GB2558259A

GB2558259A - Proximity detection and machine shutdown system

Info

Publication number: GB2558259A
Application number: GB1622097.2A
Authority: GB
Inventors: Victor Thomas Robert; Thomas David
Original assignee: AVONWOOD DEV Ltd
Current assignee: AVONWOOD DEV Ltd
Priority date: 2016-12-23
Filing date: 2016-12-23
Publication date: 2018-07-11
Also published as: GB201622097D0

Abstract

A proximity detection and shutdown system with a reader 11 configured to detect a transponder 13 within a detection range D. A controller S, which is in communication with the reader, is capable of performing a machine shutdown operation when the transponder is detected. The reader may be an RFID reader. The detection range may be re-configurable. The system may further include at least one additional satellite detector 12 located adjacent a limit of the detection range. The satellite detector may communicate with the controller to monitor the integrity of radio frequency (RF) transmissions sent from the reader and/or monitor the extraneous RF environment for factors which would prevent RF communications between the reader and transponder. The controller may be configured to activate a sound or visual warning upon detection of the transponder. The system may have a transponder tester capable of checking the functionality of a transponder. The transponder may use an active RFID tag. Also disclosed is a corresponding automatic machine shutdown method using RF communication. The method may also include requiring a site operator working close to machinery to wear an active RFID tag which functions as the transponder.

Description

(71) Applicant(s):

Avonwood Developments Limited (Incorporated in the United Kingdom)

Knoll Technology Centre, Stapehill Road, Hampreston, WIMBORNE, Dorset, BH21 7ND, United Kingdom (72) Inventor(s):

Robert Victor Thomas David Thomas (74) Agent and/or Address for Service:

Urquhart-Dykes & Lord LLP Altius House, 1 North Fourth Street,

MILTON KEYNES, Buckinghamshire, MK9 1NE, United Kingdom

1622097.2 (51) INT CL:

F16P3/14 (2006.01)

23.12.2016 (56) Documents Cited:

GB 2492332 A WO 2008/041143 A US 20140309918 A US 20070205861 A

GB 2473061 A US 4722574 A US 20120112905 A

Final Rule on Proximity Detection Systems, rule came into effect March 2015, video published February 2016, available at: https://www.msha.gov/ news-media/special-initiatives/2015/09/27/final-ruleproximity-detection-systems-continuous-mining

Field of Search:

INT CL F16P Other: WPI, EPODOC (54) Title ofthe Invention: Proximity detection and machine shutdown system Abstract Title: Proximity Detection and Shutdown System (57) A proximity detection and shutdown system with a reader 11 configured to detect a transponder 13 within a detection range ‘D’. A controller ‘S’, which is in communication with the reader, is capable of performing a machine shutdown operation when the transponder is detected. The reader may be an RFID reader. The detection range may be re-configurable. The system may further include at least one additional satellite detector 12 located adjacent a limit of the detection range. The satellite detector may communicate with the controller to monitor the integrity of radio frequency (RF) transmissions sent from the reader and/or monitor the extraneous RF environment for factors which would prevent RF communications between the reader and transponder. The controller may be configured to activate a sound or visual warning upon detection of the transponder. The system may have a transponder tester capable of checking the functionality of a transponder. The transponder may use an active RFID tag. Also disclosed is a corresponding automatic machine shutdown method using RF communication. The method may also include requiring a site operator working close to machinery to wear an active RFID tag which functions

At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

03 18

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Proximity Detection and Machine Shutdown System

The present invention relates to a proximity detection and machine shutdown system, e.g. for use with industrial machinery. Particularly, the system utilises radio frequency (RF) communication to determine whether a machine operator or other personnel are in a dangerous position relative to operation of the machine.

Background to the Invention

Industrial accidents can take place when a machine operator or other personnel stray into a dangerous area relative to a machine's operation. For example, a conveyor system is typically blind to what it is conveying toward further processing, such as a press or compactor. If someone were to fall onto a conveyor then there may be no opportunity for the machine to be stopped before serious injury occurs.

