CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional

Patent Application Serial Number 62/944,997 filed December 6, 2019. The entire disclosure of the above application is incorporated herein by reference.

FIELD

[0002] The present disclosure relates to personnel safety systems and methods.

BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Machines may need to be enabled or disabled when a machine operator is within a certain distance from the machine. For example, hardwired emergency stop stations are often used in connection for machine and equipment safety, to allow operators to safely bring a machine or process to a safe state. However, these hardwired stations can require time for an operator to move to the location of the hardwired stop switch in order to trigger the emergency stop process.

DRAWINGS

[0005] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0006] FIG. 1 is a diagram illustrating a personnel safety system according to an exemplary embodiment of the present disclosure.

[0007] FIG. 2 shows an exemplary vest, harness, or halter that may be worn by personnel for use in a personnel safety system (e.g., FIG. 1, etc.) according to exemplary embodiments. [0008] FIG. 3 shows infrared emitters defining a safe zone (Zone 1) and an unsafe/shutdown zone (Zone 2) relative to a machine for use in a personnel safety system (e.g., FIG. 1, etc.) according to exemplary embodiments.

[0009] FIG. 4 shows an integrated infrared (IR) unit or head that may be used for defining at least a first safe zone relative to a machine for use in a personnel safety system (e.g., FIG. 1, etc.) according to exemplary embodiments.

[0010] FIG. 5 shows an IR controller and three IR emitters that may be used for defining at least a first safe zone relative to machine for use in a personnel safety system (e.g., FIG. 1, etc.) according to exemplary embodiments.

[0011] FIG. 6 shows an exemplary machine control unit (MCU) that may be used in a personnel safety system (e.g., FIG. 1, etc.) for controlling operation (e.g., shutting down, etc.) a machine (e.g., FIG. 3, etc.) according to exemplary embodiments.

[0012] Corresponding reference numbers may indicate corresponding (but not necessarily identical) parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0013] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0014] Exemplary embodiments are disclosed of personnel safety systems and methods, which may be configured for protecting workers and other personnel from machines by using automatic position sensing. In exemplary embodiments, a vest, harness, or halter (broadly, a wearable and/or portable item) includes a number of infrared (IR) sensors. The IR sensors are configured (e.g., spaced apart, oriented, etc.) for sensing (e.g., detecting, receiving, picking up, et.) an encoded infra-red (IR) beam(s) covering a defined zone(s) relative to a machine(s). There may be one or more zones (e.g., a safe zone and an unsafe/shutdown zone, etc.), and each zone may have a unique IR code.

[0015] The vest may include a controller (e.g., a control pack with a rechargeable battery pack, etc.) that decodes the infra-red (IR) beam(s) and then re-encodes the data into an radio frequency (RF) transmitter. The RF transmitter transmits or sends secure RF message(s) to an RF receiver. [0016] The RF receiver is configured to process the received RF message(s) and determine a relatively precise or exact location of the operator (or other personnel) wearing the vest based on the coded IR. The controls outputs of the RF receiver may comprise safety relays, normal relays, EtherNet and/or Serial data, which may be integrated into a machine to control the machine functions based on the determination or knowledge of the whereabouts of the person(s) relative to the machine.

[0017] With reference now to the figures, FIG. 1 illustrates an exemplary embodiment of a personnel safety system 100 embodying one or more aspects of the present disclosure. As shown in FIG. 1, the personnel system 100 generally includes an infrared (IR) encoder 104, IR sensors 108, an IR decoder 112, a secure radio frequency (RF) encoder 116, a secure RF decoder 120, an IR zone decoder 124, and safety relays 128.

[0018] In operation, the IR encoder 104 may be configured to continuously send an encoded message(s) via a secure IR beam 106, which may be received, detected, and/or sensed by one or more of the IR sensors 108. An IR decoder 112 may decode the secure message(s) received by the one or more IR sensors 108. The decoded message may be re-encoded by the secure RF encoder 116. The re-encoded RF message may be decoded by the secure RF decoder 120 for use by the IR zone decoder 124.

