WO2014032119A1

WO2014032119A1 - Machinery safety system

Info

Publication number: WO2014032119A1
Application number: PCT/AU2013/000987
Authority: WO
Inventors: Loretta Mary REID; Charles Fairlie Russell SHARP; Daniel Hendrik ROSSOUW
Original assignee: Machinery Safety Systems Pty Ltd
Priority date: 2012-08-31
Filing date: 2013-08-31
Publication date: 2014-03-06

Abstract

The invention relates to a machinery safety system including a machinery, control unit and an electronic device, including an electronic reader. The system also includes a pre-start checklist of safety checks and one or more identification means, located on the machinery proximal to the location of each item on the checklist and readable by the electronic reader. In use, a person moves the electronic device towards the identification means and the electronic reader identifies and logs that the check has been made at that location. The process is repeated for all the safety checks on the check list and, on completion, the electronic device communicates to the machinery control unit that the pre-start has been completed The invention also relates to a method of use of a safety system.

Description

L

MACHINERY SAFETY SYSTEM FIELD OF THE INVENTION

(0001] The present invention relates to a machinery safety system, and in particular to safety system for machinery including vehicles.

BACKGROUND OF THE INVENTION

P002] Mine sites are some of the most dangerous working environments in the world. Large machinery and vehicles are manoeuvred around the mine site to transport ore from the ore face to a storage area, or for transportation for processing or sale. Utes and other smaller vehicles are also used for moving people around a site as wed as excavators, ore carriers, a plethora of different machines and vehicles. Due to the dangers to personnel at a mine site there are requirements that machinery be carefully checked and a check list regularly completed. For example, a check list for a large mine truck may include checks for fuel, hydraulics, brake fluid, oil, battery condition and wheel condition, to name just a few.

[0003] A fully laden dump truck stands more than 7 metres tall and can carry in excess of 200 tonnes of ore, and so must be handled carefully to avoid accidents. For example, if the brake fluid levels have not been checked and the brakes fail, the out of control dump truck could take out buildings, other vehicles, and any small vehicles in the way, killing the occupants. It is therefore vital that thorough checks are carried out on the vehicle on a regular basis. For this reason mine sites generally have compulsory paper checklists that must be completed on a regular basis.

[0004] However, in practise some of the checks that need to be conducted are difficult or awkward to do, requiring access through floor plates or panels. Anecdotal evidence has shown that the checks that are difficult to access are often not checked at all, and the box on the list is simply ticked by the person,- the "tick and flick" list completion. It is therefore vital that the operators of the vehicles are compelled in some way to carry out the checks that the mine have determined are necessary to keep everyone safe. It is not only lives at risk, the mine can lose days of mine production while a death is investigated or equipment repaired costing hundreds of thousands of dollars a day in lost production.

(0005] Some checklists are not property completed, monitored or stored and so it may be impossible to accurately identify who completed the "pre-start" and who operated the machinery. In the case of mechanical problems with the machinery, an accident or a person being injured it is essential to know who was operating the machinery and who completed the pre-start checklist. At present if the checklists are not completed or kept properly it may be impossible to trace back where damage occurred to a machine and separately, who was operating all the machines involved in an accident. It would be desirable to have a reliable tracking system to track all those operators who have used the machinery, who conducted the pre-start, and to track where the damage or accident occurred.

[0006] Therefore, it is highly desirable for increased safety of everyone on a mine site and to avoid loss of production for there to be a machinery safety system that requires operators to complete the safety check list on a regular basis, and verify that they have done so.

[0007] The inventors have developed a. machinery safety system that requires that each location where a "pre-start" safety check is to be conducted must be closely accessed by a person. Safety check locations may be anywhere on the machinery, around the engine, behind metal hatches or in difficult to access areas of a machinery. A reader device of the invention must be close enough to read each individual tag at the safety check location in order that the check list will be verified and deemed completed. Having been compelled to access the area, such as to open a hatch, for the check significantly increases the likelihood of the safety checks being made, and any problems identified.

[0008] In the specification the non-limiting example of the invention being used with reference to use in a mine, is described, as a particularly useful application of the invention. However, the invention may be used in any situation where it is desired to have a safety check system for machinery and or vehicles. It is not intended that the invention be limited to use in the mining industry.

[0009] For clarity, any prior art referred to herein, does not constitute an admission that the prior ait forms part of the common general knowledge, in Australia or elsewhere.

[0010] It is an object of the present invention to provide a machinery safety system that at least ameliorates one or more of the aforementioned problems of the prior art

DISCLOSURE OF THE INVENTION

[0011] Accordingly, the present invention provides a machinery safety system including:

a machinery control unit for the machinery, controlling whether the machinery can be operated or not;

an electronic device, including an electronic reader;

a pre-start checklist of safety checks to be conducted on the machinery by a person accessible through the electronic device; and one or more identification means, located on the machinery proximal to the location of each item on the checklist to be checked, and readable by the electronic reader, wherein, in use, the person moves the electronic device towards the identification means at the location of an item to be checked, and the electronic reader identifies the identification means at that location and logs that the check at that location has been made, and the process is repeated for all the safety checks on the check list and on completion of the pre-start checklist the electronic device communicates to the machinery control unit that the pre-start has been completed.

[0012J Preferably, the person is a worker at a mine site, road construction site or at an industrial site. Preferably, the person is authorised to conduct the pre-start and to operate the machinery. Preferably, the person has been given suitable training and has appropriate qualifications to enable their authorisation to conduct the pre-start and or operate the machinery. Similarly, the person may be qualified to operate the machinery and supervise and authorise other people to operate the machinery.

[0013] Most mines or industrial sites require that a pre-start checklist be completed, on a regular basis. Most preferably, a pre-start checklist is required to be completed on a regular basis for the machinery to continue to be authorised for use. Each safety check to be made is listed and must be ticked off sequentially, and the list signed-off. Each mine site may require their own checklists for the machinery.

