Abstract:
A portable wireless andon communication system and method for use in manufacturing, assembly and other industrial settings. A transmitter station and receiver station are set up for immediate use by simply connecting each to a standard power source. A user needing assistance manually activates a switch at the transmitter station, thus turning on a light and transmitting a corresponding signal to the receiver station. The receiver station receives the signal and turns on a corresponding light and tone generator. The tone generator and light alert indicate to the proper parties the request for a response. A responding party scans transmitter stations for the corresponding light and provides assistance. The switch may be a sensor activated by a change in state indicating that assistance is required. The portable system is easily reconfigured if necessitated by layout changes in a manufacturing line.

Description:
BACKGROUND OF INVENTION 
   1. Field of the Invention 
   The present invention relates to an andon communication system and method and, more particularly, a wireless system and method for using such a system in manufacturing, assembly and other industrial settings. 
   2. Background Art 
   Communication in an industrial setting is of vital importance to coordinating activities and maintaining production. Employees must communicate when they need more parts, have a quality problem, need assistance, or simply need to use the restroom. Keeping an operation running is also of vital importance to productivity that depends upon systems for keeping employees at their workstations. However, due to equipment that blocks sight lines, noise that makes conversation difficult, and other distractions, it is difficult to communicate with employees at their workstations. 
   Communication in industrial settings is addressed in several ways. No communication is required if an employee simply leaves their workstation to fix a problem. However, employees cannot perform value added work while they are away from their workstations. In addition, some problems cannot be addressed by the appropriate party and will likely reoccur. If the employee leaves their workstation to find the appropriate party to address a problem and then returns to their workstation, downtime may be caused that can impact productivity depending on the employee and the responsible party&#39;s location. Instead of leaving their workstation, an employee may yell or use hand signals to attract the attention of the responsible party. This method distracts the employee&#39;s attention away from their work and only works as long as the environment is not too loud or if visual contact is possible. 
   In an effort to overcome the shortcomings of these previous methods, two-way radios may be used to enable employees to communicate to one another. However, high quality radios are expensive, often costing over a thousand dollars each to purchase. Two-way radios require new or recharged batteries to keep the system functioning properly. In addition, employees must stop value-added production activities to talk on a radio, thus defeating the purpose of having the radios in the first place. 
   Another system for communication in an industrial facility is commonly referred to as an “andon system.” An andon system typically has a rope that runs through an employee&#39;s workstation and is tied to a switch. When the switch is activated, a light on a “scoreboard” illuminates to indicate the station that activated the system. When activated, a tone generator may begin to play to attract attention. In addition, andon systems may be tied into a conveyor system or a production control system to stop the line. This system and method is very effective because it allows employees to quickly activate the system without leaving their workstation and then continue to work while waiting for assistance. However, andon systems are hardwired which makes them expensive to install. Andon systems tend to be inflexible so that changes in layout of a line necessitate revamping the andon system. Andon systems are also expensive to build and maintain due to the need to integrate them with other systems. Andon systems are too expensive and impractical for manufacturers who frequently change production line layouts. As a result, most industrial environments do not use andon systems but rely on simpler, less efficient methods as discussed above. 
   In view of the foregoing, a system and method is needed for providing communication quickly and effectively while keeping employees on task. The system and method must be cost effective, easy to install, adaptable to changes in layout, and applicable to non-conveyor driven environments. 
   SUMMARY OF INVENTION 
   One aspect of the present invention is to provide a wireless communication system and method for using the same in an industrial setting, such as manufacturing, assembly, and processing facilities. In one embodiment, multiple transmitter stations and a receiver station communicate via a wireless signal. 
   Each transmitter station may comprise a stand that is used to hold and elevate an indicator light. The transmitter station plugs into a conventional power outlet for power and no additional wiring is necessary. When assistance is needed, the transmitter station is activated using a manual or automatic switch. A light on the transmitter station is activated and a transmitter transmits a signal. A receiver in the receiver station receives the signal. 
   Alternatively, the transmitter stations may have a plurality of sensor input ports that may be used to collect data. The sensors may or may not be connected to indicator lights or tone generators of the transmitter and receiver. 
