Abstract:
A system for the wireless activation or deactivation of one or more switches associated with one or more communication indicators within an industrial or professional working environment. The system includes at least one portable, handheld transmitter comprising at least one manually operated switch and a signal transmitter. Further included is at least one fixed indicator assembly comprising a signal receiver, at least one automatically operational switch, and at least one indicator capable of audibly or visually communicating a condition to workers within the industrial or professional working environment. The wireless indicator switch system is a highly flexible combination of a lightweight, small key fob type transmitter paired with a flexible receiver circuit board for controlling a variety of industrial and/or professional working environment indication devices. The wireless indicator switch will allow the indication device to be placed at its optimal location while allowing the worker to remain at their location and still activate the device. With the key fob sized transmitter, for example, the operator can easily activate an indicator light without leaving the work station.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit under Title 35 United States Code §119(e) of U.S. Provisional Patent Application Ser. No. 61/100,757; filed Sep. 28, 2008; the full disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to indicators and status information communication systems within industrial and professional working environments. The present invention relates more specifically to a handheld wireless system for activating and deactivating audio/visual indicators and other switchable loads used in industrial facilities and professional working environments. 
         [0004]    2. Description of the Related Art 
         [0005]    Communication in an industrial or professional business setting is of vital importance to coordinating activities and maintaining operation and production. Employees in an industrial environment must communicate when they need parts, have a quality problem, require assistance, or need to stop the movement of an assembly line. Employees in professional working environments such as laboratories, schools, hospitals, etc. often need to alert others within the facility of similar needs, conditions, or requirements. Keeping an operation running is also of vital importance to productivity and service quality in a manner that depends upon systems for keeping employees at their workstations. However, due to equipment, walls, and other physical divisions that block sight lines, noise that makes conversation difficult, and other distractions, it is often difficult for employees to communicate with each other while they are restricted at their workstations. 
         [0006]    Communication in industrial and professional work settings is addressed in several ways. No communication is required if an employee is able to simply leave their workstation to fix a problem. However, employees are not, in many circumstances, able to continue to perform their work while they are away from their workstations. In many situations employees are not able to leave their work in a safe condition to seek help or acquire materials. In addition, some problems can only be addressed by a person that is physically removed from the workstation that is in need of assistance. 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. 
         [0007]    Efforts have been made in the past to develop systems for communication in industrial and professional services facilities. Some of these systems are commonly referred to as “andon” systems. An andon system typically has a cord or light chain 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 sound to attract attention. In addition, andon systems may be tied into a conveyor system or a production control system to stop the production line. These systems are effective because they allow employees to quickly activate the system without leaving their workstation and then continue to work while waiting for assistance. However, andon systems are typically “hardwired” which makes them expensive to install and limited in range. 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 generally 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. 
         [0008]    Similar problems arise in a professional services environment. While individual employees may be responsible for a particular lab or instrument room they are seldom fixed in position within that room such that they might always be adjacent a call button or other andon type switch. In professional services environments, employees must be free to move about within their labs or test facilities, and yet must still be able to call for assistance when necessary. 
         [0009]    Some efforts have been made to provide more versatile devices to serve as communication indicators in industrial and professional service working environments. One such effort is reflected in the systems and methods disclosed in co-owned U.S. Pat. No. 7,006,792; issued Feb. 28, 2006; entitled Wireless Andon Communication Method and System; the entire disclosure of which is incorporated herein by reference. While the systems and methods of the cited reference solve many of the problems associated with portability and versatility in industrial working environments there remain many situations where an even more “portable” method for activating such work space communication indicators would be desirable. 
         [0010]    In view of the foregoing, a system is needed for providing communication in industrial and professional work environments quickly and effectively while keeping employees on task and in safe conditions. Such a system must be portable and compact, cost effective, easy to install, adaptable to changes in layout, and applicable to a wide range of industrial and professional working environments. The present invention provides a unique and beneficial way to activate an industrial or professional work space communication indicator, whether it is a light, sound, vibration, strobe, or other type of indicator or signaling device or combination thereof. The system of the present invention allows for even greater portability and convenience to the employee, allowing them greater mobility, and therefore greater safety, in their working environment. The system remains relatively simple to construct, install, and maintain, with fewer fixed and hardwired components than similar systems that attempt to carry out the same function. 
