Patent ID: 12222256

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

The various systems and methods disclosed herein relate to the automated monitoring of tool calibration status in automated tool control systems.

The automated monitoring of tool calibration status is performed using a calibration measurement instrument or device such as an electronic torque tester. The calibration measurement device is communicatively connected with an automated calibration monitoring device, such as an automated inventory control system, which stores calibrated devices such as calibrated torque wrenches and other calibrated tools and monitors the tools issuances/removals from and returns to the system. The calibration measurement device additionally communicates with a calibration database storing calibration values for the tools. The automated calibration monitoring device is configured to uniquely identify tools (and other objects, reference generally as inventory items) stored therein, and to selectively allow issue of individual tools/objects/inventory-items from storage and/or return of the tools/objects into storage based on the result of a calibration measurement such as a torque measurement of the tools/objects. In operation, the calibration measurement device, such as the electronic torque tester, receives a unique identification of a tool/object from the automated calibration monitoring device, retrieves a calibration value for the identified tool/object from the calibration database, and performs a calibration measurement based on the retrieved calibration value. In turn, the automated calibration monitoring device determines whether the calibration measurement is within an acceptable range for the tool/object, and selectively allows issue of the tool/object from the automated calibration monitoring device and/or return of the tool/object to the automated calibration monitoring device based on the result of the determination (e.g., based on determining that the tool/object is accurately calibrated).

In one example, the tool/object is a calibrated torque wrench that is designed to apply a pre-calibrated maximum torque value stored in the calibration database. In the example, the automated calibration monitoring device uniquely identifies the torque wrench on the basis of a tag or identifier applied thereto, and detects that a user has removed the torque wrench from the automated calibration monitoring device. Based on the detection, the automated calibration monitoring device prompts a user to test a current calibration of the torque wrench and, for measurement purposes, communicates the calibration value for the torque wrench to an electronic torque tester. Upon a torque measurement being performed on the torque wrench based on the communicated calibration value, the automated calibration monitoring device determines whether the measurement falls within an acceptable range surrounding the calibration value and allows issue of the torque wrench from the automated calibration monitoring device. However, if the measurement falls outside of the acceptable range surrounding the calibration value, the automated calibration monitoring device alerts the user and instructs the user to return the torque wrench to the automated calibration monitoring device for recalibration.

In general, the tools or other inventory objects stored in the automated calibration monitoring device are individually identifiable by the automated calibration monitoring device. For this purpose, the tools/objects can have tags or other identifiers applied thereto to enable tools/objects that visually appear similar to each other (e.g., two visually identical torque wrenches) to be uniquely/individually identified. The tags or identifiers may encode a tool's serial number or other unique identifier, and enable the calibration status of each tool/object to be individually monitored and recorded in association with the tool/object's unique identifier. The calibration of each tool/object can then be monitored upon each issuance or return of the tool/object from/to the automated calibration monitoring device, and/or on a pre-scheduled basis, on a periodic basis based on a number of issues/returns since a previous calibration measurements, or the like.

Each tool/object's issuance and/or return can further be associated with a work order or job order, and the tool/object's most recently recorded calibration measurement value can be associated with each operation (e.g., tightening of each bolt or fastener) performed as part of the work order or job order. In this way, a record is created for auditing purposes of all operations performed by a tool/object between calibration measurements in case the tool/object is determined to have veered out of calibration during a next calibration measurement operation.

Reference now is made in detail to the examples illustrated in the accompanying drawings and discussed below.

FIG.1Ais a block diagram showing components of an automated calibration monitoring device100, such as the automated tool control system200functioning as a calibration monitoring device illustratively shown inFIG.2A. The automated calibration monitoring device100may be used as part of an automated calibration monitoring system190such as that shown in the block diagram ofFIG.1B.

As shown inFIG.1A, the automated calibration monitoring device100includes storage locations130for storing objects/tools therein, and one or more sensing subsystem(s)150for determining the inventory status of objects/tools in the automated calibration monitoring device100. Additionally, the automated calibration monitoring device100can include one or more of a user interface105, an access control device106, and a network interface108. The automated calibration monitoring device100can also include a direct wired or wireless communication interface, such as a Bluetooth communication interface for communicating directly with a calibration device160or other automated calibration monitoring device.

The storage locations130are provided within a body of the automated calibration monitoring device100within which tools/objects can be securely stored. The storage locations130can include one or more storage drawers (see, e.g.,230inFIGS.2A-2C), shelves, cabinet doors, or the like.

The user interface105may include one or more user input/output devices, such as a display (e.g., a touch-sensitive display), a keyboard, a mouse or touchpad, a speaker and/or microphone, or the like. The user interface105can be used to output information to a user of the device100(e.g., via display) and/or receive input and selections from the user (e.g., via a touch-sensitive input device).

The access control device106may include one or more of a card reader (e.g., identification card reader), an iris scanner, or the like for receiving identification information from a user seeking access to the device100. The access control device106can also include an alarm used for issuing alerts in response to detecting unauthorized access attempts, and a locking mechanism used to securely lock or block access to the storage locations130when no authorized user is logged into the device100.

The network interface108enables the automated calibration monitoring device100to communicate across one or more wired or wireless networks with other networked automated calibration monitoring devices (e.g.,100a-100ninFIG.1B), calibration device(s) (e.g.,160a-160minFIG.1B), a calibration database170, an automated inventory control database (e.g.,180inFIG.1B), and/or other components of a networked automated calibration monitoring system190(seeFIG.1B) that may be used to monitor the calibration of and inventory statuses of objects/tools across multiple automated calibration monitoring devices100.

