention will become clear from the following description and drawings.

More particularly, for example, some embodiments of the invention provide an equipment data sensor arranged on a powered machine. The equipment data sensor includes a processing device coupled to one or more sensors for obtaining values of at least one parameter associated with running of the powered machine, a memory, and a short range transceiver configured for wireless short range communication arranged to receive short distance communication signals, wherein the processing device is configured to register, in the memory, one or more values of the at least one parameter and an associated operator identifier received over the short range transceiver.

Additional embodiments of the invention provide a revolutions per minute (RPM) sensor including an RPM antenna configured to sense RPM based at least in part on sensing electromagnetic waves created by pulses from an ignition cable of a powered machine when an engine is running.

Further embodiments of the invention provide a method for monitoring the running of a powered machine. The method includes capturing data regarding the powered machine using one or more sensors installed on the powered machine, capturing an operator identifier associated with an operator of the powered machine, and transmitting the data regarding the powered machine and the operator identifier to a remote server.

Other embodiments of the invention provide a method for sensing RPM of a powered machine component. The method includes sensing electromagnetic waves created by pulses from an ignition cable of a powered machine when an engine is running and determining RPM based at least in part on the electromagnetic waves.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Fleet Management System

Embodiments of the invention are directed to and/or facilitate systems for assisting with management of a fleet of outdoor power equipment and/or equipment operators. Therefore, embodiments of the invention are directed to systems for collecting, communicating, processing, and/or presenting data related to outdoor power equipment, operators of the equipment, and/or tasks performed by the equipment. Although the term “fleet” is used herein to describe the system, it will be appreciated that, depending on the user of the system, the “fleet” may comprise many machines of many different types with many different operators, or, for some users, may comprise only one or two machines with only one or two operators. Furthermore, although embodiments of the invention described herein have often been particularly configured for use with outdoor power equipment, some embodiments, aspects, and/or components of the invention may have broader applicability and may be similarly used to sense and/or manage information from and/or about other types of machines and/or the operators of the machines.

FIG. 1illustrates a high-level view of a fleet management system100according to some embodiments of the invention. The fleet management system100generally includes: (1) a data collection and communication system110for collecting data from the equipment and the equipment operators and communicating the data to a central location; and (2) a data management and presentation system150for receiving the collected data, processing the collected data into useful data and formats, and presenting the processed data to persons or systems that can utilize the data for management of the equipment and/or operators.

The data collection and communication system110is, in some embodiments, applied in connection to land maintenance and/or modification operations, including such operations as landscaping (e.g., lawn mowing, edging, trimming, aerating, clipping, clearing, seeding, concrete or stone cutting, etc.) and forest care (e.g., forest thinning, clearing, brush cutting, etc.). These operations may be undertaken by a fleet owner101who owns a fleet of one or more pieces of equipment. The fleet owner101may be one or more individual persons or a company. The equipment may include, for example, a handheld trimmer121, a ride-on lawn mower122, a chainsaw123, and a walk-behind lawn mower124. It will be appreciated that, in some embodiments, the equipment may be any outdoor power equipment, or even any other type of equipment, including (without limitation) zero-turn riding mowers, articulating riding mowers, lawn tractors, robotic lawn mowers, string trimmers, edgers, hedgers, brush cutters, chainsaws, walk-behind lawn mowers, aerators, tillers, dethatchers, seeders, spreaders, sprayers, stump grinders, stone/concrete cutters, blowers, sprinklers, and/or the like.

Except in the case of robotic equipment, the equipment is typically operated by one or more operators, who may be different persons from (e.g., employees of) or the same person as the fleet operator101. In the illustration, the handheld trimmer141is operated by one operator145, the riding lawn mower142is operated by another operator146, the chainsaw143is operated by another operator147, and the walk behind mower144is operated by yet another operator148.

According to the embodiment shown inFIG. 1, the data collection and communication system110comprises an equipment data sensor installed in each piece of equipment, an operator identification unit uniquely associated with each operator; and one or more communication units. For example, inFIG. 1, the handheld trimmer141has an equipment data sensor121installed therein/thereon, the riding lawn mower142has another equipment data sensor122installed therein/thereon, the chainsaw143has another equipment data sensor123installed therein/thereon, and the walk behind mower144has yet another equipment data sensor123installed therein/thereon. The equipment data sensors gather data about the status and operation of the equipment on which it is installed and, in some embodiments, may also gather data about the equipment's environment, including data about the equipment's operator and other nearby persons and equipment. The equipment sensors may be installed in the equipment during manufacture of the equipment or, in some embodiments, may be after-market additions to the equipment. In some embodiments the equipment data sensor is a self-powered (e.g., battery-powered) universal sensor that can be installed on different types of equipment with little or no modification to the sensor and/or the equipment, while in other embodiments the equipment data sensor may be specifically tailored for one or more particular types of equipment and/or integrated into the equipment's hardware. Embodiments of the equipment data sensors will be described in more detail below.

As also illustrated inFIG. 1, each operator has an identification (ID) unit associated with an operator ID code that uniquely identifies the operator. In this regard, the operator145of the trimmer141has an ID unit131, the operator146of the riding mower142has another ID unit132, the operator147of the chainsaw143has another ID unit133, and the operator148of the walk behind mower144has yet another ID unit134. The ID unit may be, for example, a data card that the operator holds in a clothing pocket or on a lanyard. In other embodiments, the ID unit may be a key fob, wristband, ankle band, ring, watch, dongle, and/or other wearable article. In still other embodiments, the ID unit is a data unit stored on the operator's mobile phone116, as also illustrated inFIG. 1. Embodiments of the ID units will be described in more detail below. The operator ID code may uniquely identify a particular operator by way of being unique amongst the ID codes in existence of at least amongst those used in a particular fleet or area, thereby allowing the ID code to uniquely identify the operator that is carrying the ID unit in which the ID code is stored. The fleet management system may or may not have a database associating each ID code with actual operator names and, in some embodiments, may only uniquely identify the operator using the actual ID code or some other particular code that a user can then, on his or her own, link to an operator name.

Each equipment data sensor is configured to identify any ID units within a predetermined range (e.g., within range of a radio-frequency antenna in the equipment data sensor) and, in some embodiments, the equipment data sensor wirelessly obtains an ID-code stored in each ID unit within a particular range. In this way, the equipment data sensors can store information about which operator is using or is near each piece of equipment at different points in time. For example, the equipment data sensor123in the chainsaw143may periodically look for any ID units within range of its wireless transceiver and, in doing this, identify the ID unit133held by the operator147of the chainsaw143. The equipment data sensor123may store this information along with other equipment and environment data that it periodically collects. Likewise, the equipment data sensor122in the riding lawn mower142also periodically looks for any ID units within a certain range and may, for example, find both the ID unit132held by the operator146of the riding mower142and the ID unit131held by the operator145of the trimmer141who happens to be, at this time, trimming nearby to where the riding lawn mower142is being operated. In such situations, the equipment data sensor122may be configured to store both IDs. As is described in greater detail below, the equipment data sensor122or another device that receives data therefrom may be able to distinguish between the two IDs to determine (e.g., based in whole or in part on signal strength) which ID represents the operator of the riding lawn mower142and which ID is that of another person located proximate to, but not operating, the riding lawn mower142.

In some embodiments of the fleet management system100, some equipment may not use ID units and may, instead, have a biosensor, such as a fingerprint reader or an iris scanner, installed thereon for identifying the operator of the equipment.

In one or more of these ways, the equipment data sensor gathers data about the operator, nearby operators, and/or nearby equipment. The equipment data sensor also has one or more sensors built into it and/or is communicably coupled to one or more sensors on the equipment that measure data about the equipment, status of equipment components, and/or the equipment's environment. Such data may, for example, include (without limitation) engine revolutions per minute (RPM), engine oil temperature, engine operation, clutch engagement, ambient temperature, vibration, geographic positioning data, speed, throttle valve position, brake engagement, power-take-off (PTO) system engagement, fuel consumption, inclination, acceleration, pressure, load, battery status, shock, user input, time, feature operation and status, humidity, nearby equipment, fuel level, oil level, and/or the like. The equipment data sensor may capture this data periodically and have a non-transitory memory device, such as a flash memory drive, that stores the captured data in a time sequence or along with timestamps indicating the moment in time when the data was captured. The equipment data sensor may store this data at least temporarily until the data communication system portion of the data collection and communication system110can transfer this data to the data management and presentation system150.

In this regard, the data collection and communication system110includes a data communication system comprised of one or more communication units for obtaining data from the equipment data sensor(s) and communicating the data to the data management and presentation system150via a global or wide area network such as the Internet and/or a cellular network105. For example, some embodiments include a base station112that periodically looks for equipment data sensors that come within range of its wireless transceiver and then uploads data from the identified equipment data sensors. For example, the base station112may be located in the fleet owner's garage106or other storage unit so that it captures data from the fleet's equipment data sensors whenever the equipment is returned to the garage106at the end of each work day. This base station112may have some local memory for temporarily storing some data, but it may be connected to the Internet so that it can transfer the data it receives to a remote web server165of the data management and presentation system150. The data collection and communication system110may also have one or more satellite stations114that relay data from the equipment data sensors to the base station112. For example, such satellite stations114may be installed on the trucks107or trailers that carry the equipment to the worksites. The communication units may also have ID codes associated with them so that they may be used to help track the location of equipment in the fleet. For example, a satellite station114installed on each truck could help identify which equipment is on which truck and a base station106located in a garage could help identify which equipment is in the garage and when the equipment is removed and/or returned to the garage.

In some embodiments the communication unit may even be a mobile phone or other mobile device that is configured to communicate information between one or more equipment data sensors and the data management and presentation system150using a global mobile network, such as a cellular telephone network105. For example, as illustrated inFIG. 1, the operator148of the walk behind mower144may hold a mobile smart phone116in his pocket that has a short-range transceiver, such as a Bluetooth® system or the like. The mobile phone116may also have a downloaded fleet management system software application stored in the phone's memory that allows the mobile phone116to wirelessly receive data from the equipment data sensor124of the mower144using the short-range transceiver and then relay the data to the data management and presentation system150via the cellular network105. In this way, it may be possible for the data management and presentation system150to receive data in real-time or near-real-time and/or, for some users, it may also negate the need for other system-specific communications units. This may be particularly well suited for some owner-operators or homeowners that would like to utilize the fleet management system100with less of an investment in communication units like base stations112and satellite stations114. In some embodiments, the ID unit134may be stored in the mobile phone134which may also negate the need for such equipment as operator data cards or wristbands. In such embodiments, the equipment data sensor124may receive the ID code from the mobile phone116or, alternatively, if the mobile phone116is the communication unit, the mobile phone116may associate the ID code stored in the ID unit134in the phone116with the data the phone116receives from the equipment data sensor124prior to sending the combined data and ID code to the data management and presentation system150. This could also potentially reduce the cost of the equipment data sensor124since some functionality of reading nearby ID units may not be needed in the equipment data sensor124in such an embodiment.

As illustrated inFIG. 1, the data collected by the data collection and communication system110is then communicated to the data management and presentation system150via a network105. The network105may be, for example, a wide or global area network including the Internet and/or a cellular telephone network. The data management and presentation system150includes a data management server system162, such as a web server, that receives the data from the data collection and communication system110, stores the data in a database165, processes the data, and presents the data or other data derived therefrom to one or more users in a useful format. For example, the data management server system162may provide a web portal where users can track information about a fleet's equipment and operators, including (for example, without limitation) such information as equipment run time, equipment performance, equipment maintenance records, equipment repair records, equipment safety concerns, equipment productivity, equipment cost, equipment location, equipment use, operator productivity, operator work time, operator machine handling information, operator performance, operator location, operator safety concerns, operator vibration records, team productivity, job resource requirements, customer information, jobsite information, parts information, contract information, warranty information, library resources, and/or the like, as is described in greater detail below. The data management server system162analyzes the collected data and, utilizing the collected data, provides some or all of the information listed above in a format useful to the user.