[0014] The machinery may be any machinery, particularly where it is desirable to conduct a pre-start check list, on a regular basis. The machinery may be a vehicle. The machinery may be chosen from the group: utility vehicle; dump truck; crane; excavator; fork lift; mining machinery; stationary machinery and vehicles.

[0015] Preferably, the machinery control unit is mounted at a protected, convenient and accessible location on the machinery. The machinery S

control unit may be mounted under the bonnet of a vehicle. Preferably, the machinery control is a sealed unit to substantially prevent ingress of water, dust or dirt. Preferably, the machinery control unit is tamperproof. Preferably, the machinery control unit includes a printed circuit board and electronic components, and may including components having one or more of the following functions: card reader; auto-sync with the electronic device; override; stages of use including pre-start required and ready to start the machinery; on and off; and machinery prevented from use; and machinery enabled for operation or authorisation. Preferably, the machinery control unit substantially includes the components as represented schematically in Figure 104. Preferably, in one form of the invention, the controlling by the machinery control unit is preventing operation of the machinery until the pre-start checks have been recognised as completed by the electronic device. Preferably, the machinery control unit disables the machinery and prevents its operation until the pre-start checks have been conducted and communicated to the machinery control unit. Once the electronic device communicates to the machinery control unit that the pre-start has been completed the machinery may be authorised for operation.

[0016] Most preferably, the controlling by the machinery control unit is preventing operation of the machinery until an authorised card is presented to the machinery control unit. The controlling by the machinery control unit may prevent operation of the machinery until an authorised card is presented to the machinery control unit and the pre-start checks have been recognised as completed by the electronic device, in one form of the invention. Preferably, the pre-start checks are required to be completed at regular intervals in order that the machinery control unit continues to enable the machinery for use on presentation of an authorised access card to the machinery control unit. [0017] Preferably, the machinery control unit is powered by being wired into the electrics of the machinery. The machinery control unit may be powered by the battery or other power source of the machinery. Alternatively, the machinery control unit may include its own power source such as one or more batteries. Preferably, the machinery control unit is connected to the electrics of the starter motor of the machinery so that it prevents the machinery from being operated unless an authorised card is presented to the machinery control unit. Alternative means of controlling and hence disabling the machinery may be used.

[Ό01β| Preferably, personal identifier means are included. Preferably, the personal identifier means will identrfy the person that will pre-start or operate the machinery. Preferably, the personal identifier means are identifiable by use of an electronic device; Preferabfy, the personal identifier means are identifiable by use of a hand-held or portable electronic device. Preferably, the personal identifier means are identifiable by use of a PDA. Preferably, the personal identifier means are identifiable by use of the machinery control unit. Most preferably, the personal identifier means include identifiers that can be read or identified by use of the electronic device and the machinery control unit. The reading or identifying may be by any suitable means. The reading or identifying may be by means of a card reader or similar. The personal identifier means may be an access card reader and access cards identify a particular user. Preferably, details of use of the access cards is logged, with a time and date and can be referred to later. The access card reader may be replaced by any similar device for controlling access to the machinery control unit. Preferably, an access card is issued to a user and configured on the machinery safety system to identify the user. Preferably, an access card reader is included on both the machinery control unit and the electronic device. Preferably, once the pre- start check list is completed and communicated to the machinery control unit the machinery cannot be operated until an authorised access card is presented to the access card reader. If an access card of a person recognised as qualified and authorised to use the machinery is presented to the access card reader the machinery control unit enables the machinery for use or inspection. The enabling may be the activation of the start motor electrics ready for starting of the machinery. The access card reader step may be omitted in an inferior version of the invention. Preferably, use of the access card reader enables a different person to operate the machinery and be recorded as having done so, to the person who was logged as performing the pre-start checks. It is a useful further advantage to the invention that each stage of use, the pre-start and any users of the machinery will be logged. In the case of an accident or mechanical failure there is a strong trail to be followed to try to identify where the problem arose. Preferably, each stage of use, the pre-start and any users of the machinery will be logged with a date and time as well as the details of the machinery.

10019] Preferably, the machinery control unit includes a means of communicating with the electronic device. Preferably, the communication is by wireless auto-sync. Alternatively, other forms of wireless communication may be used or the electronic device may be plugged into the machinery control unit, in an inferior design, such as by a USB connection. Preferably, once the pre-start checks are completed on the electronic device it communicates wirelessly with the machinery control unit to indicate that the pre-start was done.

(Ό020] Preferably, one or more warning or safety lights may be included on the machinery control unit; the lights may be chosen from the group: power on; pre-start required; or ready to start. Clearly the labelling may be varied to suit the particular situation. Preferably, a power on light is included which illuminates when power is received by the machinery control unit. The machinery electrics may be turned on, to power the machinery control unit. Internal power lights may also be included on the printed circuit board to illustrate power is being received. A light may be included which illuminates when the power is on. Preferably, a further light is included which illuminates when a pre-start needs to be conducted. Preferably, the further light will switch off when the electronic device has communicated to the machinery control unit that the pre-start checks have been conducted. Another light may indicate that the machinery is ready to start when an authorised card is presented to the machinery control unit. The lights may be labelled "power on", "pre-start required" and "ready to start" or similar.

[0021] Preferably, the machinery control unit includes an override. Preferably, the override enables the machinery to be made operational without presenting an authorised card to the machinery control unit; the override may be used in an emergency situation. The override may require a security or physical key to be operated by an authorised person. The override may include a switch block override to the power controlling the machine. The override may take any suitable form. Preferably, any operation of the machinery after an override is logged. Preferably, the time and date details of any override are logged.

[0022] Operation of the machinery may be travelling if the machinery is a vehicle or may be excavating, raising or lowering a boom or the like, or any operation of machinery. In particular any operation of a mining machinery. Preferably, the machinery is prevented from any activity until an authorised card is presented to the machinery control unit.