The automated calibration monitoring device100is further configured to include or interface with a calibration device160(e.g., a calibration measurement device) and a calibration database170. As shown in dashed lines inFIG.1A, the calibration device160and calibration database170can be located within the automated calibration monitoring device100and can interface directly with the automated calibration monitoring device100. Alternatively, the calibration device160and calibration database170can be located separate from the automated calibration monitoring device160and be communicatively connected to the automated calibration monitoring device100through a wired or wireless communication link and/or network (see, e.g.,FIG.1B).

As described in further detail below, the calibration device160may be used to measure a calibration status of a tool/object. In some examples, the calibration device160can take the form of a torque tester or other torque measurement device configured to measure an output torque of a torque wrench. For example, the calibration device160may be an electronic torque tester such as a torque tester including a piezoelectric torque transducer mounted in a frame and operative to operative to take torque readings and communicate the torque readings to the automated calibration monitoring device100. The calibration device160optionally includes a display for display of the calibration measurements (e.g., torque readings) to users. In various examples, the torque transducers in a calibration device160can be sized for measuring various applied torque loads. Additionally, the calibration device160can be communicatively connected to the automated calibration monitoring device100or to a network to enable calibration measurement data to be transferred through wired or wireless communication interfaces and links

While the foregoing description has detailed an example of a calibrated torque wrench and associated torque tester as a tool/object and calibration device160associated therewith, the automated calibration monitoring device100can be used with other types of calibrated tools. As one example, the calibrated torque wrench may have an associated torque calibration value and/or angle calibration value for measurement by the calibration device160. As another example, the calibrated tool may be a torque screwdriver having an associated torque calibration value and/or angle calibration value for measurement by the calibration device160. As a further example, a precision caliper may be used for precise distance/width/length measurements and may have its calibration measured and monitored using a calibration device160such as a precision measurement tool. As another example, a digital multimeter used for electrical measurements may be used for precise voltage, current, and resistance measurements and may have its calibration measured and monitored using a calibration device160such as a precision voltage/current/resistance measurer.

The automated calibration monitoring device100further includes a data processing system140, such as a computer, for controlling the functioning of the automated calibration monitoring device100. For purposes of inventory control, the data processing system140processes sensing data received from sensing subsystem(s)150and determines inventory conditions of objects/tools and storage locations130based on the sensing data. In one example, the data processing system140processes images captured by a camera or other image sensing device and/or signals received by RFID sensors. The data processing system140includes one or more processors142(e.g., micro-processors) and memory144(including non-transitory memory, read only memory (ROM), random access memory (RAM), or the like). The memory144includes a program memory storing program instructions for causing the automated calibration monitoring device100to perform calibration monitoring and inventory control functions such as those described herein. The memory144also includes a database of object/tool information, which may include object/tool identifiers, object/tool images, object/tool tag information (e.g., for RFID or bar-code tags), object/tool inventory status and calibration status information, and the like. The program instructions further cause the device100to communicate with calibration device(s)160to obtain calibration measurements for objects/tools as described in further detail below.

The components of the automated calibration monitoring device100ofFIG.1Aare communicatively connected with each other, for example via a communication bus or other communication links. The data processing system140functions as a central processing unit (CPU) for executing program instructions, such as program instructions stored in a non-transitory machine readable storage medium (e.g., memory144), for controlling the operation of the automated calibration monitoring device100. Additionally, the sensing subsystem(s)150and calibration device(s)160can include microprocessors operative to execute program instructions and perform functions relating to sensing/monitoring/measurement operations.

The automated calibration monitoring device100can also be in communication via network interface108with wired and/or wireless local area and/or wide area networks (e.g., the Internet). For example, as shown in the automated calibration monitoring system190ofFIG.1B, the monitoring system190may include multiple automated calibration monitoring devices100a-100n. Each automated calibration monitoring device (e.g.,100a) may be in communication with one or more other automated calibration monitoring device(s) (e.g.,100n) and/or other elements forming an automated calibration monitoring system190such as calibration device(s)160a-160m, the calibration database170(including, e.g., a calibration server storing the calibration database), and an automated inventory control database180(including, e.g., an inventory control server storing the inventory control database). In this case, the automated calibration monitoring device100amay communicate with the other systems and/or servers across the network(s), and may exchange information on calibration measurements, inventory conditions, stored objects/tools, and operation data with those systems and/or servers. The automated calibration monitoring device100amay alternatively or additionally communicate directly with some of the components of the system190, for example through direct wired or wireless (e.g., Bluetooth) links with calibration devices160a-160mor other components.

The networked calibration monitoring system shown inFIG.1Bcan use the Windows Communication Foundation (WCF) or similar technology to create a “network service” used to enable communications between devices and databases. Specifically, communications between devices and databases can use a common protocol and information format, such as protocols and formats compatible with WCF, to store and enable easy exchange of inventory, calibration, and other information between devices and servers.

The automated calibration monitoring device100can take the form of an automated tool control system200, such as that shown inFIG.2A, that provides for the monitoring of tool calibration status (e.g., torque calibration status). The automated tool control system200as depicted takes the form of an automated tool control (ATC) toolbox, but may more generally take the form of an ATC locker, an ATC tool crib, or the like. The automated tool control system200is connected via a direct wired or direct wireless communication link or via a wired or wireless network to a torque calibration device207such as a piezoelectric torque testing/measurement device functioning as a calibration device160. The torque calibration device207may be mounted on the automated tool control system200, as illustratively shown inFIG.2A, or provided separately or remotely therefrom.