In some embodiments, the user, such as the fleet owner101, accesses the web portal via a personal computing device170and a web browsing application stored thereon. The data management server system162provides the information to a secure web page in the format of graphs, charts, tables, and other graphics that help the user to quickly and intuitively see and understand what is being presented. The data management server system162also receives user input from the personal computing device170, including input about information to be displayed, user preferences, and additional data about the fleet. In some embodiments, the personal computing device is a mobile phone172, which may be operated by, for example, a team manager102, an operator, a mechanic, or other team member in the field. In some embodiments, the mobile phone172has a fleet management application stored thereon that works with the data management server system162to communicate information back and forth between the user and the server system162.

In some embodiments, the data management server system162provides different experiences, features, functions, and permissions to different types of users. As mentioned above, some types of user may include a fleet owner/manager101, a team manager102, an operator, and/or a mechanic. Another type of user may be a dealer103or other salesperson or the equipment manufacturer. The dealer103or manufacturer may also access the web portal via a computing device or company-owned server and may have access to a dealer portal or a manufacturer portal configured to provide information useful to dealers or manufacturers and configured to allow the dealer or manufacturer to enter information about equipment, equipment use, and/or customers that can be used by the data management server system162, in conjunction with data collected by equipment data sensors, to provide equipment and operator information to a fleet manager, an equipment operator, or other user.

FIGS. 2A and 2Bprovide a block diagram200that illustrates components of the fleet management system100in more detail, in accordance with some embodiments of the invention. In this regard,FIG. 2Aprovides a block diagram of the data collection and communication portion of the system100, including a data collection system210with an equipment data sensor230, a data communication system260, and an ID unit250. FIG.2B provides a block diagram of the data management and presentation portion of the system100, including a data management server system270and a client computing device290.

As used herein, the terms “processing device” and “processor” refer to circuitry for implementing one or more of the communication and/or logic functions of the device within which the processor/processing device is installed. For example, the processing devices described herein may include a digital signal processor device, a microprocessor device, and various analog to digital converters, digital to analog converters, and/or other support circuits. Control and signal processing functions of the device within which the processing device is installed are allocated between these circuitry devices according to their respective capabilities. The processing device thus may also include the functionality to encode and interleave messages and data prior to modulation and transmission. The processing device can additionally include an internal data modem, a data bus, and/or a power bus for communicating data and or power to other components and devices that are communicably coupled to the processing device. Further, the processing device may include functionality to operate one or more software programs, which may be stored in the memory to which the processing device is coupled. For example, the processing device may be capable of operating a connectivity program, such as a web browser application. The web browser application may then allow the device to transmit and receive web content, such as, for example, location-based content and/or other web page content, according to a Wireless Application Protocol (WAP), Hypertext Transfer Protocol (HTTP), and/or the like. A processing device may include a single processor or a plurality of processors that together perform the stated function(s). Where a processing device includes a plurality of processing devices/processors, the processing devices/processors are generally communicably coupled to each other via one or more communication devices, but they may not be physically coupled to each other; in other words, such processors may be located together or may be located separate and apart from each other.

The processing devices described herein may be configured to use one or more transceivers, network interfaces, or other communication interfaces to communicate with one or more other devices or networks. In this regard, “transceivers” described herein generally include an antenna operatively coupled to a transmitter and/or a receiver and configured to passively and/or actively send and/or receive data and/or power via electromagnetic waves (e.g., radio frequency waves, infrared waves, etc.) and wave modulation. The processing device may, therefore, be configured to provide signals to and/or receive signals from the transceiver. Where the transceiver is configured to communicate with a cellular network, the signals may include signaling information in accordance with the air interface standard of the applicable cellular system of the wireless telephone network. The transceiver may also be configured to operate in accordance with other communication mechanisms and standards, such as via a wireless local area network (WLAN), a Bluetooth® standard, a RFID (radio frequency identification) tag standard, proprietary wireless communication protocols, and/or other communication/data standards and networks.

As used herein, “memory” or “memory device” includes any computer readable medium (as defined herein below) configured to store data, computer-executable program code (e.g., software), or other information. Memory may include volatile memory, such as volatile Random Access Memory (RAM) including a cache area for the temporary storage of data. Memory may also include non-volatile memory, which can be embedded and/or may be removable. The non-volatile memory can additionally or alternatively include an electrically erasable programmable read-only memory (EEPROM), flash memory or the like. The memory may be configured to store any of a number of applications which comprise computer-executable instructions/code executed by the processing device to implement the functions of the devices described herein. The memory can also store any of a number of pieces of information/data used by the devices described herein. Memory or a memory device may include a single memory device or a plurality of memory devices that together perform store the stated information. Where the memory or memory device includes a plurality of memory devices, the memory devices are generally communicably coupled to each other via one or more communication devices and/or processing devices, but they may not be physically coupled to each other; in other words, such memory devices may be located together or may be located separate and apart from each other.

Referring again toFIG. 2A, a block diagram of an ID unit250is provided, according to an example embodiment of the invention. The ID unit250includes a processing device252communicably coupled to a short-range transceiver264and memory254. The memory254includes a unique ID code255stored therein. Being unique, this ID code255can be associated with a particular operator204in order to uniquely identify the operator. For example, a particular ID code255may be associated with a particular operator204if the operator204always or usually carries an ID unit250with the same ID code255stored therein. In some embodiments, a particular ID code255may be associated with a particular operator204in a database stored in the memory276of the data management server system270, described in greater detail below. The code can be any alphabetic, numeric, alphanumeric, or other type of code.

The processing device202is configured to use the short-range transceiver264to communicate the ID code255to the data collection system210at appropriate times using an appropriate wireless communication standard. For example, in one embodiment of the ID unit250, the transceiver264comprises a 2.4 GHz antenna that is configured to work close to an operator's body. In one embodiment, the reading range for the transceiver264is two meters, although other ranges are possible. In some embodiments, the ID unit250is a passive RFID tag where the short-range transceiver264receives a wireless signal from the equipment data sensor230and, by virtue of this signal being received in the transceiver's antenna, the ID unit250is powered and automatically responds by transmitting the ID code255via a wireless signal that is received by the equipment data sensor230. In other embodiments, the ID unit250comprises a battery (not shown) and actively transmits the ID code255either continuously, periodically (e.g., every second), or in response to receiving a signal from an equipment data sensor230. In some embodiments where the ID unit250comprises a battery, the ID unit250also comprises a motion detector (not shown) and, to conserve battery, is configured to stop transmitting signals when no motion is detected for longer than a predetermined amount of time and then resume transmissions when motion is detected again. Where the ID unit250has a battery, it may be preferable to configure the ID unit250and the battery so that the battery life is at least one year.

In one embodiment of the invention, the operator ID unit250uses the CC 2510 Short Range Device (SRD) RF transceiver provided by Texas instruments, which is a system on chip transceiver with a built-in microprocessor. In one such embodiment, the operator ID unit250uses the CC 2510 which is based on the CC 2500 used for the transceiver in both the equipment data sensor230and the data communication system260. The supported modulation schemes at 250 kbit/s are OOK, 2-FSK, GFSK and OQPSK Offset Quadrature Shift Keying). The frequency range is 2.400 GHz to 2.483 GHz allocated as ISM (Industrial, Scientific and Medical). The data rate over the air may be 250 kbit/s. The receiver sensitivity may be 81 dBm.

As described above, the ID unit250may take a variety of forms, but is preferably a water-resistant, wearable device that can be easily carried by or attached to an operator204. For example, the ID unit may be a data card (e.g., a credit-card sized card), a wristband, a chip sewn into the operator's gloves, a key fob, a watch, a necklace, and/or the like. Although the typical example may utilize RFID technology, other wireless communication arrangements are conceivable such as, e.g., Bluetooth® or WiFi. As described above, in some embodiments of the invention the ID unit250is combined with a mobile phone and, as such, the memory254, processing device252, and short-range transceiver264may be those of a mobile phone capable of also performing other functions of the mobile phone. In some embodiments, the ID unit250may also include a user interface (e.g., a keypad, touch pad, display, LED, or the like) (not shown) for receiving user input and/or providing user output. For example, the ID unit250may have a keypad for receiving a PIN code or a biometric device for authenticating the operator holding the ID unit. In some embodiments, the ID unit250may have the ID code255printed thereon along with the operator's name and/or image or a place for an operator to write his or her name or attach a picture.

Although only a single ID unit250and operator204are shown inFIG. 2A, it will be appreciated that the fleet management system may comprise a large number of operators and ID units, where each ID unit is carried by or otherwise associated with a particular operator. In some embodiments, one or more ID units250come with the purchase of a piece of equipment202and/or an equipment data sensor230, but also can be purchased individually or in packs.

FIG. 2Afurther provides a block diagram of a data collection system210comprising an equipment data sensor230, in accordance with an example embodiment of the invention. As illustrated, each piece of outdoor power equipment202in the fleet that is to be monitored by the fleet management system100is equipped with a data collection system210for collecting data about parameters related to the equipment and/or the equipment's environment and communicating the collected data to the data communication system260. Each data collection system210generally includes an equipment data sensor230installed on the equipment202or otherwise positioned proximate to the equipment202during operation of the equipment202. The equipment data sensor230may encompass the whole data collection system210or the equipment data sensor230may be combined with other components, such as other components of the equipment202, to form the data collection system210. Each equipment data sensor230includes a processing device232communicably coupled to one or more transceivers234, a clock/timer248, a power source246, memory240, and one or more sensors249.

The memory240includes a sensor application242stored therein. The sensor application242comprises computer readable program code (e.g., software, etc.) for instructing the processing device232to operate the various hardware components and to store, process, and communicate data244. The memory240can be any computer-readable medium, such as flash memory. In one embodiment, the equipment data sensor230is configured to automatically update the sensor application242, and any firmware in the other hardware, when in communication with a data communication system260that is connected to the data management server system270.

The processing device232executes the sensor application242to, amongst other things:

(i) use the transceiver(s)234to receive and process wireless signals from one or more ID units250or other equipment data sensors;

(ii) use the transceiver(s)234to send wireless signals to one or more ID units250or other equipment data sensors;

(iii) use the sensor(s)249and/or communicate with the equipment's control system212to gather other data about the equipment202or its environment;

(iv) store data in the memory244;

(v) use the transceiver(s) to send data to and receive data from the data communication system260;

(vi) use the clock248to determine absolute or relative time and associate data with a time; and/or

(vii) use the equipment's user interface209to communicate information to the operator204.

The memory240also, at least temporarily, stores the data244collected by the processing device232from the sensor(s)249and/or the equipment's control system212. This data244may be comprised of individual data packets/packs, where each data packet relates to one instance or period of time and includes: (i) sensor data or other equipment-related data collected at that point in time; (ii) any ID codes identified from nearby ID units250at that point in time; (iii) any identification codes identified from other equipment data sensors nearby at that point in time; (iv) any identification codes identified from data communication systems260nearby at that point in time; (v) a timestamp indicating the point in time; and/or other data. This data244may be deleted from the memory240after the data244is uploaded to a data communication system260or the data management server system270, and/or the data244may be deleted after it reaches a certain age or as the memory244reaches certain capacities.

As illustrated, some embodiments of the equipment data sensor230are also uniquely associated with an ID code245that can be used by the data management server system270to identify the particular equipment data sensor230and, thereby, the particular piece of equipment202to which the equipment data sensor230is attached or otherwise associated. This equipment ID code245may be transmitted to the data management server system270via the data communication system260along with data244. This way the data244can be properly associated with a particular piece of equipment. For example, the equipment ID code245may be transmitted at the beginning and/or end of any transmission from the equipment data sensor230and/or the equipment data sensor230could add the equipment Id code245to each data packet along with the captured equipment data and any operator ID codes. The equipment ID code245may also assist with routing communications back to a particular equipment data sensor230from a data communication system260and/or the data management server system270.