[0019] The location of the operator (or other personnel) wearing the vest may be determined based on the coded IR. The safety relays 128 may be used to control machine functions based on the determination of the whereabouts of the person(s) relative to the machine. For example, the safety relays 128 may be used to shut down operation of a machine (e.g., machine 340 in FIG. 3, etc.) if it is determined that a person wearing the vest with the IR sensors (e.g., vest 202 with IR sensors 208 in FIG. 2, etc.) is within an unsafe zone (e.g., zone 2 in FIG. 3, etc.) or if it is determined that no person wearing the vest with the IR sensors (e.g., vest 202 with IR sensors 208 in FIG. 2, etc.) is within a safe zone (e.g., zone 1 in FIG. 3, etc.).

[0020] FIG.2 illustrates a vest 202 (broadly, a wearable/portable item) that may be worn by personnel for use in a personnel safety system (e.g., system 100 shown in FIG. 1, etc.) according to exemplary embodiments. As shown in FIG. 2, the vest 202 includes including a plurality of infrared (IR) sensors 208 spaced apart from each other along the vest’s front and back over-the-shoulder straps 230 (broadly, portions). The IR sensors 208 may be configured for receiving encoded message(s) sent via a secure IR beam (e.g. , secure IR beam 106 (FIG. 1), etc.) from an IR encoder (e.g., IR encoder 104 (FIG. 1), etc.).

[0021] The vest 202 includes a control pack 232. In this example, the control pack 232 is positioned along a back of the vest 202. The control pack 232 may be supported by and/or coupled to (e.g., removably attachable/detachable from, etc.) a waist strap 236 (broadly, a portion) of the vest 202.

[0022] In this exemplary embodiment, the vest 202 may be relatively lightweight, comfortable to wear, and suitable for all weather conditions and clothing requirements. The IR sensors 208 may be preferably be configured (e.g., spaced apart, oriented, arranged, a sufficient number, etc.) to provide comprehensive IR zone detection around the wearer of the vest 202. For example, the multiple IR sensors 208 along the front and back straps 230 of the vest 202 preferably provide complete 360 degree IR sensing.

[0023] By way of example only, FIG. 2 shows eight total IR sensors 208 along the front straps 230, e.g., four IR sensors along each front strap 230. The back straps may also include eight total IR sensors 208, e.g., four IR sensors along each back strap. Alterative embodiments may be configured differently, such as having more or less than sixteen total IR sensors, more or less than eight IR sensors along the front and/or back straps, IR sensors located elsewhere (e.g., one or more IR sensors along the waist strap 236, etc.), etc. Preferably, the number, arrangement, and location of the IR sensors provide complete 360 degree IR sensing.

[0024] The control pack 232 may include a rechargeable battery pack. The battery pack may be relatively easy to change (e.g., not fixedly attached/integrated into the vest 202, etc. ) and/or comprise a relatively long life battery pack.

[0025] FIG. 2 shows an example of a vest, harness, or halter 202 that may be used in a personnel safety system (e.g., 100 in FIG. 1, etc.) according to exemplary embodiments. Other exemplary embodiments may include one or more other portable/wearable items (e.g., hard hat, protective helmet, other headgear, etc.) in addition to, or as an alternative to, a vest, harness, or halter, which other portable/wearable items may include IR sensors and controllers for use in personnel safety systems.

[0026] FIG. 3 shows infrared (IR) emitters 344 along portions of a machine 340. The IR emitters 344 are configured (e.g., mounted, located, oriented, etc.) to define a first or safe zone 348 and a second or unsafe/shutdown zone 352 relative to the machine 340. The infrared emitters 344 and zones 348, 352 defined thereby may be used in a personnel safety system (e.g., system 100 shown FIG. 1, etc.) for protecting workers or other personnel with automatic position sensing in exemplary embodiments.