Summary of the Invention

The present invention seeks to provide a proximity detection and shutdown system to improve safety in and around industrial plants.

In a broad aspect of the invention, a proximity detection and shutdown system is provided according to claim 1. Particularly, the system utilises an RFID based apparatus preferably comprised of active RFID tags and detection zone antennas. In a preferred form, the system consists of a reader, one or more detectors and one or more transponders. The system is intended to raise an alarm and immediately shutdown a machine when an operator wearing a tag is identified in the antenna's detection zone of the machine. Preferably, the detection zone can be set up to detect at a specified distance, e.g. up to 10 metres.

Brief Description of the Drawings

Figure 1 illustrates a schematic view of a proximity detection and shutdown system according to an embodiment of the invention;

Figure 2 illustrates a pictorial view of a further embodiment of the invention; and

Figure 3 illustrates active RFID tag and detector components of the embodiment from Figure

2.

Detailed Description of a Preferred Embodiment of the Invention

The prime intention and benefit of the invention is that the system protects users from harm by detecting their proximity to an unsafe area of a machine and instructs the machine to shut down if they are too close. Referring to Figure 1, a preferred aspect of the invention is achieved by a system arrangement comprised of a primary detector/reader/transceiver 11 mounted at or closely adjacent a machine M (or particularly, a dangerous part of a machine), with one or more satellite detectors 12 positioned at the limit of the reader's detection area D, the boundary for which is indicated by a dotted line L. The reader 11 is in electrical communication with the safety control system S of the machine.

In use, reader 11 transmits short-range radio frequency (RF) communication transmissions T for the purpose of communicating with any number of user transponders 13 that may happen to enter the detection area, i.e. cross line L. The detector(s) 12 are electrically connected to the reader 11 to allow for digital communications between the two; they are also electrically connected to the safety control system S of the machine. In practice, a wired satellite detector 12 monitors the integrity of the RF communication transmissions sent from the reader 11 and also monitors the extraneous RF environment to determine if there are any factors that would prevent RF communications T between the reader 11 and transponder 13. Detectors 12 could also be configured to be readers, positioned proximate to other dangerous parts of the machine, and having their own detection ranges to monitor the proximity of RFID tag transponders.

A machine operator or other factory personnel (not shown) wears a transponder 13 upon their person that communicates, via RF transported messages, with either/or both the reader and detector, allowing it to indicate its presence in the detection area D, over line L. Upon receiving communications from a transponder, at least the primary detector/reader (and potentially the satellite detectors) can determine the proximity thereof (and therefore the person) to the machine. This may result in an instruction for the machine safety system S to perform a shutdown of the machine M if the transponder is deemed to be too close (to a dangerous area) or at least sound or visibly activate a warning.

Figure 2 illustrates a practical implementation of the invention, where multiple detection antenna units are fitted close to hazardous or dangerous zones, e.g. a conveyor C leading to a compactor of a piece of recycling equipment M. In this particular embodiment a first upper unit 11 is analogous to the reader of Figure 1, while a second unit 12, slightly further from the danger zone and at a limit of the reader's range, is analogous to the satellite detector of Figure 1. In principle these positions could be reversed or installed in any other suitable configuration, such as both detectors 11/12 having the capability to detect the range of each other for monitoring integrity. Detectors 11, 12 provide continuous detection zone monitoring for the presence of an active RFID tag worn by an operator. When a transponder (e.g. tag) 13 (Figures 1 and 3) is detected in the detection zone, the system is capable of immediately shutting down the machine M.

To implement the invention, every site operator working close to the machinery must wear a transponder (e.g. active RFID tag) 13. This can be a small credit card sized unit to be placed into a closed pocket, inside PPE work wear, integrated into wearable intelligent clothing or worn with a lanyard to provide visitor-type personnel protection. The RFID tag is detected by the reader and/or detector antenna as soon as it enters the detection zone and the system automatically shuts down the machine ensuring the employee is safe. Preferably, each transponder has in-built fail safe operation and error checking to ensure a high level of safety and compliance with safety standard requirements.

