Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: MASTER SAFETY LOCKOUT SYSTEM
INVENTORS: Darren Lucien Rivet, Tomas Diaz Jimenez, Carlos
Mauricio Estay Oyarzo, Bradley Dean Chrabaszcz,
and Raul Hernan Fernandez Ramirez
TECHNICAL FIELD:
[001] The present disclosure is related to the field of methods and
apparatuses of lockout systems, in particular, methods and apparatuses for
master safety lockout systems.
BACKGROUND:
[002] The operation of equipment by those who are not properly
qualified and certified can be dangerous and can lead to damage and injury.
Further, operation of equipment in the inappropriate location, at the
inappropriate time, or under inappropriate circumstances, can lead to the
same results.
[003] Current equipment monitoring and access systems are
inadequate. Safer and more reliable systems are required. It is, therefore,
desirable to provide methods and apparatuses for lockout systems that can
overcome the shortcomings of the prior art and provide a greater degree of
safety and reliability.
SUMMARY:
[004] Methods and apparatuses for master safety lockout systems are
provided herein. In some embodiments, a master safety lockout system is
provided which can include a control data module ("CDM") and can lock out
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the operation of equipment for any one or more of the following reasons: an
attempt by an operator to use the equipment who lacks the required
credentials, qualifications, and/or training, the equipment is moving outside
a
prescribed area and there are applicable geo-fencing restrictions, emergency
shutdown procedures have been commenced, remote disablement of the
equipment is necessary as a result of safety concerns, and/or the equipment
is disabled, by one or more persons, for servicing. In some embodiments, a
Near Field Communication ("NFC") Module, a database, and a
communications system can be used.
[005] In one embodiment, by requiring operators to scan their
company issued credentials before being authorized to access and operate
equipment, which can include mobile or stationary equipment, unqualified
individuals can be prevented from using equipment they are not qualified to
use and thereby reduce injury and damage to themselves, third parties,
and/or property. Interconnecting multiple pieces of equipment can also
provide for the ability to remotely control the operation of the multiple
pieces
of equipment, allowing the implementation of the master safety lockout
system.
[006] A method is provided which can regulate individuals ability to
operate equipment, such as vehicles, machinery or other devices, based on
the qualifications, for example certifications, credentials and/or training,
of that
individual. For example, an individual without the required qualifications to
operate particular equipment would be prevented from operating that
equipment, whereas individuals who did have the required qualifications to
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operate particular equipment would be granted access to operate that
equipment. The method of locking out an individual/operator from activating a
mobile or stationary unit or device, can include acquiring qualification data
of
the operator through the NFC module, which can be an NFC reader/writer;
communicating the credential data from the NFC module to a CDM
comprising a processor; processing the qualification data with the processor
to form a signal; transmitting the signal from the CDM to a valve control unit
("VCU"), and controlling whether a valve is opened or closed using the VCU
based on the signal from the CDM, whereby when the required qualification
data are not present, the valve is closed and locks out the operator from
activating the mobile or stationary unit and when the required qualification
data are present, the valve is opened and allows the operator to operate the
mobile or stationary unit. In some embodiments users can be locked out by an
equipment control device, which can use an electronic means to disable the
equipment via a relay system, the ignition system or send a disable command
to the engine computer.
[007] In some embodiments, the qualification data can include
licenses, certifications, credentials, training, orientation and/or
authorizations
necessary to operate the mobile or stationary unit, device or equipment and/or
expiration date(s) of the license, certification, credential, training,
orientation
and/or authorization. In some embodiments, the qualification data can be
acquired from a modem, and compared to a database of operator
qualifications, and/or to the qualifications necessary to operate the machine
for existence, relevance, status, and/or validity.
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[008] Broadly stated, in some embodiments, a method is provided for
controlling operation of a piece of equipment, the method comprising:
providing a control data module (CDM) comprising a processor functionally
connected to the piece of equipment; receiving data to the CDM as received
date; processing the received data using the processor thereby providing
processed data; creating a determination if the piece of equipment should be
active or locked out based on the processed data; processing the
determination with the processor to form a signal; transmitting the signal
from
the CDM to a vehicle control unit (VCU), and updating an operational status of
the piece of equipment based on the signal transmitted to the VCU.
[009] In some embodiments, the methods can further comprise
wherein the data is received from at least one of a modem, a 900 Mhz
meshing system, a GPS module, an auxiliary input/output, an NFC module
and the VCU, wherein the data is qualification data, wherein the qualification
data includes credentials, certificates, training, orientation and/or
authorizations necessary to operate the piece of equipment, wherein the
qualification data includes expiration dates of the certifications,
credentials,
training, orientation and/or authorizations, wherein the qualification data is
received from an NFC module; and wherein the determination of whether the
piece of equipment should be active or locked out is based on whether the
processed data shows a potential operator holds the required qualifications to
operate the piece of equipment, wherein when the potential operator does not
hold to required qualifications to operate the piece of equipment operational
status of the piece of equipment is updated to locked out, transmitting a
signal
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from the VCU to an equipment control device; and wherein when the updated
operational status is to activate the piece of equipment the VCU signals the
equipment control device to allow access to the equipment and when the
updated operation status is to lockout the piece of equipment the VCU signals
the equipment control device to deny access to the piece of equipment,
wherein the equipment control device is a valve and when the operational
status of the piece of equipment is active the valve is open and when the
operational status of the piece of equipment is locked out the valve is
closed.
[0010] Broadly stated, in some embodiments, an apparatus is provided
for controlling the operation of a piece of equipment, the apparatus
comprising: a Control Data Module (CDM) comprising a processor and being
functionally connected to the piece of equipment for controlling the operation
of a piece of equipment according to the methods described herein.
[0011] In some embodiments, the apparatus can further comprise an
equipment control device, at least one of a modem, a GPS module, an
auxiliary input/output and an NFC module, a Global System for Mobile (GSM)
Modem, a 900 MHz module, a CAN bus connection, a display module, and a
VCU and CDM as one unit.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0012] Figure 1 is a diagram of an embodiment of a master lockout
system.
[0013] Figure 2 is a block diagram of an embodiment of a control data
module (CDM) of a master lockout system and its interconnections.
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[0014] Figure 3 depicts an embodiment of a CDM of a master lockout
system and its interconnections shown in a different manner.
[0015] Figure 4 depicts an embodiment of a piece of equipment
configured for use in a master lockout system.
[0016] Figure 5 is a block diagram further depicting an embodiment of a
CDM of a master lockout system and its potential communications.
[0017] Figure 6 is a block diagram depicting a CDM and its potential
communications with an embodiment of a Global Positioning System (GPS).
[0018] Figure 7 is a block diagram depicting a CDM and its potential
communications with an embodiment of a modem.
[0019] Figure 8 is a block diagram depicting a CDM and its potential
communications with an embodiment of a Near Field Communication (NFC)
Module.