[0023] Preferably, the electronic device is a portable or hand-held electronic device. Use of a hand-held electronic device is useful to enable ready application, proximal to the check locations. Preferably, the electronic device is a Personal Digital Assistant ("PDA"). The electronic device may be any suitable device, including any suitable portable or handheld device. The hand-held device may be chosen from the group: tablet computer; iPad (TRADE MARK); smart phone; iPhone (TRADE MARK); or laptop or netbook. Alternatively, a hand-held electronic device may be used that communicates to another device on which the pre-start checklist is assessable. The another device may be a laptop, desktop computer or similar.

[0024] The electronic reader may be any suitable reader to read and identify the or each identification means. Preferably, details of the or each / identification means is stored in the electronic device so that reading the or each identification means recognises that a particular location on the machinery has been read, and completes the instruction list item found at that particular location. Preferably, the electronic reader is a Radio Frequency Identification ("RFID") reader and the or each identification means are RFID tags at the locations on the machinery where checks are to be conducted. Preferably, each RFID tag is logged wit in the software of the electronic device so that when read by the RFID reader the checklist item at the location of the particular RFID tag is checked as completed, when read.

[0025] Preferably, the pre-start checklist is a list of safety checks to be made of the machinery before it can be in a pre-started state. The checklist may be determined by the customer or govemment regulations. The checklist may take any suitable form. The checks may be chosen from the group: oil check; brake fluid; brakes; coolant fluid; lights; reversing siren; wheels and tyres; wind-screen wash fluid; hydraulics; battery; and flag check.

[0026] Preferably, the pre-start checklist is accessible by being viewed on the screen of the electronic device. Preferably, the checklist is viewable on the screen after an authorised person accesses the safety system and selects a particular piece of machinery and the appropriate instruction list appears on the screen. The checklist may take any suitable form.

[0027] Preferably, the electronic device includes an access card reader and the safety system can only be accessed by use of an access card of an authorised person. Preferably, before commencing the pre-start checks a person authorised to conduct the pre-start check list uses an access card and it is read by the card reader of the electronic device to enable access to the machinery safety system software. Preferably, the electronic device is configured with authorised users and on presenting an authorised access card the electronic device recognises and logs the authorised user. Preferably, the machinery safety system includes a database of authorised users. Preferably, the authorised users are logged as to who has conducted pre-start checks. Preferably, a real time clock is included to record the time and duration of the activity.

[DOES] Preferably, there are a plurality of identification means, one each for each check of the pre-start to be conducted. Preferably, the or each identification means are mounted on the machinery very close to where the checks are to be conducted. For example, identification mean may be located under the bonnet where each check needs to be conducted and on each wheel. The or each identification means may be fixed using screws, other fastenings or be glued. The or each identification means may be mounted on a suitable bracket. Where it not suitable to mount the identification means very close to the site of where a check is to be conducted the identification mean may be located a small distance away.

[0029] Preferably, the or each identification means is identified and logged on the electronic device so that the checks are recorded as being completed. Preferably, the time and person conducting the checks are also logged. Preferably, there are a plurality of identification means and each identification means must be read by the electronic device until the check list is completed. Preferably, each of the checks of the checklist must be conducted in a predetermined order. Preferably, the sequence of performing the checks is the same as the order in the checklist. Preferably, the pre-start requires the checks to be conducted in sequential order and will only put the machinery in the pre-start state if the check was conducted in that order.

[0030] preferably, on completion of the pre-start checklist the electronic device communicates the information to the machinery control unit. Preferably, the communication is wireless communication. Preferably, the machinery is in the pre-start state once the communication that the pre-start has been completed has been communicated to the machinery control unit from the electronic device.

[0031] Preferably, each stage of pre-start, authorisation and operation is recorded. For example, through use of access cards the person using the electronic device and conducting the pre-start checks is recorded. Similarly a person who operates the machinery must present their access card and a log is kept of who has used the machinery and when.

The serial number of the electronic device may be recorded including embedded in the installed software.

(Ό032] The electronic reader for identifying the or each identification means may be separate to the rest of the device, in an alternative form of the invention.

[0033] Accordingly, the present invention provides in a variation, a machinery safety system including:

a machinery control unit for the machinery, controlling whether the machinery can be operated or not; an electronic device, including an electronic reader;

a pre-start checklist of safety checks to be conducted on the machinery by a person accessible through the electronic device;

a personal identifier means to identify the person that will pre-start, authorise or operate the machinery, readable by the electronic device and or machinery control unit; and

one or more identification means, located on the machinery proximal to the location of each item on the checklist to be checked, and readable by the electronic reader, wherein, in use, the person moves the electronic device towards the identification means at the location of an item to be checked, and the electronic reader identifies the identification means at that location, and list of checks to be made, and logs that the checks at that location has been made, and the process is repeated for all the safety checks on the check list and on completion of the pre-start checklist the electronic device communicates to the machinery control unit that the pre-start has been completed, and the personal identifier means identifies and records the person who conducts the pre-start, authorises or operates the machinery

[0034] Accordingly, the present invention provides in a further variant a machinery including:

a machinery control unit for the machinery, controlling whether the machinery can be operated or not, including an access card reader; a Personal Digital Assistant ("PDA"), including a Radio Frequency

Identification ("RFID") reader and access card reader,

a pre-start checklist of safety checks to be conducted on the machinery by a person accessible through the PDA; and

a plurality of RFID tags located on the machinery proximal to the location of each item on the checklist to be checked, and readable by the RFID reader, wherein, in use, the person presents an access card to the PDA to identify and record the person, and the safety checks are made at locations on the machinery by moving the PDA towards the RFID tag at that location and the RFID reader identifies the RFID tag at that location and logs that the check at that location has been made, and the process is repeated for all the safety checks on the check list, in sequential order, and on completion of the pre-start checklist the PDA communicates to the machinery control unit that the pre-start has been completed,

[00351 The same or a different person my present their personal identification card to the machinery control unit and will be recorded as authorised to use the machinery. A log of the users of the machinery following pre-start may be recorded. Preferably, the controlling of the machinery includes disabling the machinery if the pre-start is not completed.