       SUMMARY OF THE INVENTION 
       [0011]    In fulfillment of the above stated objectives and directed to solving the above stated problems, the present invention provides a system for the wireless activation or deactivation of a switch associated with a communication indicator within an industrial or professional working environment. The system includes a portable, handheld transmitter comprising at least one manually operated switch and a signal transmitter. Further included is a fixed indicator assembly comprising a signal receiver, at least one automatically operational switch, and at least one indicator capable of audibly or visually communicating a condition to workers within the industrial or professional working environment. The wireless indicator switch system is a highly flexible combination of a lightweight, small, key fob type transmitter paired with a flexible receiver circuit board for controlling a variety of industrial and/or professional working environment indication devices. 
         [0012]    The present invention is therefore comprised of two primary components, a transmitter and a receiver, and optionally a third component, a local area data network. The transmitter as described above is a very small device similar to an automotive key fob used to lock and unlock one&#39;s vehicle. The transmitter would be lightweight and have a very small form factor to allow it to easily be carried around by the individual workers. The transmitter would be battery powered and can be set to different channels using a dip switch or trace cut selection system. The transmitter would be flexible and allow for different configurations and types of buttons depending on the user&#39;s needs. The transmitter could have one to eight (or more) buttons that could be of various types of rubber, plastic, or other tactile surface type buttons or switches. 
         [0013]    The receiver of the present invention is comprised of a small circuit board that would receive the signals from the transmitter and then turn on and off the various communications indicators and items attached to it. The receiver would allow for various combinations of inputs to allow it to control a variety of output configurations or capabilities simply by attaching the device wires to the circuit board in another configuration. The receiver would also incorporate a dip switch (or other resettable selection device) to allow for secure communication (a confirmation signal “handshake”) between it and the specified transmitter with the same dip switch setting. 
         [0014]    The receiver of the present invention would preferably include a communications processor and a wireless data communications transceiver that would allow it to convey activation and deactivation data to a central processing system through a local (or wide) area data processing network. Such interconnection will allow for not only the local communication of the employee&#39;s requirements but also a record keeping function and the communication of the need to remote systems and personnel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a schematic block diagram showing each of the major elements of the system of the present invention and their internal functional components. 
           [0016]      FIGS. 2A and 2B  are plan views of two examples of the hand carried transmitter component of the system of the present invention. 
           [0017]      FIG. 3  is a perspective view of one basic embodiment of the system of the present invention showing a hand carried transmitter component and a fixed receiver component associated with an industrial indicator. 
           [0018]      FIG. 4  is a partially schematic diagram showing the multi-indicator hand carried transmitter of  FIG. 2B  utilized in conjunction with multiple industrial indicators as might typically be found within an industrial environment implementing the system of the present invention. 
