EP2643802A1 - System for monitoring and deploying engineers - Google Patents

System for monitoring and deploying engineers

Info

Publication number
EP2643802A1
EP2643802A1 EP11791624.7A EP11791624A EP2643802A1 EP 2643802 A1 EP2643802 A1 EP 2643802A1 EP 11791624 A EP11791624 A EP 11791624A EP 2643802 A1 EP2643802 A1 EP 2643802A1
Authority
EP
European Patent Office
Prior art keywords
server
handheld device
engineer
data
maintenance
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP11791624.7A
Other languages
German (de)
French (fr)
Inventor
Clebert O'bryan Ricardo Yearwood
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP2643802A1 publication Critical patent/EP2643802A1/en
Ceased legal-status Critical Current

Links

Classifications

    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06QINFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00Administration; Management
    • G06Q10/06Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063Operations research, analysis or management
    • G06Q10/0631Resource planning, allocation, distributing or scheduling for enterprises or organisations
    • G06Q10/06311Scheduling, planning or task assignment for a person or group

Definitions

  • the invention is in the field of production and manufacturing lines, and in particular, monitoring and deploying engineers.
  • the fault will need to be identified so that a suitable engineer can be called. For example, if the fault is mechanical, a mechanical engineer will be needed, but if the fault is electrical, an electrical engineer will be needed. Once the fault has been identified, the line manager will need to contact a suitably qualified engineer to fix the faulty equipment. This can lead to significant delays in a busy production environment.
  • an automotive manufacturing plant has many machine tools performing maybe hundreds of different tasks. If one of the machine tools is non-functional, it can not only affect its own performance, but may hold up an entire production line. In an industry such as this, this can lead to huge losses in productivity and hence revenue. If a production line is held up, the line manager will typically check the production line to identify the faulty machine tool. Once this is identified, the line manager will try to determine the type of fault. He can then contact a suitably qualified engineer to attend to the faulty machine tool and fix the fault.
  • POSMon a system known as "POSMon” that can diagnose faults on a production line and quickly provide an error code to the line engineer.
  • the system comprises hundreds of sensors collecting data on the performance of the machine tools of the production line. The data is collected by programmable logic controllers which are connected to a diagnostic server via a network.
  • the server is connected to a database holding information about the process line and each of the equipment, and is able to provide fault analysis data to the server.
  • the server is then able to analyse the data from the sensors and PLCs to determine the location and nature of a fault.
  • the system can then generate an error code that can be understood by the line manager, who can then locate a suitable engineer to fix the problem.
  • Diagnostic systems such as Ford's POSMon have been able to cut downtimes of large manufacturing plants significantly, and thus increase the industry's efficiency and profits.
  • the engineer will likely need to contact the line manager to discuss the fault and obtain the necessary service manuals and equipment necessary to fix the fault, and ensure that he has the right tools for the job.
  • the selection could be based on a variety of information, including the location of the personnel, their availability and their qualifications.
  • the present invention provides a system capable of identifying the most appropriate engineer or maintenance person to respond to a maintenance request based on the location of the available engineers.
  • the system monitors the location of handheld devices carried by the engineers or maintenance personnel within a specified area, for example a manufacturing plant, factory, chemical plant or oil rig, to allow the system to determine who is conveniently located nearest to the fault that is to be fixed.
  • the system may also determine who is the most appropriately trained engineer who is available or currently unassigned to another job.
  • the specified area could be any area for example, a single floor in a building, multiple floors in a building or an outside area.
  • the system then provides data to the handheld device in order that the engineer can identify the location and nature of the fault.
  • the system comprises a server and a plurality of nodes connected to a network.
  • the nodes comprising sensors arranged to determine the locations of handheld devices, carried by the engineers, within a specified area, and communicate location data of the engineer to the server.
  • the server configured to receive a maintenance request and to select a suitable engineer from a pool of one or more engineers, for example all engineers that are employed by a company, to respond to the maintenance request based on the locations of the handheld devices, and to provide the selected engineer instructions to respond to the maintenance request.
  • the server may provide maintenance data to the selected engineer via two-way communication with the handheld device.
  • the system is configured to select the suitable engineer based on a record of the skills of the members of the maintenance personnel.
  • At least one of the plurality of nodes is configured to allow the two-way communication between the handheld devices and the server.
  • the network is wired or wireless, such as a wireless LAN.
  • the handheld devices emit a signal and the node sensors are arranged to receive the signal and to determine the position of the handheld device based on the signal, and preferably the signal is a UWB signal.
  • the node sensors are arranged to determine the time of arrival and the angle of arrival of the UWB signal, so that the location of the handheld device can be determined more efficiently.
  • the system is further arranged to receive the maintenance request from a computer system in response to an error code generated by a programmable logic circuit in communication with industrial apparatus.
  • the maintenance data could include details of the location and nature of the fault requiring maintenance, and could include at least one of CAD data, EPLAN data, map data or a service manual.
  • the system is configured to allow access to restricted areas by allowing a secured door to be opened when the maintenance personnel is determined to be near the secured door and the maintenance personnel needs access to the restricted area in order to perform the maintenance function.
  • the handheld device could be a mobile phone, a PDA, a laptop or a tablet PC.
  • the handheld receive could further comprise a GPS receiver and is arranged to communicate the location of the handheld device to the server when it is not within the specified area and maybe further arranged to receive maintenance data from the server via a GPRS mobile communication network.
  • the specified area could be an automobile manufacturing plant, a factory, a chemical plant or an oil rig.
  • the handheld device being configured to allow its location to be determined by a plurality of nodes connected to a network and to receive maintenance data from a server.
  • a method of monitoring and deploying engineers comprising determining the locations of handheld devices, carried by an engineer, within a specified area, using a plurality of nodes and communicating the location data of the handheld devices along a network to a server, receiving a maintenance request at the server and selecting a suitable engineer to respond to the maintenance request based on the locations of the handheld devices.
  • a computer program according to claim 28 The computer program providing instructions to carry out the above method.
  • Figure 1 shows a block diagram of the system for monitoring and deploying engineers according to an embodiment of the invention
  • Figure 2 shows a handheld device according to an embodiment of the invention
  • Figure 3 shows a node according to an embodiment of the invention
  • Figure 4 shows a schematic diagram of the system of an embodiment of the invention in use
  • Figure 5 shows another schematic of an embodiment of the invention in which part of the specified area is restricted
  • Figure 6 shows a block diagram of an embodiment of the invention in which the maintenance request is provided by a automated diagnostic system
  • Figure 7 shows a flow diagram of the steps of an embodiment of the invention.
  • Figure 1 shows a preferred embodiment of the invention.
  • a plurality of nodes is arranged throughout a specified area.
  • the specified area is an area in which engineers, or other maintenance personnel, will typically be working.
  • an engineer shall refer to any person who may be called upon to perform some type of maintenance task.
  • an engineer may refer to a mechanical or electrical engineer, or it may refer to a specialised engineer relating to a specific task, or it may even refer to a cleaner or other staff.
  • the specified area may be a manufacturing plant, a factory, a chemical plant, an oil rig or any other industrial area.
  • the plurality of nodes 20 are configured to determine a location of a handheld device 30 located within the specified area. The location of the handheld devices 30 could be determined in a number of ways, including by RFID or GPS, However, in a preferred
  • the handheld devices 20 emit a signal, preferably an ultra-wide bandwidth (UWB) signal, which is received by sensors in the plurality of nodes 30.
  • the frequency of the UWB signal would typically be in the range 3.1 to 10.6 GHz, but maybe outside of this range.
  • These signals are then sent via a network 100 to a server 10, where they can be processed.
  • the difference in arrival times of the signals at the nodes can be used to calculate the position of the handheld devices within the specified area, as described in US2010/0001905A1 .
  • FIG. 2 shows a handheld device 30 according to a preferred embodiment of the invention that could be carried by the engineers or other maintenance staff.
  • the handheld device 30 is configured to allow the location of the handheld device 30 to be determined within a specified area by the nodes.
  • the handheld device 30 could be any suitable portable device that is able to be located by the nodes and receive and display data from the server.
  • the handheld device could be a mobile telephone (cell phone), a Personal Digital Assistant (PDA), a tablet PC, a laptop, a notebook or any other suitably configured mobile device.
  • PDA Personal Digital Assistant
  • the handheld device will typically comprise a case 38 and a screen 36 to display data received from the server 10.
  • the handheld device 30 further has a module that allows the handheld device to be located by the nodes 20.
  • the handheld device could comprise an UWB signal transmitter 31 .
  • the UWB signal transmitter could transmit periodic pulses that could be received by the nodes 20 in order to determine the position of the handheld device 30.
  • the nodes could determine the position of the handheld devices 30 via other techniques, for example RFID.
  • the handheld device 30 further comprises a data receiving module for receiving data from the server.
  • the device could have at least one of a Wi-Fi module 32, a GPRS antenna 33 or any other suitable data receiving module.
  • the module can also transmit data, for example via the Wi-Fi module 32, the GPRS antenna 34 or other data transmitting module.
  • Figure 3 shows a typical node 20 according to a preferred embodiment.
  • the node comprises a location determining module, for example a UWB receiver 21 capable of receiving an UWB signal from the UWB signal transmitter 31 in the handheld device 30.
  • the UWB receiver 21 could be a single detector, but it is preferable to have an array of detectors so that the angle of arrival (AOA) of the UWB signal can be determined.
  • the AOA could be determined by the relative phase differences of the UWB signal along the array, as described in
  • the node determines the time that the UWB signal was received and the direction (azimuth angle and elevation) that the signal was received from.
  • the node 20 further comprises a network interface device 25 for connecting to a network 100.