[00361 Preferably, regular checks of the checklist of safety checks are made in order that the machinery continue to be authorised for use.

[0037] Accordingly, the invention also provides a method of using a machinery safety system for conducting the pre-start for a machinery, the machinery safety system including a machinery control unit for controlling use of the machinery, an electronic device including an electronic reader and one or more identification means readable by the electronic device, the method including the following steps:

a) accessing the electronic device;

b) selecting the machinery for pre-start checks to be conducted c) moving the electronic device close to the identification means until read by the reader, whereby the appropriate item on the checklist is marked as completed; d) repeating for all the identification means listed on the checklist until the checklist is completed;

e) communicating between the electronic device and the machinery control unit that the pre-start has been completed so that the machinery control unit enables the machinery to be in the pre-start state.

[0038] Preferably, the method includes an additional step before step a) of presenting an access card to a card reader of the electronic device and if authorised to make the pre-start access to the electronic device is enabled and the user details logged.

[0039] Preferably, the method include the further step of presenting an authorised access card to the machinery control unit after the pre-start has been completed but before the machinery can be made operational by the machinery control unit. Preferably, presenting an authorised access card to the machinery control unit of the machinery after the pre-start has been completed enables the machinery for operation.

[0040] Preferably, the or each identification means are a plurality of RFID tags and the electronic reader is a RFID reader.

IP041] Preferably, the method uses the machinery safety system as described above, in any of its forms or variants.

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The invention will now be described in connection with non-limiting preferred embodiments with reference to the accompanying drawings, in which:

Figure 1 is a perspective front view of a machinery control unit of a safety system according to a preferred embodiment of the invention; Figure 2 is a front view of a PDA and cradle of the safety system according to a preferred embodiment of the invention;

Figure 3 is a RFID tag of the safety system according to a preferred embodiment of the invention;

Figures 4 to 100 are screenshots from the PDA of Figure 2 illustrating the menus and actions through use, configuration and and pre-start;

Figure 101 is a table listing the steps for . the method of use of the preferred embodiment of the invention;

, Figure 102 is a table listing the steps for the method of operating machinery of the preferred embodiment of the invention;

Figure 103 is an example checklist for pre-start as displayed on the PDA screen during use for a forklift; and

Figure 104 is schematic block diagram of the electrical components of the machinery control unit and wireless communication to the PDA and use of personal access cards.

DETAILED DESCRIPTION OF THE INVENTION INCLUDING A BEST MODE

[0043] We note that the wording in the drawings is necessary to particularly facilitate understanding of the invention, for example, to illustrate the screenshots and checklist of the invention.

|Ό0 4] Referring to Figures 1 to 104, a preferred embodiment of the Machinery Inspection Operating Control System ("MiOCS" (TRADEMARK)) according to the invention is disclosed. MiOCS includes a machinery control unit, a Personal Digital Assistant ("PDA") and Radio Frequency Identification tags ("RFIDs"), as described below. These components of MiOCS are used with machinery (not shown) to enable an authorised person to conduct a "pre-start" checklist and on doing so put the machinery in a pre-start state. The machinery may be a vehicle for transporting personnel, a forklift, excavator, dump truck or any vehicle or machinery that may be need to be used, such as on a mine site. Non-vehicular machinery can similarly be authorised by completion of the "pre-start" system.

[00453 Referring to Figure 1 in particular, machinery control unit 10 of MiOCS is illustrated as a sealed and secure box for containing the electrical components. It is important that the contents of machinery control unit 10 is kept secure but also to prevent ingress of moisture, dust and to help to stabilise the temperature. Machinery control unit 0 is mounted at a suitable location on the machinery to protect unit 10 but to enable ready access by the user, such as in a cabin. iOCS will be used on industrial and mine sites predominantly and therefore it is important that the moisture, dust and dirt from these touch environments do not enter the electronic components. It is also important that the position of machinery control unit 10 is chosen to minimise vibration or physical damage.

[0046] Machinery control unit 10 includes a DATAPRO (TRADE MARK) printed circuit board with a unique serial number which is embedded in the software to enable unique identification of each unit. Figure 104 in particular illustrates as schematic the circuitry of the DATAPRO (TRADE MARK) printed circuit board, and the wireless communication to PDA 26. When machinery control unit 10 is installed, external fixing holes must be used for screws 1 to maintain the secure rating. Machinery control unit 10 is connected to the battery and electrical system of the vehicle to provide power to the system, in the usual manner (refer Figure 104). Further, unit 10 is connected to the electrics of the starter motor so as to prevent the vehicle being started unless an authorised card is presented to machinery control unit 10. Once properly installed by a MiOCS technician, machinery control unit 10 is ready to use.

[0047] Contact information for MiOCS technicians, such as a phone number and e-mail address will be clearly available on the front of machinery control unit 10, in case technical support is required. Machinery control unit 10 includes PDA auto sync area 12, personal access card area 14, three lights, "power on" 16, "pre-start required" 18 and "ready to start" 20, as well as override 22.

[0043] When power is supplied from the machinery to unit 10 "power on" light 16 illuminates. At the same time the Lifting Techniques DATAPRO (TRADE MARK) printed circuit board itself has a red LED illuminated to show that power is reaching the board and a system clock (neither shown) which blinks twice a second to indicate that the memory cards are operational. Should there be any problems with the power supply to unit 10. "power on" light 16 will fail to light and maintenance will need to be carried out. Power is supplied to unit 10 only when the key is in the ignition and partially rotated to power the electrical devices of the vehicle. At this stage, the machinery cannot be started in the conventional manner as unit 10 prevents the starter motor from operating without an authorised card being first presented to machinery unit 10. Assuming the memory cards are properly installed and power supplied to the unit 10, and it itself is properly installed, unit 0 is now ready for use.

[0049] Referring to Figure 2 in particular PDA 26 can be seen, including screen 28 and buttons 30. PDA 26 as illustrated is a M3 (TRADE MARK) product preinstalled with MiOCS software. PDA 26 is of rugged construction suitable for outdoor use, with wireless transmission and receiving capabilities. Other types of PDA or hand-held electronic devices can be used instead, and the firmware and or software adapted accordingly.