While not shown inFIG.2A, the automated tool control system200includes a database (e.g., object database stored in memory144and/or calibration database170and inventory control database180) for storage and retrieval of tool related data, including torque tool usage and calibration data. The database may be local to the automated tool control system200(see, e.g.,FIG.1A) or communicatively connected thereto through a network interface (see, e.g.,FIGS.1A and1B).

The automated tool control system200is an example of a highly automated inventory control system that utilizes one or more sensing technologies to identify inventory conditions of tools and other objects in the storage unit. The term inventory condition as used throughout this disclosure means information relating to an existence/presence or non-existence/absence condition of objects in the storage system, and/or information on the issuance and return of objects from/to the tool control system200and storage locations130thereof. In various examples, the inventory conditions are determined using machine imaging, radio frequency (RF) sensing, and/or other sensing methodologies used by the tool control system200to identify inventory conditions of objects configured for storage therein.

As shown in each ofFIG.2A, the tool control system200includes a user interface205, an access control device206, such as a card reader, for verifying identity and authorization levels of a user intending to tool control system200, and multiple tool storage drawers230for storing tools. Instead of drawers230, the storage system may include shelves, compartments, trays, containers, or other object storage devices from which tools or objects are issued and/or returned, or which contain the storage device from which the objects are issued and/or returned. In further examples, the storage system includes storage hooks, hangers, tool boxes with drawers, lockers, cabinets with shelves and/or doors, safes, boxes, closets, vending machines, barrels, crates, and other material storage means.

User interface205is an input and/or output device of tool control system200, configured to display information to a user including tool calibration and measurement information. Access control device206is used to limit or allow access of users to the tool storage drawers230. Access control device206, through the use of one or more electronically controlled locking devices or mechanisms, keeps some or all storage drawers230locked in a closed position until access control device206authenticates and authorizes a user for access to the storage system. The access control device206further includes a processor and software to electronically identify a user requesting access to the secure area or object storage device and determine the level of access which should be granted or denied to the identified user. If access control device206determines that a user is authorized to access control system200, it unlocks some or all storage drawers230, depending on the user's authorization level, allowing the user to remove or replace tools. In particular, the access control device206may identify predetermined authorized access levels to the system (e.g., a full access level providing access to all drawers230, a partial access level providing access only to particular drawer(s)230, or the like), and allow or deny physical access by the user to the three dimensional space or object storage devices based on those predetermined authorized levels of access. The access control device206may also be used to deny a user access to drawers230storing tools that are identified as being out of calibration, and/or to deny a user access to stored tools until a tool identified as being out-of-calibration is returned to an appropriate storage location.

Tool control system200includes one or more different sensing subsystems. In an illustrative example, the tool storage system200includes an image-based sensing subsystem configured to capture images of contents or storage locations of the system using one or more cameras. The image sensing subsystem is further configured to process the images to identify tools/objects present therein or absent therefrom, and to determine inventory conditions based on the processed image data. The image sensing subsystem may include one or more lens-based cameras, CCD cameras, CMOS cameras, video cameras, or other types of devices that captures images.

The tool control system200can additionally or alternatively include an RFID sensing subsystem including one or more RFID antennas, RFID transceivers, and RFID processors. The RFID sensing subsystem is configured to emit RF sensing signals through the RFID transceivers and antennas when an RF-based scan of the inventory control system200is performed, receive RFID signals sensed by the RFID antennas and transceivers from RFID tags mounted on or incorporated in tools or other inventory items in response to the emitting the RF sensing signals, and process the received RFID signals to identify individual tools or inventory items. Specifically, the received RFID signals may be processed to extract tag identification data included in the returned RFID signals, and to identify individual tools or inventory items located in the tool control system200based on an association between tag identification data and tool data stored by the system.

FIG.2Bshows a detailed view of one illustrative drawer230of the control system200in an open position. The storage drawer230includes a foam base280having a plurality of storage locations, such as tool cutouts281, for storing tools. Each cutout is specifically contoured and shaped for fittingly receiving a tool with a corresponding shape. Tools may be secured in each storage location by using hooks, Velcro, latches, pressure from the foam, etc.

In general, each storage drawer230includes multiple storage locations for storing various types of tools. As used throughout this disclosure, a storage location is a location in a storage system for storing or securing objects. In some embodiments, each tool has a specific pre-designated storage location in the tool storage system. In other embodiments, multiple storage locations may have similar (or identical) shapes, and several similarly shaped tools may thus be placed in any of the multiple storage locations.

As shown inFIG.2B, one or more tools in the drawer230may have unique identifiers such as identification tags231aand231bmounted or attached thereon or therein. The identification tags may be RFID tags, bar-code tags, or the like. In the case of RFID tags, the RFID tags may be placed on a surface of the tools and may thus be visible to users, such as tag231a, or the RFID tags may be placed within the tool or may otherwise not be visible to users, such as tag231b. In general, bar-code tags would be placed on a surface of the tools, such as tag231a.

As illustratively shown inFIGS.2C-2E, the tags placed on tools may be visible and each tag may encode the identifier unique to the tool it is placed on. The visible tags can be placed on the tools so as to be visible to the image sensing system of the tool storage system200. For example, tags can include a tag231chaving a visible pattern thereon for recognition by an imaging-based sensing subsystem (FIGS.2C and2D) or a tag231ddisposed on or in a tool and having an RFID-readable (or other wirelessly-readable) code encoded therein (FIG.2E). Combination tags including both visible and RFID-readable codes may also be used. One or more of the inventory control database180, calibration database170, and object database (stored in memory144) store each tag's unique identifier in association with information on the associated object/tool, such that information on each object/tool can be retrieved from the database(s) based of the tool tag's identifier.