[0020] Figure 9 is a block diagram depicting a CDM and its potential
communications with an embodiment of a Valve Control Unit (VCU).
[0021] Figure 10 is a diagram depicting a meshing or relay of
communication between towers in an embodiment of a master lockout
system.
[0022] Figure 11 depicts an embodiment of a user interface of a master
lockout system.
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DETAILED DESCRIPTION OF EMBODIMENTS:
[0023] Methods and apparatuses for individual and master safety
lockout systems are provided herein. In some embodiments, a master safety
lockout system is provided which can include a control data module ("CDM")
and can lock out the operation of equipment for any of: operator lacking
required qualifications, geo-fencing restrictions, emergency shutdown
procedures, remote disablement, and/or disablement for servicing. In some
embodiments, a Near Field Communication ("NFC") Module, a database, and
a communications system can be used.
[0024] For the purposes of this specification, the term "qualifications"
can refer to actual credentials, certificates, training, orientation and/or
authorizations of a particular individual which indicate that that specific
user
has the training and ability necessary and that is required to operate a
specific
piece of equipment. The equipment can be any form of equipment used on a
work site including, but not limited to, vehicles, devices, units, plant
equipment
and can be mobile or stationary. In some embodiments, the qualifications can
be non-government issued, but self-regulated in the industry. A user ID
number and other identifying markers can be connected to the qualifications.
[0025] Each piece of equipment can be programmed to unlock for any
NFC access device 52, which can be a key card or a fob, with the proper,
unexpired, qualifications, and/or an authorized user ID. A list of authorized
operators can be held and maintained to restrict access to equipment,
however, a primary focus of the present methods and apparatuses can be to
restrict access to specific types of equipment from those who are not
qualified
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to operate them. The qualifications to be monitored and verified can be
dynamic in nature, as they can be company specific and have expiration
and/or renewal dates that can be monitored.
[0026] In some embodiments of system 10, the apparatus can include,
and the methods can use, an equipment control device, a valve control unit
("VCU") 30, a control data module ("CDM") 40, a NFC module 50, a modem
(GSM or Satellite) 60, 900 MHz communication 70, Bluetooth
communication 80, GPS 90, CAN bus interface 100, and/or a display module
110.
[0027] In some embodiments the equipment control device can be a
valve 20, which can be the component that if closed will prevent air and
hydrocarbons from entering the air intake system of any equipped engine. In
other embodiments the equipment control device can be a power relay that
can control ignition systems within the equipment. The equipment control
device can directly or indirectly disable starter buttons or starter solenoids
of
equipment, electronically send a disarm command to an engine computer and
can regulate other control systems of equipment.
[0028] In some embodiments, the equipment control device can
communicate with the VCU 30. When a valve 20 is used as the equipment
control device, the valve 20 can report the present state of the valve 20, for
example open, closed, or jammed, using valve sensors 22 built into valve 20.
When the VCU 30 senses a predetermined condition which requires a
shutdown of the system 10 or equipment 12, for example to prevent damage
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or injury, it can automatically initiate a shutdown of the system or
equipment.
For example the VCU 30 can supply power to the valve 20 to operate motor
24 thereby closing valve 20. The VCU 30 can also receive a command from
the CDM 40 to initiate a deactivation, to shut down or turn off the system or
equipment, or an activation/reactivation, to allow use of the system or
equipment when it is ready and/or safe to be used. For example, initiating a
deactivation or activation can involve closing or opening a valve 20.
Whenever an event occurs a log can be created or generated. Events can
include the initiation of any activation, reactivation or deactivation of a
system
or equipment, the opening or closing of a valve 20, low battery voltage, a
jammed valve 20, swipe of an NFC access device 52 and the use of the
wrong credentials. Logs can be tagged with meta-data, for example
equipment information such as speed, rpm, tilt angle and ambient
temperature, and GPS coordinates, which can describe the conditions
surrounding the event. Once these logs are formed, they can be transmitted
to the CDM 40 to be locally stored and then transmitted via modem 60 to a
remote-server or Cloud 62 to be retrieved via a web interface 112.
[0029] The VCU 30 can communicate with both the equipment control
device, for example a valve 20, and CDM 40 while also monitoring several
conditions in the VCU 30 itself. The VCU 30 can be responsible for monitoring
vital statistics data of equipment 12 and which the CDM 40 supplies, and
compares them to programmed thresholds to determine if valve 20 should be
closed or remain open. Traditionally, the VCU 30 has directly monitored the
vehicles rpm via clean tach output (CTO), fast Fourier transform (FFT), or an
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alternator tap, all of which have stability and accuracy issues between
different models of engines. With the VCU 30 now communicating with the
CDM 40, it can directly access this data and more from a CAN bus interface
100 with an Electronic Control Unit ("ECU") 14 of equipment 12. The VCU 30
can also be capable of having multiple auxiliary inputs attached to give
custom monitoring capabilities and different triggers to initiate closure of
valve
20. Again whenever an event occurs, a log can be generated and stored in
CDM 40 as well as transmitted to the Cloud server 62.
[0030] In some embodiments, VCU 30 and CDM 40 can be built into a
single unit. In some embodiments, VCU 30 and CDM 40 can be separate
and/or separable.
[0031] While the VCU is an abbreviation for "valve control unit" it is
meant to refer to a unit which controls the equipment control device, which
may be a relay rather than a valve or an electrical signal that can control
the
equipment by controlling the activation state of the engine or motor.
[0032] CDM 40 can receive data from any sensors, attached devices,
and communication devices implemented. The CDM 40 can then process the
received data and act upon it as programmed. Based on its programming and
the data received, the CDM 40 can transmit a signal to the VCU 30 to update
the operational status of a piece of equipment so that it is active or locked
out.
In some embodiments, CDM 40 can have inputs/outputs 42 for: multiple RS-
232/RS-485 connections, USB, analog voltage comparator auxiliary inputs,
Controller Area Network (CAN) protocol (for CAN bus interface), VR sensor,
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magnetic sensor, Alternator Tap, CTO output, analog/digital input of a
periodic
wave indicating RPM translated by a Digital Signal Processor (DSP) or tach
chip. The CDM 40 can be capable of communicating via Bluetooth0 80, RF
(with frequency hopping) 82, GSM (a serial TOP connection) 84, or any other
form of communication which can interface via RS-232/RS-485. Internal
communication protocols used can be UART, SPI or I20.