   According to yet another aspect of the invention, the receiver station comprises a box containing a receiver and has lights, a tone generator and data output ports that may be mounted on or off of the box. The receiver unit plugs into a standard power outlet and no additional wiring is necessary. The receiver activates a light and turns on the tone generator when the receiver detects a signal. Upon hearing the tone generator, responsible parties may look to the receiver unit to see which light is illuminated to determine the type of assistance required and the responsible party. The responsible party then identifies and approaches the activated transmitter station to give assistance. The switch on the transmitter station is then turned off and the whole andon system returns to standby mode. Alternatively, the receiver may receive some signals from the transmitter that do not activate the receiver&#39;s lights and tone generator. These signals can be provided to a computer for record keeping and interpretation. 
   The system and method according to the present invention provides many advantages and improvements over the prior art. The system does not require running conduits or cables to system components, because the system can simply be plugged into an available power source that is within close proximity to the components. The installation method of the present invention consists of simply placing the transmitter stations and the receiver station where desired, placing the transmitter station switches where desired, and plugging the stations into a power source. There is no costly, time-consuming installation as with other andon systems. Employees can quickly activate the system without having to leave their workstation and can continue to work while waiting for assistance. The system can be used with or without a conveyor system. The system does not utilize expensive control devices and is more affordable than other communication systems. The system is very flexible because the transmitter stations can be moved and rearranged as easily as moving a lamp in one&#39;s home. 
   The foregoing and other features of the invention are more fully described in the following description that describes certain illustrative embodiments of the invention. These illustrative embodiments are merely indicative of but a few of the various ways in which the principles of the present invention may be employed. Accordingly, specific structural and functional details of the illustrative embodiments are not interpreted as limiting, but merely as representative to teach one skilled in the art how to employ the present invention. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
       FIG. 1  is a perspective view of one embodiment of a transmitter station according to the invention; 
       FIG. 2  is a front perspective view of one embodiment of the transmitter box according to the invention; 
       FIG. 3  is a perspective view of one embodiment of a receiver station according to the invention; 
       FIG. 4  is a simplified schematic of one embodiment of a receiver station according to the invention; 
       FIG. 5  is a simplified schematic of one embodiment of a transmitter station according to the invention; 
       FIGS. 6A and 6B  are two parts of a flowchart of one embodiment of a method according to the invention; 
       FIGS. 7A and 7B  are two parts of a flowchart of another embodiment of a method according to the invention; and 
       FIG. 8  is a flowchart showing an alternative embodiment of the invention. 
   

   DETAILED DESCRIPTION 
   Referring now to  FIG. 1 , a transmitter station is generally indicated by reference numeral  10 . The transmitter station  10  has a transmitter housing  12  that is connected by a bracket  14  to a stand  16 . The transmitter station  10  may be simply installed by connecting a power cord  18  to a conventional electrical outlet (not shown). The power cord  18  is secured to the stand  16  by means of plastic ties  20  to reduce the risk of snagging the power cord  18  and pulling the transmitter station  10  over. 
   The transmitter station  10  also includes a plurality of lights  22 . The lights may be colored lights of any type including, but not limited to incandescent lights, LED lights, or the like. The lights may be flashing or rotating lights (not shown) that enhance their visibility. Flexible conduit  24 , protected wire, or shielded wire, is connected between the transmitter housing  12  and a switch box  26  that includes manually operable switches  28 . The manually operated switches  28  may be toggle switches or push button switches (not shown). The conduit  24  encloses wires (not shown) connecting the switches  28  to the transmitter housing  12  as will be more specifically described below. Sensors  30 , such as proximity switches, limit switches, (not shown),or scale switches (not shown) can attached to the transmitter housing  12 . The sensors  30  may be connected to part supply ends (not shown), hoppers (not shown), or flow racks (not shown) to indicate that a line station (not shown) requires restocking. One or more connectors  32  may be provided for connecting a sensor  30 , monitor (not shown) or counter devices (not shown) to the control circuitry in the transmitter stion  10 . One light  22  is provided for each switch  28  or sensor  30  so that it can be visually determined which switch  28  or sensor  30  triggered the transmitter station  10 . 