The tags may be formed of a polycarbonate, polyester, or other suitable material, and may have an adhesive backing so as to adhere to the tools they are mounted on. In one example, the information encoded in the tags is encoded using differently colored bands or stripes such as those shown in the illustrative example ofFIG.2C(in which white, purple, red, black, dark blue, light blue, green, and yellow stripes are shown). Both primary colors and/or blended colors may be used. Each color stripe on the tag equates to a number (or alphanumeric character) and the combination of colors creates a code. In the embodiment depicted inFIG.2C, all stripes have a same length and width; in other embodiments, adjacent stripes may have different lengths and/or widths.

In implementations in which the sensing subsystem150includes an RF-based sensing subsystem, the RF sensing subsystem may be configured to sense RFID tags of tools located in all storage locations130and storage drawers230of system100/200, or configured to sense RFID tags of tools located in a particular subset of the storage locations130or drawers c30of system100/200. In one example, the RF sensing subsystem is configured to sense RFID tags of tools located only in the top-most and bottom-most drawers230of system200, and the RF sensing subsystem includes RFID antennas disposed directly above the top-most and bottom-most drawers230within system200to sense RFID tags of tools located in those drawers. Other configurations of RFID antennas can also be used.

As described above, the automated calibration monitoring device100is configured to monitor calibration statuses of storage objects such as tools. Operation of the automated calibration monitoring device100will now be described in relation toFIGS.3A-3Ewhich show simplified flow diagrams outlining operations involved in automatically monitoring the calibration status of inventory objects such as tools.

FIG.3Ashows a simplified flow diagram of a method300for automatically monitoring the calibration status of objects/tools. As shown inFIG.3A, the method includes detecting a change in inventory condition of at least one object/tool in step301. For instance, the automated calibration monitoring device100detects using its sensing subsystem150that the inventory status of one or more objects/tools has changed. In one example, the automated calibration monitoring device100may detect that an object/tool that was previously stored in a storage location130of the device100has been removed from or issued from the storage location. In another example, the automated calibration monitoring device100may detect that an object/tool that was previously not stored in the device100has been placed in or returned to a storage location130of the device100. In a further example, the automated calibration monitoring device100may detect that an object/tool has entered a sensing and detection range of the sensing subsystem150, for instance as a result of the object/tool having been placed within an RF reading range of RF sensors of the sensing subsystem150. For instance, an RFID sensor located adjacent to the calibration device160may detect an object/tool's RFID tag within its sensing range and thereby satisfy step301.

In response to the detection in step301, the automated calibration monitoring device100proceeds to verify the object calibration status of the object/tool in step305. The verifying of the calibration status will be described in more detail in relation toFIGS.3C-3E, below. In general, however, the verification may involve performing a measurement of the calibration of the object/tool using the calibration device160and determining whether the measurement is within a calibration range for the object/tool. For instance, the verification may involve performing a torque calibration measurement on a tool such as a calibrated torque wrench using an electronic torque tester, and determining whether the resulting torque measurement is within an acceptable range for the wrench.

FIG.3Bshows a simplified flow diagram of the method301for detecting the change in the inventory condition. Note that the method301may be initiated as a result of detecting a change in the inventory condition of a tool/object by the sensing subsystem150of the automated calibration monitoring device100. In general, the change may be detected as part of performing a scan for objects/tools in the automated calibration monitoring device100using the sensing subsystem150so as to identify objects/tools that may have been issued from or returned to the device100. The scan may be triggered automatically by the device, for example on a periodic basis. The scan may be triggered by a user, for example in response to the user selecting a calibration option on the user interface105of the device100. The scan may also be triggered in response to detecting that a user has logged into the device100(e.g., using the access control device106), that a drawer230, door, or lock of the device100has been opened or closed (or is being opened or closed), that a scan request has been received via the network interface108(e.g., from a central calibration monitoring server), or the like.

As shown inFIG.3B, the method301includes the performing of a scan of the inventory condition of the automated calibration monitoring device100using the sensing subsystem150in step302, and processing the sensing signals from the sensing subsystem150. For example, in the case of an image-based sensing subsystem, one or more images of the storage locations130may be captured and processed by the data processing system140to identify objects/tools currently located in the storage locations. In the case of an RFID-based sensing subsystem, one or more RF scans of the device100may be performed and processed by the data processing system140to identify codes of RFID tags currently located within the RF range of the RF sensing antennas.

In turn, the automated calibration monitoring device100proceeds in step304to identify objects/tools that are subject to a change in inventory condition based on the result of the scan (of step302) and a previous record of inventory conditions for the device100. For example, the data processing system140may compare a list of objects/tools identified as being present in the device100as a result of the scan to a list of objects/tools previously recorded as being present in the device100to identify any objects/tools subject to a change in inventory status. Step304may result in the device100identifying one or more objects that are subject to a change in inventory condition, such as one or more objects that are determined to have been returned to the device100, issued from the device100.

In response to the identification of object(s) in step304, the automated calibration monitoring device100proceeds to verify the object calibration status of the object/tool in step305as described in more detail below in relation toFIGS.3C-3E.