[0033] In addition to these specifications, in some embodiments, the
CDM 40 can also have the following characteristics: Processor 44 (32-bit
architecture, 40 MHz), Inputs/Outputs 42 (Forty Discrete Pins, One USB, six
Serial Ports, one CAN bus), Clocks (two Real Time Clocks, 32 kHz), Memory
(128 kb Integrated, 4 Mb Flash memory, 8 kb fRam), Power Modes (Low-
power mode, 100 pAmps/MHz, and Full power mode), Total current should
not exceed 1 Amp and supply at the following voltages: 1.8V, 2.5V, 3.3V, 5 V,
12 V, 24 V, and can handle an input up to 36V, Operational Temperatures (-
40 C to + 85 C) and can include Peripheral Components (Gyroscope,
Accelerometer, Thermostat).
[0034] In some embodiments, CDM 40 can directly or indirectly control
the equipment 12 via the control device. For example, CDM 40 can control
the operation of equipment 12 by directly or indirectly disabling the starter
buttons, controlling ignition systems with power relays, and/or disabling
starter
solenoids. With the flexibility of the auxiliary inputs to CDM 40, other
equipment systems can be controlled directly or with the addition of
controlling
components or equipment control devices.
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[0035] NFC module 50 can be an NFC reader/writer and can be used
in a multitude of ways, depending on the specific installation requirements,
and can also be used in a tiered system of monitoring and authorization
levels. In the most simplistic form, the NFC module 50 can be used to allow
activation or deactivation of equipment via the equipment control device, for
example the opening or closing of a valve 20. In one embodiment, a user,
also referred to as an operator, individual or employee, would swipe their NFC
access device 52, which can be loaded with an employee identification
number, and the valve 20 can unlock and open, allowing the starting of the
engine 24. The NFC access device 52 can be a card or fob. In a simple
lockout system, a user could use their NFC access device 52 to lockout
access to the equipment control device, for example valve 20, preventing
equipment 12 from being started, to ensure the safety of those who are
working on equipment 12. If the NFC module 50 is utilized in this manor, the
identification of the individual who initiated the lockout can be stored in
the
CDM 40, and then only that individual can be capable of unlocking it.
[0036] In a more complex and comprehensive use of the NFC module
50, users' qualifications, along with their expiry dates, can be stored in the
NFC access device 52 along with the user identification ("ID"). CDM 40 can
then read the qualifications from the NFC access device 52 and, by way of
modem 60, can compare them to the qualifications stored in the cloud 62
related to the equipment the user is attempting to access. If the employee has
the proper corresponding qualifications (to be determined and setup per
device upon installation) to operate the connected equipment 12, the
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equipment control device will allow the employee to operate the equipment
12. For example, valve 20 can unlock and allow the use of equipment 12. The
use of compared qualification data addresses the problem of having to make
specific lists for each and every piece of equipment listing those employees
who can access the equipment. It also allows a user to have one NFC access
device 52 for multiple sites as all the information is stored on a central
database 114 and can be accessed locally by the CDM 40. Additionally, as
the qualifications of a potential operator change, only the NFC access device
52 and/or database 114 need to be updated, rather than having to review
access lists for each piece of equipment.
[0037] All NFC access device 52 swipes can be treated as events and
can be logged, including the individual's ID number. These logs again can be
stored locally and/or sent to the Cloud server 62 for later retrieval if
required.
The NFC module 50 specifications can support ISO/IEC 14443 Type A and B,
ISO/IEC 15693 (single or double subcarrier) and ISO/IEC 18092
communication protocols. It can also support the detection, reading and
writing of NFC Forum Type 1, 2, 3 and 4 tags.
[0038] The modem 60 can be either a GSM (cellular) or satellite
modem, and can be used to both retrieve data/commands from remote/web
based interfaces, as well as send current statistics and conditions that
equipment 12 is in, along with any logs in which have been generated. When
the modem 60 is receiving remote commands, they could be from a web
interface 112 issuing a lockout specific to a single piece of equipment 12 or
a
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signal from a master shutdown. Modem 60 can facilitate the storing of all logs
and reports at a remote location for review in the event of an emergency.
[0039] Another benefit of modem 60 can include the ability of its users
to enter in reports, for example safety inspections, incident reports and/or
hours on site, and submit them directly. Modem 60 can also allow messages
to be pushed to the user, relaying pertinent information to those in the
field.
Modem 60 can be of several varieties; typically a GSM (cellular) modem can
be used, however, in regions where signal strength is a concern an Iridium
satellite connection can be utilized. Modem 60 can send and receive all of the
data internally with CDM 40; the encryption/decryption, data sorting,
compression can be handled by CDM 40 prior to being handed off to modem
60 to be sent onwards.
[0040] In specific scenarios equipping multiple pieces of equipment 12
with a modem could be cost intensive. As an alternative a 900 MHz meshing
system 70 can be implemented. Such a system can interconnect equipment
12 with a 900 MHz transceiver, and transmit all data to a central
tower/station
16, which will be equipped with a singular modem 60, from here all data can
be transmitted and received. By having all equipment 12 interconnect the
effective range of this system can be significantly extended. Individual
equipment 12 can have a range of -1km. By interconnecting, this range can
be extended by as many pieces of equipment 12 as are in range of each
other.
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[0041] To ensure that data has been successfully received by central
transmission tower 16 this system can also employ a conformation of
communication. The 900 MHz system 70 can communicate with CDM 40 in a
similar manner as modem 60, specifically, all data handling procedures can
be completed on the CDM 40 before being transmitted by the 900 MHz
transceiver 70. The same can be said about receiving information; the 900
MHz transceiver 70 can receive all data encrypted and encoded with a
specific method, which it can hand off to CDM 40 to be decoded.
[0042] In some embodiments, the specifications of the 900 MHz
meshing system 70 can be: Desired range for each device (Key fob 52 range
= 150m, VCU 30 in equipment = 500m, Relay stations 18 = 1000m, Master
tower 16 = 1000m), Footprint area available on printed circuit boards (PCBs)
(Key fob 52 = must fit inside intrinsically safe casing, VCU 30 = there is a
total
of 25mm * 40mm available, Relay stations 18 and Master tower 16 = no
restrictions), Communications (Two way communications for all devices,
Mesh communication among VCUs 30, relay stations 18, and master tower
16, Key fob 52 must work alongside all other communications(between VCU
30 and Key fob 52), Utilize 115200 Baud rate), Power (Must comply with FCC,
IC, ATEX, and UL regulations, Operational voltage 3.3V DC), Temperature
(Standard industrial temperature tolerance range of -40 C to 85 C), Interface
(5 PI, UART) and Modules (Limit to a single module for the VCU 30 and key
fob 52, May have multiple modules for the relay stations 18 and master tower
16).
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[0043] Bluetooth module 80 can be primarily utilized when initializing
VCU 30 at the time of installation, or updating the firmware. Monitoring
statistics and issuing commands can also be done via Bluetooth . However,
this can have a limited range and can present connection issues in certain
conditions. When using Bluetooth , data can be transmitted to a display
module 110, which can be a tablet, phone and/or laptop, where a qualified
user can adjust the thresholds VCU 30 can recognize to instigate a shutdown
procedure. Another use for Bluetooth module 80 can be when an inspector
wants to gather the maintenance history of a piece of equipment 12. The
inspector can walk up to a piece of equipment 12, connect to the Bluetooth
module 80, and retrieve the desired data. This retrieval of information/data
can also be accomplished remotely via other remote connection methods.