   Referring now to  FIG. 2 , the contents of the transmitter housing  12  is schematically shown. The transmitter housing  12  houses a power transformer  36  that provides power to a transmitter  38 . A port connector  32  may also be provided. The power transformer  36  may also provide power for the lights  22 , switches  28  and sensors  30 , as shown in  FIG. 1 , if necessary. A circuit board  40  may be provided to control inputs and outputs. Holes  42  are provided in the transmitter housing  12  for wire that extends to the lights  22 , switches  28  and sensors  30  as shown in  FIG. 1 , through the flexible conduit  24 , shielded wire, or the like, as shown in  FIG. 1 . A plurality of single channel transmitters  38 ′, 38 ″, 38 ′″ may be provided or a single transmitter  38  having multiple channel capabilities may be provided. The transformer  36  may be used to convert alternating current to direct current power. Other current supplies may be used and other power outputs may be provided as is well known in the art. If alternating current is not available in a particular location, power may be obtained from a battery, solar or other source (not shown). 
   Referring now to  FIG. 3 , a receiver station  46  is illustrated that includes a housing  48 . The housing  48  may be connected to a mounting surface by means of hanging clips  50 . Alternatively, a pipe bracket  52  may be provided to connect the housing  48  to a pipe  54 . A control circuit  56  is actuated by receivers  58 . When the control circuit  56  is actuated, tone generator  60  or lights  62  may be switched on; and, if desired, data signals may be sent to a computer via a parallel, serial, usb port or other connector  70 . The tone generator  60  may be a horn, buzzer, or audio speaker that are used to provide an audible alarm or audible voice message. The lights  62  are preferably of different colors and may be incandescent, LED or other types of light fixture. The light fixtures may include a rotating or flashing display element (not shown) if desired. The receiver station  46  includes its own power source  64  that may be connected by a power cord  66  to a source of AC current. Alternatively, power source  64  can be battery powered or solar powered (not shown), particularly if a source of AC current is not readily available. The lights  62  may be mounted at a distance from the housing  48  and, if so, may be connected by conduit  68  to the housing  48 . 
   Referring now to  FIG. 4 , a simplified schematic of the receiver station  46  is shown. Receivers referred to by reference numeral  58  are housed in a receiver box  48 . Receivers, upon receipt of the appropriate signal from the transmitter, actuate the control circuit  56  that operates the tone generator  60 . Also, the control circuit  56  actuated by the receiver activates receiver lights A, B, and C that are referred to by reference numeral  62 . The receiver  58 , control circuit  56 , lights  62 , tone generator  60 , are all powered by the power source  64  that may, if desired, be a dual AC/DC power supply. One or more port connectors  70  may be provided to permit connection of the receiver to a computer. 
   Referring now to  FIG. 5 , a simplified schematic of a transmitter station is shown to include a transmitter housing  12 . Transmitter  38  is housed within the housing  12  along with a power source or power transformer  36  that provides power to the transmitter  38 . A switch box  26  houses switches A, B and C referred to by reference numeral  28  that are used to turn the transmitter on and off. When the transmitter is turned on, an analog or digital signal such as a radio frequency, Bluetooth, infrared, cellular and/or microwave signal is transmitted to the receiver as previously described with reference to  FIG. 4 . In addition, transmitter lights A, B and C, commonly referred to by reference numeral  22 , are illuminated to provide line-of-sight communication if the service personnel or responsible party is in a location from which the transmitter lights may be observed. In this way, responsible personnel would be alerted to a problem by any transmitter lights that are associated with the transmitter station  10  or may be alerted by means of the receiver station  46 . In addition, monitoring and data collection sensor input  32  allows for additional sensors, monitors or switches to be connected to the transmitter unit. 