FIG.3Cshows a simplified flow diagram of the method305for verifying the calibration status of the identified object. The method can include the automated calibration monitoring device100triggering in step306the taking of a calibration measurement of the object(s) identified in step304and, based on the result of the calibration measurement, determining an up-to-date calibration status of each object in step314. Steps306and314are described in further detail in relation toFIGS.3D and3E, below. Note that in cases in which multiple objects/tools are identified in step304, step305may be repeated for each identified object/tool.

FIG.3Dshows a simplified flow diagram of the method306for triggering the taking of a calibration measurement. In accordance with the method306, the automated calibration monitoring device100determines in step307whether the object identified in step304is a calibrated object that is subject to calibration. To make the determination, the automated calibration monitoring device100may consult the database of object information stored in memory144and determine whether the object is identified as a calibrated object therein. Additionally or alternatively, the automated calibration monitoring device100may consult the calibration database170or the inventory control database180to determine whether the object is identified therein as a calibrated object. If the object is not subject to calibration, then control is returned to step301. Alternatively, in cases in which multiple objects are identified in step304, control is returned to step305to trigger calibration measurement of a next identified object.

In cases in which the object is identified as being subject to calibration, the automated calibration monitoring device100proceeds to step309in which at least one calibration parameter value(s) for the identified object is retrieved from the calibration database170. The calibration parameter value(s) for the identified object typically includes a calibration target value and a calibration range of acceptable calibration values. The calibration parameter value(s) can additionally include information on the last calibration performed on the object, such as a time of the last calibration, an elapsed time since the last calibration, a number of issuances and/or returns since the last calibration, a number of operations since the last calibration, or the like.

In step311, the automated calibration monitoring device100optionally determines whether a calibration measurement of the object is needed and, in cases in which calibration is determined not to be needed, control is returned to step301, or to step305in cases in which multiple objects are identified in step304. In general, the automated calibration monitoring device100will by default determine that a calibration measurement is needed in step311such that control will proceed to step313. However, the automated calibration monitoring device100may determine that a calibration measurement is not needed in cases in which a calibration measurement was recently performed on the object and/or in cases in which the object was identified as being out of calibration based on a previous measurement. The device100determines that a calibration was recently performed based on the time of the last calibration (e.g., if the last calibration measurement was performed less than a predetermined threshold time t prior to the current time, such as less than 1 hour, 1 day, or 1 week prior to the current time), an elapsed time since the last calibration (e.g., if the elapsed time is less than the predetermined threshold time), a number of issuances and/or returns since the last calibration (e.g., if the number of issuances since the last calibration is less than a predetermined threshold number, such as less than 2 issuances), a number of operations since the last calibration (e.g., if the number of operations involving the object since the last calibration is less than a predetermined threshold number, such as less than 10 fastening operations), or the like.

In step313, the calibration measurement of the object is performed. The measurement of calibration can include the automated calibration monitoring device100providing instructions to a user via the user interface105to perform the calibration measurement. The measurement can further include the device100providing the calibration device160with the calibration target value for the object in order to enable the calibration device160to perform the measurement on the basis of the target value. In response to performing the measurement, the calibration device160returns to the device100a calibration measurement value corresponding to the measured calibration of the object.

FIG.3Eshows a simplified flow diagram of the method314for determining the calibration status of the object. In accordance with method314, the automated calibration monitoring device100receives the calibration measurement value for the object as obtained in step313from the calibration device160. The device100proceeds in step315to compare the calibration measurement value to the calibration range of acceptable values to determine whether the measurement value falls within the range of acceptable values for the object. If the calibration measurement value falls within the calibration range of acceptable values, the device100determines that the object is in calibration; alternatively, if the calibration measurement value falls outside of the calibration range of acceptable values, the device100determines that the object is out of calibration.

The device proceeds in step317to update the calibration status (in calibration, or out of calibration) for the object in the calibration database170and/or the inventory control database (e.g.,180, or stored in memory144). The calibration database170may additionally be updated to store the calibration measurement value and other data relating to the calibration measurement of step313(e.g., date/time of calibration measurement, calibration target value used, identity of the calibration device160used for measurement, etc.).

In turn, the automated calibration monitoring device100can enable or disable the issue and/or return of objects/tools based on the updated object calibration status in step319. For example, upon determining that the object/tool is in calibration, the automated calibration monitoring device100may enable or authorize issue and/or return of the object/tool from/to the storage locations of the device100. Alternatively, upon determining that the object/tool is out of calibration, the automated calibration monitoring device100may disable or block issue of the object/tool from the device100and may request that the object/tool be promptly returned to the device100.

The foregoing discussion has focused on situations in which one or more calibrated objects/tools (e.g., a torque tool such as a torque wrench) are issued. The system can handle situations in which a single object/tool is issued by assuming the single issued tool is the only tool available for calibration measurement and by associating all calibration measurement related data and results received from the calibration device160pertain to the single object/tool being issued or returned.

In cases in which multiple objects/tools are being issued or returned at the same time, there are various options which can be presented by the system. One option is to provide the user with a choice. The system displays via the user interface105a list of calibrated objects/tools being issued or returned and the user selects one for the current calibration measurement and proceeds to perform the calibration measurement on the selected object/tool. Once the calibration measurement of the selected object/tool is completed, the object/tool disappears from the display screen and the user is given the opportunity to select a next object/tool for calibration.

An alternative provides for the system to select which object/tool is to be subject to calibration measurement and to display system-selected object/tool's data on the display screen. The user is then charged with providing the selected object/tool to the calibration device160for the calibration measurement. After this tool is tested, a next object/tool is selected by the system and identification for the next object/tool is displayed. The process is repeated until all objects/tools being issued and returned are subject to calibration measurement.