[0050J When PDA 26 is not in use it rests in cradle 32. Cradle 32 is supplied with PDA 26 with a suitable adapter to plug into a 240 AC socket to enable PDA 26 be charged. The positioning of PDA 26 and cradle 32 is again important to prevent needless damage such as through vibration, water, high temperatures or dust. PDA 26 and cradle 32, can be protected by being kept in a cabinet or other suitable location until needed. In alternative embodiments of the invention, PDA 26 and cradle 32 are kept in a secured cabinet accessible only be a person with an authorised access card. In this form of the invention the cabinet includes an electronic lock which opens only when a suitably authorised security card is presented to a card reader associated with the cabinet. Once an authorised card is presented to the card reader an electronic actuator unlocks the cabinet door to enable the PDA to be removed from the cradle for use.

[0051] PDA 26 includes an access card reader at the rear (not shown) for enabling a person to log into MIOCS software held on PDA 26 by presenting their access card to the Mifare Reader ( F7 Model M47 for Mifare item number "I -smart-mii-mullion: 34 bit CSN configuration, brand l- Smart) TRADE MARKS. Access cards are only issued to personnel authorised to use the machinery. Authorisation may require qualifications such as a truck license and mining ticket, skills such as experience with the machinery and or permission from a supervisor. It is important with dangerous machinery such as the massive dump trucks used in mines that only authorised personnel are able to operate them, and who does operate and when is recorded, in case of an accident. f0O52] PDA 26 is preinstalled and preconfigured with an operating system and MiOCS software. However, before use MiOCS must be configured to be set-up for the client's particular requirements including card holders, tag holders and shift start and finish times. To do so PDA 26 is turned on by use of "on button" 33, causing PDA 26 to power up and the installed operating system to boot for use. As illustrated the operating system is MS WINDOWS (TRADE MARK) mobile software which is preinstalled and configured on PDA 26 to enable operation. ANDROID (TRADE MARK) or other operating systems may be used instead. [0053J Referring to Figure 3, Radio Frequency Identification "RFID" tag 93 is illustrated as used with MiOCS according to a preferred embodiment of the invention. RFID tags each contain a unique identity that can be read by a tag reader when passed near or on a particular tag. The identifying number or tag can be recognised by the MiOCS software due it the unique identifier when read by the reader. RFID tags 93 are installed on the machinery subject of the pre-start at positions as close to possible to the components to be checked. RFID tags 93 can be mounted using a simple mounting bracket, glued or use of fixing screws to fix to a surface. It is important that the location of RFID tags 93 are chosen carefully to minimise the risk of damage due to vibration, physical contact, heat or naked flames. Each piece of machinery requires numerous safety checks to be conducted before the machinery can be operated and each check will be identified by a separate RFID tag 93, as identified with the MiOCS software.

[0054] Referring to Figures 4 to 100, in particular, each Figure illustrates a screenshot from screen 28 of PDA 26 at different stages of the setup and use. These will be described in generally in order, illustrating the method of use of the invention on PDA 26.

[0055] A start-up screen (Figure 4) is shown as would be seen on first startup of PDA 26. Using the provided stylus (not shown) the "Start" menu item is clicked on and a second screen will appear (Figure 5) with a choice of short-cuts, including to enable web access, send e-mails, calendar; the usual kind of things found on a hand-held electronic device: Choosing the ^uMiOCSM3ⁿ icon opens the MiOCS application, ready for use (Figure 6). The menu options as can be seen toward the bottom of the screen for "file", 'user" "maintenance" and "action". Once the application is open various options and information are displayed to the user. For example, "Pre- start?", Tagholder?" are as yet undetermined in Figure 6 and need to be set up in order that the iOCS application can be used. In the "maintenance" option these details can be defined by selecting to select "operator 3" and entering the "info": 3A3EB3F5 (Figure 7).

[0056] An example of use of the pre-start for a crane are given, having selected action, "pre-start". A prompt is given on the screen (not shown) instructing to present PDA 26 to each item to be checked in turn. First, to "Present PDA to: 01. Hoist" and once PDA 26 is moved close to the hoist and the reader reads the appropriate RFID tag 93 a list of checks (Figure 8) appears on the screen. These checks are: check the ropes for cuts; and second that the hook is operating correctly. On completion of the checks the user is required to enter ΌΚ" or "NOT OKAY" to verify that the check has been completed. Clearly, the particular list of checks can be varied to suit the desires of the customer and the particular machinery. Once the hoist checks are completed PDA 26 displays the instruction "Present PDA to: 02. Tyres ΑΙΓ (Figure 9) to indicate that this is the second check and that each tyre must be checked. For tyres the checks may be listed as: 1. Check air pressure; and 2. Cuts and abrasions (Figure 10). Each tyre has its own RFID tag 93 so that the user must present PDA 26 actually close to each tyre in order for the reader to read RFID tags 93 and for the check to be recognised as completed. Since the user is compelled to do so they may as well look and see that the wheel nuts are tight, the tyres in good condition etcetera. Further, should there be a need for maintenance by being compelled to look at each tyre, it is much more likely that any potentially dangerous damage or fault will be noticed and rectified.

[0057] Moving through the checks, once the tyre checks have been completed the "Next Check" as can be seen noted in the top left corner is instructed "Present PDA to: 03. Engine" (Figure 11). Once the presentation has occurred "Current Check" can be seen in the top left corner with the list of engine checks displayed: oil topped up; transmission oil; and windscreen fluid (Figure 12). Similarly, the "Next Check" is instructed "Present PDA to: 04. Fire extinguisher" (Figure 13). Again once the presentation has occurred "Current Check" can be seen in the top left corner with the list of "Fire extinguisher checks" displayed, for example, to check the pull pin and date of expiry (Figure 14).