The Bluetooth module 80 can be installed directly on CDM 40 (or VCU 30 on
some models). Therefore, the handoff of information can be shortened by a
step and can be directly accessed.
[0044] Each master lockout system 10 can also be equipped with a
GPS device 90. The GPS device 90 can track the current location of
equipment 12, and can tag each or every log and transmission with this
positioning data. Another feature which can be implemented utilizing GPS
device 90 is Geo-fencing. Geo-fencing can set a boundary within which
equipment 12 can operate. If the equipment 12 roams outside of the
prescribed boundary an automatic shutdown command is issued. This can be
referred to as a geo-fencing restriction. Currently companies can lose track
of
assets as they are transferred from site to site. However, these features can
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help companies and/or individuals monitor and keep track of equipment 12
assets in the field. In one embodiment, GPS device 90 can continuously
update the current coordinates to CDM 40, and CDM 40 can, in turn, attach
the coordinates to any and/or all transmissions and logs encoded by CDM 40.
[0045] Most equipment 12 data can be obtained via the CAN bus
connections 100 between the attached equipment 12 and CDM 40. The CAN
bus connections 100 can include the J-1939 protocol, OBD2 protocol and
IS015031 protocol, among other protocols. Each equipment 12 manufacturer
can maintain specific protocols to handle equipment data such as; speed,
rpm, tilt, fuel level, fault codes, etc. The CDM 40 can continuously poll the
ECU of equipment 12 for this information. This information can also be logged
and transmitted on a set interval. Equipment 12 operating statistics can also
be monitored and sent to the VCU 30 so that they can be analyzed and
compared to the previously set threshold levels to indicate whether or not a
shutdown sequence is required.
[0046] Some embodiments can also include a display module 110 to
provide for more options. With a display module 110, data stored in the cloud
(remote server) 62, as well as data stored in the CDM 40 can be viewed and
interacted with. Display module 110 can allow users to input reports and view
old reports. Also, the display module 110 can show notifications sent from
supervisors or site wide alerts. The display module 110 can give real-time
data on some or all of the data points being monitored, for example, the GPS
location with a map, weather conditions, vehicle data, and logged hours, etc.
Display module 110 can also display any and/or all active qualifications when
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an NFC access device 52 is swiped and can indicate whether or not the
individual is permitted to operate equipment 12. The display module 110 can
also show pending expiration date for active qualifications. The display
module 110 can be directly or wirelessly connected to the CDM 40, thereby
allowing information and data from all other connected peripherals to be sent
to display module 110.
[0047] Referring to Figure 1, a diagram of an embodiment of a master
lockout system 10 is provided. The master lockout system 10 can
communicate with any equipment 12 which can have a VCU 30 connected to
it. In this embodiment of the master lockout system 10 a 900 Mhz meshing
system 70 provides the centralized monitoring system that can remotely
shutdown individual pieces of equipment 12 or a group of equipment all at
once.
[0048] In operation, a remote master lockout 32 can send out a signal
via a 900 Mhz meshing system 70 which is received by a transmission tower
16 and/or a repeater tower 34, which in turn transmits the signal to equipment
12. The transmission tower 16 can also transmit the signal onwards to a
repeater tower 34 or to a master lockout device 36. The transmitted signal can
be directed to a particular zone or to multiple zones. For example in Figure 1
the signal from the remote master lockout 32 located outside a particular zone
can be transmitted to the repeater tower 34 in zone B which is then sent
onwards to the evacuation equipment which are monitored and controlled by
VCU's 30. Alternatively, a person within a particular zone may send a signal
via a remote master lockout 32 to a repeater tower 34 or a transmission tower
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16, which can then send the signal onwards to equipment 12, a repeater
tower 34, a transmission tower 16 and/or to a master lockout device 36. If the
signal is sent to a repeater tower 34, a transmission tower 16 or a master
lockout device 36, the signal can be again forwarded by various paths, as
shown in Figure 1, until it reaches the equipment 12. A person with a remote
master lockout 32 can also receive a signal from a repeater tower 34 or a
transmission tower 16.
[0049] The master lockout device 36 can be connected to a control
computer 28 via a wire connection, for example in a plant operation as shown
in Zone A in Figure 1. The control computer then can transmit instructions
over its wired connection to various equipment 12, for example VCU
controlled pumps 46 and/or VCU controlled valves 48 as shown in Figure 1.
The master lockout device 36 can also transmit signals via the 900 Mhz
meshing system 70 to mobile equipment. The control computer 28 can also
receive and send signals via its wire connection to the transmission tower 16.
[0050] As an alternative to the 900 Mhz meshing system 70, the master
lockout system 10 can utilize a cellular connection at various points in the
signal transmission process in systems with this capability.
[0051] Once a piece of equipment 12 has been locked out it can only
be reinstated by the person who locked it out. Similarly, when a master
shutdown, via a remote master lockout 32 or otherwise, is initiated all
equipment 12 are locked out by zone until an authorized safety officer, or
other qualified person, and the person who initiated the lockout advise that
the
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concern is dealt with or no longer present and the zone is cleared for
continued use.
[0052] Referring now to Figure 2, a block diagram of an embodiment of
CDM 40 is provided. The CDM 40 can comprise a communication and data
management board 41, which can have bilateral communication with the VCU
30, NFC module 50, auxiliary input/output 42, GPS module 90, display
module 110, modem 60 and 900Mhz transmission control board 72. The CDM
40 can simultaneously communicate with all the attached modules and
devices and compile the data it receives to be sent to the database 114. The
CDM 40 can also decipher which data is needed at particular modules or
devices.
[0053] The VCU 30 can communicate bilaterally with valve 20,
confirming valve commands, and can receive statistical information about the
engine 25. This information can be relayed to the CDM 40 and then to any of
the outputs of the CDM. For example, the information may be sent to a
display module 110 where a user or operator can monitor and review various
information regarding the equipment 12. The information can also be
forwarded to a web interface 112 and then stored in a database 114 through
either a 900 Mhz transmission control board 72 and a communication tower
26 or via a modem 60. More particularly, the CDM 40 compiles data as
required to be sent to the database 114 and web interface 112. The modem
60 can accept transmissions from the web interface 112 and sends data to
the CDM 40 for processing. The CDM 40 compiles data from all sources into
JSON format for burst transmission. The communication protocols can include
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Serial (SPI), 14400 bps Baud rate, 8 bit data, 1 bit stop, no parity, with
flow
control, voltage levels +/- 5V.