[0027] FIG. 4 shows an integrated IR unit or head 456 that may be used with a personnel safety system (e.g., system 100 in FIG. 1, etc.) according to exemplary embodiments. The integrated IR unit 456 may be used for defining at least a first safe zone relative to a machine. For example, the integrated IR unit 456 may be used to define the first/safe zone 348 relative to the machine 340 shown in FIG. 3. In this example, the personnel protection system may be configured to only allow operation (e.g., via safety relay(s), etc.) of the machine 340 if an operator or other personnel is determined to be within the safe zone 348.

[0028] By way of example, the integrated IR unit or head 456 may comprise an IR head with integrated emitters 24-32Vdc. As another example, the integrated IR unit or head 456 may comprise an IR head with integrated emitters 90-260Vac.

[0029] FIG. 5 shows an IR controller 560 and three IR emitters 544 that may be used with a personnel safety system (e.g., 100 in FIG. 1, etc.) according to exemplary embodiments. The IR emitters 544 may be mounted at appropriate positions (e.g., along portions of a machine, etc.) to define at least a first safe zone relative to a machine.

[0030] For example, the IR emitters 544 may be used to define the first/safe zone 348 and the second/unsafe zone 352 relative to the machine 340 shown in FIG. 3. In this example, the personnel protection system may be configured to only allow operation (e.g., via safety relay(s), etc.) of the machine 340 if the system determines that an operator or other personnel is within the safe zone 348. But if the system is unable to determine that an operator or other personnel is within the safe zone 348, then the system may be configured to shut down and/or prevent operation of the machine 340 until the system determines that an operator or other personnel is within the safe zone 348. In addition, the personnel protection system may also be configured to prohibit operation of or shut down the machine 340 if the system determines that an operator or other personnel is within the unsafe zone 352. [0031] Although FIG. 5 shows three IR emitters 544, more or less than three IR emitters may be used in other exemplary embodiments. By way of example, the IR controller 560 may comprise an IR controller with three ports 24-32Vdc, etc.

[0032] FIG. 6 shows an exemplary machine control unit (MCU) 660 that may be used in a personnel safety system {e.g., FIG. 1, etc.) for controlling machine operation (e.g., shutting down the machine 340 (FIG. 3), etc.) according to exemplary embodiments. In the example shown in FIG. 6, the MCU 660 generally includes five N/O (normally open) function relays 1, two N/O function safety relays 2, two C/O (change-over) function safety relays 3, two main contactor safety relays 4a and 4b, two fuses 5a and 5b for the main contactor safety relays 4a and 4b, and terminals 6a and 6b for the main contactor safety relays 4a and 4b. Accordingly, this exemplary embedment includes the MCU 660 having an enhanced safety design with the two main contactor safety relays 4a and 4b, five N/O function relays 1, two N/O function safety relays 2, and two C/O function safety relays 3.

[0033] In exemplary embodiments, a system is configured for providing personnel safety from a machine via automatic position sensing. The system includes an infrared encoder including one or more infrared emitters and configured for sending encoded infrared signals defining at least a first safe zone and a second unsafe/shutdown zone relative to a machine. A portable item is configured to be worn and/or carried by personnel. The portable item includes one or more infrared sensors configured for sensing encoded infrared signals covering the defined first and second zones; an infrared decoder configured to decode the encoded infrared signals; and a radio frequency encoder configured to re-encode the decoded data for transmission as a radio frequency message. The system also includes a radio frequency decoder configured to decode the re-encoded data of the radio frequency message; and an infrared zone decoder configured to determine whether a location of the personnel wearing and/or carrying the portable item is within the first safe zone or the second unsafe/shutdown zone based on the decoded data from the radio frequency decoder.