           [0019]      FIG. 5  is a perspective view of an alternate embodiment of the system of the present invention showing the use of multiple hand carried transmitter components and a single fixed receiver component associated with multiple indicator devices. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    Reference is now made to the accompanying Drawing figures for a more detailed description of the preferred embodiments of the present invention. In these Drawing figures the following elements and components are consistently identified across the Drawing figures with the reference numerals that correspond as follows: 
       1. COMPONENT LISTING 
       [0000]    
       
         
           
               10  industrial indicator control system 
               12  hand carried transmitter component 
               14  fixed receiver component 
               16  wireless local area data network component 
               18  manual pushbutton switches 
               20  transmitter control circuitry 
               22  transmitter power supply (batteries) 
               24  signal transmitter 
               26  receiver pairing switches (DIP) 
               28  transmitter status indicators 
               30  control signal from transmitter 
               32  signal receiver 
               34  receiver control processor 
               36  solid state load switches 
               38  power transformer 
               40  external power supply 
               42  industrial indicators (switched loads) 
               44  transmitter pairing switches (DIP) 
               46  receiver communications processor 
               48  wireless data communications transmitter/receiver 
               50  wireless data communications signal 
               52  wireless data communications transmitter/receiver 
               54  industrial facility data processing system 
               60  single switch hand carried transmitter 
               62  transmitter case 
               64  key ring 
               66  off button switch 
               68  on button switch 
               70  transmitter status indicator 
               72  multi-switch hand carried transmitter 
               74  transmitter case 
               76  transmitter antenna 
               78  component off button switch 
               80  component on button switch 
               82  component status indicator 
               84  industrial indicator strobe light 
               86  indicator cabinet mount 
               88  indicator power supply conduit 
               90  strobe support and motor 
               92  strobe light 
               94  wireless switch receiver 
               96  industrial indicator illuminated sign 
               98  wireless switch receiver 
               100  overall industrial environment 
               102  indicator sign panel 
               104  industrial machinery power interrupt 
               106  wireless switch receiver 
               108  electrical plug connectors 
               110  industrial indicator audible alarm 
               112  wireless switch receiver 
               114  loudspeaker/siren 
               116  indicator lights 
               120  multi-indicator system 
               122   a - 122   c  multi switch hand carried transmitters 
               124  multi-indicator cabinet mount 
               126  multi-indicator power supply conduit 
               128  wireless switch receiver 
               130  wireless receiver antenna 
               132   a - 132   c  multiple indicator devices 
           
         
       
     
       2. DETAILED DESCRIPTION OF THE DRAWING FIGURES 
       [0080]    Reference is made first to  FIG. 1  for a detailed description of the functional components associated with the overall system of the present invention and the manner in which these components interact to achieve the objectives of the system. While the examples given in the following detailed description might specifically refer to either an industrial environment or to a professional services work environment, those skilled in the art will recognize that the systems described might function to achieve the objectives of the invention in most any working environment where visual or audible communication is required. As such the use of “industrial” and “professional” should be considered to be interchangeable in the present descriptions. 
         [0081]    Wireless industrial indicator control system  10  as shown in  FIG. 1  generally comprises three primary functional components. Hand carried transmitter  12  provides the basic mechanism whereby the user is able to initiate the activation or control of an indicator. Fixed receiver  14  is the basic receiving unit for receiving a signal from a hand carried transmitter and performing the activation of the indicator. Data processing network  16  provides wireless data communications with the balance of the components of the system of the present invention and integrates this communication into an existing industrial environment data processing and control system. 
         [0082]    Hand carried transmitter  12  as shown in  FIG. 1  is a schematic example of a typical hand carried transmitter, further examples of which are described in more detail below. The basic components for each of the various types of hand carried transmitters  12  utilized in the system of the present invention are essentially the same. The device shown schematically in  FIG. 1  represents a hand carried transmitter  12  that might serve to control a single industrial indicator or through multiple duplicate circuit components serve to control more than one industrial indicator. The manner in which a single hand carried transmitter might control multiple indicators is described in more detail below. 
         [0083]    Transmitter  12  is comprised primarily of manual switches  18  which in the preferred embodiment of the present invention may number anywhere from 2 to 8. These switches are typically associated in pairs in order to provide both an on switch and an off switch for the specific industrial indicator. Those skilled in the art will recognize that in place of button switch pairs, a single switch may be provided that can be placed in an on or off condition. Manual switches  18  are connected directly to control circuitry  20  which in the preferred embodiment may be a microcontroller or microprocessor integrated into the hand carried transmitter  12 . Control circuitry  20  conveys the condition of the manual switches  18  to both signal transmitter  24  and optional status indicators  28 . Signal transmitter  24  generates the necessary radio frequency or other electromagnetic wave signal  30  that is transmitted over a distance to one or more fixed receivers  14 . Status indicators  28  are optionally provided on hand carried transmitter  12  as a manner of allowing the user to determine the status of the switch without actually viewing the switched indicator at the remote location. 