Preferably, an accessible user control unit is wired into the machine and provides an indication of the system status, including faults and system errors. When the machine M has been automatically shut down by the invention, the machine will need to be reset. This can be achieved by a key turn or equivalent authorisation.

In a further preferred form, a transponder diagnostic unit, i.e. tag test station (not illustrated) is supplied as an additional unit to check functional integrity and battery status of the transponder 13. Such a unit can be used by every operator before starting their shift or entering the operational area of the worksite. The unit can be integrated with access control as well as linked with tag management software.

As described above, the main components that make up a proximity detection and machine shutdown system according to the invention are:

• Detection Antenna(s): this may be an integrated reader and detector that has a set safety range radius proximate to a dangerous piece of equipment, or separate reader and detector where a detector is set at a limit of reader transmission range in order to verify the system is working correctly. •Transponders: preferably active RFID Tags that are worn by a machine operator or anyone that could potential come too close to an operating machine.

• Control Unit (Optional Extra): while the detector/reader must have a capability to shutdown a machine, a fully functional control unit with various diagnostic features is not necessarily essential.

• Tag Test Station (Optional Extra): it is useful for operators to regularly check the integrity of worn tags so confidence in the safety system is maintained.

Claims

CLAIMS:

1. A proximity detection and shutdown system including:

a reader, configured to detect a transponder within a detection range; a controller, in communication with the reader, capable of performing a machine shutdown operation upon detection of the transponder within the detection range by the reader.

2. The proximity detection and shutdown system of claim 1 wherein the reader is comprised of an RFID reader configured to transmit short-range radio frequency (RF) communication transmissions and receive reply signals from the transponder within the detection range.

3. The proximity detection and shutdown system of claim 1 or 2 further including at least one satellite detector located adjacent a limit of the detection range.

4. The proximity detection and shutdown system of claim 3 wherein the at least one satellite detector is in communication with the controller, in order to monitor the integrity of RF communication transmissions sent from the reader and/or monitor the extraneous RF environment to determine if there are any factors that would prevent RF communications between the reader and transponder.

5. The proximity detection and shutdown system of any preceding claim wherein the controller is configured to activate a sound or visible warning upon detection of the transponder within the detection range.

6. The proximity detection and shutdown system of any preceding claim further including, or integrated with the controller, a transponder tester capable of checking function of a transponder.

7. The proximity detection and shutdown system of any preceding claim wherein the detection range is re-configurable.

8. The proximity detection and shutdown system of any preceding claim wherein a transponder, detectable by the reader is an active RFID tag.

9. An automatic machine shutdown method using RF communication wherein:

5 a reader is arranged proximate a part of a machine, to detect a transponder within a detection range; including the step of:

performing a machine shutdown operation upon detection of the transponder within the detection range by the reader.

10 10. The automatic machine shutdown method of claim 9 wherein the reader is comprised of an

RFID reader configured to transmit short-range radio frequency (RF) communication transmissions and receive reply signals from the transponder within the detection range.

11. The automatic machine shutdown method of claim 9 or 10 further including at least one

15 satellite detector located adjacent a limit of the detection range.

12. The automatic machine shutdown method of claim 9, 10 or 11 wherein the at least one satellite detector monitors the integrity of RF communication transmissions sent from the reader and/or monitors the extraneous RF environment to determine if there are any factors

20 that would prevent RF communications between the at least one detector and transponder.

13. The automatic machine shutdown method of any preceding claim 9 to 12 wherein a sound or visible warning is activated upon detection of the transponder within the detection range.

25

14. The automatic machine shutdown method of any preceding claim 9 to 13 wherein a site operator working close to the machinery must wear an active RFID tag which functions as the transponder.

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