[0034] The infrared encoder may be configured to substantially continuously send the encoded infrared signals to define the first safe zone and the second unsafe/shutdown zone relative to the machine, whereby each of the first safe zone and the second unsafe/shutdown zone has a unique infrared code. [0035] The infrared encoder may be configured to substantially continuously send encoded message(s) via a secure infrared beam detectable by the one or more infrared sensors of the portable item. The infrared decoder of the portable item may be configured to decode the secure encoded messages received by the one or more infrared sensors. The radio frequency encoder may be configured to re-encode the decoded messages from the infrared decoder, which re-encoded radio frequency messages are transmitted to the radio frequency decoder. The radio frequency decoder may be configured to decode the reencoded radio frequency message for use by the infrared zone decoder in determining whether the location of the personnel wearing and/or carrying the portable item is within the first safe zone or the second unsafe/shutdown zone.

[0036] The system may be configured to only allow operation of the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the first safe zone and that no personnel wearing and/or carrying the portable item is within the second unsafe/shutdown safe zone.

[0037] The system may include one or more safety relays configured for shutting down operation of the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the second unsafe/shutdown zone and/or that no personnel wearing and/or carrying the portable item is within the first safe zone.

[0038] The system may include an integrated infrared unit or head comprising the infrared encoder including the one or more infrared emitters and that is configured for sending encoded infrared signals defining at least the first safe zone and the second unsafe/shutdown zone relative to the machine. The one or more infrared emitters of the integrated infrared unit or head may comprise one or more integrated infrared emitters 24- 32Vdc and/or one or more integrated emitters 90-260Vac.

[0039] The system may include an infrared controller comprising the infrared encoder and three 24-32Vdc ports.

[0040] The system may include a machine control unit (MCU) configured for controlling operation of the machine including: shutting down or disabling the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the second unsafe/shutdown zone and/or that no personnel wearing and/or carrying the portable item is located within the first safe zone; and enabling operation of the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the first safe zone and that no personnel wearing and/or carrying the portable item is located within the second unsafe/shutdown zone.

[0041] The machine control unit (MCU) may comprise one or more N/O (normally open) function relays, one or more N/O function safety relays, one or more C/O (change-over) function safety relays, one or more main contactor safety relays, one or more fuses for a corresponding one or more main contactor safety relays, and one or more terminals for the corresponding one or more main contactor safety relays.

[0042] The portable item may comprise a wearable item, such as a vest, haress, or halter to be worn by the personnel.

[0043] The portable item may comprise a vest including a waistband and front and back straps. The one or more infrared sensors may comprise a plurality of infrared sensors spaced apart along the front and back straps to thereby provide a comprehensive and/or 360 degree infrared zone detection around the wearer of the vest. The vest may include a controller supported by and/or coupled to the waistband of the vest, the controller comprising the infrared decoder and the radio frequency encoder. The controller may include a control pack with a rechargeable battery pack.

[0044] Exemplary embodiments include methods of providing personnel safety from a machine via automatic position sensing. An exemplary method includes defining at least a first safe zone and a second unsafe/shutdown zone relative to a machine by sending encoded infrared signals; sensing encoded infrared signals covering the defined first and second zones via one or more infrared sensors along a portable item being worn and/or carried by personnel; decoding the encoded infrared signals sensed by the one or more infrared sensors along the portable item; re-encoding the decoded data and transmitting as a radio frequency message; receiving the transmitted radio frequency message and decoding the re-encoded data of the received radio frequency message; and determining whether a location of the personnel wearing and/or carrying the portable item is within the first safe zone or the second unsafe/shutdown zone based on the decoded data of the received radio frequency message. [0045] Defining at least the first safe zone and the second unsafe/shutdown zone relative to the machine may comprise substantially continuously sending the encoded infrared signals to define the first safe zone and the second unsafe/shutdown zone relative to the machine, whereby each of the first safe zone and the second unsafe/shutdown zone has a unique infrared code.

[0046] Defining at least the first safe zone and the second unsafe/shutdown zone relative to the machine may comprise substantially continuously sending encoded message(s) via a secure infrared beam detectable by the one or more infrared sensors of the portable item.

[0047] The method may include only allowing operation of the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the first safe zone and that no personnel wearing and/or carrying the portable item is within the second unsafe/shutdown safe zone.