[0058] Figure 15 illustrates that once all the checks for the crane have been conducted, e.g. for the hoist, tyres, engine and fire extinguisher the next action indicated is to switch on the crane, the last action on the list. Once the crane has been switched on confirmation that this has occurred is requested by the software (Figure 16). It is at this stage that power is supplied to machinery control unit 10 from the electrics of the crane. Pre- start has been completed (Figure 17) and is recognised as occurring giving the instruction to turn off the ignition of the crane and return PDA 26 to its cradle.

[0059] If, during the pre-start a problem is found, such as w^'rth the tyres (Figure 18), or the pre-start is not completed properly, such as due to the checks being read out of sequence (Figure 22) a warning will be shown, with a suitable instruction to the user. As shown in Figure 19 this is an instruction to report to the supervisor. In this case, where the pre-start has been aborted, no pre-start has been completed and the crane will not be put in the pre-start state. A fresh pre-start will need to be conducted with all the steps and checks completed.

[0060] Another option if during the pre-start it is found that the checks cannot be completed, such as a maintenance issue is found the "Action" of "Cancel Pre-start" can be selected (Figure 20). The user can then report the need for maintenance to a supervisor or suitable technician as is the policy of their employer or worksite. (0061] The users conducting the pre-start are recorded and logged (Figure 21 ) with the details shown towards the top of the screen. This is so that the actions can be logged with times and user information for any particular action. Each user is set up on the ^'rOCS application so that they can logon with their own specific details by use of the on-screen keyboard (Figures 23 and 24) Figures 25 and 26 show a fictional user 3 with a password logon.

|pfJ62] Each user has to be set up for the first use by selecting "maintenance" giving a menu of choices including "cards", "cardholders" "tags", "tagholders" (the machinery to be pre-started) and workers "shifts" (Figure 27). Cards must be added to the database and linked to a cardholder before use. The user selects "cardholders" in order that a new cardholder can be setup to use MiOCS on PDA 26. Figure 28 lists the details of card holders, and an example card for a fictional "John GRANT", who has a card number saved on PDA 26. Numerous card holders can be stored on PDA 26.

[0063] Figure 29 illustrates the menu for the card options of "view card" (Figure 30), "edit card" (Figure 31, 32, 33 and 35). "add card" (Figure 34) and "delete card" (Figure 36, 37). The user selects "add card" so that a new card can be set up for a new user. Similarly, the cardholder options can be accessed from the appropriate menu (Figure 38) for the list of cardholders (Figure 39) and options of "view cardholder"(Figure 40, 41 ), "edit cardholder"(Figure 43-45), "add cardholder" (Figure 46-49) and "delete cardholder" (Figure 50,51). The user selects "add cardholder" so that a new cardholder and details can be entered for use.

[0064] All of the foregoing editing and viewing of cards and cardholders is still under the maintenance tab, as is "Tags" which can be similarly edited (Figures 52-82). Again each tag, which is a RFID tag 93 fixed to a check location is entered for a particular vehicle, say a crane (Figure 55) and can be viewed, edited, added or deleted by use of a menu (Figure 58), similar to other menus on the system. Each tag relates not only to a specific machinery and location but also can include instructions of a list of checks to be made during presenting of that particular RFID tag 93. These instructions can be entered by use of the onscreen keyboard (Figures 57, 59-63). For example, the specific action such as to replace cap when checking the oil of a vehicle may be required to be checked as completed and ensure oil is full (Figure 62) and can be typed in to the check list for the tag. Other useful information can also be included relating to a specific tag as may be required for a particular application.

[0065] Figure 64 illustrates the list of tags and the machinery to which each tag relates so that these can be accessed and the checks edited, as may be required from time to time. Tags can be added (Figure 65-71) by adding all the details and saving in the usual manner. Tags can also be deleted if they become surplus to requirements (Figure 72).

[0066] Tagholders, that is the machinery to which the tags are attached, can similarly be accessed by use of the menu (Figure 73), selecting a crane and viewing tagholder, for example (Figure 74, 75). All the tags associated with the tagholder are listed: 01 Hoist; 02 Tyres; 03; Engine; and 04 Fire (extinguisher) (Figure 76). Each of the tags associated with the tagholder can again be viewed, added or deleted as necessary (Figures 77-82).

I0067] The final menu item under the maintenance tab (Figure 83) is shifts. There is an internal clock and so use of MiOCS enables a record to be kept of who pre-starts a machinery and who uses it and for how long. These shifts can be edited manually and reports run on to access the information (Figures 84-99). The reporting side of MiOCS can be adapted to suit a particular user and can track back who conducted a pre-start, who authorised use of a machine and the length of time used, as an example. The reports can be exported either to the removable memory card of PDA 26 or could be downloaded wireless or otherwise to a network, PC or other devices for review and storage. The final screenshot shows the version of MIOCSM3 software running, details of which can be obtained from the applicant. Figure 101 lists the steps of use of MiOCS to pre-start machinery as would be provided during training to a user or for reference. Figure 102 similarly, lists the steps for operating the machinery including authorisation by use of an authorised access card. Figure 103 gives an example of the checks to be completed to pre-start a forklrft.

[0068] In use, only a person authorised to carry out the pre-start check will be able to do a pre-start using MiOCS by being allocated an access card with pre-start privileges for specific machinery. To do a pre-start so the person switches on PDA 26 by use of on button 33 and presents their access card which is recognised as authorised and enables access to MIOCS. Screen 28 or PDA 26 will display numerous icons including for each of the tagholders/machinery that are available for pre-start. A selection, say of a utility vehicle ("ute") (not shown) is made so that the person can pre-start the Ute for use.

