Patent Publication Number: US-6985085-B1

Title: Safety view blind finder for a crane

Description:
TECHNICAL FIELD 
   The present invention relates to crane safety methods and devices and, in particular, to improved safety devices and methods which provide a crane operator a view of the movement of portions of the crane. 
   BACKGROUND 
   Most conventional crane safety devices must be manually attached to the load each time that a new load is secured to the crane. Also, a warning beacon on the safety device can easily be obscured by the load, especially where the load is large or of an unusual shape. And, finally, the warning indicators on the device are active regardless of whether the load is actually in motion, leading to a tendency to disregard the warning indicators. 
   Because of these deficiencies, crane safety devices mounted proximate to moving crane parts are not widely utilized. Accordingly, there is a need for an improved crane safety device. 
   In addition, the devices that are most commonly used are not directed to provide information to the crane operator—the person who may have the greatest capability of influencing the safe outcome of an event leading to a potential accident. Therefore, there is an urgent need for an improved crane safety device, which directs and provides information to the crane operator. 
   SUMMARY 
   Accordingly, a crane safety system providing a view of the operation of the crane to the crane operator is disclosed. The crane safety system comprises: (1) a camera subs-system having a monitor providing images to the operator, (2) a sensor subsystem for sending signals into and receiving signals from the environment in the vicinity of the crane, and (3) a control device that directs and controls the camera to capture images and display the images on the monitor, the images selected by the control device based upon actions taken by the crane operator, or caused by events captured by the sensor sub-system occurring proximal to the crane. 
   The camera device is mounted on a crane boom, and captures images according to the control device. Images captured by the camera device are displayed on the monitor, which is nearby to, or in clear sight of, the crane operator. 
   The camera device comprises either: (a) a single camera selectable and steerable by the control device, or (b) a plurality of cameras selectable and steerable by the control device, wherein the control device selects a camera based upon an event detected by the control device, and the control steers or directs the camera to capture images related to the event. Images captured by the selected, steered camera or cameras are sent to the monitor, where they are displayed for viewing by the crane operator. Depending upon the nature of the event, the control device may send a signal that is integrated with images captured by the camera. For example the control device may send a signal that will be rendered as a warning sound to alert the operator to images that should be noticed and given attention. 
   The monitor comprises a video device having a display monitor with audio capability that is mounted near to the operator so that images captured by the camera are continually within the field of view of the crane operator. 
   The control device comprises: (a) a sensor sub-system for capturing signals from the environment in the vicinity of the crane boom; (b) a sensor processing device for processing signals, selecting, activating either a camera or a steering device; the steering device controlling the direction a camera lens points, and also controlling the focusing mechanism of a selected camera. 
   The sensor subsystem comprises standard transducers for generating and acquiring infrared and sonic signals, although other types of signals may be used, also. Signals, under control of the sensor-processing device, are generated by the transducers, broadcast into the vicinity, are reflected from objects in the vicinity. Transducers in the sensor sub-system capture the reflected signals, and send information related to the captured signals to the sensor-processing device. 
   The sensor processing device comprises stored-program logic in the form of micro-code or compiler-generated instructions for (a) controlling the sensor subsystem; (b) acquiring signals and information from the sensor sub-system; (c) signal processing algorithms to process data received from the sensor subsystem; (d) decision-control logic to select and control cameras, and; (e) communications programs to communicate with the operator, for example to send urgent signals to the monitor video and audio devices. 
   The crane safety system will be seen to have several benefits and advantages over prior art safety systems, for example, the safety system will transmit alerts to the crane operator only when a hazard is detected. 
   Another advantage is that the system is adaptable and is able to filter and select events that should be brought to the attention of the crane operator. 
   And another advantage is the safety system is that the operator is able to obtain information related to the environment in places outside the operator&#39;s visual field. 
   These advantages, benefits and others will be apparent from the descriptions and drawings that follow. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a diagram of the invention comprising a sensor subsystem having signal transducers, a camera mechanism for capturing images, a monitor for displaying images to a crane operator, and a control device for controlling the sensors, processing signals and for controlling cameras and the monitor. 
       FIG. 2  shows an exemplary embodiment of the control implemented within a computing environment. 
       FIG. 3  shows an exemplary camera mechanism for capturing images in the vicinity of crane operations. 
       FIG. 4  is a logic diagram of the operation of the control device, and servomechanisms for controlling the camera mechanism and the sensor devices. 
       FIG. 5  is a logic flow diagram of the operation of the control device. 
   