         [0084]    Transmitter  12  in the preferred embodiment is powered by power supply  22  generally comprised of a small lithium battery or the like. In addition to the above described circuitry, transmitter  12  integrates receiver pairing component  26  that allows the transmitter to be matched with or paired with a fixed receiver  14 . In the preferred embodiment, this receiver pairing component may comprise an array of four DIP switches that can be set to match a similar set of DIP switches on the fixed receiver  14 . Other mechanisms (solid state or mechanical switches) for coding and pairing a transmitter  12  with one or more fixed receivers  14  are anticipated. 
         [0085]    Fixed receiver  14  as shown in  FIG. 1  provides a typical example of the circuitry required for receiving a signal from transmitter  12  and activating or de-activating an indicator. One or more of fixed receivers  14  would be positioned in association with a variety of different industrial and/or professional services communication indicators as described in more detail below. Receiver  14  in the preferred embodiment includes signal receiver  32  which is tuned and configured to receive the activation signal  30  from the signal transmitter  24  positioned in hand carried transmitter  12 . As mentioned above, fixed receiver  14  incorporates transmitter pairing switches  44  which in the preferred embodiment are DIP switches that may be set to match and pair with the similar set of switches in hand carried transmitter  12  as described above. 
         [0086]    Signal receiver  32  receives and conveys the activation signal  30  to control processor  34  within fixed receiver  14 . Control processor  34  may in the preferred embodiment be either a microcontroller or a microprocessor. Because the present invention anticipates the optional communication of additional data to a local area network, it may be preferable for control processor  34  to be a basic microprocessor that can be programmed and re-programmed according to the specific needs of the particular work environment within which the system operates. 
         [0087]    Control processor  34  directs the operation of solid state load switches  36  which may receive power from power transformer  38  which in turn receives power from an external power supply  40 . Power transformer  38  also provides the necessary electrical power for the operation of the balance of the electronic components within fixed receiver  14 . Solid state load switches  36  may be any of a number of different types of solid state power switching devices such as MOSFET type electronic devices capable of switching the voltages and currents typically associated with industrial indicators. 
         [0088]    Fixed receiver  14  will generally be configured on a circuit board and connected with and attached to the industrial indicator (switched load)  42  that it is intended to control. Indicator  42  may receive a separate source of power directly from external power supply  40  or may receive its switched power through solid state load switches  36 . Those skilled in the art will recognize that the switching mechanism may occur through one or more (multiple) solid state switches and/or physically switching solenoids that may be positioned within the fixed receiver component  14  or positioned within the indicator switched load component  42 . Various industrial indicators and switching devices configured in this manner are described in more detail below. 
         [0089]    As indicated above, the system of the present invention, in addition to activating or de-activating an industrial indicator or switching a load, serves to communicate the status of these industrial and professional work environment systems to a data processing network associated with the environment. The system accomplishes this by directing appropriate data transfer from control processor  34  through communications processor  46  within fixed receiver  14 . Communications processor  46  may in the preferred embodiment be a separate microprocessor whose function it is to receive, accumulate, and transmit informational data through wireless data communications component  48  by way of a wireless data signal  50  through to the local area network associated with the operation of the industrial environment. Communications processor  46  may also be integrated into control processor  34  and carry out the necessary functions associated with each controller. 
         [0090]    The local area network data processing system  16  associated with the industrial or professional work environment will have a wireless data communications component  52  designed to receive and transmit data signals back and forth with the wireless data communications component  48  of the various fixed receivers  14  throughout the system. In this manner, data regarding the status of the system as a whole is communicated to the central data processing system  54  associated with the industrial environment, warehouse, assembly line, laboratory, etc. Computer system  54  may in the preferred embodiment also be a monitoring and control system that allows centralized control over all of the indicators within the system. 