[0069] If the person needs to pre-start a utility vehicle (not shown) PDA 26 is then presented to the first or any of FID tag 93 installed on the ute and the integral tag reader of PDA 26 recognises a unique identifier of the ute which activates MIOCS on PDA 26 if the person is authorised to do a pre-start on the ute. If RFID tag 93 that the person presented PDA 26 to is not the first checkpoint, a message will be displayed on PDA 26 informing that the check was made out of sequence. The person must then click on the message to close it. A screen on PDA 26 will up informing the person the description of the first checkpoint, say "ENGINE". Once the person presents PDA 26 to the engine, a screen will come up on showing the instruction list. [0070] The person now needs to follow the instructions to make the pre-start checks make the pre-start checks and these appear on the screen as described above. First a check of the oil level is made and once completed the coolant level must be checked. Once all the checks in the instruction list for the engine are made and are in a satisfactory condition, the person clicks on the ΌΚ" button. Since each RFID tag 93 has been set up individually on PDA 26 during installation each tag is recognised uniquely for particular machinery and its location as a checkpoint. When the tag is read the unique code is read by the tag reader and recognised by the software as being mounted at a certain location.

[0071] Having pressed the "OK" button, a screen on PDA 26 will come up informing the person the description of the next checkpoint, say "Front wheel". The person must then present PDA 26 to RFID tag 93 at the front wheel checkpoint will come up on PDA 26 The process is repeated for the remaining checkpoints each of the wheels and tyres, and fire extinguisher. Although in theory the person could hot check the item, since they are compelled to go to each wheel and pass PDA 26 over RFID tag 93 they will see the wheel and likely make the check. In previous situations a person could simply look casually from the front of the vehicle and tick the boxes. With the described embodiment the person must go to each wheel and present PDA 26 so that any fault or misalignment of the wheel nuts for example will be noticed, and hopefully rectified before use of the vehicle. Other checks that require lifting the bonnet or other access, again compel the user to lift the bonnet in order that RFID tag 93 can be scanned and read again encouraging conducting of the check.

[0072] Once all the pre-start checkpoints have been completed screen 28 or PDA 26 displays the pre-started complete advice. PDA 26 is then presented to "PDA auto sync with MCU" 12 to communicate one with the other through wireless connections. Once the completion of the pre-start is communicated to machinery control unit 10 red "pre-start required" light 18 goes out and the green "ready to start" light 20 illuminates. The pre-start is now completed, so the person can present their access card to personal access card area 14 which will record the user of the vehicle on PDA 26. The Ute can now be used as usual for the length of the shift. It is anticipated that usually the person conducting the pre-start will also be the authorised person for using the machinery. However, the person who conducts the pre-start may then hand over to another authorised person to use the machinery. A key benefit of MiOCS is the absolute tracking of who conducts the pre-start on machinery and separately who actually uses the machinery. Use of MiOCS records who checks and uses the machinery, only enabling authorised personnel to do so but also to keep an accurate record. In the case of an accident or machinery failure it is then a simple matter to track back who has used or checked the machinery to see where the problem may have occurred or who was operating the machinery during an accident. MiOCS stores the data with a real time clock so the actual times of use can be tracked.

[0073] Data can be e-mailed to a network or desktop PC or server for backup and consideration by senior personnel if necessary. Data can also be viewed on PDA 26 in the form of reports.

[0074] After use the machinery is switched off and the user is logged off the system. To use the machinery again the user must present his or her access card to machinery control unit 10 which will indicate with the green LED, ready to start, if the user is authorised to operate the vehicle, for example. Pre-start can be completed for any set period of time, for example for a 12 hour shift or 24 hour period before the pre-start needs to be completed again. [00751 System override 22 on machinery safety unit 10 enables operation of the machinery without conducting the pre-start such as in an emergency situation. Authorised personnel will keep or have authority to turn the key to override MiOCS and enable power to the start motor of the vehicle to enable operation.

[0076] Use of MiOCS is a surprisingly clever way of compelling users to look closely at each part of a machinery to be checked. By doing so the likelihood that the check will be made is significantly increasing and that any problems will be identified.

1P077] The aforementioned preferred embodiment describes a standalone system using proprietary access cards and equipment. In a variant MiOCS may be integrated to use security access cards already issued to personnel. In this case the PDA may be used with a separate card reader to read the cards of the particular customer. In this case MiOCS firmware/software may be adapted to recognise the particular identifiers used by the customer's access cards.

INDUSTRIAL APPLICABILITY

[0078] The subject safety system can be manufactured industrially from several electrical and other components including an electronic device, and machinery control unit. The safety system can be supplied direct to individual customers or to companies for installation in machinery, including vehicles for use.

[0079] It will be apparent to a person skilled in the art that changes may be made to the embodiments disclosed herein without departing from the spirit and scope of the invention in its various aspects.

Claims

THE CLAIMS:

1. A machinery safety system including: a machinery control unit for the machinery, controlling whether the machinery can be operated or not;

an electronic device, including an electronic reader;

a pre-start checklist of safety checks to be conducted on the machinery by a person, accessible through the electronic device; and one or more identification means, located on the machinery proximal to the location of each item on the checklist to be checked, and readable by the electronic reader, wherein, in use, the person moves the electronic device towards the identification means at the location of an item to be checked, and the electronic reader identifies the identification means at that location and logs that the check at that location has been made, and the process is repeated for all the safety checks on the check list and on completion of the pre-start checklist the electronic device communicates to the machinery control unit that the pre-start has been completed. ^/

2. The machinery safety system according to claim 1 , wherein a pre- start checklist is required to be completed on a regular basis for the machinery to continue to be authorised for use.

3. The machinery safety system according to claim 1 or 2, wherein the person is authorised to conduct the pre-start and to operate the machinery.

4. The machinery safety system according to any one of claims 1 to 3, wherein the controlling by the machinery control unit is preventing operation of the machinery until the pre-start checks have been recognised as completed by the electronic device.

5. The machinery safety system according to any one of claims 1 to 4, wherein the machinery control unit disables the machinery and prevents its operation until the pre-start checks have been conducted and communicated to the machinery control unit.

6. The machinery safety system according to any one of claims 1 to 5, wherein personal identifier means are used identifiable by use of the electronic device and or the machinery control unit and the personal identifier means include identifiers that can be read or identified by use of the electronic device and the machinery control unit.