[0048] The method may include: shutting down or disabling the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the second unsafe/shutdown zone and/or that no personnel wearing and/or carrying the portable item is located within the first safe zone; and enabling operation of the machine if it is determined that the location of the personnel wearing and/or carrying the portable item is within the first safe zone and that no personnel wearing and/or carrying the portable item is located within the second unsafe/shutdown zone.

[0049] The portable item may comprises a wearable item, such as a vest, harness, or halter to be worn by the personnel.

[0050] The portable item may comprise a vest including a waistband and front and back straps. The one or more infrared sensors may comprise a plurality of infrared sensors spaced apart along the front and back straps to thereby provide a comprehensive and/or 360 degree infrared zone detection around the wearer of the vest. The vest may include a controller supported by and/or coupled to the waistband of the vest. The controller may comprise an infrared decoder, a radio frequency encoder, and a rechargeable battery pack.

[0051] Exemplary embodiments may include or provide one or more (but not necessarily any or all) of the following features and/or advantages. For example, the exemplary personnel safety systems and methods disclosed herein may provide constant, immediate, and secure personnel safety protection to the wearer. For example, the vest 202 may comprise a relatively lightweight halter or harness system that may be worn constantly/continuously by personnel. In exemplary embodiments, the personnel protection systems may provide relatively immediate or instantaneous responses (e.g., machine shutdown, etc.) to zone changes by personnel (e.g., movement from a safe zone to an unsafe zone defined relative to a machine, etc.). Exemplary embodiments may be configured with a PLd protection level via secure IR and RF links. Exemplary embodiments may be configured to be in compliance to EN/ISO 13849 with a Cat3 PLd design, e.g., redundant dual channel hardware design with safety critical firmware, etc. Exemplary embodiments may be configured such that a machine(s) (e.g., machine 340 in FIG. 3, etc.) can only be operated or run when it is determined that an operator is in a safe zone (e.g., safe zone 348 in FIG. 3, etc.) as predefined by IR emitters (e.g., IR emitters 344 in FIG. 3, etc.) and when it is determined that no operator is in an unsafe zone (e.g., unsafe zone 352 in FIG. 3, etc.) as predefined by IR emitters (e.g., IR emitters 344 in FIG. 3, etc.). Exemplary embodiments of the person safety systems disclosed herein may be implemented relatively easily, e.g., via safety rely integration, etc. Exemplary embodiments may be configured to allow for an unhindered operator, e.g., workers) or other personnel may wear a lightweight safety vest (e.g., vest 202 in FIG. 2, etc.) with integrated protection.

[0052] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well- known processes, well-known device structures, and well-known technologies are not described in detail. In addition, advantages and improvements that may be achieved with one or more exemplary embodiments of the present disclosure are provided for purpose of illustration only and do not limit the scope of the present disclosure, as exemplary embodiments disclosed herein may provide all or none of the above mentioned advantages and improvements and still fall within the scope of the present disclosure.

[0053] Specific dimensions, specific materials, and/or specific shapes disclosed herein are example in nature and do not limit the scope of the present disclosure. The disclosure herein of particular values and particular ranges of values for given parameters are not exclusive of other values and ranges of values that may be useful in one or more of the examples disclosed herein. Moreover, it is envisioned that any two particular values for a specific parameter stated herein may define the endpoints of a range of values that may be suitable for the given parameter (the disclosure of a first value and a second value for a given parameter can be interpreted as disclosing that any value between the first and second values could also be employed for the given parameter). Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping or distinct) subsume all possible combination of ranges for the value that might be claimed using endpoints of the disclosed ranges.

[0054] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. For example, when permissive phrases, such as “may comprise”, “may include”, and the like, are used herein, at least one embodiment comprises or includes the feature(s). As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. [0055] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

[0056] The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally,” “about,” and “substantially,” may be used herein to mean within manufacturing tolerances. Whether or not modified by the term “about,” the claims include equivalents to the quantities.

[0057] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0058] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0059] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.