   DETAILED DESCRIPTION 
   An Exemplary Embodiment 
   With reference to  FIG. 1 , the invention comprises: (1) a sensor mechanism  1200  for generating and detecting signals; (2) a camera sub-system  1300  for acquiring images; (3) a monitor for displaying images captured by cameras; and (4) a control device  1100  for controlling the sensor mechanism  1200 , the camera sub-system  1300 , and the monitor  1400 . 
   The control device  1100  has connections to the other devices and mechanisms of the invention; the connections may be physical-wire, optical fiber-or may be wireless, depending upon the requirements of applying the device in the operation of a crane. 
   The control device  1100  exchanges signals with the sensor mechanism  1200  over physical connections or communications channels or paths  1210   1240 . The control device sends control signals  1210  to the sensor transducers, and receives signals  1240  from the sensor transducers. The control device activates sensors and processes signals received from the sensor transducers. 
   Signal processing in the control device comprises software or hardware implementation of algorithms to perform digital signal processing algorithms used to determine the distance and location of objects that have occluded signals transmitted by the sensor subsystem. The algorithms for object location and distance estimation by signal processing methods such as triangulation are well known in the art, and will not be described. 
   The control device  1100  communicates with the camera sub-system  1300  by means of channels or paths  1310   1340 . From results computed from signals acquired by the sensors, the control device determines whether an occluding object exists in the range of the sensors. If an object is detected, the control device selects and activates a camera having the best vantage point for capturing images of the object. 
   The control device  1100  obtains images from the camera subsystem by the channel  1340  and routs the images to the monitor  1400 , by video channel  1410 . If the control device computes the object as being within a certain predetermined distance from the crane, the control device  1100  also sends a warning signal, such as a loud audio signal to the monitor over the channel  1420 . 
   The sensor sub-system  1200  is comprised of devices capable of generating signals, for example infrared or acoustic signals. Signals transmitted by the sensor sub-system are “broadcast” into the surrounding environment of the crane, and if there is an occluding object, a certain amount of energy is reflected back to the sensor sub-system. Transducer-receivers in the sensor sub-system capture returning, reflected signals, which are sent to the control device  1100  by channel  1240 . The control device  1100  may activate other sensors in order to obtain information to triangulate an occluding object, in order to compute its distance, size and rate of closure of distance to the crane. 
   The control device uses an internal table or some similar means to select a camera that is closest to sensors that have captured signals, or is best suited to acquire images of the occluding object. 
   With reference to  FIG. 2 , the control device is implemented; for example, within a computing environment  2000 , which includes at least one processing unit  1200  and memory  1300 . In  FIG. 2 , this most basic configuration  2000  is included within  2100  a dashed line. The processing unit  2200  executes computer-executable instructions and may be a real or a virtual processor. In a multi-processing system, multiple processing units execute computer-executable instructions to increase processing power. The memory  2300  may be volatile memory (e.g., registers, cache, RAM), non-volatile memory (e.g., ROM, EEPROM, flash memory, etc.), or some combination of the two. The memory  2300  stores executable software-instructions and data  2250  -written and operative to execute and implement the software applications required to support the interactive environment of the invention. 
   The computing environment may have additional features. For example, the computing environment  2000  includes storage  2400 , one or more input devices  2550 , one or more output devices  2560 , and one or more communication connections or interfaces  2570 . An interconnection mechanism (not shown) such as a bus, controller, or network interconnects the components of the computing environment, for example with the servo-mechanisms and sensor device. Typically, operating system software (not shown) provides an operating environment for other software executing in the computing environment, and coordinates activities of the components of the computing environment. 
   The storage  2400  may be removable or non-removable, and includes magnetic disks, CD-ROMs, DVDs, or any other medium which can be used to store information and which can be accessed within the computing environment. The storage  2400  also stores instructions for the software  2250 , and is configured, for example, to store signal processing algorithms, intermediate results and data generated from sensor inputs. 
   The input device(s)  2550  may be a touch input device such as a keyboard, mouse, pen, or trackball, a voice input device, a scanning device, or another device that provides input to the computing environment. For audio or video, the input device(s) may be a sound card, video card, TV tuner card, or similar device that accepts audio or video input in analog or digital form. The output device(s)  2560  may be a display, printer, speaker, or another device that provides output from the computing environment. 
   The communication interface  2570  enable the operating system and software applications to exchange messages over a communication medium  2600  with the sensor device, servo-mechanism and monitor. The communication medium conveys information such as computer-executable instructions, and data in a modulated data signal. A modulated data signal is a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, the communication media include wired or wireless techniques implemented with an electrical, optical, RF, infrared, acoustic, or other carrier. 
   With reference to  FIG. 3 , an exemplary camera sub-system  3300  comprises a mounting-steering device  3310  for mounting cameras and for rotating or tilting cameras by direction of the control device. 
   The mounting steering device  3310  is mounted onto a crane at a place or location that is most appropriate to providing the view of the cranes working environment. The mounting-steering device comprises gears, motors and other components for rotating, and tilting the cameras  3330 , which are attached thereto. Sensors  3320  may also be attached either to the mounting-steering device directly or may be installed or mounted directly on the cameras. 
   The cameras  3330  are “hardened” or made to withstand the rigors of an industrial environment, and have lenses  3340  that are selected and controlled by the control device. 
   In an exemplary operation, and with reference to  FIG. 4 , the combined devices  4000  operate as a closed-loop feedback control system in that the control device  4100  controls servo-mechanisms  4500  of the camera, sensor sub-systems in order to position and select cameras and sensors. From signals obtained through input channels  4150 , the control device  4100  selects sensors and cameras, and receives sensor-transducer input signals, which are processed. Based upon processing the control device  4100  sends further signals to the servo-mechanism  4500  thorough control channel  4160  to select and sensors and cameras. 
   With reference to  FIG. 5. , the control device executes the steps of the process  5000 , comprising: (1) in step  5100 , the control devices activates and operates the sensors; (2) in step  5200 , the control device acquires signals from the sensor transducers; (3) in step  5300 , the control device processes signals acquired and determines whether an occluding object has been detected; (4) if an occluding object has been detected, in step  5400 , the control device selects and focuses a nearest camera or cameras to capture images of the occluding object; (5) in step  5500 , images are transmitted to the monitor, which is located in the vicinity of the crane operator; (6) the control device in step  5600  computes the proximity of the object, and (7) in step  5700 , if the proximity is within a predetermined distance, the control device (8) in step  5800 , the control device sends an alarm signal to the monitor, preferably a loud audio alarm signal. 
   The invention has been disclosed in an exemplary embodiment. In view of this disclosure, it will be appreciated that variations in the location, arrangement and components are possible, therefore the scope of the invention is most properly described by the claims that follow.