The equipment data sensor230also includes one or more transceiver(s)234, which may comprise one or more transmitters and/or receivers. In some embodiments of the invention, the transceiver234is comprised of a relatively short-range transceiver236and a relatively long/medium-range transceiver238. In such an embodiment, the short-range transceiver236may be used to identify and communicate with nearby ID units250and/or equipment data sensors on other equipment, and the long-range transceiver238may be used to identify and communicate with data communication systems260(e.g., base stations112, satellite stations114, mobile phones116, or other communication units) to send collected data to the data communication systems260and/or to receive information or updates from the data communication systems. In one such an embodiment, the short-range transceiver236is configured to have a maximum range of approximately two meters and the long-range transceiver238is configured to have a range of at least twenty meters. Of course, these ranges are examples and other ranges are possible. In some embodiments the short-range transceiver236and the long-range transceiver238share a single antenna, such as a 2.4 GHz antenna but use different communication protocols, modulation techniques, and/or amounts of power. In other embodiments a single transceiver234is used to communicate to both the ID units250and the data communication systems260, but the equipment data sensor230may be configured to adjust the power to limit the range in which ID units250are recognized to something less than the range used to communicate with the data communication system260.

In addition to communicating wireless signals to and/or from operator ID units250and data communication systems260, in some embodiments the processing device232uses the short range transceiver236of the equipment data sensor230to periodically broadcast an equipment ID code245over a short range to allow the equipment ID code245to be sensed by other equipment data sensors that may be in the nearby area. Also, in some embodiments, the equipment data sensor's transceiver234communicates with other types of ID units similar to the operator ID unit250that uniquely identify equipment that do not have equipment data sensors230(such as a ID data tag on the bed of a truck in the fleet or in a storage unit or service garage).

The equipment data sensor230also includes a clock248which may be any timing device. The clock248may keep track of global standard time or a relative time and is used to allow the processing device232to perform actions, such as capturing data from the sensors249or transmitting signals using the transceiver234, in regular intervals. The clock248also allows the processing device232to store collected data in time sequence or with a timestamp that shows when the data was collected relative to when other data was collected and, in some embodiments, relative to global standard time or another standardized temporal indicator.

The processing device232of the equipment data sensor230is configured to communicate with one or more sensors to collect data about the equipment, operation of the equipment, and/or the equipment's environment. In some embodiments, the equipment data sensor230has sensors249built into the equipment data sensor230, itself. In fact, in some embodiments the equipment data sensor230is entirely self-contained, and in some cases self-powered, and does not require any hard-wired connections to any electrical components of the equipment202. Such an embodiment may make installation of the equipment data sensor230easier and more universal, particularly if the installation occurs after manufacturing of the equipment202.

In other embodiments, in addition to or as an alternative to having sensors249incorporated into the equipment data sensor230, the processing device232may be configured to collect data from one or more sensors222that are built into the equipment202apart from the equipment data sensor202. For example, the equipment data sensor230may be configured to obtain and store in memory240the status of an operator presence sensor typically built into the seat of a riding lawn mower to identify whether an operator is seated in the seat of the riding lawn mower. In this regard, the processing device232may be communicably coupled (e.g., coupled by a wired or wireless connection) to an equipment control system212of the equipment202to “tap into” the equipment's electrical system and receive data from the equipment sensors222. As such, some embodiments of the equipment data sensor230include a wiring harness arranged to exhibit connecting ports for providing connection between the processing device232of the equipment data sensor230and the equipment control system212and/or various external sensors222or switches224. The equipment control system212may include a processing device (e.g., one or more processors, a data bus, circuits, etc.) for communicating with the equipment's sensors222. It should be appreciated that the equipment sensors222may include switches224where the sensed data from a switch224comprises the status of the switch224(e.g., on, off, etc.). The equipment control system212may also be communicably coupled to the equipment power source246and the equipment user interface209and, therefore, in some embodiments the processing device232of the equipment data sensor230can receive and store information about user inputs entered through the equipment user interface209and provide user output via the equipment user interface209(e.g., user output that may originate from the data management server system270).

In some embodiments, the sensors249and/or222that are communicably coupled to the processing device232of the equipment data sensor230include one or more of the following: GPS receivers, RPM sensors (e.g., RPM-sensing antennas), three-axis accelerometers or other accelerometers, electro-mechanical switches, inclinometers, thermocouples or other temperature sensors, proximity sensors, fluid level sensors, pressure transducers or other pressure sensors, moisture sensors, motion detectors, magnets and magnetic field sensors, Hall-effect switches, RF antennas, infrared sensors, lasers, shock sensors, speed sensors, vibration sensors, and/or other sensors. In some embodiments, the equipment data244collected and stored by the equipment data sensor230includes one or more of the following: GPS or other location data, engine RPM, component (e.g., cutting blades) RPM, accelerations, orientation, incline, ambient temperature, engine temperature, transmission temperature, component temperature, nearby equipment ID codes, nearby communication system ID codes, throttle status, PTO status, brake status, clutch status, user input commands, switch statuses, fuel consumption, fuel level status, oil level status, battery level status, voltage, electrical current, velocity, operator presence in a seat or other operator station, heading, run time, ignition status, vibration, shock, tire level, tire condition, differential locking, wheel spinning, emissions, wheel slipping, humidity, force, moisture, pressure, altitude, tampering, equipment hatch opening or closing, user input, component replacement, and/or other parameters/metrics about the equipment's status, use, operation, and/or environment.

For example, in some embodiments of the equipment data sensor230, the sensor(s)249include sensors for sensing the engine speed, the PTO speed, and/or the work performed by the engine. For example, the engine speed may be sensed by an RPM sensor for sensing (exactly or approximately) the revolutions per minute (RPM) of the motor shaft, which may be the crankshaft of an internal combustion engine or the shaft driven by an electric or hybrid engine. The PTO speed may be sensed by the RPM of a PTO shaft or pulley. The engine workload may be sensed by some ratio of the actual engine speed, throttle position, reference engine speed, and/or PTO speed.

According to one embodiment of the invention where the equipment data sensor230is arranged to collect information regarding the RPM of the equipment's internal combustion engine, the equipment data sensor230may include an “intelligent sensor” in the form of a registration unit mounted around or adjacent to the ignition cable. This registration unit is capable of sensing and storing electrical impulses that arise at each ignition, meaning the RPM may be retrieved since increased engine speed results in more frequent ignition pulses.

In another embodiment described in detail below with reference toFIGS. 3A, 3B, 4A, and 4B, the RPM sensor comprises a RPM antenna that is located some distance (e.g., between 1 and 40 centimeters) away from the ignition cable that is configured to determine engine RPM by sensing electromagnetic waves generated by equipment components that vary with the RPM of an internal combustion engine (e.g., waves generated by the electrical ignition pulses that arise in the ignition circuit and that change based on the engine speed). This embodiment may have an advantage over other embodiments because it may be more cost effective and permits sensing of engine RPM from a distance away from the ignition cable, senses the RPM passively, provides for easier installation, and avoids interfering with the ignition cable or other engine components since it does not require that the RPM sensor be hardwired into electrical or engine systems of the equipment202. Hereby it may also be possible to register and store when the engine is started as well as when it is shut down, and moreover the RPM-levels between start and shut down. In some embodiments where such an RPM antenna is used and actual engine RPM may not be needed or cannot be obtained, such as for some types of riding mowers or some other vehicles, then an adapter/sensor combination may be attached to equipment to sense one or more other characteristics about the equipment or the equipment's use and convert the sensed information into electromagnetic pulses that simulate ignition circuit pulses. Different “RPM” values can be used to communicate different information according to some predetermined rules. For example, the adapter could create electromagnetic pulses consistent with an engine RPM of 500 to indicate to the equipment data sensor230(via the RPM antenna) something like “engine on and PTO not engaged” and an pulses consistent with an engine RPM of 1000 to indicate something like “engine on and PTO engaged.” In this way, the same equipment data sensor230, such as the universal equipment data sensor described with respect toFIGS. 3A, 3B, 4A, and/or4B, could be used for a greater number of equipment types and to sense a greater variety of data according to the particular needs of the user and requirements or limitations of the equipment type or its environment.

In another embodiment, the RPM sensor of the equipment data sensor230comprises at least one intelligent powered sensor that is configured to be self-energized and, in some cases, power the rest of the equipment data sensor230. Specifically, in some embodiments the RPM sensor of the equipment data sensor230includes an inductor powered by electromagnetic energy from the engine of the equipment202. A magnet is added to one portion of the flywheel of the engine of the equipment202. The RPM sensor is then located in such a way that passing magnetic fields (created by the magnet as the flywheel turns and the magnet passes the sensor) can be sensed and registered by the RPM sensor (e.g. by means of a RPS sensor comprising metal portions). The RPM sensor then transforms these magnetic fields into electrical signals which can be further transmitted to the processing system232of the equipment data sensor230and used thereby to estimate RPM and engine start and stop, and/or to power the equipment data sensor230(including charge any of the its batteries). A similar setup could be used to sense the speed (e.g., RPM) of and receive power from other rotating/moving devices on the equipment202, such as a PTO shaft, a belt, a pulley, a cutting element, and/or the like, by similarly attaching a magnet to the rotating/moving component to be sensed. Other sensors may also be used to sense RPM or other speed indicators of an engine or component, such as Hall-effect switches located near the moving component.

In some embodiments, the equipment control system212is configured to control fuel supply to the internal combustion engine of the machine, and the equipment data sensor230is communicably coupled to the equipment control system212. On some such embodiments, the equipment data sensor230may receive power from this connection. In some embodiments the equipment control system212may be arranged to control the carburetor of the equipment202and include: (i) a throttle position detecting mechanism for sensing the position of the throttle valve; and/or (ii) a fuel valve mechanism for controlling the fuel supply to the engine. The equipment data sensor230may be communicably coupled to the throttle position detecting mechanism (e.g., via the equipment control system212) at least for sequentially obtaining values representing the position of the throttle valve. The equipment data sensor230may also be an integrated part of the equipment control system212and vice versa. Such an arrangement may allow for use of the equipment control system212for adjusting the air/fuel mixture to the engine for current conditions, thereby lowering the fuel consumption, and at the same time being able to use the equipment data sensor230for registering and storing information about to what extent the equipment control system212has been activated during the running of a machine. Thus, in embodiments where the equipment202includes an equipment control system212for, for example, controlling a fuel supply to an internal combustion engine of the machine, the equipment data sensor230can be configured to receive values of at least one parameter from the equipment control system212. One such parameter could be the throttle position which, taken together with the RPM, can be used for rendering an estimated value of load and/or fuel consumption.

In some embodiments, the equipment control system212includes an ignition module for controlling the ignition timing of an internal combustion engine of the equipment202. In such embodiments, the equipment data sensor230may be preferably integrated with the ignition module or capable of being attached to the ignition module, and said ignition module may be arranged to control the ignition timing of an internal combustion engine of the machine. In such an embodiment, the equipment data sensor230may be connected to the ignition system and may be arranged to become activated when the ignition system is switched on.

Powering of the equipment data sensor230can be achieved in different ways, some of which have been described above. According to some embodiments, the power source246of the equipment data sensor230comprises one or more batteries. In some such embodiments, the batteries are rechargeable batteries and, in some embodiments, are charged by electromagnetic induction generated by moving magnets, e.g. placed on the engine flywheel of the equipment202. An example of electromagnetic converting means arranged to convert magnetic energy into electrical energy is described in U.S. Patent Application Publication No. 2011/0095215, which is hereby incorporated by way of reference and which is commonly owned by an assignee of the present application. Thus the batteries of the equipment data sensor230may be charged while the equipment202is running by this induction method or by otherwise connecting the batteries to the equipment's power source208(battery, electrical circuits, engine, solar cell, generator, etc.).