A further alternative provides a sensing subsystem150on or adjacent to the calibration device160to enable the calibration device (e.g., a torque testing device) to directly sense and identify the unique identifier attached to an object/tool provided therein for calibration. For example, an RFID sensor provided adjacent to the calibration device160and having a short RFID reading range (e.g., up to 20 centimeters in front of the calibration device160) may be used to automatically identify objects/tools with RFID tags that are located in close proximity to the calibration device160. The calibration device160can then report measured calibration values together with the identity of the object/tool detected in its close proximity to the automated calibration monitoring system.

A purpose of the systems and methods disclosed herein is to provide an efficient process for enabling the automated monitoring of tool calibration using, e.g., an automated tool control system in concert with a calibration device such as torque testing device. As detailed, a number of efficiencies and advanced functionalities are enabled through the combined use of the devices executing advanced functions enabled by software programming executed on system processors.

The systems and method described above make use of databases storing calibration data for objects/tools. The calibration monitoring system190can include individual data stores or databases in individual calibration monitoring devices100a-100nand/or one or more centralized master databases residing in one or more central servers. In general, calibration related data for each of the calibrated objects, tools, and other inventory items are pre-stored in the calibration database170and/or preloaded into the memory144of an automated calibration monitoring device100for use in calibration status monitoring as described above.

In general, the calibration data for tools stored in the calibration database170includes one or more of the data entries shown in Table 1 below:

Cali-LastLastCali-brationCalibrationCali-Object/Object/brationAccept-Measure-brationToolToolTargetablementTime-IDDescriptionValueRangeValuestampX450-ATECH3F25010098-102100Sep. 20, 2017400Torqueft-lbft-lbft-lb12:00:00WrenchGMT. . .. . .. . .. . .. . .. . .

In more detail, the calibration database170can store the following data for each calibration tool/object:a) a device identifier code, such as a unique tool ID and/or the code included on a tag attached to the object/tool;b) a description of the object/tool;c) a calibration target value for the object/tool, corresponding to the calibration value to which the object/tool should be calibrated. The calibration target value can be provided as a single target value or as a target calibration profile including a plurality of target values each associated with applied test criteria (e.g., a different applied load, such as 40, 80, 120, 160 and 200 N*m). When a target calibration profile is used, the calibration measurement includes measuring the object/tool's calibration as each of the test criteria are sequentially applied thereto and reporting of the measurement obtained for each test criteria;d) a calibration target acceptable range, corresponding to a range of calibration values within which the object/tool is considered to be in calibration. The target acceptable range can be expressed as a range of calibration values and/or as a percentage of deviation from the calibration target value (e.g., +/−0.5%);e) one or more previous calibration measurement values, corresponding to the last recorded calibration measurement value/level and, optionally, additional previous recorded calibration measurement values/levels;f) timestamp(s) (e.g., date(s) and time(s)) of each of the one or more previous calibration measurement values;g) optionally, calibration device identity (e.g., transducer ID and, optionally, capacity rating) of the calibration device160used for each of the one or more previous calibration measurement values;h) when appropriate, the database can also store: (i) units of measurement for each calibration target value, range, and previous calibration measurement), (ii) a deflection or angular displacement (e.g., for each previous calibration measurement, a deflection or an angular measurement of the displacement reached during the calibration test) or a measure of calibration curve fit, (iii) air pressure and/or temperature (e.g., for each previous calibration measurement), or the like.

In addition, the calibration database170can store additional calibration data including an object/tool calibration interval or schedule (e.g., indicating a maximum interval between calibrations of the instruction), that can include a next calibration due date (e.g., calculated based on the object calibration schedule and the date of the last calibration measurement) which may be recorded by date or by time interval (e.g., measured in minutes, hours, days, weeks, or the like), by number of uses, by number of days, or the like. The calibration interval or schedule, when stored, may be specific to each tool/object such that a different schedule is stored for each tool; specific to a category of tool/object such that a same schedule is stored for each tool category while different schedules are stored for different tool categories; or the same for all tools/objects.

The calibration database170can store further calibration data including object calibration data, including maximum and/or minimum acceptable torque level ranges at various loads, and/or maximum and/or minimum acceptable torque angular displacement ranges at various loads (e.g., in the case the tools/objects are calibrated torque wrenches).

The calibration database170can store further calibration data including process data, which may include (a) calibration and test process data per ISO 6789-2:2017; (b) conformance tests to ISO 6789-1:2017; (c) uncertainty tests to ISO 6789-2:2017; (d) 20%, 60%, 100% max torque values for each tool/object; (e) number of test points required; (f) a target torque value; and/or (g) upper and lower limits.

One of the calibration database170, the inventory control database180, and/or the memory144of the automated calibration monitoring device100may additionally store data associated with each object/tool including data identifying the object/tool (such as a part number, a description, or other a unique identifier), a storage location for the object/tool within the device100, a manufacturer or supplier, related objects/tools/parts, or the like.

Data associated to the specific torque device and related to calibration of the device can include calibration intervals, scheduled calibration, last calibration, optimal torque profile, torque applied and resulting angular displacement, calibrated torque values, pass/fail criteria, or the like.

A variety of configurations of the automated calibration monitoring (ACM) device100in combination with the calibration device160(e.g., torque tester), the calibration database170, the inventory control (IC) database180, and the object/tool401subject to calibration measurement and testing will be described below.