         [0091]    Reference is now made to  FIGS. 2A &amp; 2B  which are plan views of two examples of the hand carried transmitter component of the system of the present invention.  FIG. 2A  shows a handheld transmitter integrating a single activation/deactivation switch pair while  FIG. 2B  shows a larger (but still handheld) transmitter that includes four sets of activation/deactivation switch pairs. Single switch pair handheld transmitter  60  as shown in  FIG. 2A , comprises transmitter case  62 , key ring  64 , off button switch  66 , and on button switch  68 . Case  62  is sized similar to an automotive key fob with similar types of push buttons. Two push buttons, off button  66  and on button  68 , are shown although it is known in the art that a single button may be configured to alternately switch on or switch off some function intended to be activated or deactivated. Other switch arrangements can be implemented, but in general the embodiment shown in  FIG. 2A  is directed to a simple activation or deactivation of a single, specific communication indicator of the types described below. Transmitter  60  may optionally include status indicator  70  which allows the user to view the state of the switched indicator without actually viewing or hearing the indicator (which is positioned specifically for others to take notice of). 
         [0092]    It is also possible to structure the functionality of the single switch system shown in  FIG. 2A  such that sequential activations of the single switch progressively alter the actions or characteristics of the associated indicator assembly. The indicator assembly may, for example comprise a light stack with a column or row of three lights, as an example, red, yellow, and green (such as those shown in  FIG. 5 ). The single transmitter may readily serve to allow a progression through the lights in the light stack such that a single press of the on button changes the stack light from green to yellow (suggesting that assistance may be needed but is not urgent) and a second press of the same on button changes the yellow indicator light to red (suggesting that the assistance required is more urgent). 
         [0093]    The embodiment of the handheld transmitter  72 , shown in  FIG. 2B , is directed to a multi-indicator assembly or to multiple indicator assemblies. The embodiment shown may be considered to operate like four separate single indicator transmitters. Each (on/off) switch pair  78 / 80  may, once again, be replaced by a single button switch that serves to sequentially turn on or off the switch with which it is associated. The entire array of switches (four in the example shown) could also be directed to an association with either four discrete communication indicator assemblies or could be associated with a single assembly with multiple states. With the light stack example given above, the multi-switch embodiment could control an indicator to illuminate the green light (or not) with switch pair “A”; the yellow light (on/off) with switch pair “B”; the red light (on/off) with switch pair “C”; and finally, perhaps, an audible alarm with switch pair “D”. Any combination of multi-indicator assemblies or single indicator assemblies can be controlled through the appropriate pairing and “programming” of the transmitters and receivers. 
         [0094]    The multi switch handheld transmitter  72  shown in  FIG. 2B  includes a transmitter case  74  and a transmitter antenna  76 . The added antenna  76  may be necessary in order to provide a sufficient multi-frequency signal transmission that is not necessary with the embodiment shown in  FIG. 2A . In a manner similar to the transmitter of  FIG. 2A , an optional status indicator  82  may optionally be provided for each of the on/off ( 80 / 78 ) switch pairs that are present on the multi-indicator device. The manner in which this embodiment of the handheld transmitter operates is described in more detail below with regard to  FIG. 4 . 
         [0095]      FIG. 3  is a perspective view of one basic implementation embodiment of the system of the present invention showing a hand carried transmitter component and a fixed receiver component associated with an industrial or professional work environment indicator.  FIG. 3  provides an example of the simplest connection between the handheld transmitter  60  and a typical fixed indicator assembly  84  of the present invention. In this example, a single switch handheld transmitter  60  is configured to control the operation of a simple flashing strobe light  92  associated with the indicator assembly  84 . Strobe light  92  may be an AC powered rotating lamp extending from strobe support and motor  90 . These components are mounted to indicator cabinet mount  86  which in turn may preferably be mounted to the wall or ceiling of the work area. Integrated into cabinet mount  86 , or attached to its side, is wireless switch receiver  94  which, as described above, includes the necessary receiver and control circuitry to receive a signal from the handheld transmitter  60  and translate it into the activation or deactivation of a switch (preferably solid state) to turn the indicator (light in this case) on or off. Because this indicator assembly is typically fixed, power to the unit may be supplied by hardwired electrical lines through the power supply conduit  88  as shown. 
         [0096]      FIG. 4  is a partially schematic diagram showing the multi-indicator hand carried transmitter of  FIG. 2B  utilized in conjunction with multiple industrial indicators as might typically be found within an industrial environment implementing the system of the present invention. This multi-indicator device functions generally as described above, and can serve to activate/deactivate as many as four different indicator assembly devices. Shown as examples in  FIG. 4  are the industrial indicator strobe light  84 , as described with  FIG. 3  with wireless switch receiver  94  associated therewith. In a similar manner, multi-switch handheld transmitter  72  may control: industrial indicator illuminated sign  96  (having wireless switch receiver  98  and indicator sign panel  102 ); industrial machinery power interrupt  104  (having wireless switch receiver  106  and electrical plug connectors  108 ); and (as a further example) industrial indicator audible alarm  110  (having wireless switch receiver  112  and loudspeaker/siren  114  with optional indicator lights  116 ). Collectively these components may, as an example, make up the entire industrial/professional working environment system  100  shown as a typical example in  FIG. 4  of the functional implementation of the multi-channel operation of the system. 
       3. ALTERNATE PREFERRED EMBODIMENTS 
       [0097]    Reference is finally made to  FIG. 5  for a description of an alternate embodiment of the present invention that includes multiple transmitters and a single indicator assembly that includes multiple indicators. In this embodiment, a number of different users (workers in different locations) may each carry one of a number of multi switch (or single switch) handheld transmitters  122   a - 122   c  that are paired to a fixed receiver  124  and more specifically to one of a number of discrete indicators  132   a - 132   b  controlled by that fixed receiver  124 . By appropriate pairing of the signal transmissions and receptions a single receiver  124  may distinguish the signals it receives and activate or deactivate one of a number of discrete indicators  132   a - 132   c  at a particular location. In the example shown, each indicator is a stack light of the type discussed above wherein (for example) the repetitive press of the single switch on the transmitter progressively moves the indicator light from green to yellow to red depending on the urgency of the need. Alternately, the multi switch transmitters  122   a - 122   c  as shown in  FIG. 5  may discretely activate the various functions (lights) within each stack light device. Each of the different stack light sets  132   a - 132   c  would (for example) be associated with a different physical location within the facility and the appropriate personnel could respond according to the location of the need and the urgency of the request for assistance. 
         [0098]    The receiver unit shown in  FIG. 5  may preferably include multi-indicator cabinet mount  124  which is supplied with the requisite power through power supply conduit  126 . Wireless switch receiver  128  includes wireless receiver antenna  130  to facilitate resolution of the incoming signals from the multiple transmitters in this embodiment of the system. As with the systems described above, this alternate embodiment may include data communications links to a local area network (LAN) or optionally into a wide area network (WAN) such as the Internet, for remote data logging or monitoring. Such connection to a data network may be accomplished through the use of components integrated into the cabinet  124  as shown in  FIG. 5 , or may comprise connection to a separately mounted wireless (or wired) network transceiver. 
         [0099]    The multiple indicator devices  132   a - 132   c  shown in  FIG. 5  are of the stack light type of indicators that may serve to best display the type of assistance that is required by a particular employee at a particular location. Using the standard green/yellow/red (G/Y/R) color combination, these indicators may easily provide information about the urgency of the request for assistance. These color coded lights (in G/Y/R or some other color combination) may alternately serve to indicate different needs such as “parts needed” or “relief needed” or “job completed” or the like. 
         [0100]    Although the present invention has been described in terms of the foregoing preferred embodiments, this description has been provided by way of explanation only, and is not intended to be construed as a limitation of the invention. Those skilled in the art will recognize modifications of the present invention that might accommodate specific industrial or professional working environments and requirements. Those skilled in the art will further recognize additional means for implementing suitable communication indicator assemblies to accommodate various commonly encountered conditions and requirements in various industrial and professional settings. Such modifications, as to system structure, configuration, size and communication methodologies, where such modifications are coincidental to the type of industrial or professional environment present, do not necessarily depart from the spirit and scope of the invention.