In some embodiments, the equipment data sensor230is configured to transmit information about battery status (e.g., voltage) to the data management server system270so that any worn-out battery can be identified by the fleet management system and an appropriate alert can be sent by the data management server system270to a person responsible for changing the battery. Furthermore, the equipment data sensor230may also be configured to collect, store, and communicate information related to the voltage of the ID unit250(e.g., via the power of the wireless signal detected by the equipment data sensor230when it's known how far way the ID unit250is from the sensor230, for example, by determining that the ID unit250is carried by the actual equipment operator) whereby battery status of a battery in the ID unit250(in embodiments where there is such a battery) can be monitored by the fleet management system100and worn out batteries promptly replaced by users of the system100.

In sum, it is to be understood that the equipment data sensor230may refer to any type of unit which provides one or more functions, namely to: (i) obtain/collect and store values of parameters associated with a piece of equipment202or the operation or environment thereof, and, optionally (unless expressly claimed otherwise) (ii) receive and store incoming operator ID-codes. In this regard, the equipment data sensor230typically includes a central processing device232arranged to sequentially obtain and store values of said at least one parameter during operation of the machine, whereby a wide variety of informative data related to a given moment in time may be achieved. The obtained parameters and any ID codes are stored together in memory240in a respective data packet. Each data packet may also include a timestamp so that the equipment data sensor230may collect various data in data packets containing information about, for example, the operator and an equipment parameter together with a timestamp whereby the collected information is correlated with the period or point in time when the information was collected or stored.

It is to be understood that the equipment data sensor230and the components described herein may be constituted by various sub-units (e.g. different types and number of sensors depending on what type of data is to be collected) as well as it can be mounted into the equipment202in many different ways, e.g. depending on the type of engine (combustion engine or electrical engine) and type of equipment202(e.g., wheeled, handheld, etc.), and can be powered in various ways (e.g. with separate batteries or via the engine of the powered machine). In situations where the equipment202is powered by an electric motor, the equipment data sensor230may have another composition compared to some of the previously-described embodiments for equipment having a combustion engine. For instance, for electric equipment, the equipment data sensor230or a portion thereof may be an integrated part of the electric motor control system, such as a data chip on a printed circuit board.

FIG. 2Aalso provides a block diagram of a data communication system260in accordance with some embodiments. The data communication system260may be, for example, the base station112, the satellite station114, the mobile phone116, or other communication unit or combination of communication units described with reference toFIG. 1. The data communication system260is configured to relay information collected by one or more equipment data sensors230to the data management server system270via network206. The data communication system260generally comprises a processing device262communicably coupled to one or more transceiver(s)264, a network interface265, and a memory266. The processing device262uses the network interface265and the transceiver264in accordance with computer-executable instructions of the collector application268stored in the memory266. In some embodiments, the equipment data sensor202periodically looks for a data communication system260so that when the equipment202is brought within the broadcasting range of the data communication system260the equipment data244(including any operator ID codes255, equipment ID code245, and captured equipment data) is submitted thereto by, for example, the equipment data sensor230wirelessly transmitting the information in the form of the previously-described data packets. In other embodiments, the equipment data sensor202may be configured so that it only looks for a data communication system260when the engine is shut down. The equipment data sensor202may determine, for example, that the engine is shut down when no ignition signals are received through the RPM sensor or by some other communication with the equipment's control system212, user interface209, or power source208.

Each data communication system260may receive and store information from at least one, and perhaps from more than one, equipment data sensor230located within broadcasting range. The data communication system260, which may temporarily store the data244in the memory266, thereafter uses the network interface to transmit the data244(in the form of the digital data packets) to the data management server system270. The data management server system270is thereby provided with information in the form of equipment and operator data, and is continuously/periodically updated about the status of a fleet in operation as new information from the data communication system260is received.

As illustrated inFIG. 2A, the memory266of the data communication system260may, in some embodiments, include an operator ID code255and/or a communication system ID code269. The communication system ID code269may be uniquely associated a particular data communication system260and then used by the data management server system270to identify the particular data communication system260. This ID code269may be useful to the data management server system270for: (i) identifying the source of data generally; (ii) identifying problems with a data communication system260(iii) tracking the location of one or more pieces of the equipment (e.g., by associating the location of the equipment202with a known location of the data communication system260at the time of the communication between the equipment's data sensor230and the data communication system260); (iv) identifying the fleet owner or account associated with certain incoming data; and/or (v) routing communications back to a particular data communication system260and/or equipment data sensor230from the data management server system270. This communication system ID code269may be transmitted to the data management server system270along with data244. For example, the communication system ID code269may be transmitted at the beginning and/or end of any transmission from the data communication system260and/or the data communication system260could add the equipment ID code269to each data packet along with the captured equipment data and any operator ID codes and equipment ID code. As described above, in some embodiments of the fleet management system100where the data communication system260comprises a mobile device116that can be assumed to be specific to and carried by a particular operator, the data communication system260may also function as an ID unit250. Therefore, in such embodiments, the memory266may also contain an operator ID code255. This may be transmitted to the equipment data sensor230using the transceiver264in much the same way(s) described above with reference to the ID unit250or, alternatively, it may be added to the data244as the data244passes through the data communication system260on its way to the data management server system270.

The network206may be any data communication network. In some embodiments, the network206comprises a global area network such as the Internet and/or a cellular telephone network. However, the network206may also comprise a local area network (LAN) or a wide area network (WAN). The network206may comprise one or more wireless networks and/or one or more wired networks.

In one embodiment of the invention, the network206comprises the Internet and the data communication system's network interface265comprises an Ethernet interface and is configured to communicate with the data management server's network interface272using Hypertext Transfer Protocol (HTTP), Transmission Control Protocol/Internet Protocol (TCP/IP), Dynamic Host Configuration Protocol (DHCP), and/or Domain Name System (DNS) protocol. In another embodiment of the invention, the network206comprises a mobile communication network and the data communication system's network interface265comprises one or more known cellular/mobile antennas and is configured to communicate with the data management server's network interface272using one or more known cellular/mobile communication and data formatting protocols.

The data management server system270is configured to receive the data244including the various ID codes from a plurality of equipment data sensors230via a plurality of data communication systems260and process the data244to provide the data and other data based thereon in a useful form and/or to provide one or more services for users of a fleet management portal that is hosted on the network206by the data management server system270. For example, in some embodiments, the data management server system270provides a fleet management service for numerous fleet owners across the world. In some embodiments, portions of the fleet management portal are geared to fleet owners while other portions may be targeted to operators, dealers, manufacturers, and/or other users. Furthermore, in some embodiments of the invention, the data management server system270can use the data it receives to provide other useful data back to the equipment data sensor230for presentation to an operator of the associated equipment202via the equipment user interface209and/or for use by the equipment control system212.

The data management server system270generally includes a processing device274communicably coupled to a network interface272and memory276. These components may be located on a single network server or distributed across several coupled or independent servers. The network interface292is configured to connect to the network206and communicate via the network's protocols, such as HTTP and/or other Internet or mobile network protocols. As such, depending on the embodiment, the network interface292may include, for example, a web modem and/or some other type of data transceiver.

The memory276includes a fleet management server application278comprising computer-executable code that, when executed by the processing device274instructs the processing device274to perform the various functions of the data management server system270described herein. For example, the fleet management server application278instructs the data management server system270to receive data from the network206, store the data, processes the data, provide feedback to the data communication systems260and equipment data sensors230, and/or host a fleet management web portal or mobile application that presents users203with the fleet and operator data in the form graphs, tables, charts, numbers, graphics, images, audio, alerts, and/or the like in the context of a web page or mobile application and/or via emails, text messages, printouts and/or other communication formats. In this regard, embodiments of the fleet management server application278may include computer-executable program code that, in combination with a processing device capable of executing the code, provides: (i) a receiver module278A for receiving data from the data communication systems260(e.g., the HTTP Posts) via the network interface272and storing the data282in the fleet management system database280; (ii) a parser module278B for taking the data282received by the receiver module278A, which in the native format as created by the equipment data sensor230or other devices in the data collection system, and parses and translates the data282for eventual conversion and presentation in a fleet management portal; and (iii) a converter module278C for converting and enriching collected data282before it is presented in a fleet management portal as processed fleet data284(e.g., performing data conversions, performing lookups like warning levels, rules, calculated performance indicators, equipment information, baselines, references, etc., and calculating ratios, totals, averages, etc.). In some embodiments, the fleet management server application278also includes computer-executable program code that, when executed by the processing device274provides over the network206different versions of a fleet management portal, such as a user portal278D intended for fleet owners, fleet managers and/or equipment operators, a dealer portal278E intended for dealers or other sales personnel, a manufacturer portal278F intended for equipment manufacturers, and/or a service provider portal278G intended for the provider of the fleet management system or the provider's service personnel.

The memory280also includes, as mentioned above, a fleet management system database280that stores: (i) the collected fleet data282received from the equipment data sensors230via the data collection systems260; (ii) processed fleet data284which includes data derived by the data management server system270from the collected fleet data282; (iii) fleet owner account data286which includes data about the fleet owners, their accounts, and their account preferences; and (iv) dealer account data288which includes data about the equipment dealers, their products and services, equipment parts, the dealers' accounts, and their account preferences.

Users203of the fleet management system100, who may be fleet owners, equipment dealers, equipment repairmen, homeowners, operators, customers, and/or others, can access the fleet management portal using a client computing device290. The client computing device290may be, for example, a personal computer or a mobile smart phone. As illustrated inFIG. 2B, the client computing device290generally includes a processing device communicably coupled to a network interface292, a user interface293, and memory295. The network interface292is configured to connect to the network206and communicate with the data management server system270via the network's protocols. As such, depending on the embodiment of the client computing device290, the network interface292may include, for example, a web modem and/or a cell phone transceiver. The memory295includes a web browsing application296and/or a fleet management client application297that are executed by the processing device291to allow the user to access, view, and interact with the fleet management portal via the network206. Information provided via the fleet management portal by the data management server system270is, in some embodiments, displayed on the display294or otherwise provided through other user output devices of the client computing device290. The user203interacts with the fleet management portal and provides input to the data management server system270using one or more user input devices of the client computing device's user interface293.

Universal Equipment Data Sensor with RPM Sensor

FIGS. 3A, 3B, 4A, 4B, and 5provide schematic and electrical diagrams of an example equipment data sensor300including an example engine RPM sensor550, according to some embodiments of the invention. This particular example of the equipment data sensor230described with reference toFIG. 2Ais referred to herein as the “universal equipment data sensor”300because it is configured so that, in some embodiments of the fleet management system, it may be used across all or at least many different types of outdoor power equipment in the fleet with little or no modification to the sensor and/or the equipment. However, the universal equipment data sensor300may or may not be completely “universal” depending on the embodiment. Furthermore, elements of the equipment data sensor and engine RPM sensor described with reference toFIGS. 3A, 3B, 4A, and 4Bmay be used in other embodiments of the equipment data sensor230and are not necessarily limited to the universal equipment data sensor300.

FIGS. 3A and 3Bprovide schematic diagrams showing a possible construction and layout of the universal equipment data sensor300, in accordance with one embodiment of an equipment data sensor230. Specifically,FIG. 3Aillustrates a top view of the sensor's printed circuit board (PCB)310, which in one embodiment is between thirty and forty millimeters wide and between thirty and forty millimeters long.FIG. 4Ais an electrical diagram520showing an example embodiment of the electrical circuits of the universal equipment data sensor300or, more generally, the equipment data sensor230and components thereof.