[0054] The communication tower 26 can be either the transmission
tower 16 or the repeater tower 34.
[0055] The CDM 40 can issue commands to the VCU 30. For example,
the CDM 40 may relay a lockdown or reinstatement signal to close or open a
valve 20 which could have been initiated from the modem 60, user input, NFC
authorization or as a result of GPS geo-fencing restrictions. In one
embodiment data communication between the CDM 40 and the VCU 30 can
be formatted into ba5e64 and encrypted with XTEA. Communication protocols
can include RS-323/RS-485, 115200 bps Baud rate, 8 bit data, 1 bit stop, no
parity, no flow control and voltage levels +/- 10V.
[0056] The CDM 40 can also receive positioning information from a
GPS module 90, which is connected to a GPS satellite system 92. The CDM
40 requests updates in the current location from the GPS module 90 and the
GPS module 90 transmits current longitude and latitude data to the CDM 40.
Other data, such as altitude, speed and direction, may also be retrieved from
GPS module 90. In one embodiment the data format can be standard
encoded numerical data is Hex format. The communication protocol can be
Serial (SPI), 9600 bps Baud rate, 8 bit data, 1 bit stop, no parity, no flow
control, voltage levels +/- 5V.
[0057] The CDM 40 sends the NFC module 30 user and credential data
to be written onto cards. It also sends commands to request data. The NFC
module 30 sends the CDM 40 user information stored on their NFC access
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devices 52, along with qualifications and their expiration dates. The data can
be formatted with Mifare API and encrypted with a randomly generated key
with every authentication request. Communication protocol can be Serial
(USB), 9600 bps-115200 bps Baud rate, 8 bit data, 1 bit stop, no parity, no
flow control, voltage levels +1- 3.3V.
[0058] Referring now to Figure 3, an embodiment of the CDM 40 of a
master lockout system 10, and its interconnections are depicted in a different
manner.
[0059] Referring now to Figure 4, an embodiment of a piece of
equipment 12 configured for use in a master lockout system 10 is depicted.
[0060] The VCU 30 can be the primary device that directly connects to
the vehicle engine, a CDM 40, and the equipment control device. The VCU 30
can control the equipment control device(s) installed in the vehicle or
device,
which impede the function of the equipped vehicle or device, based on
information retrieved from the engine, or transmitted to it via the CDM 40.
While the VCU 30 and the CDM 40 are different in terms of their function and
action, the same type of enclosure can be used to enclose either device, and
therefore the VCU 30 and the CDM 40 can resemble each other externally.
[0061] In one embodiment, the valve 20 can be installed on the air
intake of a piece of equipment or vehicle, and when closed restricts the air
from entering the combustion chamber, effectively preventing the engine from
running.
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[0062] Figure 4 shows a dash controller 150, which can be the manual
controls for the VCU 30 and/or valve 20 and can instruct the opening or
closing the VCU 30. In some embodiments the dash controller 150 can
include an NFC access device 52 where an operator can scan and have their
credentials read. The main benefit of a dash controller 150 is to be able to
manually engage a valve 20 in an emergency situation where the emergency
event is not directly monitored by the VCU 30, CDM 40, or other sensors.
[0063] In some embodiments the equipment can include a modem 60
that can communicate with GPS satellite and can relay latitude and longitude
information of the equipment on at various intervals.
[0064] The CAN bus 152 can be installed as a standalone transceiver
to talk to the CDM 40 and/or VCU 30, or it can be installed directly on the
CDM 40 and/or VCU 30. The CAN bus 152 can translate and allow
communication directly with the engine and can requesting exact data points
in real time from the on board engine computer.
[0065] The NFC access device 52 can be an RF key-fob, as shown in
Figure 4, and can act as a wireless version of the dash controller 150. The
NFC access device 52 can enable the operator to open/close the valve 20
remotely. This can be used, for example, by fuel haulers who, in the event of
a spill, can pre-emptively shutdown the system remotely.
[0066] In some embodiments an E-Stop button input 154 can be
installed on a trailer or other area as a remote button to initiate an
emergency
shutdown.
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[0067] In some embodiments a VR-sensor 156 can be used as an
alternative means to detect the RPM of the equipped engine. In some
installations, obtaining the RPM via standard means is not possible. A VR-
sensor 156 can detect magnetic fluctuations in the alternator, which can then
be translated into an RPM reading on the VCU 30.
[0068] A power take-off ("PTO") is a device that transfers an engine's
mechanical power to another piece of equipment. In some embodiments a
PTO 158 can be used to monitor and react to particular events. For example,
when an operator is using a piece of equipment or vehicle while outside of the
piece of equipment or vehicle, the PTO can detect unsafe hydrocarbons and
shutdown the primary engine even though the vehicle is not being used in a
standard configuration.
[0069] In some embodiments a sensor or multiple sensors 160 can be
integrated into a system and can be used in custom installations to initiate
an
event that the VCU 20 and/or CDM 30 can react to. In Figure 4 a pressure
sensor 160 is depicted, however, any appropriate type of sensor can be used.
[0070] Referring now to Figure 5, an embodiment of a CDM 40 used in
a master lockout system 10 and its potential connections are provided. The
processor 44 of the CDM 40 can define data to be requested from VCU 30,
process data, store data in on-board memory, format data for use, define data
to be requested from the database 114, and define data to be requested from
the web interface 112. The CDM board 41 can also contain a power
converter, Bluetooth0 module and other optional components. Along with the
types of information and steps being completed, Figure 5 uses different
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connecting lines to show where different sources of information can travel.
For
example, modem 60 information is shown to travel to and from the CDM 40,
but also from the CMD 40 to the step where data is gathered to send to the
NFC module 50.
[0071] Referring to Figure 6 a block diagram depicting a CDM 40 and
its potential communications with an embodiment of a GPS module 90 are
provided. In summary, the CDM 40 can prepare and encode a request which
can then be sent to the GPS module 90. The GPS module 90 can process the
request, check the number of satellites to see if there are enough satellites
in
range to acquire a position. If there are not enough satellites in range then
these results can be returned to the CDM 40. Otherwise, satellites are pinged
for connections, incoming data can be collected and processed and the
results are returned to the CDM 40. Transmissions between the CDM 40 and
the GPS module 90 can be sent via RS-232/RS-484 connection. The GPS
module 90 can respond to the CDM 40 command with GPS coordinates.
When the GPS coordinates are successfully updated on the CDM 40 and then
the data can be stored on the CDM 40 and sent to peripherals (if it was
requested) and/or the CDM 40 can prepare and encode another request. The
new request can be then sent to the GPS module 90 and the cycle continues.