FIGS.4A-4Dshow various system connection configurations that may be used in the automated calibration monitoring systems described above. InFIG.4A, a first configuration is used in which the object/tool401subject to calibration measurement is not configured for electronic data transfer or communication (or the object/tool's electronic data transfer or communication functionality is not used). In this case, the calibration device160can be co-located with the ACM device100and be communicatively connected to the ACM device for communication of calibration measurements. In turn, the ACM device100(e.g., a tool control system toolbox200) is communicatively connected to the networked calibration and/or inventory control databases170/180for information exchange purposes.

FIG.4Bshows a second configuration in which the calibrated object/tool401is configured for electronic data transfer and is communicatively connected to the calibration device160(e.g., a torque tester). The calibration device160is again communicatively connected to the ACM device100. In turn, the ACM device100is communicatively connected to the networked calibration and/or inventory control databases170/180for information exchange purposes.

FIG.4Cshows a third configuration in which the calibrated object/tool401is not configured for electronic data transfer (or the calibration object/tool's electronic data transfer functionality is not used). In this case, the calibration device160can be located at the ACM device100or remote from the ACM device100and is communicatively connected to the networked calibration and/or inventory control databases170/180for information exchange purposes. The ACM device100and the calibration device160are thus both independently connected to the networked calibration and/or inventory control databases170/180for information exchange purposes.

FIG.4Dshows a fourth configuration in which the calibrated object/tool401is configured for electronic data transfer. The calibrated object/tool401and the calibration device160can be located at the ACM device100or can be remote from the ACM device100. The calibrated object/tool401, the ACM device100, and the calibration device160are all communicatively connected to the networked calibration and/or inventory control databases170/180for information exchange purposes.

While the inventory control system discussed in relation toFIG.2Atakes the form of a toolbox, calibrated tools including torque devices are stored in a central repository (e.g., a tool crib) in many work environments and the tools are issued from the central repository to technicians for use in disparate or remote work locations. In such environments, a calibration device160can be provided within a tool crib or at the point of issue (e.g., entrance and exit) of the tool crib to enable calibration measurements to be performed at the time of entrance or exit from the tool crib. When an object/tool equipped with a unique identifier is scanned to be issued from the automated tool control system (e.g., to be issued at a tool crib issue portal), the calibration monitoring system automatically identifies the object/tool and retrieves calibration data associated to the object/tool. The system also provides an alert to the user that the object/tool must have its calibration measured prior to issuance.

Calibration devices160such as electronic torque testers can be equipped with the capability to measure or test the calibration of tools (such as torque devices) using manually input pass/fail criteria and to display results. More advanced versions of the calibration tools can electrically transfer torque measurement data to software packages for analysis. The transfer and analysis can be done locally on the calibration device or the data can be transferred to another device (e.g., an automated calibration monitoring device) across a network. In either case, however, the calibration device did not previously have the capability to automatically identify specific objects/tools/devices and associate pass/fail criteria or test data to the system for the specific identified object/tool/device. For example, previously, the identity of the object/tool/device to be tested had to be manually input into the calibration device by a user.

In contrast, in the automated calibration monitoring system described herein, the calibration device160(e.g., torque tester) is configured with data processing and data storage capabilities, computing software, wired and/or wireless network communications capabilities, a user interface, and the means for automatically inputting data. The calibration device160may be powered by an AC power supply, by batteries, or by a combination of both batteries and/or AC power. The user interface may be an LED display, an LCD display or monitor, or other currently utilized technologies for displaying information. The data input interface for the calibration device160can include wired or wireless communications capabilities, keyboards, keypads, mice, RFID, optical (barcode) scanners, cameras, or the like.

Based on the functionalities described above, the automated calibration monitoring device can be used for auditing purposes. In particular, if an object/tool (e.g., a torque device) fails the calibration measurement test when it is returned to the automated calibration monitoring system, the system may retrieve from memory data indicating the work location and/or the work order that the object/tool was issued under. In such cases, the system can produce a report indicating that the object/tool failed the calibration measurement test and identifying the work location and/or the work order under which the object/tool was last issued. The report can be automatically distributed by email or text message to appropriate individuals as identified by the system administrator. For auditing purposes, the report can also indicate all work locations and/or work orders that the object/tool was issued to since the tool's last in-calibration measurement.

If the work order contains routings or information that describes the products on which the object/tool was used (e.g., a list of fasteners torqued as part of the work order), the system can also list in the report each of the products (e.g., individual fasteners) that may have been improperly worked on since the object/tool was last issued and passed a calibration measurement test. The system can also create a validation report showing all calibrated objects/tools issued against a work location or work order and their recorded calibration measurement test values and other pertinent data.

As detailed above, the automated calibration monitoring device100is operative to request calibration measurements (e.g., torque measurements) from a calibration device160and validate the calibrations status of tools or other inventory objects stored in the automated calibration monitoring device100. The tools/objects generally have unique identifiers associated therewith and associated with tags provided on the tools/objects, and the identifiers and associated tools/objects devices are identified in inventory control and/or calibration database(s) as being tools/objects for which calibration is to be monitored. The automated calibration monitoring device100can thus recognize calibrated tools/objects through recognition of the unique identifiers attached to the tools/objects when the tools/objects are issued from or returned to the system. The tools/objects further have calibration data, including target calibration values, stored and associated therewith in the database(s). The automated calibration monitoring system can thus require that a calibration measurement or test be performed on a tool/object to confirm whether the calibrated tool/object is accurately in calibration prior to and/or after each use of the object. The parameters of the calibration monitoring (used to determine whether the tool is in calibration or out of calibration) can be determined by a user but are generally retrieved from the calibration database as calibration target values associated in the database with the unique identifier of the tools/objects.