Referring again toFIG. 3A, the PCB310comprises a component area312having a microprocessor350(which, in this embodiment, is part of the processing device232shown inFIG. 2A) located therein. The microprocessor350is operatively coupled to a radio325(which, in this embodiment, is part of the transceiver234ofFIG. 2A), a memory device330(which, in this embodiment, is part of the memory240ofFIG. 2A), a 26 MHz crystal oscillator349(which, in this embodiment, is part of the clock248ofFIG. 2A), a 32 KHz crystal “wake-up” oscillator345(which, in this embodiment, is part of the clock248ofFIG. 2A), a plurality of capacitors360(which, in this embodiment, are part of the processing device232, the RPM sensor249, and perhaps other components having capacitors in their circuits ofFIG. 2A), and an opto-coupler390(which, in this embodiment, is part of the processing device232ofFIG. 2A), which are all also located in the component area312of the PCB310. The microprocessor350is also operatively coupled to a 2.4 GHz antenna320(which, in this embodiment, is part of the transceiver234ofFIG. 2A) and a RPM antenna380(which, in this embodiment, is part of a RPM sensor249ofFIG. 2A) located on the PCB310in the area surrounding the component area312. It will be appreciated that, although the only sensor shown inFIGS. 3A and 3Bis an engine RPM sensor, other embodiments of the universal equipment data sensor300may have other sensors incorporated therein and/or may receive data from other sensors located elsewhere on the equipment.

In one embodiment, the microprocessor350comprises an xmega256 microprocessor provided by Atmel Corporation. The microprocessor350may be a low power, high performance 8/16-bit AVR microcontroller featuring an 8 KB boot code section, 16 KB SRAM, 4096-Byte EEPROM, external bus interface, 4-channel DMA controller, 8-channel event system, and up to 32 MIPS throughput at 32 MHz.FIG. 4Ashows an electrical diagram of an example MicroControl Unit (MCU) circuit525which may comprise the microprocessor350. Other microprocessors may be used in addition to or in place of this particular example.

The memory of the universal equipment data sensor300may include memory in the microprocessor for storing computer-executable code, such as a 256 KB self-programming flash program memory, and the memory device330for storing collected data244and/or additional computer-executable code. In one embodiment, the memory device330is a 32 MB flash memory device.FIG. 4Ashows an electrical diagram of an example memory circuit522which may comprise the memory device330. Other memory devices may be used in addition to or in place of these particular examples.

The radio325and the 2.4 GHz antenna320form the RF transceiver234of the universal equipment data sensor300. This radio325is configured to use the 2.4 GHz antenna320to wirelessly communicate with both the ID units250and the data communication system260. In one embodiment, the radio325comprises the CC2500 radio provided by Texas Instruments. In this regard, the radio325may be a low-cost, 2.4 GHz transceiver designed for very low-power wireless applications and having a circuit intended for the 2400-2483.5 MHz ISM (Industrial, Scientific and Medical) and SRD (Short Range Device) frequency band. The radio325may be integrated with a baseband modem that supports various modulation formats and has a configurable data rate up to 500 kBaud. The radio325works with the microprocessor350to perform packet handling, data buffering, burst transmissions, clear channel assessment, link quality indication and wake-on-radio.FIG. 4Ashows an electrical diagram of an example transceiver526which may comprise the radio325and the antenna320. Other radios and antennas may be used in addition to or in place of these particular examples.

Since accurate start-up and general system timing is desired in the universal equipment data sensor300, the sensor300comprises a 32 KHz crystal oscillator345and a 26 MHz crystal340. The 32 KHz crystal oscillator345is the “wake-up” oscillator and is used as a wake-up timer. The 32 KHz crystal oscillator345is calibrated by the 26 MHz oscillator, which controls start-up of components and general system timing. These crystals may be quartz crystals.FIG. 4Ashows an electrical diagram of an example clock circuit521comprising a Real-Time Clock (RTC) circuit which may include the crystal oscillator345and/or crystal340. Other crystals and oscillators may be used in addition to or in place of these particular examples.

The universal equipment data sensor300may also include other electrical components for managing power, safety, and/or performance of the sensor300such as one or more capacitors360for regulating power and an opto-coupler390(also sometimes referred to as an opto-isolator) for preventing damage to the other electrical components caused by rapidly-changing voltage or high voltage differentials across the circuit.

The universal equipment data sensor300also includes a RPM sensor for sensing the RPM of the equipment's engine. In this embodiment, the RPM sensor comprises an RPM antenna380that senses electromagnetic waves created by pulses in the equipment's ignition cable when the engine is running. The pulses and frequency of the electromagnetic waves vary with the engine's RPM and, therefore, can be used to sense the engine's RPM.

In one embodiment, the sensor300is capable of using the RPM antenna380to wirelessly sense engine RPM up to forty centimeters away from the ignition cable. As such, placement of the universal equipment data sensor300on the equipment is somewhat flexible. Where all of the sensors (such as the RPM sensor) used by the universal equipment data sensor300to collect data about the equipment are contained within the PCB310as shown in this example, and where the sensor300has its own power source such as a battery, the universal equipment data sensor300can be installed on a variety of machines with relative ease. In one embodiment, where a battery is used to power the sensor300, the battery and power usage of the sensor300may be configured such that the 1200 hour-per-year user may have to replace the battery every year, while a 600 hour-per-year user may only have to replace the battery every other year.

FIG. 4Ashows an electrical diagram of an example engine RPM sensor circuit550which may comprise the antenna380.FIG. 4Bprovides a combination block diagram and electrical diagram illustrating the engine RPM sensor circuit550and how it functions in more detail according to one embodiment. As illustrated inFIG. 4B, for equipment202where the equipment power source208includes an internal combustion engine216, the equipment control system212will generally include an ignition module213electrically coupled to one or more spark plugs215in the engine216via an ignition wire214. The illustrated embodiment of the engine RPM sensor550senses engine RPM by sensing electromagnetic pulses/waves555emanating from the ignition wire214whenever the signal changes in the wire corresponding to a spark being generated in a spark plug215. This particular solution takes no energy from the ignition system and may allow for wireless sensing of engine RPM from a variety of locations on or around the equipment202.

More particularly, the input to the RPM sensor unit550is an area on the printed circuit board of the equipment data sensor230that works as an antenna580with enough area to pick up the electric field555generated by the ignition circuit (e.g., the ignition wire214). The antenna580is electrically coupled to the rest of the RPM sensor circuit550, which in this embodiment includes two very-low-power integrated circuits582and590and two inverters560and570(one having a Schmitt trigger input).

Together with the other components, the current consumption of this RPM sensor550may be a maximum of approximately 0.1 μA when the engine is turned off, and the current may vary, according to the RPM, between 0.5 and 5 μA when the engine is on. Higher RPM results in higher current consumption. In some embodiments, all electronics in the RPM sensor550work with a power supply at approximately three volts.

The first circuit582located electrically between the antenna580and the first inverter560contains a capacitor584and a resistor586, which together work as a filter and set the input impedance. The filter584protects against noise from internal high frequencies in the equipment data sensor230and external sources like mobile phones or the like. At the same time the filter584integrates the RPM-pulse from every ignition. When the engine is turned off the inverter input for the first inverter560is held low “0”=>0 volt, because the resistor586is connected to ground. Consequently, the output from the inverter560is high “1”=>3 volts. When a RPM-pulse occurs on the input via the antenna580with a peak level passing half the supply voltage, the inverter output of the first inverter560changes from “1” to “0”. This functionality also protects against generated noise levels on the input below half the supply voltage.

The second circuit590located electrically between the first inverter560and the second inverter570has two functionalities. First, when the RPM—pulse sensed by the antenna changes the output of the first inverter560from “1” to “0”, it quickly discharges a capacitor594in the second circuit590through a diode592and resistor596, which lowers the voltage on the input to the second inverter570. When that voltage passes the lower Schmitt trigger hysteresis voltage, then the output on the second inverter570, and hence the input to the processing device232, goes high “1”. Second, when the RPM—pulse ends and the output from the first inverter560goes “1” high, then the second capacitor594is charged slower through the second resistor598. And when that voltage over the second capacitor594passes the higher Schmitt trigger hysteresis voltage, then the output on the second inverter570and the input to the processing device232goes low “0”. Consequently, one RPM—pulse is generated to the processing device232enabling the processing device to count the RPM pulses. The slower charge of the second capacitor594increases the output pulse length so it covers and minimizes double pulse detection. This “disable window” does not detect any pulse after the first detection for 270 uS.

In some embodiments, the equipment data sensor520has the capability to sample and process engine RPM data within the range of 0 and 15,000 RPM. As described above, this may be done by registering signal changes in the machine ignition cable, but other RPM sensors are also possible. In one embodiment, the equipment data sensor520stores samples in sessions of 15 minutes in order to preserve memory in an effective way. Each session may be stored as a histogram containing the number of samples per RPM interval over a particular period of equipment operation.

In some embodiments, the RPM sensor520samples every 5 ms (200 Hz). During ten seconds it will collect the samples without the help of the processing device525and all the sampling will be achieved by the an event system, sampling timer. During the RPM sampling the microprocessor525may be in idle mode allowing the peripherals to continue working. The microprocessor525and peripheral clock may be driven by the external 32,768 KHz crystal and therefore the current during the sampling may be as low as 97 μA. Once the raw RPM data is stored in memory522, it is processed by the microprocessor525to assign the data in the correct RPM segments. These segments will create the RPM histogram that may be used by the data management server system270. When it is time to process the data, the microprocessor525and peripheral clock521will be changed to 24 Mhz allowing the equipment data sensor520to process the data fast. (e.g., 136 ms). This processing will take place once every 10 seconds.

Referring again to the electrical diagram of the equipment data sensor520illustrated inFIG. 4A, battery523(an example of power source246) is shown. In the illustrated embodiment, it may be important to have a small battery dimension, but the drawback is low current capability. As such the battery may be supported by a large capacitor bank for high current pulse capability. Voltage: 3.0-3.6 V; Peak current capacity: <20 mA; Battery capacity: >500 mAh; Type: CR2450 or better.

Other sensors527are also included in this embodiment of equipment data sensor520, including a temperature sensor528and a vibration/tilt sensor529. In the illustrated embodiment of the temperature sensor, the approximate machine temperature data is obtained from a common NTC-resistor mounted on the printed circuit board of the equipment data sensor520. For better linearity in the lower region a bleeder resistor is used (parallel connected). The equipment data sensor also uses the RTC521to keep track of time and therefore it can time stamp every event when it happens. This data is stored in non-volatile memory522. In some embodiments, the equipment data sensor520uses the temperature sensor528to log the surrounding temperature during engine-on time and twenty minutes thereafter.

An omnidirectional tilt/vibration sensor529is also used in the example equipment data sensor520. When in rest, the tilt/vibration sensor529is normally open, giving a true zero quiescent current. An averaging filter keeps the sensor signal in rest until several movements occur, resulting in low CPU activity and power consumption. Due to low power consumption the circuit resistors have very high resistance. The tilt/vibration sensor529on is used during engine OFF mode, to identify two major states (engine OFF state is when data logging is not active while a base station search or a data transfer is active): (i) active base station search mode (when the vibration sensor is triggered); and (ii) passive base station search mode (when the vibration sensor is not triggered).

The example equipment data sensor520also includes LEDs and a lightsensor circuit530. When the user installs the battery for the first time or has just replaced the battery, the equipment data sensor520will enable its indication LED's. The purpose of the LEDs is to see that the main functionality of the equipment data sensor520is working. These indication LEDs will be active for only 10 minutes and then they will be turned off down. There are three LEDs in this embodiment that indicate different functionalities: (i) LED 1 (green)—Communication LED—this led will light up every time the equipment data sensor520sends a wireless packet to the Base Station; (ii) LED 2 (red)—Tilt Sensor LED—this led will indicate when the tilt sensor is activated and, therefore, when the sensor is moved then this LED should light up for 200 ms; and (iii) LED 3 (yellow)—RPM LED—this LED should light up every time the equipment data sensor520is positioned next to a handheld equipment engine. It will constantly be lighted as long as the engine is on and the sensor is in an appropriate sensing distance (less than 20 cm from the engine)

The example equipment data sensor520, also includes debug pins531comprised of a JTAG interface that is available for debugging and software download.

In the example equipment data sensor520, the memory522includes 256 kB of In-System Self-Programmable Flash, 4 kB EEPROM, and 16 kB Internal SRAM.