[0072] Referring now to Figure 7, a block diagram depicting a CDM 40
and its potential communications with an embodiment of a modem 60 are
provided. The CDM 40 can collect data to send to the database, and then
based on the data can send a modem command (for example connect or
disconnect etc.). The command CDM 40 can then send the commands and/or
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sort data. Data can also be requested from the database by peripherals
through the CDM 40. The requested or sorted data can be encoded and
encrypted and held by the CDM 40 while a connection is being established. If
a connection is found, then the data can be sent. If the connection is not
found then it can continue to be held while the connection is established. The
CDM 40 can send commands and data to the modem 60 to be sent to the
database 114.
[0073] The modem 60 can receive the command or data. If data has
been received the modem 60 can prepare to transmit the data and then it is
transmitted to the database 114. If a command has been received, the
command can be identified and then acted upon. If required, a connection
with the database 114 can be established and the data requested. The
modem 60 can also have been directed to execute internal commands, for
example to adjust modem settings. The modem 60 can then set an interval to
self-connect to the database 114 to check for remote commands and
information.
[0074] When a self-connection interval has been initiated, the modem
60 can determine if it is time to connect. If not, it can wait longer to make
the
connection. If the correct amount of time has elapsed, the modem 60 can
prepare a command to request updated information and/or commands,
establishes a connection with the database 114 and transmits the request.
[0075] The modem 60 can receive input from the database 114. If there
is no new information from the self-connection, then the connection is closed.
If there is a return confirmation of a connection these results are sent to
the
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CDM 40. The modem 60 can store data until the entire message is received
and then can close the connection and send the results to the CDM 40.
[0076] The modem 60 can send to the CDM 40 connection status and
incoming data. If the connection status is sent and the connection is
confirmed then that allows the CDM 40 to send any pending data or
commands. If the modem 60 has sent data then the CDM 40 can decrypt and
decode the data, sort the responses and then send the data to the main
processor 40 or to the requesting peripheral.
[0077] The CDM 40 can access the processes handled on the central
board for use by all peripherals
[0078] Referring to Figure 8 a block diagram depicting a CDM 40 and
its potential communications with an embodiment of a NFC module 50 is
provided. Data from the database to be encoded onto NFC access devices 52
can be collected and prepared to be sent to the NFC access device 52. The
data can be stored on the CDM 40 until the access device is detected and
then the data can be sent to the NFC module 50. The CDM 40 can send
commands for the NFC module 50 to interact with the NFC access device 52.
The NFC module 50 can hold the data to ensure that the card is ready and
hold the data until the NFC access device 52 is detected. Once the NFC
access device 52 is detected and ready the data can be transmitted to the
NFC access device 52.
[0079] When an NFC access device 52 is detected the NFC module 50
can attempt to connect to the NFC access device 52. If the NFC access
device 52 is not detected then another attempt to connect can be made. If the
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NFC access device 52 is detected the communication can be sent from the
NFC access device 52. The NFC module 50 can also receive information from
the NFC access device, and the NFC module 50 can then relay that data to
the CDM 40.
[0080] The NFC module 50 can send communication parameters and
data contents of the NFC access device 52 to the CDM 40. If the input
information to the CDM 40 is that the NFC access device 52 has been found
the information is relayed so that the CDM 40 recognizes the NFC access
device 52 has been detected and data can be sent to the NFC module 50. If
the input information is data then the CDM 40 processes the data retrieved
from the NFC access device 52 and stores the data to be used to verify the
user in other areas. If the input information is from the authentication
process
then the authentication data can be processed for re-transmission and sent to
be inserted into a command. The CDM 40 can collect commands for the NFC
access device 52 and then prepares to send data to the NFC access device
52, as outlined above.
[0081] All transmissions in Figure 8 can be sent via serial connection.
[0082] Referring to Figure 9 a block diagram depicting a CDM 40 and
its potential communications with an embodiment of a VCU 30 is provided.
The CDM 40 can receive commands from a remote site via a modem 60. The
CDM 40 then can format the data for the VCU 30. Other data formatted for the
VCU 30 can come from the display module 110. Commands from the display
module 110 can be verified NFC data by the NFC scanner. If the user is
determined to be authorized then the command data is formatted for the VCU
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30. The formatted data is encrypted and then the CDM 40 sends update
requests and remote/local valve commands to the VCU 30.
[0083] The VCU 30 can decrypt the data and then can determine what
type of input the CDM 40 provided. If it is a local command then the VCU 30
opens or closes the valve 20 and determines if the valve 20 is locked.
Similarly, if the input is a remote command, then it can be determined if the
valve should be opened or closed. If the valve 20 is not locked then the valve
20 is sent a command and data is collected on the actions taken and
associated events. If the valve 20 is locked then data can be simply collected
on the actions taken and the associated events. Similarly, if the input is a
remote command then it is determined whether or not to lock or unlock the
valve 20 to give local access to the valve 20 and then data can be collected
on the actions and associated events. Associated events can include the
valve state and/or engine data. Once this data is collected, it is determined
if
there is any new data to send to the CDM 40 and the collected data becomes
stored data in logs on the VCU 30.
[0084] If the input received by the VCU 30 is to update a request then
the VCU 30 obtained the data requested. The data requested can be
combined with the new and stored collected data on actions taken and the
associated events and then sorted so that the VCU 30 returns only what is
new or requested. The data can be then encrypted and the VCU 30 sends
valve data, event data, log data, engine data, fault codes and error codes to
the CDM 40.
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[0085] The CDM 40 decrypts and processes the data and then
determines if the data is for the display module 110 or the database 114 or
both. For data that is to be sent to the database 114, including data also
being
sent to the display module 110, it is formatted, along with data from other
sources to be sent with the VCU data, for example GPS data, timestamp data
and weather conditions, and the formatted data is sent to the modem 60. For
the data that is being sent to the display module 110, including data also
being sent to the database 114, it is formatted to update the display module
110 with current information and then sent to the display module 110. This
step is optional and only occurs when the display is available.
[0086] The transmissions in Figure 9 can be encrypted and sent via a
RS-232/RS-485 connector.
[0087] Referring to Figure 10, a diagram depicting wireless
communication between towers in an embodiment of a master lockout system
is provided. At certain distances, in this example the distance can be 500
meters, equipment 12 can both receive and send wireless communication
signals from and to a master tower 16 (also referred to herein as a
transmission tower) or a relay tower 34 (also referred to herein as a repeater
tower). In this example within a range of 1000 meters the master tower 16 can
only send information to the equipment 12, but not receive any information in
return. Therefore, equipment between 500 meters and 1000 meters would
have to store their data until they were back within the 500 meter range of
the
master or relay tower. However, if two pieces of equipment 12 are within
range of each other, the piece of equipment 12 located outside the 500 meter
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range could send information back to the master tower 16 or the relay tower
34 (together referred to as the communication tower 25) via the closer piece
of equipment 12 located within the 500 meter range of the communication
tower 25. For equipment 12 located outside the 1000 meter range of the
communication tower 25, they would store there data until they came back
into range. Equipment 12 that is within range of more than one
communication tower 25 may communicate with either tower, but would
preferentially communication with the master tower 16. The communication
between the towers 16, 34 and the equipment 12 can be done by a 900 Mhz
meshing system 70.