  • the network interface device 25 could be an Ethernet connection for connecting to Ethernet cabling forming the network 100.
  • the node could connect to a network using wireless technology using a wireless network adapter. In this manner, the node is able to
  • This data can then be sent to the server 10 via a network 100.
  • the node may further comprise a data transmitter 22, for example a Wi-Fi module or other radio transmitter capable of transmitting data, for transmitting data to the handheld device 30.
  • a data transmitter 22 for example a Wi-Fi module or other radio transmitter capable of transmitting data
  • the handheld device 30 and the node 20 are capable of two-way data transfer via radio waves, and would typically use the 2.4GHz frequency band. Only one node 20 is needed for two-way
  • the handheld device 30 could determine the node 20 with the strongest signal and connect to that node 20.
  • the node 20 could further comprise a controller 26 to interface between the UWB receiver 21 , the data transmitter 22 and the network interface device 25.
  • the equipment in the node 20 will need to be powered. This could be done in a number of ways.
  • the node could comprise a battery power supply (not shown) which could be used to power the equipment. However, such a system would require frequent changing of the battery.
  • a separate power supply (not shown) could be connected to the node via a dedicated power cable.
  • the node is connected to the network 100 via an Ethernet cable, and the node is powered from the Ethernet cable using power-over-Ethernet technology, for example according to the IEEE
  • FIG. 1 An example of an engineer monitoring and deployment system according to an embodiment of the present invention is depicted schematically in figure 1 .
  • a plurality of nodes 20 are arranged within a specified area. This area could be a factory, automobile manufacturing plant, chemical plant, oil rig or other industrial area.
  • the nodes 20 could be distributed throughout the specified area, for example on the ceiling, the walls or on posts.
  • the nodes 20 will be distributed approximately every 15 m, but this can vary depending on the method used to locate the handheld devices 30, the power used and the terrain.
  • the nodes 20 are connected to a server 10 via a network 100.
  • the network 100 preferably comprises an Ethernet cable capable of power-over- Ethernet technology.
  • the nodes 20 are configured to determine the position of handheld devices 30 within the specified area.
  • the handheld devices 30 may emit a short pulse of UWB radio waves from the UWB signal transmitter 31 .
  • These UWB radio waves travel to the nodes 20 and are detected by the UWB receivers 21 .
  • the time of arrival of the signal and the angle of arrival of the signal are detected by the UWB receivers and passed to the controllers 26. This data is then sent along the network 100 via the Ethernet cables and provided to the server 10.
  • the server 10 can then determine the time difference of arrival of the UWB signal at the nodes, and the direction (azimuthal angle an inclination) of the signal from the nodes which are able to receive the UWB signal. If at least two nodes 20 receive the UWB signal, then the server is able to compute the 3D location of the handheld devices 30. In some circumstances, the location of the handheld device 30 can be determined with an accuracy of 15 cm.
  • the identity of the handheld device 30 which transmitted a particular UWB signal could be determined in a variety of ways.
  • the UWB signal itself could have an identifying signal embedded within it, or the handheld device 30 could transmit via a radio signal the time at which it transmitted the UWB pulse, so that the UWB signal could be identified as being transmitted by a particular handheld device 30.
  • the server 10 can therefore monitor the positions of any handheld devices 30 that are in the specified area, and may represent this graphically on a screen 12 if required.
  • the server 10 is configured to receive a maintenance request.
  • This request could be for any occurrence for which an engineer is required to fix a problem. For example, a machine tool may have stopped working and require a mechanical or electrical engineer, a computer terminal may have crashed and require an IT engineer, or maybe something has been spilt and a cleaner is required to clean the area.
  • the request may contain the location of the fault or occurrence requiring the engineer, details of the type of engineer that is required, and details of the fault or occurrence.
  • the maintenance request could be received from a dedicated automated diagnostic system, for example Ford's POSMon system, or it could be entered manually.
  • the server 10 determines the most appropriate engineer to respond to the request.
  • the server 10 may be in communication with a database 14 that has information on all of the available engineers, and can identify which of the engineers are suitably qualified to respond to the maintenance request. For example, if an electrical fault had been reported, the server 10 could access the details of all electrical engineers that were suitably qualified to deal with the fault. The server could then determine which of the appropriate engineers are on site, and determine which are closest to the fault. Using this information, the server can then determine which engineer should respond to the maintenance request and attempt to fix the fault in the most efficient manner. This is likely to be the closest engineer that his suitably qualified, but the server could take into account other factors, for example security clearances needed to enter certain areas.
  • the handheld device 30 could allow an engineer to inform the server 10 of his availability. For example, if he is already engaged in a repair job, he could inform the server 10, via the handheld device 30, that he is not available.
  • figure 4 schematically shows a specified area 300 that is monitored by a plurality of nodes 20.
  • a specified area 300 that is monitored by a plurality of nodes 20.
  • the server determines the location of the most suitable engineer to be sent to respond to the request by considering the location of the engineers' handheld devices 30.
  • handheld device 330 is the nearest to the fault, and so instructions are sent to the closest engineer's handheld device 330, via the network 100 and radio communication through a node 20. In this manner the engineer is provided with instructions to fix the fault.
  • the instructions could include details of the fault and its location.
  • the engineer is provided with map data that can be displayed on the screen 36 of the handheld device 30.
  • This map data could indicate the location of the fault and the engineer's current positions, as determined by the server 10, using data from the nodes 20.
  • the map data could include internal map data that could be used as a point to point reference guide for equipment collection and retrieval.
  • the map data also could include a schematic layout of the specified area 300 and/or a perspective view data that could help the engineer navigate to the fault. This data could be in the format of CAD data, or EPLAN data or other suitable format capable of
  • the engineer may also be sent data regarding the equipment that is to be fixed.
  • the engineer may be sent the service manual of the faulty equipment so that he can consult the service manual prior to, or whilst, attending to the fault.
  • the service manual may be in any suitable format that can be displayed by the handheld device 30, for example PDF.
  • the specified area could have restricted zones, in which not all personnel are allowed to enter. If the location of the fault is within a restricted zone, or if an engineer must pass through a restricted zone to reach the area of the fault, the system could be used to allow the engineer automatic access to the restricted zone. As an example, figure 5 depicts the situation where the fault 500 is located in a restricted zone 400.
  • the engineer needs to open a locked door 420, to which he does not normally have access, in order to fix a fault.
  • the system could guide the engineer from his original positions 430 to a position 431 close to the secured door 420.
  • the engineer's positions is monitored by the server based on the position of his handheld device 30, and when the location of the engineer is determined to be at or near the locked door 420, the system could permit the engineer access to the locked door. This could be performed, for example, by the system electronically opening the door until the engineer has passed through the door, or maybe an electronic code could be sent to the engineer's handheld device 30, which could be entered into a keypad to permit the engineer temporary access.
  • the system could be expanded to cover an area larger than the specified area 300 in which the nodes are located.
  • the nodes 20 will not be able to determine the position of the handheld devices 30 or transmit data to them because the handheld device 30 will be out-of-range of the nodes 20.
  • the handheld devices 30 could be further fitted other location devices, such as a GPS module (not shown), such that its position could be determined using GPS technology. The position of the handheld device 30 could be
  • the server 10 communicates to the server 10 via GPRS mobile communication networks.
  • the server will be able to determine the location of handheld devices that are outside the area monitored by the nodes 20.
  • Data could also be sent to the handheld device 30 via GPRS mobile communication networks, to provide the engineer with data regarding any maintenance request.
  • the server 10 could receive a maintenance request for which there are no suitably qualified engineers available in the specified area.
  • the server 10 could check the database 14 for a list of suitable engineers that are off-site. For example, the engineers may be off duty but be "on call" for emergency repairs.
  • the server could determine the position of any suitable engineer, potentially anywhere in the world, from the GPS modules in their handheld devices 30. From this data, the server could select the most suitable engineer to contact to instruct to come to respond to the
  • the server could then provide the necessary details about the fault and location data via GPRS mobile communication.
  • the handheld device 30 might then be used as a GPS navigation device to guide the engineer to the location of the fault. Once the engineer enters the specified area 300 that is monitored by the nodes 20, the engineer could be guided to the fault 500 in the manner described above.
  • Several specified areas that are monitored by a plurality of nodes 20 may be in communication with each other and share details of the locations of engineers.
  • a manufacturing company might have several factories, each of which is monitored by nodes 20. Whilst each factory may have their own engineers for day-to-day maintenance, there may only be a few specialised engineers at deal with specialised problems.
  • the server may communicate with the server in the other factory to query if any specialised engineers are located in that factory, and if so provide data to the engineer via the nodes within that factory to respond to the fault.
  • the nodes 20 in a plurality of specified areas may all be connected by a network to a single server 10.
  • the maintenance request could be received from a dedicated automated diagnostic system, for example Ford's POSMon system, or it could be entered manually.
  • Figure 6 illustrates an example in which the request is received from an automated diagnostic system.
  • a machine tool 60 for example a robotic arm in an automobile production line, is monitored by a plurality of sensors (not shown) connected to a programmable logic controller (PLC) 52.
  • PLC 52 monitors the actions of the machine tool 60 with the sensors and looks for any signs of failure. If the PLC 52, determines that the machine tool 60 has developed a fault it communicates this information to the clients diagnostic server 50.
  • the client's diagnostic server examines the data from the PLC 52 and sensors and determines the fault with the machine tool 60.
  • the client's diagnostic server 50 then issues a maintenance request to the server 10.
  • the request could provide the location of the faulty equipment 60 and an error code providing details of the fault that has occurred.
  • the system can then select a suitable engineer to respond to the fault as detailed above.
  • Figure 7 shows a flow diagram of a method of operation of an embodiment of the invention.
  • the PLC 52 connected to the sensors arranged on the robotic arm will send an error signal to the client's diagnostic server 50 via a network.
  • the client's server 50 will compare the error code from the PLC 52 and determine the fault.
  • the client's diagnostic server 50 will then issue a
  • the server 10 consults the database 14 to select which of the engineers that work for the plant are qualified to deal with the fault.
  • the fault could be a mechanical fault, so that a mechanical engineer is needed.
  • the server will identify all of the mechanical engineers.
  • the database may also contain information of which engineers are on duty and which are not, in which case it could narrow down the candidate engineers to the ones that are on duty.
  • the server 10 could then determine the position of the mechanical engineers that are on duty by locating their handheld devices 30 using the real time locating system based on the nodes 20.
  • the handheld devices 30 might provide data to the server 10 via Wi-Fi radio link through the nodes 20 as to whether the engineer is available or not.
  • the server 10 determines the most appropriate engineer to select to repair the fault in the most efficient manner. Once the engineer has been selected, information regarding the fault is sent to the engineer from the server 10, along the network 100 and to the handheld device 30 via the Wi-Fi connection to a node 20.
  • This data includes the location of the faulty robotic arm 60 and a map of the plant in order that the engineer can navigate to the fault as quickly as possible.
  • the map could show the current location of the engineer and the location of the faulty equipment overlaid onto a schematic plan of the plant or it could show a 3D perspective view of the direction in which he should walk.
  • the handheld device 30 will direct him to a secured door 420.
  • the server 10 recognises that the engineer is at the secure door, the server 10 unlocks the door until the engineer has entered the restricted zone 400.
  • the server 10 Whilst the engineer is travelling to the faulty equipment the server 10 could be sending the engineer important documentation to help him recognise and fix the fault. This might include a service manual or pictures of the equipment. The server 10 may also order any spare parts if it is known that the particular fault will need specific parts to fix the equipment. It may be that the parts are kept onsite, and so the server 10 could also locate a suitable engineer or assistant to fetch the part and bring it to the fault equipment for the engineer.
  • the engineer Whilst the engineer is repairing the equipment, he could communicate with the server 10 via the handheld device 30. For example, he may need to more information or need to order some parts or a specialist tool that he does not have. Alternatively, he may need assistance if the fault cannot be repaired by the engineer alone.
  • the server 10 could also be used to keep a log of the efficiency of the engineers in order that any deficiencies can be identified. In this manner, the management of the plant could more effectively target the engineers with the most appropriate training.
  • the system comprises three main elements a server of a main computer system which monitors and assigns and collates tasks according to priority, and interfaces with other system required applications.
  • Nodes which are used to communicate, transfer data and triangulate a device's position.
  • Handheld devices which are used as a location, Tele-Communication, Data transferable information and monitoring devices. Also commercially used mobile devices maybe configured to be used in this connection.
  • the server is then configured with the appropriate handheld devices and attached with predefined protocols (i.e.
  • Siemens or Rockwell notification of a process fault during the manufacturing of a vehicle the PLC via the standard programmed (BMW, Ford, GM) generates an error code specific to each unit / equipment being used throughout the production process.
  • This information / data via POSMON client's collection and processing server / software is also forwarded to the Server for processing and dispatching.
  • the Server Upon receiving a fault notification, the Server in conjunction with the processing of other elements such as the overview of the client's facility in regards to the location of all engineers specifying their current assignments and job specifications and their relationship to the fault flagged.
  • the Server administration program After engineer selection, the Server administration program notifies the Engineer and sends him or her the precise location of the fault, including guidance to the fault's location, while this is in progress the said handheld device/unit is sent EPLAN and CAD information for help with the diagnosis and remedy of the fault.
  • the system's administration software monitors the complete process for evolution and assistance should the engineer require it. This can also be requested by the Engineer's handheld device.
  • the clients would be assigned a dedicated double redundancy server. This allocated system, would run bespoke applications.
  • An example of the options available would be:
  • Handheld device Resources, Time and Motion, Entry and Access, Security Level Access, Tracking objects, Communication between the system or interfacing with other communication networks
  • the handheld devices are used for communicating between colleagues and with the guidance of the system server the locating and diagnosing of system faults.
  • Information in the form of text, video and / or digital overlaying CAD, EPLAN, PDF or other media
  • CAD computerized trademark of Lucent Technologies Inc.
  • EPLAN electronic local area network
  • PDF digital overlaying
  • GPS, GPRS, WIFI and RFID are some of the communication media included in both the handheld device and the data nodes. Via the connectivity between the units and the strategically placed nodes located around the clients premise would enable the triangulation of the handheld device's current location.
  • nodes Using multiple nodes would guarantee a clear data triangulation and transmission while within a building or other structure (i.e. Maritime Vessel). When outside of the zoned (node) area, GPS technology could be used for continues positioning.
  • data could be stored on the handheld device, for security reasons, data would preferably be stored on the system's or client's server where it could be accessed after security/protocol procedures.
  • the engineer unit can be used as a diagnostic unit for the client's equipment and services.
  • ID Company and Other Data
  • SIM Subscriber Identity
  • Name Company
  • ID Position
  • Security Level Job
  • Job Other Data
  • the handheld device could also be used as an entry system, notification, and communication and ordering system: Entry into assigned areas (Commercial and Manufacturing building / Structures, Maritime Vessels, Oil & Gas Platforms and outside venues)
  • the handheld engineers unit could also be used for communications between colleges and the location of faults as transmitted though the allocated node/Server linked to a main computer.
  • Information in the form of text and / or digital maps identifies the fault / error and provides the location for a quick remedy. This could be used for: ordering equipment (i.e. via SAP), Transmitting & Receiving Data via the E.D.A. NODES (CAD, EPAN, Electronic Data).
  • sim card functions maybe required for communication outside of the Clients facility
  • the node modules are used for data transfer and triangulation, located on commercial and manufacturing building / structures, maritime vessels, oil & gas platforms and outside venues.
  • locating a Person/Equipment / fault can be facilitated at any given time by authorized personnel via the administration application running on the client's/system's Server.
  • the nodes, handheld devices and server also communicate with other applications such as SAP, POSMON, EPLAN, CAD and other approved applications. If the object concerned (Person/Equipment) should either enter an unauthorized area the client's/system's server would notify the appropriate person concerned or activate pre-programmed protocols.
  • the CAD rendering of the client's facility is housed on the system's server. This facilitates the overlaying of schematics and the interfacing with the client's current database structure. This system also keeps a real-time update location of all engineers and objects stored on the server with the attached communications module. This allows for effective allocation of personnel and the monitoring of equipment.
  • the nodes collectively triangulate the engineers' positions and overlays all data in relationship to the relevant system. Subject to the positioning of the fault CAD rendering directions are then given to the relevant engineer with directions.
  • the server uploads further CAD and EPLAN information to the engineer unit.
  • the engineer has reached the desired location further information from the
  • EPLAN, CAD, TEXT or Telecommunications are all accessible functions via the nodes and server-database connections. Therefore, any relevant protocol driven data could be pulled down to the engineer's handheld diagnostic device.
  • the engineer need additional help, equipment or information, he/she could request further assistance from the server-side application or upon reaching a predetermined time limit the server- side application could assign further engineers.
  • Nodes are used for the notification of a system errors, and server applications. Communication, data transfers and triangulation are function used to locate engineers, clients, staff, guests and intruders, via the nodes the overlays of relevant CAD images and other information can be transmitted to the appropriate diagnostic unit.
  • the assigning of the relevant Engineer via the server would depend on the criteria set out by the client.
  • the server side application Upon the notification of a system error, the server side application would locate all engineers with the capability of rectifying the error.
  • the assigning of the relevant Engineer via the server would depend on the criteria set by the client. For example: nearest engineer to the error, Jobs per day allocation, and other functions
  • Nodes are defined as a communication modules for the use of transmitting and receiving data, the Triangulation of an object in GPS or "X, Y, Z, A, B, C" coordinates.
  • the node technology is based on, but not exclusive to GPS, GPRS, RFID, SIM and WiFi Nodes are used for the notification of system errors, and the communicating with the assigned server-side applications.
  • Tele-Communication, data transfers and triangulation are functions used to locate engineers, clients, staff, guests and intruders. Via the nodes, the overlays of relevant CAD images and other information can be transmitted to the appropriate diagnostic unit as well as interfacing with our applications such as SAP and others.
  • Handheld devices for communication between engineers and the location of faults as transmitted through a server linked to a main computer Information in the form of text and / or digital maps identifies the fault / error and provides the location for a quick remedy.
  • Handheld device's data to be stored either on the unit itself or stored directly on a server with the capability of communicating with other engineering modules as verified by the assigned server.
  • Handheld devices have the capability of functioning and communication via GPS, GPRS, SMS, SIM and WIFI and / or other data transferable devices.
  • Entry connectivity functions for accessing areas that have been verified and approved by the server i.e. Cabins, and selected areas
  • Client/Staff units may incorporate some or all of the following function (door entry system, GPS, GPRS, SMS, WIFI, SIM, and direct communication to the server via Nodes or other internal or external data transferable devices)/
  • the clients' handheld devices could be used for sending and receiving communication from the server in digital form for safety monitoring and / or assignments.
  • the nodes may communicate with other devices not exclusive to the handheld devices and to use known technology.

Abstract

A system and method for monitoring the location of engineers within a specified area. The system comprises a plurality of nodes arranged throughout the specified area. The system monitors the locations of handheld devices carried by the engineers. When a maintenance request is received by the system, the system determines which of the engineers to respond to the maintenance request based on the locations of the handheld devices within the specified area. The system is then able to instruct the engineer via the handheld device to respond to the maintenance request. The system may also transmit further data to the handheld device for the engineer to view.

Description

System for monitoring and deploying engineers
Field of the invention
The invention is in the field of production and manufacturing lines, and in particular, monitoring and deploying engineers.
Background of the invention
Industrial equipment requires maintenance in order to remain operational. This maintenance may be preventative in order to reduce the chances of the equipment developing a fault, or remedial in order to correct a fault that has already occurred. Whilst preventative maintenance can be easily timetabled in advance using the equipment manufactures recommended maintenance schedule, the need for remedial maintenance will usually occur unexpectedly. Therefore, it can be difficult to organise suitable maintenance personnel to be able to fix the fault at short notice.
Firstly, the fault will need to be identified so that a suitable engineer can be called. For example, if the fault is mechanical, a mechanical engineer will be needed, but if the fault is electrical, an electrical engineer will be needed. Once the fault has been identified, the line manager will need to contact a suitably qualified engineer to fix the faulty equipment. This can lead to significant delays in a busy production environment.
As an example, an automotive manufacturing plant has many machine tools performing maybe hundreds of different tasks. If one of the machine tools is non-functional, it can not only affect its own performance, but may hold up an entire production line. In an industry such as this, this can lead to huge losses in productivity and hence revenue. If a production line is held up, the line manager will typically check the production line to identify the faulty machine tool. Once this is identified, the line manager will try to determine the type of fault. He can then contact a suitably qualified engineer to attend to the faulty machine tool and fix the fault.
Systems have now been developed to reduce the time taken to identify faults in such production line assemblies. For example, the automobile manufacturer, Ford, have developed a system known as "POSMon" that can diagnose faults on a production line and quickly provide an error code to the line engineer. The system comprises hundreds of sensors collecting data on the performance of the machine tools of the production line. The data is collected by programmable logic controllers which are connected to a diagnostic server via a network. The server is connected to a database holding information about the process line and each of the equipment, and is able to provide fault analysis data to the server. The server is then able to analyse the data from the sensors and PLCs to determine the location and nature of a fault. The system can then generate an error code that can be understood by the line manager, who can then locate a suitable engineer to fix the problem.
Diagnostic systems such as Ford's POSMon have been able to cut downtimes of large manufacturing plants significantly, and thus increase the industry's efficiency and profits.
However, there is still a significant delay in identifying an engineer who is both suitably qualified and available. Even then, it may be that the selected engineer is not the closest engineer to the faulty equipment, such that if a different engineer was selected, the equipment may have been repaired quicker and the downtime of the equipment less.
Further, the engineer will likely need to contact the line manager to discuss the fault and obtain the necessary service manuals and equipment necessary to fix the fault, and ensure that he has the right tools for the job.
Summary of the invention
It would be desirable to provide a system that could automatically identify the most suitable member of maintenance personnel to respond to a
maintenance request. The selection could be based on a variety of information, including the location of the personnel, their availability and their qualifications.
It would be further desirable to provide the selected engineer with the location and maintenance data relevant to the maintenance request.
The present invention provides a system capable of identifying the most appropriate engineer or maintenance person to respond to a maintenance request based on the location of the available engineers. The system monitors the location of handheld devices carried by the engineers or maintenance personnel within a specified area, for example a manufacturing plant, factory, chemical plant or oil rig, to allow the system to determine who is conveniently located nearest to the fault that is to be fixed. The system may also determine who is the most appropriately trained engineer who is available or currently unassigned to another job. The specified area could be any area for example, a single floor in a building, multiple floors in a building or an outside area. The system then provides data to the handheld device in order that the engineer can identify the location and nature of the fault.
Accordingly, there is provided a system for monitoring and deploying engineers according to claim 1. The system comprises a server and a plurality of nodes connected to a network. The nodes comprising sensors arranged to determine the locations of handheld devices, carried by the engineers, within a specified area, and communicate location data of the engineer to the server. The server configured to receive a maintenance request and to select a suitable engineer from a pool of one or more engineers, for example all engineers that are employed by a company, to respond to the maintenance request based on the locations of the handheld devices, and to provide the selected engineer instructions to respond to the maintenance request. Optionally, the server may provide maintenance data to the selected engineer via two-way communication with the handheld device.
Preferably, the system is configured to select the suitable engineer based on a record of the skills of the members of the maintenance personnel.
Preferably, at least one of the plurality of nodes is configured to allow the two-way communication between the handheld devices and the server.
Preferably, the network is wired or wireless, such as a wireless LAN.
Preferably, the handheld devices emit a signal and the node sensors are arranged to receive the signal and to determine the position of the handheld device based on the signal, and preferably the signal is a UWB signal. Preferably, the node sensors are arranged to determine the time of arrival and the angle of arrival of the UWB signal, so that the location of the handheld device can be determined more efficiently.
Preferably, the system is further arranged to receive the maintenance request from a computer system in response to an error code generated by a programmable logic circuit in communication with industrial apparatus. The maintenance data could include details of the location and nature of the fault requiring maintenance, and could include at least one of CAD data, EPLAN data, map data or a service manual.
Preferably, the system is configured to allow access to restricted areas by allowing a secured door to be opened when the maintenance personnel is determined to be near the secured door and the maintenance personnel needs access to the restricted area in order to perform the maintenance function.
The handheld device could be a mobile phone, a PDA, a laptop or a tablet PC.
Preferably, the handheld receive could further comprise a GPS receiver and is arranged to communicate the location of the handheld device to the server when it is not within the specified area and maybe further arranged to receive maintenance data from the server via a GPRS mobile communication network.
The specified area could be an automobile manufacturing plant, a factory, a chemical plant or an oil rig.
There is further provided a handheld device according to claim 14. The handheld device being configured to allow its location to be determined by a plurality of nodes connected to a network and to receive maintenance data from a server.
There is still further provided a method of monitoring and deploying engineers according to claim 21 . The method comprising determining the locations of handheld devices, carried by an engineer, within a specified area, using a plurality of nodes and communicating the location data of the handheld devices along a network to a server, receiving a maintenance request at the server and selecting a suitable engineer to respond to the maintenance request based on the locations of the handheld devices. There is yet further provided a computer program according to claim 28. The computer program providing instructions to carry out the above method.
Brief description of the drawings
Embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings of which:
Figure 1 shows a block diagram of the system for monitoring and deploying engineers according to an embodiment of the invention;
Figure 2 shows a handheld device according to an embodiment of the invention;
Figure 3 shows a node according to an embodiment of the invention;
Figure 4 shows a schematic diagram of the system of an embodiment of the invention in use;
Figure 5 shows another schematic of an embodiment of the invention in which part of the specified area is restricted;
Figure 6 shows a block diagram of an embodiment of the invention in which the maintenance request is provided by a automated diagnostic system; and
Figure 7 shows a flow diagram of the steps of an embodiment of the invention.
Detailed description of preferential embodiments
Figure 1 shows a preferred embodiment of the invention. A plurality of nodes is arranged throughout a specified area. The specified area is an area in which engineers, or other maintenance personnel, will typically be working.
Throughout this specification, the term engineer shall refer to any person who may be called upon to perform some type of maintenance task. For example, an engineer may refer to a mechanical or electrical engineer, or it may refer to a specialised engineer relating to a specific task, or it may even refer to a cleaner or other staff. The specified area may be a manufacturing plant, a factory, a chemical plant, an oil rig or any other industrial area. The plurality of nodes 20 are configured to determine a location of a handheld device 30 located within the specified area. The location of the handheld devices 30 could be determined in a number of ways, including by RFID or GPS, However, in a preferred
embodiment, the handheld devices 20 emit a signal, preferably an ultra-wide bandwidth (UWB) signal, which is received by sensors in the plurality of nodes 30. The frequency of the UWB signal would typically be in the range 3.1 to 10.6 GHz, but maybe outside of this range. These signals are then sent via a network 100 to a server 10, where they can be processed. The difference in arrival times of the signals at the nodes can be used to calculate the position of the handheld devices within the specified area, as described in US2010/0001905A1 .
Figure 2 shows a handheld device 30 according to a preferred embodiment of the invention that could be carried by the engineers or other maintenance staff. The handheld device 30 is configured to allow the location of the handheld device 30 to be determined within a specified area by the nodes. The handheld device 30 could be any suitable portable device that is able to be located by the nodes and receive and display data from the server. For example, the handheld device could be a mobile telephone (cell phone), a Personal Digital Assistant (PDA), a tablet PC, a laptop, a notebook or any other suitably configured mobile device.
The handheld device will typically comprise a case 38 and a screen 36 to display data received from the server 10. The handheld device 30 further has a module that allows the handheld device to be located by the nodes 20. For example, the handheld device could comprise an UWB signal transmitter 31 . The UWB signal transmitter could transmit periodic pulses that could be received by the nodes 20 in order to determine the position of the handheld device 30.
Alternatively, the nodes could determine the position of the handheld devices 30 via other techniques, for example RFID.
The handheld device 30 further comprises a data receiving module for receiving data from the server. For example the device could have at least one of a Wi-Fi module 32, a GPRS antenna 33 or any other suitable data receiving module. Preferably, the module can also transmit data, for example via the Wi-Fi module 32, the GPRS antenna 34 or other data transmitting module. Figure 3 shows a typical node 20 according to a preferred embodiment. The node comprises a location determining module, for example a UWB receiver 21 capable of receiving an UWB signal from the UWB signal transmitter 31 in the handheld device 30. The UWB receiver 21 could be a single detector, but it is preferable to have an array of detectors so that the angle of arrival (AOA) of the UWB signal can be determined. The AOA could be determined by the relative phase differences of the UWB signal along the array, as described in
US2009/0079366A1 . Therefore, in this embodiment, the node determines the time that the UWB signal was received and the direction (azimuth angle and elevation) that the signal was received from.
The node 20 further comprises a network interface device 25 for connecting to a network 100. The network interface device 25 could be an Ethernet connection for connecting to Ethernet cabling forming the network 100. Alternatively, the node could connect to a network using wireless technology using a wireless network adapter. In this manner, the node is able to
communication with the server 10 to provide the time of arrival of the signal and the angle of arrival data. This data can then be sent to the server 10 via a network 100.
The node may further comprise a data transmitter 22, for example a Wi-Fi module or other radio transmitter capable of transmitting data, for transmitting data to the handheld device 30. Preferably, the handheld device 30 and the node 20 are capable of two-way data transfer via radio waves, and would typically use the 2.4GHz frequency band. Only one node 20 is needed for two-way
communication with the handheld device 30. Since the handheld device 30 is likely to be able to connect to more than one node 20, the handheld device 30 could determine the node 20 with the strongest signal and connect to that node 20.
The node 20 could further comprise a controller 26 to interface between the UWB receiver 21 , the data transmitter 22 and the network interface device 25.
The equipment in the node 20 will need to be powered. This could be done in a number of ways. For example, the node could comprise a battery power supply (not shown) which could be used to power the equipment. However, such a system would require frequent changing of the battery. Alternatively, a separate power supply (not shown) could be connected to the node via a dedicated power cable. However, in a preferred embodiment, the node is connected to the network 100 via an Ethernet cable, and the node is powered from the Ethernet cable using power-over-Ethernet technology, for example according to the IEEE
802.3af standard. In this manner, both the networking and powering of the node 20 can be achieved using the same cabling.
An example of an engineer monitoring and deployment system according to an embodiment of the present invention is depicted schematically in figure 1 . A plurality of nodes 20 are arranged within a specified area. This area could be a factory, automobile manufacturing plant, chemical plant, oil rig or other industrial area. The nodes 20 could be distributed throughout the specified area, for example on the ceiling, the walls or on posts.
Typically the nodes 20 will be distributed approximately every 15 m, but this can vary depending on the method used to locate the handheld devices 30, the power used and the terrain.
The nodes 20 are connected to a server 10 via a network 100. The network 100 preferably comprises an Ethernet cable capable of power-over- Ethernet technology. The nodes 20 are configured to determine the position of handheld devices 30 within the specified area. For example, the handheld devices 30 may emit a short pulse of UWB radio waves from the UWB signal transmitter 31 . These UWB radio waves travel to the nodes 20 and are detected by the UWB receivers 21 . The time of arrival of the signal and the angle of arrival of the signal are detected by the UWB receivers and passed to the controllers 26. This data is then sent along the network 100 via the Ethernet cables and provided to the server 10. The server 10 can then determine the time difference of arrival of the UWB signal at the nodes, and the direction (azimuthal angle an inclination) of the signal from the nodes which are able to receive the UWB signal. If at least two nodes 20 receive the UWB signal, then the server is able to compute the 3D location of the handheld devices 30. In some circumstances, the location of the handheld device 30 can be determined with an accuracy of 15 cm.
The identity of the handheld device 30 which transmitted a particular UWB signal could be determined in a variety of ways. The UWB signal itself could have an identifying signal embedded within it, or the handheld device 30 could transmit via a radio signal the time at which it transmitted the UWB pulse, so that the UWB signal could be identified as being transmitted by a particular handheld device 30. The server 10 can therefore monitor the positions of any handheld devices 30 that are in the specified area, and may represent this graphically on a screen 12 if required.
The server 10 is configured to receive a maintenance request. This request could be for any occurrence for which an engineer is required to fix a problem. For example, a machine tool may have stopped working and require a mechanical or electrical engineer, a computer terminal may have crashed and require an IT engineer, or maybe something has been spilt and a cleaner is required to clean the area. The request may contain the location of the fault or occurrence requiring the engineer, details of the type of engineer that is required, and details of the fault or occurrence. The maintenance request could be received from a dedicated automated diagnostic system, for example Ford's POSMon system, or it could be entered manually.
On receiving the maintenance request, the server 10 determines the most appropriate engineer to respond to the request. The server 10 may be in communication with a database 14 that has information on all of the available engineers, and can identify which of the engineers are suitably qualified to respond to the maintenance request. For example, if an electrical fault had been reported, the server 10 could access the details of all electrical engineers that were suitably qualified to deal with the fault. The server could then determine which of the appropriate engineers are on site, and determine which are closest to the fault. Using this information, the server can then determine which engineer should respond to the maintenance request and attempt to fix the fault in the most efficient manner. This is likely to be the closest engineer that his suitably qualified, but the server could take into account other factors, for example security clearances needed to enter certain areas.
The handheld device 30 could allow an engineer to inform the server 10 of his availability. For example, if he is already engaged in a repair job, he could inform the server 10, via the handheld device 30, that he is not available.
As an example, figure 4 schematically shows a specified area 300 that is monitored by a plurality of nodes 20. For simplicity, in this example there are two handheld devices 330, 30 shown. However, in reality there are likely to be many more handheld devices 30 within the specified area 300.
If a maintenance request is sent to the server 10 indicating that there is a fault located at the area marked with an exclamation mark 500, the server determines the location of the most suitable engineer to be sent to respond to the request by considering the location of the engineers' handheld devices 30. In this example, handheld device 330 is the nearest to the fault, and so instructions are sent to the closest engineer's handheld device 330, via the network 100 and radio communication through a node 20. In this manner the engineer is provided with instructions to fix the fault. The instructions could include details of the fault and its location.
In a preferred embodiment, the engineer is provided with map data that can be displayed on the screen 36 of the handheld device 30. This map data could indicate the location of the fault and the engineer's current positions, as determined by the server 10, using data from the nodes 20. Alternatively, the map data could include internal map data that could be used as a point to point reference guide for equipment collection and retrieval. The map data also could include a schematic layout of the specified area 300 and/or a perspective view data that could help the engineer navigate to the fault. This data could be in the format of CAD data, or EPLAN data or other suitable format capable of
representing the area. The engineer may also be sent data regarding the equipment that is to be fixed. For example, the engineer may be sent the service manual of the faulty equipment so that he can consult the service manual prior to, or whilst, attending to the fault. The service manual may be in any suitable format that can be displayed by the handheld device 30, for example PDF. The specified area could have restricted zones, in which not all personnel are allowed to enter. If the location of the fault is within a restricted zone, or if an engineer must pass through a restricted zone to reach the area of the fault, the system could be used to allow the engineer automatic access to the restricted zone. As an example, figure 5 depicts the situation where the fault 500 is located in a restricted zone 400. Therefore, the engineer needs to open a locked door 420, to which he does not normally have access, in order to fix a fault. The system could guide the engineer from his original positions 430 to a position 431 close to the secured door 420. The engineer's positions is monitored by the server based on the position of his handheld device 30, and when the location of the engineer is determined to be at or near the locked door 420, the system could permit the engineer access to the locked door. This could be performed, for example, by the system electronically opening the door until the engineer has passed through the door, or maybe an electronic code could be sent to the engineer's handheld device 30, which could be entered into a keypad to permit the engineer temporary access.
The system could be expanded to cover an area larger than the specified area 300 in which the nodes are located. However, in this case, the nodes 20 will not be able to determine the position of the handheld devices 30 or transmit data to them because the handheld device 30 will be out-of-range of the nodes 20. However, the handheld devices 30 could be further fitted other location devices, such as a GPS module (not shown), such that its position could be determined using GPS technology. The position of the handheld device 30 could
communicate to the server 10 via GPRS mobile communication networks. In this manner, the server will be able to determine the location of handheld devices that are outside the area monitored by the nodes 20. Data could also be sent to the handheld device 30 via GPRS mobile communication networks, to provide the engineer with data regarding any maintenance request.
As an example, the server 10 could receive a maintenance request for which there are no suitably qualified engineers available in the specified area. In this case, the server 10 could check the database 14 for a list of suitable engineers that are off-site. For example, the engineers may be off duty but be "on call" for emergency repairs. As shown in figure 6, the server could determine the position of any suitable engineer, potentially anywhere in the world, from the GPS modules in their handheld devices 30. From this data, the server could select the most suitable engineer to contact to instruct to come to respond to the
maintenance request. The server could then provide the necessary details about the fault and location data via GPRS mobile communication. The handheld device 30 might then be used as a GPS navigation device to guide the engineer to the location of the fault. Once the engineer enters the specified area 300 that is monitored by the nodes 20, the engineer could be guided to the fault 500 in the manner described above.
Several specified areas that are monitored by a plurality of nodes 20 may be in communication with each other and share details of the locations of engineers. For example, a manufacturing company might have several factories, each of which is monitored by nodes 20. Whilst each factory may have their own engineers for day-to-day maintenance, there may only be a few specialised engineers at deal with specialised problems. In this case, when a fault occurs that requires a specialised engineer and the specialised engineer is in a different factory, the server may communicate with the server in the other factory to query if any specialised engineers are located in that factory, and if so provide data to the engineer via the nodes within that factory to respond to the fault. Alternatively, the nodes 20 in a plurality of specified areas may all be connected by a network to a single server 10.
As mentioned earlier, the maintenance request could be received from a dedicated automated diagnostic system, for example Ford's POSMon system, or it could be entered manually. Figure 6 illustrates an example in which the request is received from an automated diagnostic system. In this case, a machine tool 60, for example a robotic arm in an automobile production line, is monitored by a plurality of sensors (not shown) connected to a programmable logic controller (PLC) 52. The PLC 52 monitors the actions of the machine tool 60 with the sensors and looks for any signs of failure. If the PLC 52, determines that the machine tool 60 has developed a fault it communicates this information to the clients diagnostic server 50. The client's diagnostic server examines the data from the PLC 52 and sensors and determines the fault with the machine tool 60. In order to do this it may have access to a database (not shown) of possible faults and provides an error code. The client's diagnostic server 50 then issues a maintenance request to the server 10. The request could provide the location of the faulty equipment 60 and an error code providing details of the fault that has occurred. The system can then select a suitable engineer to respond to the fault as detailed above.
Figure 7 shows a flow diagram of a method of operation of an embodiment of the invention.
To further illustrate the working of the system described above and to illustrate some specific features, a specific embodiment will now be explained. It should be noted that the invention is not restricted to the specific example, which is only one of many ways in which the skilled person would understand the invention could be implemented.
An automobile manufacturing plant with the system installed, if a robotic arm 60 develops a fault, the PLC 52 connected to the sensors arranged on the robotic arm will send an error signal to the client's diagnostic server 50 via a network. The client's server 50 will compare the error code from the PLC 52 and determine the fault. The client's diagnostic server 50 will then issue a
maintenance request to the server 10 indicating the fault and the location of the robotic arm that has developed the fault.
The server 10 consults the database 14 to select which of the engineers that work for the plant are qualified to deal with the fault. In this example, the fault could be a mechanical fault, so that a mechanical engineer is needed. The server will identify all of the mechanical engineers. The database may also contain information of which engineers are on duty and which are not, in which case it could narrow down the candidate engineers to the ones that are on duty.
The server 10 could then determine the position of the mechanical engineers that are on duty by locating their handheld devices 30 using the real time locating system based on the nodes 20. The handheld devices 30 might provide data to the server 10 via Wi-Fi radio link through the nodes 20 as to whether the engineer is available or not. The server 10 then determines the most appropriate engineer to select to repair the fault in the most efficient manner. Once the engineer has been selected, information regarding the fault is sent to the engineer from the server 10, along the network 100 and to the handheld device 30 via the Wi-Fi connection to a node 20. This data includes the location of the faulty robotic arm 60 and a map of the plant in order that the engineer can navigate to the fault as quickly as possible. The map could show the current location of the engineer and the location of the faulty equipment overlaid onto a schematic plan of the plant or it could show a 3D perspective view of the direction in which he should walk.
If the engineer needs to enter a restricted zone, the handheld device 30 will direct him to a secured door 420. When the server 10 recognises that the engineer is at the secure door, the server 10 unlocks the door until the engineer has entered the restricted zone 400.
Whilst the engineer is travelling to the faulty equipment the server 10 could be sending the engineer important documentation to help him recognise and fix the fault. This might include a service manual or pictures of the equipment. The server 10 may also order any spare parts if it is known that the particular fault will need specific parts to fix the equipment. It may be that the parts are kept onsite, and so the server 10 could also locate a suitable engineer or assistant to fetch the part and bring it to the fault equipment for the engineer.
Whilst the engineer is repairing the equipment, he could communicate with the server 10 via the handheld device 30. For example, he may need to more information or need to order some parts or a specialist tool that he does not have. Alternatively, he may need assistance if the fault cannot be repaired by the engineer alone.
The server 10 could also be used to keep a log of the efficiency of the engineers in order that any deficiencies can be identified. In this manner, the management of the plant could more effectively target the engineers with the most appropriate training.
The person skilled in the art would readily appreciate that may
modifications and variations may be made to the specific examples given above without departing from the scope of the invention as defined by the appended claims.
As a further example of the invention, the following paragraphs provide further details of embodiments of the invention:
The system comprises three main elements a server of a main computer system which monitors and assigns and collates tasks according to priority, and interfaces with other system required applications. Nodes, which are used to communicate, transfer data and triangulate a device's position. Handheld devices which are used as a location, Tele-Communication, Data transferable information and monitoring devices. Also commercially used mobile devices maybe configured to be used in this connection.
As a specific example, after CAD renderings of a client's facility have been completed and linked to a client based diagnostic software (for example EPLAN and POSMON) for online monitoring, the server is then configured with the appropriate handheld devices and attached with predefined protocols (i.e.
Engineers, Staff, Guests modules and the parameters for exit and entry and any intruders).
Upon the PLC's (Programmable Logical Controller, for example by
Siemens or Rockwell) notification of a process fault during the manufacturing of a vehicle the PLC via the standard programmed (BMW, Ford, GM) generates an error code specific to each unit / equipment being used throughout the production process. This information / data via POSMON (client's collection and processing server / software) is also forwarded to the Server for processing and dispatching.
Upon receiving a fault notification, the Server in conjunction with the processing of other elements such as the overview of the client's facility in regards to the location of all engineers specifying their current assignments and job specifications and their relationship to the fault flagged.
After engineer selection, the Server administration program notifies the Engineer and sends him or her the precise location of the fault, including guidance to the fault's location, while this is in progress the said handheld device/unit is sent EPLAN and CAD information for help with the diagnosis and remedy of the fault. The system's administration software monitors the complete process for evolution and assistance should the engineer require it. This can also be requested by the Engineer's handheld device.
The clients would be assigned a dedicated double redundancy server. This allocated system, would run bespoke applications. An example of the options available would be:
1 : Handheld device: Resources, Time and Motion, Entry and Access, Security Level Access, Tracking objects, Communication between the system or interfacing with other communication networks
2: Data Collection
3: Client's Schematics and applicable data
4: Interface with reference databases
5: Work allocations and distributions
The handheld devices are used for communicating between colleagues and with the guidance of the system server the locating and diagnosing of system faults. Information in the form of text, video and / or digital overlaying (CAD, EPLAN, PDF or other media) identifies the fault and provides the solution via the attached database as controlled by the Client's or the system's server.
GPS, GPRS, WIFI and RFID are some of the communication media included in both the handheld device and the data nodes. Via the connectivity between the units and the strategically placed nodes located around the clients premise would enable the triangulation of the handheld device's current location.
Using multiple nodes would guarantee a clear data triangulation and transmission while within a building or other structure (i.e. Maritime Vessel). When outside of the zoned (node) area, GPS technology could be used for continues positioning.
Although data could be stored on the handheld device, for security reasons, data would preferably be stored on the system's or client's server where it could be accessed after security/protocol procedures.
Upon authorisation, the engineer unit can be used as a diagnostic unit for the client's equipment and services. 1 : ID (Company and Other Data), SIM, Name, Company, ID, Position, Security Level, Job, Other Data
2: Tracking: Area, X, Y, Z, A, B, C Coordinates, Notification
3: Diagnostics: CAD, EPLAN, Engineering Data, Technical Data, Server
Controlled Applications
4: Door entry and restriction: Area Entry, Restriction, Server Controlled Entry 5: Phone: Communication between Personnel when authorized, including SMS. 6: Technologies:. WIFI, GPS, GPRS, RFID, SIM.
The handheld device could also be used as an entry system, notification, and communication and ordering system: Entry into assigned areas (Commercial and Manufacturing building / Structures, Maritime Vessels, Oil & Gas Platforms and outside venues)
The handheld engineers unit could also be used for communications between colleges and the location of faults as transmitted though the allocated node/Server linked to a main computer. Information in the form of text and / or digital maps identifies the fault / error and provides the location for a quick remedy. This could be used for: ordering equipment (i.e. via SAP), Transmitting & Receiving Data via the E.D.A. NODES (CAD, EPAN, Electronic Data). However, sim card functions maybe required for communication outside of the Clients facility
In combination with the node and engineers/staff/guest handheld device, the notification of the following would be possible: Engineers location, Staffs location, Guests location, Intruders location
The node modules are used for data transfer and triangulation, located on commercial and manufacturing building / structures, maritime vessels, oil & gas platforms and outside venues. Using the nodes and the handheld devices assigned to the client, locating a Person/Equipment / fault can be facilitated at any given time by authorized personnel via the administration application running on the client's/system's Server. The nodes, handheld devices and server also communicate with other applications such as SAP, POSMON, EPLAN, CAD and other approved applications. If the object concerned (Person/Equipment) should either enter an unauthorized area the client's/system's server would notify the appropriate person concerned or activate pre-programmed protocols.
The CAD rendering of the client's facility is housed on the system's server. This facilitates the overlaying of schematics and the interfacing with the client's current database structure. This system also keeps a real-time update location of all engineers and objects stored on the server with the attached communications module. This allows for effective allocation of personnel and the monitoring of equipment.
The nodes collectively triangulate the engineers' positions and overlays all data in relationship to the relevant system. Subject to the positioning of the fault CAD rendering directions are then given to the relevant engineer with directions.
Tracking Engineers or personnel within a structure is possible via the triangulation and data communication modules (nodes) installed throughout the facility. This includes structures for a verity of industries:
1 : Manufacturing Plants: Automotive Industry, Packaging (Food & Drink, Domestic and Industrial products)
2: Oil & Gas, Maritime: Oil & Gas Platforms (Maritime), Oil & Gas trains, Commercial and Private Vessels
3: Commercial Plants and Building: Banks, Financial Institutions, PLC, LLP
Companies, Airports
Apart from the engineering functionality of the system, the security industry would also be enhanced by the accuracy and functions of our system
Subject to the engineers' location data, Images and instructions are sent to his/her diagnostic unit regarding the current situation, during this time the status of the fault is continuously monitored by the server. Should further help be required the assignment of additional engineers would be either allocated by the server or requested by the assign engineer.
As the assigned engineer's guided to the system fault further detailed information is transmitted to the diagnostic unit, allowing for quicker identification of the faulty unit. This allows for the quickest response time possible to the unit. (3D modelling in the form of CAD could be used, to show the Engineer a real world location).
As previously mentioned this allows for one engineer to cover a greater service area without previously working in that location, however using this system he/her would have the equipment (handheld device) to deal with any given situation.
As an engineer approaches the facility of the faulty application the server uploads further CAD and EPLAN information to the engineer unit. When the engineer has reached the desired location further information from the
manufacturer's database could be accessible allowing for minimal downtime. EPLAN, CAD, TEXT or Telecommunications are all accessible functions via the nodes and server-database connections. Therefore, any relevant protocol driven data could be pulled down to the engineer's handheld diagnostic device.
As mentioned previously should the engineer need additional help, equipment or information, he/she could request further assistance from the server-side application or upon reaching a predetermined time limit the server- side application could assign further engineers.
Nodes are used for the notification of a system errors, and server applications. Communication, data transfers and triangulation are function used to locate engineers, clients, staff, guests and intruders, via the nodes the overlays of relevant CAD images and other information can be transmitted to the appropriate diagnostic unit. The assigning of the relevant Engineer via the server would depend on the criteria set out by the client. Upon the notification of a system error, the server side application would locate all engineers with the capability of rectifying the error. The assigning of the relevant Engineer via the server would depend on the criteria set by the client. For example: nearest engineer to the error, Jobs per day allocation, and other functions
Below are some further points concerning embodiments of the invention: Nodes are defined as a communication modules for the use of transmitting and receiving data, the Triangulation of an object in GPS or "X, Y, Z, A, B, C" coordinates. The node technology is based on, but not exclusive to GPS, GPRS, RFID, SIM and WiFi Nodes are used for the notification of system errors, and the communicating with the assigned server-side applications. Tele-Communication, data transfers and triangulation are functions used to locate engineers, clients, staff, guests and intruders. Via the nodes, the overlays of relevant CAD images and other information can be transmitted to the appropriate diagnostic unit as well as interfacing with our applications such as SAP and others.
Handheld devices for communication between engineers and the location of faults as transmitted through a server linked to a main computer. Information in the form of text and / or digital maps identifies the fault / error and provides the location for a quick remedy.
Handheld device's data to be stored either on the unit itself or stored directly on a server with the capability of communicating with other engineering modules as verified by the assigned server.
Handheld devices have the capability of functioning and communication via GPS, GPRS, SMS, SIM and WIFI and / or other data transferable devices.
Entry connectivity functions for accessing areas that have been verified and approved by the server, (i.e. Cabins, and selected areas)
Client/Staff units may incorporate some or all of the following function (door entry system, GPS, GPRS, SMS, WIFI, SIM, and direct communication to the server via Nodes or other internal or external data transferable devices)/
The clients' handheld devices could be used for sending and receiving communication from the server in digital form for safety monitoring and / or assignments.
The nodes may communicate with other devices not exclusive to the handheld devices and to use known technology.

Claims

CLAIMS:
1 . A system for monitoring and deploying engineers comprising:
a server connected to a network;
a plurality of nodes connected to the network, the nodes comprising sensors arranged to determine the locations of handheld devices, adapted to be carried by the engineers, within a specified area, and communicate location data of the engineer to the server;
the server configured to receive a maintenance request and to select a suitable engineer from one or more engineers to respond to the maintenance request based on the locations of the handheld devices, and instruct the suitable engineer to respond to the maintenance request.
2. The system of claim 1 wherein the server is further configured to provide at least one of location data and maintenance data to the selected engineer via two-way communication with the handheld device.
3. The system of claim 1 or 2 wherein the system is further configured to select the suitable engineer based on a record of the skills of the one or more engineers.
4. The system of any preceding claim where the system is further configured to select the suitable engineer based on the availability of the one or more engineers.
5. The system of any preceding claim wherein at least one of the plurality of nodes configured to allow the two-way communication between the handheld devices and the server.
6. The system of any preceding claim wherein the network is a wired or wireless LAN.
7. The system of any preceding claim wherein the handheld devices emit a signal and the node sensors are arranged to receive the signal and to determine the position of the handheld device based on the signal.
8. The system of claim 7 wherein the signal is a UWB signal.
9. The system of claim 8 wherein the node sensors are arranged to determine the time of arrival and the angle of arrival of the UWB signal.
10. The system of any preceding claim wherein the system is further arranged to receive the maintenance request from a computer system in response to an error code generated by a programmable logic circuit in communication with industrial apparatus.
1 1 . The system of any preceding claim wherein the maintenance data includes details of the location and nature of the fault requiring maintenance.
12. The system of claim 11 wherein the maintenance data includes at least one of CAD data, EPLAN data, map data or a service manual.
13. The system of any preceding claim wherein the server is further configured to allow access to restricted areas by allowing a secured door to be opened when the maintenance personnel is determined to be near the secured door and the maintenance personnel needs access to the restricted area in order to perform the maintenance function.
14. The system of preceding claim wherein the handheld device is one of a mobile phone, a PDA, a laptop or a tablet PC.
15. The system of any preceding claim wherein the handheld device further comprises a GPS receiver and is arranged to communicate the location of the handheld device to the server when it is not within the specified area.
16. The system of claim 15 wherein the handheld receive is arranged to receive maintenance data from the server via a GPRS mobile communication network.
17. The system of any preceding claim wherein the specified area is outdoors.
18. The system of any one of claims 1 to 16 wherein the specified area is indoors.
19. The system of any one of claims 1 to 16 wherein the specified area is one of an automobile manufacturing plant, a factory, a chemical plant or an oil rig.
20. A handheld device configured to allow its location to be determined by a plurality of nodes connected to a network and to receive instructions from a server.
21 . The handheld device of claim 20 further configured to receive
maintenance data.
22. The handheld device of claim 20 or 21 further comprising a screen, and arranged to display the maintenance data on the screen.
23. The handheld device of claim 22 wherein the maintenance data includes at least one of CAD data, EPLAN data, map data or a service manual.
24. The handheld device any one of claims 20 and 23 further arranged for two-way communication with the server via at least one of the plurality of nodes.
25. The handheld device any one of claims 20 to 24 further arranged to emit a signal so that sensors in the nodes can receive the signal and determine the handheld device's location.
26. The handheld device of claim 25 wherein the signal is a UWB signal.
27. The handheld device of any one of claims 20 to 26 further comprising a GPS receiver and a GPRS transceiver, and arranged to communicate its location to the server via a GPRS mobile communication network.
28. The handheld device of any one of claims 20 to 27 wherein the handheld device is one of a mobile phone, a PDA, a laptop or a tablet PC.
29. A method of monitoring and deploying engineers comprising:
determining the locations of handheld devices, carried by an engineer, within a specified area, using a plurality of nodes
communicating the location data of the handheld devices along a network to a server;
receiving a maintenance request at the server and selecting a suitable engineer from one or more engineers to respond to the maintenance request based on the locations of the handheld devices; and
providing instructions to the selected engineer to respond to the maintenance request.
30. The method of claim 29 wherein the server further provides at least one of location data and maintenance data to the selected engineer via two-way communication with the handheld device.
31 . The method of claim 29 or 30 wherein the system selects the suitable engineer based on a record of the skills of the one or more engineers.
32. The method of any one of claims 29 to 31 wherein the system selects the suitable engineer based the availability of the one or more engineers.
33. The method of any one of claims 29 or 32 wherein the server
communicates with the handheld device via at least of the plurality of nodes.
34. The method of any one of claims 29 to 33 wherein the handheld devices emit a signal and the node sensors receive the signal and determine the position of the handheld device based on the signal.
35. The method of claim 34 wherein the signal is a UWB signal.
36. The method of any one of claims 29 to 35 wherein the system receives the maintenance request manually.
37. The method of any one of claims 29 to 35 wherein the system receives the maintenance request from a computer system in response to an error code generated by a programmable logic circuit in communication with industrial apparatus.
38. The method of any one of claims 29 to 37 wherein the server allows access to restricted areas by allowing a secured door to be opened when the maintenance personnel is determined to be near the secured door and the maintenance personnel needs access to the restricted area in order to perform the maintenance function.
39. The handheld device of any one of claims 29 to 38 wherein the handheld device further comprises a GPS receiver and a GPRS transceiver, and communicates its location to the server via a GPRS mobile communication network.
40. A computer program providing instructions to carry out the method of any one of claims 29 to 40.
EP11791624.7A 2010-11-23 2011-11-21 System for monitoring and deploying engineers Ceased EP2643802A1 (en)

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GBGB1019858.8A GB201019858D0 (en) 2010-11-23 2010-11-23 Engineering diagnostic application (E.D.A)
PCT/GB2011/052280 WO2012069814A1 (en) 2010-11-23 2011-11-21 System for monitoring and deploying engineers

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GB (1) GB201019858D0 (en)
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