   Operation of the system and method is described with reference to  FIG. 6 , which is a flowchart showing the logic of one embodiment of the invention. In step  100 , the employee or user determines that they need assistance. For illustration purposes only, it will be demonstrated that the user needs assistance from a supervisor; and for illustration purposes only, it will be demonstrated that a yellow light corresponds to “Supervisor Assistance Needed.” In step  101 , the user activates the switch  28  in  FIG. 1  labeled for supervisor and then returns to task. Now that the “Supervisor” switch has been activated, in step  22  the yellow light  22  in  FIG. 1  on the transmitter station  10  is illuminated. Simultaneously, in step  103 , one of the transmitters  38  begins transmitting a signal. In step  104 , the receiver  58  in  FIG. 3  receives a specific signal which the receiver recognizes as the “Supervisor Assistance Needed” signal. In step  105 , communication of data to a computer may be ported through data port  70 . In step  106 , the receiver turns on the yellow “Supervisor Assistance Needed” light  62  in  FIG. 3 . Simultaneously, in step  107 , the receiver  58  turns on the tone generator  60  in  FIG. 3 , which begins to emit an audible tone. In step  108 , the supervisors hears the tone. In step  109 , the supervisor looks to the receiver unit and sees that the “Supervisor Assistance Needed” light is on. In step  110 , the supervisor then scans the transmitter units to identify the transmitter unit with the illuminated yellow light. In step  111 , the supervisor goes to the activated transmitter station  10  to give assistance. In step  112 , the switch  28  at the transmitter station  10  is turned off. Then in step  113 , the light  22  on the transmitter station  10  is turned off; and at  114 , the transmitter  38  stops transmitting a signal. In step  115 , the receiver  58  stops receiving a signal. At  116 , data port communication to the computer is terminated. In step  117 , the light  62  on the receiver station  46  is turned off; and at  118 , the tone generator  60  is turned off. In step  119 , the wireless andon communication system returns to stand-by mode. 
   Another example illustrating operation of the system and method is described with reference to  FIG. 7 , which is a flowchart showing the logic of another embodiment of the invention. This flowchart is designed, not to limit, but to illustrate how the system and method can be applied to sensors  30  that are not manually actuated and may aid in summoning material handling or maintenance assistance. For this illustration, a sensor  30  in  FIG. 1  has been added to detect the presence of a box at a certain position in a flow rack. The flow rack has to be restocked when the sensor  30  no longer detects a box or article. In addition, for illustration purposes only, it will be demonstrated that a green light corresponds to “Material Handler Assistance Needed.” In step  120 , the number of boxes or articles in the flow rack reaches a restocking point. In step  121 , the sensor  30  is activated since there is no box present to turn the sensor  30  off. At  122 , the control circuit responds to actuation of the sensor  30 . Now that the sensor  30  has been activated, in step  123 , a green light  22  in  FIG. 1  on the transmitting station  10  is illuminated. In step  124 , one of the transmitters  30  begins transmitting a signal. At  126 , the control circuit may initiate sending data to the computer via the port  70 . In step  127 , the receivers  58  in  FIG. 3  receives a specific signal which the receiver recognizes as the “Material Handler Assistance Needed” signal. In step  127 , the receiver  58  turns on the green “Material Handler Assistance Needed” light  62  in  FIG. 3 . Simultaneously, in step  128 , the receiver  58  turns on the tone generator  60  in  FIG. 3 , which begins to emit an audible tone. In step  129 , the material handler hears the tone. In step  130 , the material handler looks to the receiver unit  46  and sees that the “Material Handler Assistance Needed” light is on. This tells the material handler that an operator or a flow rack in their area needs attention. In step  131 , the material handler then scans the transmitter units  10  to identify the transmitter unit  10  with the illuminated green light  22 . In step  132 , the material handler goes to the activated transmitter station  10  to restock the flow rack. In step  133 , the sensor  30  at the flow rack is turned off once it detects that a box is present. Then in step  134 , the light  22  on the transmitter station  10  is turned off and at  135  the transmitter  38  stops transmitting a signal. In step  136 , the receiver  58  stops receiving a signal and at  137  the control circuit terminates communication to the computer. In step  138 , the light  62  on the receiver station  46  is turned off; and at  139 , the tone generator  60  is turned off. In step  140 , the wireless andon communication system returns to standby mode. 
   While the above embodiment discloses the use of a tone generator, it should be understood that the system could also be developed or programmed for silent operation as illustrated in  FIG. 8 . At  150  sensor, such as a motion detector, proximity switch, manual switch, light switch, or the like detects a change in state. The transmitter begins at  151  to transmit a coded signal that is most likely a digitally coded signal. The receiver receives the coded signal at  152  that was sent by the transmitter at  151 . The control circuit within the receiver unit outputs data to a computer that monitors an operation at  153 . At  154 , the sensor returns to its “normal” state. When the sensor returns to its normal state, the transmitter stops sending the digital signal at  155  and the receiver stops receiving the signal at  156 . As a result, the control circuitry, at  157 , stops sending data to the computer at  157 . The system then returns to the standby mode at  158 . 
   While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.