[0088] Key fob ranges are not depicted on Figure 10 and each remote
can be specific to each vehicle.
[0089] Referring now to Figure 11 an embodiment of a user interface or
display module 110 of a master lockout system 10 is provided. An authorized
user can use this display module 110 to access information and data
regarding the associated piece of equipment 12, for example a user may
retrieve data on alerts 116, resources 118, reports 120, logs 122, fault codes
124, location 126, engine data 128, VCU 130, user data 132 or access the
settings 134. Additional information, for example engine status 136, valve
status 138 and the user 140 may be displayed, along with the current time,
battery life, wireless and Bluetooth connections.
[0090] During the normal operation of a vehicle, carbon can build up in
the air intake system by clinging to surfaces and can effect various
mechanical devices. For example, the valve 20, can be installed directly in a
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vehicles air intake and as carbon builds up can cause the valve 20 to seize.
In
order to prevent damage to the valve 20 a user could cycle the valve 20 daily,
thereby clearing any debris before it could build up to a level that would
prevent functionality. However, this type of maintenance may be unreliable,
can drain batteries if the vehicle was not used for an extended period of time
(days or weeks for example) and may cause damage to the valve 20 if it were
cycled when the valve and/or engine were cold.
[0091] Referring now to Figure 12, an embodiment of how the valve 20
can be cleaned using an automatic cycling method is shown. In step 200, the
VCU 30 is in sleep mode and the engine is turned off. The VCU 30 can
monitor for RPM's 202 and make decisions based on whether or not there are
RPM's 204. In particular, if the VCU 30 does not sense any RPM's then it
continues in sleep mode, however, if the vehicle is turned on, then the VCU
30 detects the RPM's from the vehicle and it starts a first timer 206.
[0092] After a specific amount of time has expired if the VCU 30
determines if there are still RPM's 208. If the VCU 30 senses the vehicle is
shut off (there are no RPM's) then the VCU 30 returns to sleep mode 200. If
the VCU sensed RPM's for the specified amount of time, then the VCU 30
schedules an auto cycle of the valve 20 at step 210.
[0093] The specific amount of time that the vehicle is on and RPM's
detected can vary, but it used to ensure that the engine and valve are warm
and ready to be cycled without risk of damage associated when cycling is
performs on a cold engine and/or valve. In some embodiments the specific
time of the first timer can be 5 minutes.
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[0094] In step 212, while the vehicle is in operation it continues to
perform normally as does the VCU 30, until the vehicle is shut off and the
VCU no longer detects RPM's 214. At this point the VCU 30 can begin a
second timer 216. The length of the second timer is to ensure that the engine
has fully shutdown and to avoid any unnecessary stress on the engine. In
some embodiments the second timer can be 1 minute.
[0095] The VCU 30 can continue to monitor the RPM's for the length of
the second timer and once expired will query whether or not there are still no
RPM's 220. If the vehicle has turned on and there are RPM's detected, then
the VCU 30 returns to step 212 and continues to perform normally. If the
vehicle remains off and there are still no RPM's detected, then the VCU 30
initiates the automatic cycling process 222.
[0096] The auto cycling process can include closing the valve 224 and
then opening the valve 226. Once this automatic cycling process is completed
the VCU 30 returns to sleep mode 228 and the process starts again at step
200.
[0097] After the auto cycling process is completed a log of the
automatic cycle can be recorded in the internal log of the VCU 30, verifying
that proper maintenance of the valve 20 has been completed. The
advantages of using the automatic cycling process can include the reduction
of unnecessary cleaning cycles, saving battery power and ensuring that
proper maintenance of the valve 20 is performed, resulting in a more durable,
reliable and safer master lockout system 10.
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[0098] In some embodiments the VCU 30 can monitor the RPM's
continually during the period of the first and second timers, at regular
intervals
during the first and second timers, at the start and end of the first and
second
timers or any combination thereof.
[0099] Although a few embodiments have been shown and described,
it will be appreciated by those skilled in the art that various changes and
modifications might be made without departing from the scope of the
invention. The terms and expressions used in the preceding specification
have been used herein as terms of description and not of limitation, and there
is no intention in the use of such terms and expressions of excluding
equivalents of the features shown and described or portions thereof, it being
recognized that the invention is defined and limited only by the claims that
follow.
[00100] While the above description details certain embodiments of the
invention and describes certain embodiments, no matter how detailed the
above appears in text, the invention can be practiced in many ways. Details
of the apparatuses and methods may vary considerably in their
implementation details, while still being encompassed by the invention
disclosed herein. These and other changes can be made to the invention in
light of the above description.
[00101] Particular terminology used when describing certain features or
aspects of the invention should not be taken to imply that the terminology is
being redefined herein to be restricted to any specific characteristics,
features,
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or aspects of the invention with which that terminology is associated. In
general, the terms used in the following claims should not be construed to
limit the invention to the specific embodiments disclosed in the
specification.
Accordingly, the actual scope of the invention encompasses not only the
disclosed embodiments, but also all equivalent ways of practicing or
implementing the invention.
[00102] The above description of the embodiments of the invention is
not intended to be exhaustive or to limit the invention to the precise form
disclosed above or to the particular field of usage mentioned in this
disclosure. While specific embodiments of, and examples for, the invention
are described above for illustrative purposes, various equivalent
modifications
are possible within the scope of the invention, as those skilled in the
relevant
art will recognize. The elements and acts of the various embodiments
described above can be combined to provide further embodiments.
[00103] While certain aspects of the invention are presented below in
certain claim forms, the inventors contemplate the various aspects of the
invention in any number of claim forms. Accordingly, the inventors reserve the
right to add additional claims after filing the application to pursue such
additional claim forms for other aspects of the invention.
[00104] Without any limitation to the foregoing, the present systems and
methods are further described by way of the following examples.
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EXAMPLE 1
[00105] In some embodiments, a system can include a valve 20, VCU
30, CDM 40, Modem 60, GPS Module 90, NFC module 50, Display module
110, and CAN bus.
[00106] Situation and tasks to complete: A welding truck and operator
are alone on a remote site with a cellular signal. The operator is to weld a
valve on an adjoining pipe structure not currently in use. While working, a
leak
develops on the live pipe stem located 100 feet from the welder.
[00107] Step one ¨ While driving to the remote site, the VCU 30 is
monitoring the vehicles speed, rpm, and tilt. This data is being received via
communication between the CDM 40 and CAN bus. Every 15 minutes the
data is logged, stored, and transmitted to the database 114, which can be a
cloud server, via the modem 60.