FIG. 3Bprovides a schematic diagram of a side view/cross section of the universal equipment date sensor300showing a system400for assembling the sensor300and attaching the sensor300to the equipment in accordance with one embodiment of the invention. In this embodiment, a sensor holder480is mounted to the equipment surface495via tape430or another adhesive. Separately, the electronics are installed in the component area312of the PCB310and a battery holder450with electrical contacts for communicating battery power to the circuit is installed on PCB310opposite the electronics312. A battery440is then installed in the battery holder450. The PCB310with the battery and the electronics is then placed in the sensor holder480and a plastic cover470with sealing material460around its perimeter is placed over top of the PCB to protect the sensor300from moisture, dirt, and other debris. Screws490are then passed through holes in the plastic cover470and holes305in the PCB310and screwed into threaded holes in the sensor holder480in order to secure the sensor300and the cover470to the sensor holder480and, thereby, to the equipment surface495.

FIG. 5provides an exploded view of another system500, somewhat different from the one shown inFIG. 3B, for attaching the universal equipment data sensor300(or another equipment data sensor230) to a piece of equipment in accordance with an embodiment of the invention. In this embodiment, a plastic base508is secured to an equipment surface via screws (not shown) through holes514. The plastic base508includes a cylindrical housing in which a first flexible sealing ring506is placed, followed by the sensor300(hear having a circular PCB), another sealing ring504, and finally a plastic cover502. The sealing rings506and504function to resist moisture and debris from reaching the sensor300, but also create a snug fitting for holding the perimeter of the PCB while allowing free space for the electrical components. In the illustrated embodiment, the plastic cover502is secured to the plastic base508by inserting slides512into catches510and turning the cover502ninety degrees relative to the base508to tighten the cover502to the base508.

Data Collection Process

FIG. 6Aillustrates a process600by which the fleet management system100captures information about a fleet of outdoor power equipment and operators and uses the captured information to provide useful data and services to users203of the system, according to some embodiments of the invention. As block605illustrates, the equipment data sensor230in each piece of equipment202periodically captures and stores data about the equipment202and/or the equipment's environment from one or more sensors249/222on the equipment (which may or may not be located on the equipment data sensor230itself). In some embodiments, the equipment data sensor230is built into the equipment202when the equipment202is manufactured. In other embodiments, the equipment data sensor230is installed by the fleet owner, a dealer, or a service person after purchase of the equipment202.

In some embodiments, the sensors249of the equipment data sensor230capture data about the equipment202and/or the equipment's environment, and then the processing device232stores the data244in the memory240. In some embodiments, sensors222located on the equipment202, but not on the equipment data sensor230, capture data about the equipment202and/or the equipment's environment, and then the processing device232communicates with the equipment's control system212to capture this data244and store it in the memory240. The data captured about the equipment and/or its environment may be, for example, GPS or other location data, engine speed (e.g., motor shaft RPM), component speed (e.g., PTO speed, cutting blade RPM, etc.), acceleration, orientation, ambient temperature, engine temperature, component temperature, nearby equipment ID codes, nearby communication system ID codes, throttle status, PTO status, brake status, clutch status, user input commands, switch status, fuel level status, oil level status, battery level status, operator presence in a seat or other operator station, heading, run time, ignition status, vibration, shock, tire level, tire condition, differential locking, wheel spinning, wheel slipping, chain tension, belt tension, humidity, moisture, pressure, altitude, tampering, equipment hatch opening or closing, component replacement, and/or other parameters/metrics about the equipment's status, use, operation, and/or environment. As such, the sensors249/222may include such sensors as GPS receivers, RPM antennas, three-axis accelerometers or other accelerometers, electro-mechanical switches, thermocouples or other temperature sensors, proximity sensors, fluid level sensors, pressure sensors, moisture sensors, motion detectors, magnets and magnetic field sensors, RF antennas, infrared sensors, transducers, lasers, and/or other sensors.

In some embodiments, the processing device232uses the clock248to periodically (e.g., every minute) poll the sensors249or the equipment control system212to capture data244at that moment in time. The processing system232then stores this data244in the memory240in the form of data packets that have timestamps and/or are arranged in sequential order according to time.

As illustrated by block610inFIG. 6, the equipment data sensor230also looks for signals from any nearby operator ID units250. For example, in some embodiments, the processing device252of the operator ID units250uses the short-range transceiver264to periodically (e.g., every few seconds) or continuously transmit a wireless signal having the ID code255stored therein. Meanwhile, the processing device232of the equipment data sensor230periodically (e.g., every minute) uses its transceiver234to look within a relatively short range for the presence of any signals transmitted from any operator ID units250.

If the processing device232identifies an operator's ID unit250within the range, then, as illustrated by block615, the processing device232reads the ID code255from the received signal and stores the ID code255in the memory240with the captured sensor data as part of each data packet for as long as the signal from the ID unit250is still being received. If multiple ID units are found within a predetermined range, then those ID codes are also included in the data packets for as long as they continue to be in range. In order to determine if the ID unit250is still present, the processing device232may use the transceiver234to periodically look for the ID unit's signal at substantially the same time that the processing device232periodically captures data244from the sensors249/222.

As illustrated by decision diamond620, it is also periodically determined whether the electronic data sensor230is within range of a data communication system260. For example, in some embodiments, the processing device262of the data communication system260continuously transmits a wireless signal using its medium/long range transceiver264. The processing device232of the equipment data sensor230may periodically (e.g., every several seconds or minutes) look for a signal from a data communication system260. As illustrated inFIG. 6, if the processing device232of the equipment data sensor230does not find itself within range of the data communication system's transceiver264, then it continues its routine of periodically capturing data and ID codes and checking for any data communication systems260(blocks605-620).

As illustrated by block625, if the processing device232of the equipment data sensor230does receive a signal from the data communication system's transceiver264, then the processing device232may use the equipment data sensor's transceiver234to communicate the data244stored in the memory240to the data communication system260. As also illustrated, in some embodiments the processing device232may also continue its process of collecting data while it is also transmitting data to the data communication system260. In other embodiments, the processing device232may halt the data collecting procedures while the data244is being uploaded to the data communication system260.

In some embodiments, the processing device232may also require that one or more other conditions be satisfied before it begins uploading the data244to the data communication system260. For example, in some embodiments, the processing device232may wait until the equipment's engine is turned off or the equipment is stationary before it transmits the data244to the data communication system260. In some embodiments, the data communication system260is powered up automatically when the equipment202is powered down. For example, if the equipment202is powered down within range of a data communication system260, the equipment data sensor230may send a signal to a the data communication system260waking it up so that the equipment data sensor260can upload the data244to it.

As illustrated by block630, the data communication system260then communicates the data244to the data management server system270. Specifically, the processing device262uses the network interface265to make a connection to the data management sensor system270over the network206and transmit the data244(and in some embodiments ID codes255and269as described above) to the data management server system270using the appropriate communication protocol(s) based on the network206used.

As illustrated by block635, the data management server system270stores and processes the data244received from the one or more data communication systems260. As described in greater detail elsewhere herein with regard to the other Figures, the processing device274of the data management server system270executes a fleet management server application278to calculate other parameters from the data and/or use the data and calculated parameters to create charts, graphics, tables, alerts, tools, communications, outputs, etc. that assist a user203with management of a fleet of outdoor power equipment (or other equipment) and/or equipment operators. Much of the output and services provided to the user203by the fleet management system100is provided via a fleet management portal hosted on the network206by the data management server system270. For example, the fleet management portal may include a web portal version and a mobile app portal version. In addition to the fleet management portal, the data management server system270may send information or commands back to the equipment data sensor230so that the equipment data sensor230can take some action, control some part of the equipment202(e.g., control fuel supply and/or ignition timing of an internal combustion engine), and/or present information to the operator204. Further, some embodiments of the data management server system270send text messages, emails, or other communications outside the fleet management portal directly to client computing devices290

As such, as illustrated by block640, the data management server system270communicates processed data to one or more network-enabled client computing devices290(which may be mobile devices or other personal computing devices), equipment data sensors230or control systems212, and/or other output or feedback to systems interested in the data. In some embodiments this communication is in the form of a fleet management web portal, embodiments of which may be described in more detail herein below. With regard to the fleet management portal, different users203may have different access rights which provide different levels of information access, tools, and/or portals.

As mentioned above, the data collection and data communication steps of process600may be, in some embodiments, performed continuously, simultaneously, and/or at regular intervals, while in other embodiments some steps may be performed only in response to certain conditions which may prompt different modes of operation during which some of the steps of process600are performed while others are not. For example,FIG. 6Bis a flow chart illustrating various modes of operation of an embodiment of the equipment data sensor230and a process680that may be performed by the equipment data sensor230for selecting the proper mode of operation and communicating with other devices in the fleet management system, according to some embodiments of the invention. The process680illustrated inFIG. 6Bmay be particularly advantageous in situations where the equipment data sensor230is self-powered by its own battery (e.g., as embodiments of the universal equipment data sensor300may be) since the process680may prolong battery life relative to other processes for collecting and communicating data.

Referring now to blocks681and682in the flow chart ofFIG. 6B, when a battery is inserted into the equipment data sensor, the equipment data sensor first enters into a “shelf mode”682. In the shelf mode682, the equipment data sensor uses very little, if any, power (e.g., approximately 4.14 μA) and, as such, does not transmit any data externally nor communicate with any ID units or data communication systems.

As represented by decision diamond683, if the equipment data sensor is in shelf mode682and it detects that the engine is turned on (e.g., via receipt of a signal from the RPM sensor or some other sensor that detects engine operation), then the equipment data sensor will enter an “engine-on mode”684. In some embodiments the equipment data sensor will wait until the engine is running for at least some small predefined period of time (e.g., ten seconds) before it enters the engine-on state684. When in the engine-on mode684, the equipment data sensor will periodically sample and process data from the one or more sensors it is in communication with, such as RPM data from the engine RPM sensor. The equipment data sensor will also use its transceiver to periodically search for any nearby operator ID units. The equipment data sensor will generally consume more power operating in the engine-on mode684than in any of the other modes. In the illustrated embodiment, the equipment data sensor does not attempt to find or communicate with any data communication systems (e.g., base stations) while in the engine-on mode684. In the illustrated embodiment where the equipment data sensor utilizes a vibration sensor to sense vibration of the equipment data sensor, the equipment data sensor also disables this vibration sensor in this state to conserve power. In general, whenever the engine is turned on (at least for some small predefined minimum amount of time), then the equipment data sensor enters the engine-on mode684, regardless of which mode it is in at the time.

As represented by decision diamonds685and686, if the equipment data sensor determines that the engine has been turned off and determines that it has in its memory data that it collected about the equipment, the operator, or the equipment's operation that has not yet been communicated to a data communication system, then the equipment data sensor enters into an “active base station search mode”687. However, if the equipment data sensor determines that the engine has been turned off and determines that it does not have any data that needs to be communicated to a data communication system, then the equipment data sensor enters into a “passive base station search mode”692.

In the active base station search mode687, the equipment data sensor uses its transceiver to actively search for data communication systems (e.g., base stations) within range by periodically (e.g., every ten seconds) transmitting base station search packages. The base station search package tries, for example, up to three times in every attempt if no acknowledgement is received from the data communication system. As such, in one embodiment, the equipment data sensor sends up to eighteen packets each minute making the active base station search relatively power consuming, too.

As illustrated by decision diamonds688and block690, if a data communication system (e.g., a base station) acknowledges a transmission from the equipment data sensor, then the equipment data sensor transmits data packages stored in its memory to the data communication system in attempts to transfer all of the data that has not yet been transferred to a data communication system, using for example, the transceiver and a proprietary communication protocol. As represented by decision diamond691, if the equipment data sensor receives permission from the data communication system indicating that the data communication system has successfully received all of the data that the equipment data sensor needs to transmit, then the equipment data sensor enters the passive base station search mode692.

As illustrated by decision diamonds688and block689, in some embodiments, if the equipment data sensor does not receive acknowledgement from a data communication sensor and does not sense vibration using its vibration sensor for some predefined period of time (e.g., five minutes), then the equipment data sensor enters the passive base station search mode.

As mentioned above, the equipment data sensor will also go out of the active base station search mode687and into the engine-on mode684when the engine is turned on and allowed to run for some predefined minimum amount of time.

The passive base station search mode692is designed to reduce power consumption and, in one embodiment, the main difference between the passive base station search mode692and the active base station search mode687is the longer time between transmissions of search packages. For example, in some embodiments, the equipment data sensor in the passive base station search mode692will only transmit packages once every 300 seconds.

As illustrated by decision diamonds693,694, and695, the equipment data sensor will remain in the passive base station mode until it determines (using its sensors and/or clock) that any one of three different events happen. Specifically, as represented by decision diamond693, if the equipment data sensor senses some predefined minimum amount of vibration (e.g., some minimum vibration amplitude and/or length of time of vibration sensed by the vibration sensor) then, if there is data stored in the equipment data sensor that still needs to be transmitted to a data communication system, then the equipment data sensor again enters the active base station search mode687. As represented by decision diamond694, the equipment data sensor will also go out of the passive base station search mode692and into the engine-on mode684when the engine is turned on and allowed to run. As represented by decision diamond695, if the equipment data sensor is in the passive base station search mode692and detects that it has not been used for 30 days (or some other predefined and relatively lengthy period of time), then it enters back into the previously-described extremely-low-power shelf mode682. Otherwise it continues in the passive base station search mode692until one of the three conditions693,694, and695is satisfied.

In situations where the equipment data sensor230detects two or more operator ID codes255within range, the fleet management system100may automatically determine which operator is operating the equipment202on which the equipment data sensor230is located.FIGS. 7A and 7Billustrate a process by which the fleet management system100locates multiple persons within proximity to a piece of equipment and determines which one of these people is the operator of the piece of equipment. Specifically,FIGS. 7A, 7B and 7Cprovide a schematic diagram and flow charts illustrating operator-equipment pairing according to some embodiments of the invention.

FIG. 7Ashows a piece of equipment705(here a string trimmer) including an equipment data sensor720thereon. The equipment705is operated by a person named Karl710, who holds an operator ID unit730. Two other persons, Linda712and Sven714, work nearby and also have their own operator ID units732and734, respectively. Referring to block752in the process flow750shown inFIG. 7B, the equipment data sensor720of the equipment705periodically captures and stores data about the equipment705from one or more sensors on the equipment, as described in greater detail above. As illustrated by block754, concurrently with capturing data from the sensors, the equipment data sensor720also periodically looks for ID units within a predetermined range. As described above and as illustrated in the graphic745inFIG. 7A, the equipment data sensor720is arranged to be capable of receiving, and preferably also of transmitting, short range radio frequency signals. The operator ID units730,732, and734are carried by three operators710,712, and714shown inFIG. 7Aand are arranged to transmit radio frequency communication signals, such as, but not limited to, frequencies that are typically unlicensed.

In some embodiments, the equipment data sensor's transceiver has a maximum range that can be varied between five centimeters and thirty meters by varying the power available depending on the situation. For instance, in the case of communication between the equipment data sensor720and an operator ID unit730it may suffice with only a narrow range (e.g., maximum two meters) while the communication between an equipment data sensor720and a base station (not shown) might require a range more vast (e.g., twenty meters or more). A low-power short-range signal may be desired when searching for ID units so that the equipment data sensor230does not identify too many ID units at one time and so that, as described below, signal strength between multiple identified ID units are distinguishable, thereby allowing for an approximation of relative distance to each identified ID unit.

The equipment data sensor720is designed to receive any signal transmitted from an operator ID unit and store the related specific operator ID code obtained therefrom in the memory of the equipment data sensor720. As illustrated in graphic745inFIG. 7A, intercommunication could, for instance, be performed in time intervals in order to save energy. For example, the equipment data sensor720could be activated to listen to known ID units once every minute, while said ID units could be activated to transmit their ID-codes once every second. Furthermore, the equipment data sensor720may be configured to only look for new operator ID units every several minutes. An example of this type of process for identifying and monitoring nearby ID units is illustrated inFIG. 7Cand described in greater detail below.

InFIG. 7A, Karl710is operating the equipment705and is therefore well within the range of the equipment data sensor720. As such, the equipment data sensor720quickly finds Karl's ID unit730and listens approximately every minute for the ID code communicated by Karl's ID unit730. This listening by the equipment data sensor720is synchronized with its capturing of equipment data from the sensors, and the equipment data sensor720stores Karl's ID code with the sensor data in a new data packet periodically (approximately every minute in the illustrated example). Because Karl710and his ID unit730are very close to the equipment data sensor720, the equipment data sensor720receives a strong radio signal and many data packages with little, if any, interruption (brief interruptions due to random interferences may be possible as Karl710is operating the equipment705).

When the equipment data sensor720searches again for nearby ID units, not only does it still find Karl's ID unit730, it also finds Linda's ID unit732because Linda712has begun working within the broadcasting range of the equipment data sensor720. Accordingly, the equipment data sensor720stores both Linda's ID code and Karl's ID code in each data new data packet that it stores in its memory along with the corresponding sensor data, until it stops receiving signals from one or both of the two ID units. Without more, one could not know by looking at the data packages whether Linda712was merely in close proximity to the equipment705operated by Karl710or whether Linda actually took over operation of the equipment705and Karl710merely remained in the vicinity. However, since embodiments of the invention track operator performance, it can be very important to the accuracy and/or usefulness of the information that the fleet management system100can accurately identify the actual equipment operator and the roles of other nearby persons.

In order to assist with determining which ID code represents the actual operator of the equipment705, the equipment data sensor720is, in some embodiments, configured to identify and record a received signal strength indicator (RSSI) which is a measure of the signal strength of the ID code signal received from a ID unit (e.g., the power present in the received radio signal as measured by the power generated in the antenna of the equipment data sensor's transceiver). As illustrated by block756inFIG. 7B, the RSSI value of each transmission that the equipment data sensor720listens to is recorded in each data packet created by the equipment data sensor720along with the corresponding ID code. In one embodiment, the RSSI ranges between −100 dB and −1 dB.

As illustrated by graphic740inFIG. 7A, RSSI (and signal strength generally) is a function of distance and decreases as the distance between the ID unit and the equipment data sensor720increases. In some embodiments, certain zones are created to approximate different areas of distance (e.g., zone A=very close proximity to equipment; zone B=close proximity to equipment; and zone C=medium to long distance from equipment) and the fleet management system100recognizes these zones by a RSSI value that marks the transition from one zone to another.

In some embodiments, the equipment data sensor720is configured to ignore (e.g., not store or identify) ID units having a RSSI below a certain threshold in order to reduce noise or data that is not likely to be useful. For example, in the embodiment illustrated inFIG. 7A, the equipment data sensor720may be configured to ignore, filter-out, or otherwise exclude Sven714from the ID codes stored in the current data packet since the RSSI (here 0.7) of the radio signal currently received from Sven's ID unit734does not surpass a particular threshold (e.g., within zone C).

As illustrated by block758inFIG. 7B, the equipment data sensor720transmits data to the data management server system (e.g., via a base station or other data communication system). As illustrated by block760, the data management server system then automatically determines which ID code corresponds to the operator of the equipment705based at least in part on RSSI (i.e., signal strength), number of data packages, and/or other information received about operation of the equipment705and nearby equipment. For example, the highest RSSI generally indicates the operator, however, the data management server system may also look at the number of data packages received and the change in the RSSI over time since the operator ID code will typically be seen in most data packets received and, while it may not be the highest RSSI at all points in time, it will usually be the highest RSSI for most points in time. Other data that may also be used in the data management server system's algorithm may include, for example, information about whether the equipment705is running and/or ID codes and RSSI values received from other nearby equipment that indicate that one of the ID codes is clearly associated with the operator of the other equipment and therefore cannot likely be the operator of equipment705. In the illustrated embodiment, Karl's RSSI is 4.0, is fairly regular, and his ID code is present in many data packages, while Linda's RSSI is 1.3 and is also fairly regular, but her ID code is included in somewhat fewer data packages. Therefore, the data management server system270would determine that Karl is the most likely operator and would identify in the database that Karl was the operator at this point in time. Once this is determined, it may also be used, in some embodiments, by the data management server system270to help determine that Karl is not likely to be operating other equipment at the same time, despite other equipment sensing Karl's ID unit amongst one or more other operator ID units. An example of a process performed by the data management server system270to use RSSI values and other information to determine the likely operator is described in greater detail below.

As illustrated by block762, the data management server system may also be configured to determine and flag (e.g., send out an alert in the fleet management portal) any safety concerns or other issues based on RSSI of non-operators and the operational status of the equipment705. For example, the data management server system may be configured to alert the fleet owner or a team manager, in near real-time or after the fact, if Linda's RSSI value indicated that she crossed into zone A while equipment705had its cutting element in operation.

Although the flow charts describe an embodiment of the fleet management system where the operator is determined at the server level of the fleet management system, other embodiments may be configured so that the equipment data sensor, or even the data communication system, performs this operation of determining which ID code from a plurality of sensed ID codes represents the equipment operator at each point in time.

In some embodiments of the invention, the equipment data sensor230is arranged to also transmit radio signals so that two or more powered machines within broadcasting range of each other are able to sense each other's presence using their equipment data sensors230. As a safety measure the fleet management system may comprise a warning system arranged to alert a user of a powered machine in case the equipment data sensor registers a radio signal transmitted from another machine within its broadcasting range or with greater than some signal strength threshold. Such an alert may be any or a combination of audio, visual, or tactile signals such as for instance a sound alarm, a light signal and/or vibration signals. Hereby, unintentional interference between two operators may be prevented or avoided. In some embodiments instead of or in addition to a warning system, the fleet management system creates a safety record that is presented to a user after the fact.

In cases where the equipment is powered by a combustion engine, said communication device may further include a safety system arranged to be activated in case the equipment data sensor registers a signal transmitted from another machine within a pre-set range, where the safety system when activated may be arranged to put the engine of the powered machine on idle, shut off the engine, disengage the clutch, shutoff the PTO, and/or the like. This can be achieved for instance by means of restricting the fuel supply and/or air supply as has been described for instance in U.S. Patent Application Publication No. 2011/0095215. Also this aspect may prove to be advantageous in order to minimize the risk of two operators interfering with each other's work.

FIG. 7Cis a flow chart illustrating a process770that may be performed by an equipment data sensor720/230(e.g., via the processing device executing computer-readable program code stored in the memory and utilizing the transceiver, sensors, clock, and/or memory devices according to rules specified by the code) to look for, monitor, and store operator identification codes from a plurality of operator identification units within range of the equipment data sensor, according to some embodiments of the invention. This process may be performed as part of steps754and756of the process illustrated inFIG. 7B.

As represented by block772inFIG. 7C, when the equipment data sensor720determines that the engine is running (e.g., it senses engine RPM using the engine RPM sensor) it then, as represented by block774, spend some particular period of time (e.g., one minute) looking for any ID units within range.

As represented by decision diamond776and block778, if the equipment data sensor720does not identify any ID units within range, then it waits some particular period of time (e.g., seven minutes) before returning to step774to try again to find any nearby ID units.

As represented by decision diamond776and block780, when the equipment data sensor720does identify one or more ID units, then the equipment data sensor determines the number of ID units that can be identified and each ID unit's specific transmission period (since each ID unit will be periodically transmitting signals many times per minute and the periods of ID unit's transmission cycle will likely be offset in time at least slightly).

As represented by block782, based on the number of ID units and their specific transmission periods, the equipment data sensor720calculates a schedule for exactly when to listen to each ID unit once per minute (of course, periods of time other than one minute are also possible in other embodiments).