7. The machiner safety system according to claim 6, wherein the personal identifier means is an access card reader and access cards to identify a particular user.

8. The machinery safety system according to claim 7, wherein an access card reader is included on both the machinery control unit and electronic device.

9. The machinery safety system according to claim 7 or 8, wherein once the pre-start check list is completed and communicated to the machinery control unit the machinery cannot be operated until an authorised access card is presented to the access card reader.

10. The machinery safety system according to any one of claims 7 to 9, wherein if an access card of a person recognised as qualified and authorised to use the machinery is presented to the access card reader the machinery control unit enables the machinery for use or inspection.

1 1. The machinery safety system according to claim 10, wherein the enabling is the activation of the start motor electrics ready for starting of the machinery.

12. The machinery safety system according to any one of claims 7 to 1 1 , wherein use of the access card reader enables a different person to operate the machinery and be recorded as having done so, to the person who was logged as performing the pre-start checks.

13. The machinery safety system according to any one of claims 6 to 9, wherein each stage of use, the pre-start and any users of the machinery will be logged with a date and time as well as the details of the machinery.

14. The machinery safety system according to any one of claims 1 to 13, wherein the machinery control unit includes a means of communicating with the electronic device.

15. The machinery safety system according to claim 14, wherein the communication is by wireless auto-sync.

16. The machinery safety system according to claim 14 or 15, wherein once the pre-start checks are completed on the electronic device it communicates wirelessly with the machinery control unit to indicate that the pre-start was done.

17. The machinery safety system according to any one of claims 7 to 16, wherein the machinery control unit includes an override enabling the machinery to be made operational without presenting an authorised card to the machinery control unit. 8. The machinery safety system according to any one of claims 1 to 17, wherein the electronic device is a portable or hand-held electronic device.

19. The machinery safety system according to any one of claims 1 to 18, wherein details of the or each identification means is stored in the electronic device so that reading the or each identification means recognises that a particular location on the machinery has been read, and completes the instruction list item found at that particular location.

20. The machinery safety system according to any one of claims 1 to 19, wherein the electronic reader is a Radio Frequency Identification ("RFID") reader and the or each identification means are RFID tags at the locations on the machinery where checks are to be conducted.

21. The, machinery safety system according to claim 20, wherein each RFID tag is logged within the software of the electronic device so that when read by the RFID reader the checklist item at the location of the particular RFID tag is checked as completed when read.

22. The machinery safety system according to any one of claims 1 to 21, wherein the or identification means are mounted on the machinery very close to where the checks are to be conducted.

23. The machinery safety system according to any one of claims 1 to 22, wherein the or each identification means is identified and logged on the electronic device so that the checks are recorded as being completed.

24. The machinery safety system according to any one of claims 1 to 23, wherein the pre-start requires the checks to be conducted in sequential order and will only put the machinery in the pre-start state for use if the check was conducted in that order.

25. The machinery safety system according to any one of claims 1 to 24, wherein on completion of the pre-start checklist the electronic device communicates the information to the machinery control unit.

26. The machinery safety system according to claim 25, wherein the machinery is in the pre-start state once the communication that the pre-start has been completed has been communicated to the machinery control unit from the electronic device. 27. A machinery safety system including: a machinery control unit for the machinery, controlling whether the machinery can be operated or not

an electronic device, including an electronic reader;

a personal identifier means to identify the person that will pre-start, authorise or operate the machinery, readable by the electronic device and or machinery control unit; and , one or more identification means, located on the machinery proximal to the location of each item on the checklist to be checked, and readable by the electronic reader,

wherein, in use, the person moves the electronic device towards the identification means at the location of an item to be checked, and the electronic reader identifies the identification means at that location, and list of checks to be made, and logs that the checks at that location has been made, and the process is repeated for ail the safety checks on the check list and on completion of the pre-start checklist the electronic device communicates to the machinery control unit that the pre-start has been completed, and the personal identifier means identifies and records the person who conducts the pre-start, authorises or operates the machinery

27. A machinery safety system including:

a machinery control unit for the machinery, controlling whether the machinery can be operated or not, including an access card reader; a Personal Digital Assistant ("PDA"), including a Radio Frequency Identification ("RFID") reader; a pre-start checklist of safety checks to be conducted on the machinery by a person, accessible through the PDA; and

a plurality of RFID tags located on the machinery proximal to the location of each item on the checklist to be checked, and readable by the RFID reader, wherein, in use, the person presents and access card to the PDA to identify and record the person, and the safety checks are made at the locations on the machinery by moving the PDA towards the RFID tag at that location and the RFID reader identifies the RFID tag at that location and logs that the check at that location has been made, and the process is repeated for all the safety checks on the check list, in sequential order, and on completion of the pre-start checklist the PDA communicates to the machinery .control unit that the pre-start has been completed.

28. A method of using a machinery safety system for conducting the pre- start for a machinery, the machinery safety system including a machinery control unit for controlling use of the machinery, an electronic device including an electronic reader and one or more identification means readable by the electronic device, the method including the following steps: a) accessing the electronic device;

b) selecting the machinery for pre-start checks to be conducted c) moving the electronic device close to the identification means until read by the reader, whereby the appropriate item on the checklist is marked as completed;

d) repeating for all the identification means listed on the checklist until the checklist is completed;

29. The method of claims 28, wherein the method includes an additional step before step a) of presenting an access card to a card reader of the electronic device and if authorised to make the pre-start access to the electronic device is enabled and the user details logged.

30. The method according of claim 28 or 29, wherein the method include the further step of presenting an authorised access card to the machinery control unit after the pre-start has been completed but before the machinery can be made operational by the machinery control unit.

31. The method according to any one of claims 28 to 30, wherein the or each identification means are a plurality of RFID tags and the electronic reader is a RFID reader.

32. The method according to any one of claims 28 to 31 , wherein the checks need to be performed in sequential order.

33. The method according to any one of claims 28 to 32, wherein the method uses the safety system of any one of claims 1 to 27.