[00108] Step two ¨ Upon arriving the vehicle is turned off, this signals
the CDM 40 to issue a valve closure command, generating an event log.
[00109] Step three ¨ The operator inputs the time of arrival and job
number along with any other pertinent data via the display module 110. This
report is logged and stored both locally and remotely via the modem 60.
[00110] Step four ¨ The operator sets up and prepares to commence
with the intended work. To start the welder unit, the operator scans his/her
NFC access device 52. The NFC module 50 sends the user ID and
qualifications stored on the NFC access device 52 to the CDM 40. If a
connection is available, the CDM 40 then connects to the database 114 and
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retrieves the current qualifications associated with the ID number. If there
are
new or changed qualifications found in the database 114 the NFC module 50
writes these newly updated qualifications to the NFC access device 52. Then
the CDM 40 compares the operator's qualifications to those which are listed
as required to operate the welder unit. If the user has the correct
qualifications
the valve 20 on the welding unit is unlocked and opened, allowing it to be
started. When all of this is complete, whether successful or not, a log of the
scan and start (attempted or successful) are recorded and stored. If a user is
denied because of incorrect, expired and/or insufficient qualifications, this
is
also logged.
[00111] Step five ¨ The operator can now continue with their work; the
VCU 30 will continuously monitor the operations of the welder unit.
[00112] When the leak has now reached the welder:
[00113] Step six ¨ Hydrocarbons begin to enter the intake of the welder
motor, increasing the units rpms. The VCU 30 senses the rpms have
exceeded the present threshold and then issues a shutdown instruction to the
valve 20.
[00114] Step seven ¨ The valve 20 closes, therefore preventing the
engine from entering a runaway state and avoiding an explosive situation. A
log of the event is generated and stored.
[00115] Step eight ¨ With the welder shut off, the operator can see the
message indicating that an emergency shutdown was activated due to an
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increase in rpm. The operator can now report the incident with more detail
and dispatch the required response team to seal the leak before any damage,
or injury has occurred.
EXAMPLE 2
[00116] In some embodiments, a system can include a valve 20, VCU
30, CDM 40, 900 MHz meshing system 70, GPS Module 90, NFC module 50,
and CAN bus.
[00117] Situation and tasks to complete: A forklift is located in an
industrial complex that is equipped with a master shutdown system 10. While
the forklift is operating as intended, an incident occurred on site which
caused
a safety supervisor to initiate a master shutdown. All equipment on the site
is
then immediately shutdown, and can only be reinitiated by the same safety
supervisor.
[00118] Step one ¨ To start doing their work the operator scans his/her
NFC access device 52 to unlock the valve 20 to start the forklift. While in
this
arrangement no qualifications are involved, simply a log of who is operating
the equipment is generated, there can be situations where qualifications could
be required. In such instances, the method would proceed as in Example 1
where the operators' qualifications needed to be verified before the welding
unit could be accessed.
[00119] Step two ¨ The operator continues to perform their required
tasks.
[00120] When the incident occurs:
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[00121] Step three ¨ Upon realizing the severity of the incident the
safety supervisor determines it is pertinent to disable all equipment on the
site
to prevent further injury/damage. The supervisor then scans their NFC access
device 52 on the master lockout device 36 switch and initiates the shutdown.
The ability to initiate a master shutdown is restricted to specific user ID's
thereby ensuring only those who are authorized can initiate one.
[00122] Step four ¨ This step can be done in two ways depending on the
system setup.
[00123] Remote Master Shutdown ¨ With a remote master shutdown a
900 MHz signal is sent from a remote master lockout 32 to all equipment 12 in
range, each of which then initiate a shutdown and lockout procedure. The
signal is also relayed to any other equipment 12 within the specific shutdown
zone and back to the central system which relays the command to all wired
equipment 12.
[00124] Installed Master Shutdown ¨ With an installed master shutdown,
the required button and NFC scanner are permanently installed and hardwired
to the central system. In this arrangement, the command is sent to the central
system, the CDM 40, which is connected to a 900 MHz transceiver and sends
the shutdown and lockout command to all equipment 12. The CDM 40 also
issues the same command to all other equipment 12 which are directly wired
into the system.
[00125] Step five ¨ The forklift receives the shutdown and lockout
command via the 900 MHz transceiver. The CDM 40 sends the valve close
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command to the VCU 30 and locks the system to await the unlock command
from the person who initiated it. The forklift is now disabled. A log is
recorded
of the generated event.
[00126] Step six ¨ Once the situation has been cleared the safety
supervisor rescans his NFC access device 52, and disables the master
shutdown system, which then transmits the unlock command to all equipment
12. The unlock command is distinct from the open valve command, which
must be done at each piece of equipment 12. A log is recorded of the
generated event.
[00127] Step seven ¨ The forklift operator then rescans their NFC
access device 32 to open the valve 20, and starts the forklift to carry on
with
their work. A log is recorded of the generated event.
EXAMPLE 3
[00128] In some embodiments, a system can include a valve 20, VCU
30, CDM 40, modem 60, GPS module 90, NFC module 50, and CAN bus.
[00129] Situation and tasks to complete: A loader is in need of repair, a
supervisor disables the loader to prevent those who are unaware of the
needed repairs from using the equipment, thereby preventing injury and
damage. Then a maintenance worker also locks out the equipment to perform
the required repairs. Once the repairs are complete, the maintenance worker
lifts his lockout and then the supervisor re-inspects the loader and, once it
passes inspection, he lifts his lockout of the loader as well.
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[00130] Step one ¨ A problem is identified with the loader by an operator
and reported to the supervisor.
[00131] Step two ¨ The supervisor then scans his/her NFC access
device 52 which locks out the loader from all other access, regardless of the
access level. The user ID of the supervisor is stored in the CDM 40, and a log
is generated and stored. In order for the equipment 12 to be unlocked the
same supervisor must rescan their NFC access device 52.
[00132] Step three ¨ The supervisor calls in for repairs to be done to
the
equipment 12.
[00133] Step four ¨ The maintenance worker arrives and also scans his
NFC access device 52, not to unlock the valve (as this would not be possible)
but to add his/her ID number to the required ID's to unlock the equipment 12.
Again this is logged, stored and transmitted to the cloud. At this point if
the
supervisor attempts to unlock the device and operate the loader, the
maintenance worker is still protected as it will not unlock without the
maintenance worker also scanning his NFC access device 52.
[00134] Step five ¨ Once the repairs are complete, the maintenance
worker re-scans his NFC access device 52, releasing his lockout on the
system. A log is recorded of the generated event.
[00135] Step six ¨ The supervisor then inspects the loader to ensure
everything is complete and the loader is in working order. Then the supervisor
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also re-scans his NFC access device 52 and releases his lockout. A log is
recorded of the generated event.
[00136] Step seven ¨ The loader is now ready to be operated as normal.
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