As represented by blocks784and786, the equipment data sensor then spends a particular period of time (e.g., fourteen minutes) listening for each identified ID unit's transmission according to the calculated synchronization schedule and storing the ID codes and RSSI values for each ID unit's transmission. After the period of time expires, the equipment data sensor may then then return to step774to again look for any and all of the ID units within range and repeat the above-described process for another, for example, fifteen minute session.

The illustration745inFIG. 7Ashows conceptually an example of how the operator sensing technique described with reference toFIG. 7Cworks. It should be appreciated that there are basically two modes in this illustration: an operator search mode and an operator synchronization mode. The first mode, the operator search mode, starts in minute 0 and finishes in minute 1. This mode is later repeated between minute 8 and minute 9 of the RPM session. During the first operator search session, the equipment data sensor720managed to find operator ID unit710. After the first operator search session ends, the equipment data sensor720will enter the first operator synchronization session where it will attempt to synchronize with the ID unit710once per minute. The equipment data sensor720will record if there was a “hit” or if there was not for each minute. In this example, the equipment data sensor720managed to have three hits in the first eight minutes of the RPM session. In minute 8, a second operator search session was started and lasted a minute. During this second operator search session, two operator ID units were found: ID unit710(again) and ID unit712. At the conclusion of the second operator search session, the second operator synchronization session begins and the same procedure described for the first synchronization session repeats but with the equipment data sensor720synchronizing with both ID units according to a schedule where it is specifically looking for each identified ID unit once per minute, but with slightly offset cycles so that it synchronizes with each ID unit at different points in time during each minute. In the example shown inFIG. 7A, the equipment data sensor720received 3 “hits” with the ID unit710and3hits with the ID unit712during the second operator synchronization schedule. After the whole RPM session ends (e.g., when the engine is turned off) the data from the equipment data sensor720will be put in a table and analyzed by the data management server system270to determine which of the ID codes710and712represented the operator of the equipment associated with the equipment data sensor720during the sessions when both ID codes where received.

Process for Deciding Who is the Operator:

When there is more than one detected operator in the module data, the data management server system270uses logic in the operator module of the parser module278B to decide which of the ID codes is the one associated with the operator who is actually the one operating the machine. To do this, in one embodiment the data management server system270goes through one or more tests until it reaches a particular level of confidence that one of the ID codes represents the operator.

Test 1—Unique Operator

The first test that the server270performs is to check if in the operator table if there is one or no operators. If there are no operators, then the result of the pairing will be unknown and the process stops for this session. If the operators list has only one operator, then that operator will be paired with the equipment as the operator and, in some embodiments, no more tests will be performed. If there are two or more operators, then the server270proceeds to the next test to check some other variables in the operators table to attempt to pair the equipment with a single operator.

In one embodiment, for every Operator Session there could be up to five Operator Search Sessions, so the following calculations may need to be performed for every

Operator Search Session. For every Operator Search Session there will be one or several “wining operator” and the operator or operators that appear in more “winning” session lists will be the one that should be paired to the equipment data sensor230and, thereby, to the equipment202.

Test 2—Synchronized Hits

The first variable to consider will be the Synchronized Hits; this variable represents how many times the equipment data sensor230found the operator between two search sessions. It is not possible just to see which operator has the greatest amounts of hits, because then the server270would eliminate all other important information like RSSI. So the operator with the greatest amount of hits has at least a certain percentage more hits than the operator with the second greatest amount of hits. This percentage difference is called the Synchronized Hits Threshold. This threshold is a value between 0 and 1.

The server270first organizes the operators in an array arranged in descending order by synchronized hits where the operator with the greatest amount of hits is in position 0 (Operator[0]) and the operator with the least amount of hits is in the last position (Operator[TD0-1]).

After the arrangement by synchronized hits is done, the server270checks if the operator at position 0 has more hits than the operator at position 1 and has at least the Synchronized Hits Threshold difference between both of them. For example, in one embodiment, this threshold has a value of 0.2. As such, the test may be codes something like this:

If this test fails, then the server270next will eliminate all the operators that have less synchronized hits than the operator with the highest amount of synchronized hits multiplied by 1 minus the Synchronized Hits Threshold. So any operator that has less synchronized hits than: (Operator[0].SynchronizedHits*(1−SynchronizedHitTH)), will be eliminated. This means that in the next test the server will have fewer operators to work with.

Test 3—Average Synchronized Hits RSSI

The next variable to check is the Average Synchronized Hits RSSI. A similar logic must be applied to the new check in that the server will also have an Average Synchronized Hits RSSI Threshold which will have a value between 0 and 1. For example, this threshold may be set to have a value of 0.1. The next thing for the server270to do is to organize the remaining operators in descending order in terms of the Average Synchronized Hits RSSI. Once this is done, the server270checks if the operator at position 0 has a greater Average Synchronized Hits RSSI than the operator at position 1 and at least having the Average Synchronized Hits Threshold difference between both of them. The check may be coded something like this:

If this check doesn't yield any result, then the server270will try to eliminate some operators in a way very similar to the previous elimination. Specifically, all the operators are eliminated that have less Average Synchronized Hits RSSI than the operator with the highest Average Synchronized Hits RSSI multiplied by 1 minus the Average Synchronized Hits Threshold. This means that all operators with less Average Synchronized RSSI than: (Operator[0]. AverageSynchronizedRSSI*(1−SynchronizedHitTH)), will be eliminated from the list.

Test 4—Average Search RSSI

The next variable that the server270considers is the Average Search RSSI by applying the same logic as before:

(i) organize the operators in descending order in terms of Average Search RSSI;

(ii) check if the difference of Average Search RSSI between the operator at position 0 and the operator at position 1 is at least the Average Search RSSI of operator 0 multiplied by 1 minus the Average Search RSSI Threshold (suggested value 0.1);

(iii) if there is no result from the check, then eliminate all operators that have a smaller RSSI than the operator at position 0 multiplied by 1 minus the Average Search RSSI Threshold (Operator[0]. AverageSynchronizedRSSI*(1−AverageSearchRSSITH)).

Test 5—Search Packages

The next, and in this embodiment the final, variable that the server270considers and is the Search packages, again following a similar routine:

(i) organize the operators in descending order in terms of Search packages;

(ii) check if the difference of Search packages between operator at position 0 and the operator at position 1 is at least the Search packages of operator 0 times the Search Packages Threshold (suggested value 0.3); and

(iii) if there is no result from the check, eliminate all operators that have a smaller RSSI than the operator at position 0 times the Search Packages Threshold (Operator[0]. SearchPackages*(1−SearchPackagesTH)).

If after analyzing all the operator variables there is still not a single “winner,” then the server270should select all operators as winners, and then check the next Search session. After selecting the wining operator(s) of the first Search Session, the server270does the same evaluation for all other Search Sessions. After evaluating all Search Sessions there will be one or several winning operator(s) per Search Session. So the operator that appears the most in the winner list across all Search Sessions is the one that should be paired with the equipment data sensor230and, thereby, to the equipment202. If there are two or more operators with the same amount of Search Sessions won, then the server may then make one final test.

Test 6—Random or Historic Selection

In the final test the server may select all the operators that have the same number of wins. Then out of this list the server270may select one of them randomly, or use other history parameters to be able to decide which operator should be paired. For example, if in the last ten sessions Operator Number1000was paired to this equipment data sensor230, and suddenly we have a session with a very tight decision between Operator Number1000and Operator Number2012, then because of history parameters the server should select Operator1000again. In another example, if Operator Number2012is already paired with another equipment data sensor during this period of time and that equipment data sensor is associated with equipment that is not likely to be used at the same time as equipment202, then Operator2012may be eliminated.

The skilled person realizes that a large variety of modifications may be performed and are contemplated and made known or obvious by the above description. For instance, according to one aspect of the invention a machine which has been operated is arranged to be paired with the operator who has been running/handling the machine in order to later be able to evaluate e.g. performance for training purposes. This can be achieved in different ways. According to some embodiments of the invention, one way is to provide the machine with a communication device able to receive and store an ID-code associated with an operator. The ID-code can be transmitted to the communication device as an RF-signal, via WiFi or any other suitable communication signal. The communication device will subsequently send all registered information, including stored values of parameters associated with running of the machine and ID-code/s, to a server, and the pairing is thereafter done at a server-level. However, another possibility is that the operator actively identifies himself/herself to the communication device, for instance by means of submitting a code (e.g. a code number) by means of a keypad connected to the communication device or by means of biometrics, meaning the pairing is done already at the machine level and the communication device will register the proper user by means of registering said code number.

Yet another possibility is that the identification unit is a cell phone containing the ID-code in a data-packet which can be transmitted to the communication device, where the pairing between the operator and the machine is done either already in the cell phone or in the communication device which receives the ID-code from the cell phone. Common for many of the embodiments is the collection and storing of data associated with running of the machine, pairing of the machine with the operator and evaluating the information. Evaluation is preferably done in a server. The server may be a remote, stationary server e.g. in a control centre, or it may be a mobile smart phone which can be used in close connection to the working fleet.

In various example embodiments described herein, a device (e.g., an equipment data sensor230, a data communication system260, a data management server system270, a client computing device290, etc.), which may comprise one or more sub-devices, may execute certain functionalities described above by employing software. When software is employed, it should be understood that the software may function responsive to the operation of processing circuitry configured to execute the corresponding functionalities. In some embodiments, the processing circuitry may include at least a memory and a processor. The memory may include one or more non-transitory memory devices such as, for example, volatile and/or non-volatile memory that may be either fixed or removable. The memory may be configured to store information, data, applications, instructions or the like for enabling the corresponding device to carry out various functions in accordance with exemplary embodiments of the present invention. For example, the memory could be configured to buffer input data for processing by the processor. Additionally or alternatively, the memory could be configured to store instructions for execution by the processor. As yet another alternative, the memory may include one or more databases that may store a variety of data sets responsive to input from a sensor network or other devices described herein. Among the contents of the memory, applications may be stored for execution by the processor in order to carry out the functionality associated with each respective application.

The processor may be embodied in a number of different ways. For example, the processor may be embodied as various processing means such as one or more of a microprocessor or other processing element, a coprocessor, a controller or various other computing or processing devices including integrated circuits such as, for example, an ASIC (application specific integrated circuit), an FPGA (field programmable gate array), or the like. In an example embodiment, the processor may be configured to execute instructions stored in the memory or otherwise accessible to the processor. As such, whether configured by hardware or by a combination of hardware and software, the processor may represent an entity (e.g., physically embodied in circuitry—in the form of processing circuitry) capable of performing operations according to embodiments of the present invention while configured accordingly. Thus, for example, when the processor is embodied as an ASIC, FPGA or the like, the processor may be specifically configured hardware for conducting the operations described herein. Alternatively, as another example, when the processor is embodied as an executor of software instructions, the instructions may specifically configure the processor to perform the operations described herein. As such, in some embodiments, the processor (or the processing circuitry) may be said to cause each of the operations or functions described in connection with the devices mentioned above by directing, responsive to the execution of corresponding instructions and/or algorithms, the storage, processing, generation, display, rendering, and/or communication of the data and/or information as described herein.

As will be appreciated by one of skill in the art, the present invention may be embodied as a method (including, for example, a computer-implemented process, a business process, and/or any other process), apparatus (including, for example, a system, machine, device, computer program product, and/or the like), or a combination of the foregoing. Accordingly, embodiments of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.), or an embodiment combining software and hardware aspects. Furthermore, embodiments of the present invention may take the form of a computer program product on a computer-readable medium having computer-executable program code embodied in the medium.

As the phrase is used herein, a processor/processing device may be “configured to” perform a certain function in a variety of ways, including, for example, by having one or more general-purpose circuits perform the function by executing particular computer-executable program code embodied in computer-readable medium, and/or by having one or more application-specific circuits perform the function. As used herein, the terms “determine” or “determining” do not necessarily mean determining an exact value and, instead, are meant to include “estimate” and “estimating” unless explicitly stated otherwise.