The automated calibration monitoring device100and tool control system200(and software associated therewith and executed on system processor(s)) are thus programmed to compare calibration data such as torque data for a tool as obtained from the calibration measurement device (e.g., torque tester) with one or more calibration target values for the tool, such as calibration values which are associated with a unique identifier of the tool and which are stored in one or more of the inventory control and calibration database(s). Based on the comparison, the automated calibration monitoring device100can determine whether the tool satisfies calibration requirements set by the calibration values. If the calibration requirements are not satisfied, the automated calibration monitoring device100may identify the tool as being out of calibration and may issue an alert to any user seeking to issue or check-out the tool from the system100. The automated calibration monitoring system100can thus allow issue and return of the calibrated tool/object if the results of the calibration measurement fall within an acceptable calibration range stored for each tool/object in the calibration database.

Upon issue of an object/tool from the automated calibration monitoring system, the automated calibration monitoring system can bar issue of the calibrated object/tool if the calibration measurement value does not meet or fall within the acceptable range of calibration values for the tool/object. For example, the system can issue audible and visual instructions to return the tool/object which failed to meet the calibration test criteria to an appropriate storage location in the device. The system can alternatively or additionally issue audible and visual instructions to transfer the tool/object which failed to meet the calibration test criteria to an appropriate location where the repair and re-calibration processes occur. As part of this process, the automated calibration monitoring system can issue status alerts to users, system administrators, calibration lab personnel, or the like when the tested tool/object fails to meet the calibration criteria pre-stored in the calibration database in order to enable the alerted parties to appropriately respond to the situation (e.g., by recalibrating the object, by flagging work orders associated with the improper calibration, or the like).

Upon return of an object/tool to the automated calibration monitoring system, the system can require the object/tool be returned to its appropriate storage location within the storage device if the calibration measurement results do not meet the acceptable calibration requirements when the object/tool is being returned to the storage device after use. Alternatively, the system can require that the object/tool be transferred to an appropriate calibration lab if the calibration measurement results do not meet the calibration requirement. Again, the automated calibration monitoring system can issue status alerts to users, system administrators, calibration lab personnel, or the like when the tested object/tool fails to meet the calibration measurement criteria pre-stored in the calibration database in order to enable the alerted parties to appropriately respond to the situation (e.g., by recalibrating the object, by flagging work orders associated with the improper calibration, or the like).

The calibration monitoring device100utilizes one or more of various sensing technologies to determine issue/return or presence/absence of objects from its storage. For example, the issue/return or presence/absence of objects can be sensed using one or more of imaging-based sensing technology (e.g., using cameras), RFID-based sensing technology, individual switches or sensors (e.g., contact, capacitive, inductive, weight, or other sensors), such as sensing technologies used in automated tool control (ATC) imaging toolboxes, ATC RFID lockers, and/or ATC tool crib management systems. Further details of the sensing technologies and associated sensing methodologies used in inventory control are described in U.S. Pat. No. 9,741,014, issued Aug. 22, 2017, which is hereby incorporated by reference in its entirety.

Unique identifiers, such as color coded tags, RFID tags, bar codes, etc., can be attached to inventory objects or tools including calibrated objects/tools stored in the storage container of the automated calibration monitoring system100and used to uniquely identify items (e.g., so as to distinguish between two items that are otherwise undistinguishable to the system's sensing technology, such as two visually identical tools being sensed using an imaging system). Examples of identification tags including combinations of parallel colored lines forming unique color sequences are discussed in relation toFIGS.2B-2E.

FIG.5provides a functional block diagram illustrations of a general purpose computer hardware platform that may be used as a network or host computer platform to implement a server The computer platform ofFIG.5may be used to implement a server supporting the calibration database170and/or the automated inventory control database180and the associated functionalities as described herein, and may be used to implement an inventory control server or calibration monitoring server performing one or more of the functionalities described inFIGS.3A-3E. The computer platform ofFIG.5may also be combined with user interface elements to implement a personal computer or other type of work station or terminal device, such as to implement computing functionalities within a calibration device160or object/tool401. It is believed that those skilled in the art are familiar with the structure, programming and general operation of such computer equipment and as a result the drawings should be self-explanatory.

A server, for example that shown inFIG.5, includes a data communication interface for packet data communication. The server also includes a central processing unit (CPU), in the form of one or more processors, for executing program instructions. The server platform typically includes an internal communication bus, program storage and data storage for various data files to be processed and/or communicated by the server, although the server often receives programming and data via network communications. The hardware elements, operating systems and programming languages of such servers are conventional in nature, and it is presumed that those skilled in the art are adequately familiar therewith. Of course, the server functions may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load.

Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain.

The scope of protection is limited solely by the claims that now follow. That scope is intended and should be interpreted to be as broad as is consistent with the ordinary meaning of the language that is used in the claims when interpreted in light of this specification and the prosecution history that follows and to encompass all structural and functional equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirement of Sections 101, 102, or 103 of the Patent Act, nor should they be interpreted in such a way. Any unintended embracement of such subject matter is hereby disclaimed.

Except as stated immediately above, nothing that has been stated or illustrated is intended or should be interpreted to cause a dedication of any component, step, feature, object, benefit, advantage, or equivalent to the public, regardless of whether it is or is not recited in the claims.

It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings.